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INTRODUCTION
How to Use This Manual
This manual contains information for the 1996- 2000 ClVlC. lt is
divided into 24 sections.The first page of each section is marked
with a black tab that lines up with its correspondingthumb index
tab on this page and the back cover. You can quicklYfind the first
page of each section without looking through a tull table ol con_
tents.The symbols printed at the top corner of each page can also
be used as a quick referencesystem.
Eachsectionincludesl
1. A table of contents,or an explodedview index showing:
. PartsdisassemblYsequence.
. Bolt torquesand thread sizes.
in text
. Pagereferencesto descriptaons
proceduresand tools.
2. Disassembly/assembly
3. Inspection.
4. Testing/troubleshooting.
5. Repair.
6. Adjustments.
Special Information
Indicates a sttong possibility of sover. perconal iniurY
!@
if in3tructions are not follow€d.
ol
lite
or loss
GAUTION: Indicaiqs a possibility ot p€lsonal injury or 6quipm.nt
damage il instiuc'tions are not followod
t Noncal
i-. pu.po.. ot thes6 messages is to help provent demage lo lhe
vehicle, other property, or the €nvironment.
*Transaxle
ds
NOTE: Giveshelpfulinformation.
CAUTfON: Detaifed descriptions ol standard workshop p.oceduro3.
safoty principles and servico operations are not included. Pleaso
note that this manual contain3 wetnings and cautions against
some sp6cific sGrvic€ methods which could cause PERSONAL
INJURY, damage a vohicle or make il unsafe. Ploase undorstand
that these warnings cannot covsr all conceivable weys in which
service. whelher or not iocommgndod bY HONDA. mighi bo done,
or ol tho possiblG hazardou3 consgquonces of ev€aYconceivablg
way, nor could HONDA invqstigato all 3uch way3. AnYono using
sgrvice procedures or lools, whethei or nol rGcommendod bY
HONDA, must srtisty hifisetf thoroughlylhat nohher pefsonal sefety
nor vehiclc satsty will be reopardi2ed.
All intormationcontainedin this manual is basedon the latestprod
uct information available at the time oI printing We reserve the
right to make changes at any time without notice No part of this
publicationmay be reproduced,stored in retrievalsystem,or trans'
mitted, in any form by any means, electronic,mechanical,photo
copying, recording,or otherwise,without the prior written permission of the publisher.This includestext, figuresand tables.
1848Pages
FirstEdition8/99
All Right Reserved
HONOAMOTORCO.,LTD.
SorvicoPublicationOffico
As sectionswith * includeSRScomponents;
sDecialprecautionsare lequiredwhen servlclng
* E l e c tri c a l
*SRS
't
SRS
l
l
GeneralInformation
1-2
Ghassis
andPaintCodes.......................
1-32
ldentification
NumberLocations.........
LabelLocations.......1-33
Warning/Caution
Under-hood
Emissions
.......1-37
ControlLabel..........
Lift and SupportPoints
1-41
LiftandSafetyStands.......................
1-42
.......................
FloorJack
.........
1-43
Towing
Chassisand PaintGodes
U.S. 1996Model (2-doorHatchback)
oa
Vehicleldentification Number
2 H GE J 63 2 * T H I 0 0 0 0 1
Manufacturel, Make and
Type of Vehicle
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
Line,Bodyand EngineType
EJ6: CIVIC3-door/D16Y7
Body Type and TransmissionType
3: Hatchbaclds-speed
M an u aI
4: Hatchbacl(4'speed
Automatic
Vehicle Grade
2i CX
4i DX
6: DX
D16Y7 1500001
EngineType
D 16Y7:1600SOHC16-vatves
SequentialMultiport
Fuel-injected
Engine
SerialNumber
44RA: 4-speedAutomaticTransmission
S40 : s-speedManualTransmission
Ch€ckDigit
Model Year
T: 1996
FactoryCode
H: Alliston Plant, Ontario, Canada
Destinations
Serial Numbel
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
GY,16P
NH-503P
NH.583M
R-97
Midori GreenPearl
GranadaBlackPearl
New VogueSjlver lvletallic
RomaRed
O '
Paint Code
COLOR
GY.l6P
o e
1-2
O O
U.S. 1996Model (4-doorSedanl
' ]500001
D16Y7-
1 H GE J 6 5 2* T L 0 0 0 0 0 1
1 H G :H O N D AO FA M E R I C A
lNC.
t\4FG.,
vehicle
HONDAPassenger
2HG: HONDAOF CANADA
M F G . I, N C .
vehicle
HONDAPassenger
Line, Body and EnginsType
EJ6: CIVIC4'door/D'16Y7
EJ8: CIVIC4-door/D16Yo
Body Type and TransmissionTyPe
Manual
5: Sedan/5-speed
Sequential
D16Y7:1600SOHC16-valves
Engine
MultiportFuel-injected
Sequential
Dl6Y8: 1600SOHCVTEC16-valves
Engine
MultiportFuel-injected
, l6Yg 1500001U . S . A : D 1 6 Y 7D
I ransmlssron
TransmissionType
A4RA:4 speedAutomaticTransmission
S40 : s-soeedManualTransmission
5000001A4RA(U.S.A.):
S40{JAPAN): 1000001-
O O
7: LX with IVC
CheckDigit
Model Year
T: 1996
L: EastLiberty,Ohio Plant,U.S.A.
H: AllistonPlant,Ontario,Canada
Vehicleldentification Number
and FederalMotor Vehicle
Safety Standard Gertification
B-73M
G-82P
NH-538
NH-503P
NH-583M
R,95P
CycloneBlueMetallic
CypressGreenPearl
FrostWhite
GranadaBlackPearl
New VogueSilverMetallic
lslandCoralPearl
Paint Code
COLOR
8.73M
l a
1-3
Chassisand Paint Codes
U.S. 1996Model (2-doorCoupe)
o f
EngineNumber
I H G E J 61 2 * T L 0 0 0 0 0 1
Line. Body and Engine Type
EJ6: CIVIC2-doorD16Y7
EJ7: ClVlC2-doorDl6Y5
EJ8: ClVlC2-door/D16Y8
Body Type and TransmissionType
1:Coupe/s-speed
M an u aI
2: Coupe/4-speed
Automatic,CVT
4: DX with A'lC,HX with A,,/C,
EX
5: DX with ABS and A,/C,EX with ABS
CheckDigit
Model Year
T: 1996
L: EastLiberty,Ohio Ptant,U.S.A.
Vehicleldentification Number
and FederalMotor Vehicle
Safety Standard Certification
1300001
EngineType
D16Y5:1600SOHCWEC E 16-vatves
SequentialMultiport
Fuel-injected
Engine
D 16Y7:1600SOHC16-vatves
SequentialMultiport
Fuel-injected
Engine
D16Y8:1600SOHCWEC 16-vatves
SequentialMultiport
Fuel-injected
Engine
SerialNumber
JAPAN:Dl6Y5- 130000'1U.S.A.: D16Y7,D16YB- 150000'1-
A4RA | 4-speedAutomaticTransmission
S 4 0 : s - s p e e dM a n u aT
l ransmission
M4VA I ContinuouslyVariabte
(CVT)
Transmission
oa
A4RA: 5000001S40 : 1000001M4VA:1000001-
NH-503P
NH-538
NH 583M
R-81
R-95P
CypressGreenPearl
GranadaBlackPearl
FrostWhite
New VogueSilverMetallic
M i l a n oR e d
lslandCoralPearl
Paint Code
COLOR
G.82P
O O
1- 4
O O
CANADA 1996Model (2-door Hatchback)
VehicleldentificationNumber
D16Y7 -
2 H GE J 6 3 2 * T H 0 0 0 0 0 1
Manulacturer,Make and
Type of Vehicle
2HGr HONDAOF CANADA
D16Y7:1600SOHC'16-valves
SequentialMultiPort
Engine
Fuel-injected
HONDAPassenger
vehicle
Line, Body and Engino Type
EJ6: ClvlC3-door/D16Y7
Body Type and TransmissionTyPe
3: Hatchbacld5-speed
M a n u aI
4: Hatchbacld4-speed
Automatic
VehicleGrade
2,Cx
3:CX-G
AutomaticTransmission
A4RA:4-sDeed
S40 : 5-sDeedManualTransmission
CheckDigit
ModelYeal
T: 1996
FactoryCode
H: AllistonPlant,Ontario,Canada
selial Number
O O
Vehicleldentification Number
and CanadianMotor Vehicle
Safety Standard Certification
GY-16P
NH-503P
NH-583M
R-97
Midori GreenPearl
GranadaBlackPearl
New VogueSilverMetallic
RomaRed
Paint Code
COLOR
GY.l6P
0 0
1-5
Chassisand PaintCodes
CANADA1996Model (4-doorSedanl
Vehicleldentification Number
lHG
r-'
Manufacturer,
Make and
Tvpe oI Vehicle
I H G : H O N D AO FA M E R T C A
M F G , I, N C .
HONDAPassenger
vehicle
Line, Body and EngineType
EJ6: CIVIC4-door/Dt 6y7
Body Type and TransmissionType
5: Sedan/5-speed
Manual
6: Sedan/4-speed
Automatlc
Vehicle Grade
3: LX
4: LX with ABS
5: LX with ABS and A,/C
6: EX
7: EX with ABS
CheckDigit
Model Year
Tr 1996
FactoryCode
L: EastLiberty,Ohio Plant,U.S.A.
SerialNumber
Vehicleldentification Number
and CanadianMotor Vehicle
Safety Standard Certification
!)
EngineNumber
53 * T
800001
D 1 6 Y 7 170000'l
-[
I
EngineType
D16Y7r1600SOHC'16-vatves
SequentialN4ultiport
Fuel-injected
Engine
SerialNumber
TransmissionNumber
A4RA 5000001
T
Transmission
Type
A4RA:4 speedAutomaticTransmission
S 4 0 : s - s p e e dM a n u aT
l ransmission
SerialNumber
A4RA:5000001S40 : 1000001-
B 73M
G-82P
NH-503P
NH,538
NH.583M
t
C y c l o n eB l u eM e t a l l i c
CypressGreenPearl
GranadaBlackPearl
FrostWhite
N e wV o g u eS i l v e rM e t a l l i c
O '
Paint Code
COLOR
8.73M
)
1-6
O O
CANADA1996Model (2-doorCouPe)
EngineNumber
1 H GE J 6 1 2 . T L 0 0 0 0 0 1
Line, Body and EngineTYPe
EJ6: ClVlC2-door/D16Y7
EJ8: ClVlC2'door/D16Y8
Body Type and TransmissionTYPe
D16Y7:1600SOHCl6-valves
SequentialMultiPort
Engine
Fuel-injected
D16Y8:1600SOHCVlEC 16-valves
SequentialMultiPort
Engine
Fuel-injected
SerialNumber
A4RA- 5000001
Vehicle Glade
2: DX, Si
3: Si with ABS
5: DX with ABS
CheckDigit
Model Yeal
T: 1996
O '
44RA:4-speedAutomaticTransmission
S40 : 5-speedManualTransmission
L: EastLiberty,Ohio Plant,U S.A.
Vehicleldentification Number
and GanadianMotor Vehicle
Safety StandardCertification
G-82P
NH-503P
NH-538
NH 583M
R-81
R 95P
CypressGreenPearl
GranadaBlackPearl
FrostWhite
New VogueSilverMetallic
M i l a n oR e d
lslandCoralPearl
Paint Code
COLOR
NH-538
O O
1-7
Chassisand Paint Codes
U.S. 1997Model (2-doorHatchback)
O O
VehicleldentificationNumber
2 H G E J 63 2 * V H 1 0 0 0 0 1
Manufac-turer,Make and
Type of Vehicle
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
Lins, Eody and EngineType
EJ6: ClvtC3-door/D16y7
Body Typo and TransmissionType
3: Hatchbaclds-speed
Manual
4: Hatchbaclv4-speed
Automatic
Vehicl€ Grade
2: CX
4: DX
CheckDigit
Model Year
V: 1997
FactoryCode
H: AllistonPlant,Ontario,Canada
Destinations
D16Y7:1600SOHC16-vatves
SequentialMultiport
Fuel-iniected
Engine
A4RA:4-speedAutomaticTransmission
B4RAt4-speedAutomaticTransmisston
S40 : s-speedManualTransmission
44RA:6000001B4RA:6000001S40 : 1000001-
Serial Numbel
VehicleldentificationNumber
and FederalMotor Vehicle
Salety Standard Certification
O O
NH,5O3P
NH-583N4
PB-74P
R-97
GranadaBlackPearl
New VogueSilverMetallic
DarkAmethystPearl
RomaRed
Paint Code
COLOR
NH-583M
O O
1-8
0 0
U.S. 1997Model (4-doorSedanl
Vehicleldentification Number
D 1 6 Y 7 2300001
J-tH M E J 65 2 * V S 0 0 0 0 0 1
Makeand
Manulaqturer.
Typeof Vehicle
HONDAMOTORCO.,
LTD.
HONDAPassenger
vehicle
HONDAOFAMERICA
M F G . I, N C ,
HONDAPassenger
vehicle
HONDAOFCANADA
M F G . I, N C ,
HONDAPassenger
vehicle
Line, Body and Engine TYPe
t o
EJ6: ClVlC4-door/D16Y7
EJ8: ClVlC4-door/D16Y8
Eody Type and TransmissionTYPe
Manual
5: Sedan/S-sPeed
6: Sedan/4-speed
Automattc
Vehicle Grade
2i DX
4: EX
7: LX with A/C
CheckDigit
Model Yeal
V: 1997
FactoryCode
L: EastLibeny,Ohio Plant,U S.A
Japan
S: SuzukaPlant,Mie Prefecture,
H: AllistonPlant,Ontario,Canada
SerialNumbel
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
Sequential
D16Y7:1600SOHC16-valves
Engine
MultiportFuel-iniected
Sequentral
16-valves
D16Y8:1600SOHCWEC
Engine
MultiPortFuel-injected
JAPAN:D16Y7,D16Y8- 2300001U.S.A.: D16Y7,D16Y8- 2500001-
Number
Transmission
A4RA- 6000001
TransmissionTYpe
A4RA: 4-speedAutomaticTransmission
B4RA: 4-speedAutomaticTransmission
M4RA:4-speedAutomaticTransmissron
S4O : s-speedManualTransmission
SerialNumber
A4RA(U.S.A.): 6000001^
B4RA(U.S.A.): 6000001"
M4RA(JAPAN):2000001S40{JAPAN) : 1000001-
CycloneBlueMetallic
CypressGreenPearl
FrostWhite
GranadaBlackPearl
New VogueSilverMetallic
lnzaRed
B 73M
G-82P
NH,538
NH-503P
NH.583M
R-96P
Paint Code
COLOR
8.73M
O O
1-9
Chassisand PaintCodes
U.S. 1997Model (2-doorCoupe)
O O
EngineNumber
D16Y5- 2300001
Lino. Eody and Engine Typ6
EJ6: ClVlC2-door/D16y7
EJ7: ClVlC2-door/Dl6Yb
EJ8: ClVlC2-door/D16y8
Body Type and TransmissionType
Check Digit
Model Yeal
V: 1997
L: EastLiberty,Ohio Plant,U.S.A.
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
EngineTyp6
D16Y5:1600SOHCVTEC-E16 vatves
SequentialMultiport
Fuel-injected
Engine
D16Y7:1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
Dl6Y8r1600SOHCVTEC16 vatves
SequentialMultiport
Fuel-injected
Engine
SerialNumber
JAPAN:D16Y5 2300001U.S.A.: Dl6Y7, Dl6Y8- 2500001-
A4RA: 4 speedAutomaticTransmission
84RA: 4-speedAutomaticTransmissron
S40 :s-speedManualTransmission
M4VA:ContinuouslyVariable
Transmission(CVT)
eo
A4RA: 6000001B 4 R A :6 0 0 0 0 0 1 S40 : 1000001M4VA:2000001-
G.82P
NH-503P
NH,538
NH-583M
R-8r
CypressGreenPearl
GranadaBlackPearl
FrostWhite
New VogueSilverMetallic
M i l a n oR e d
PaintCode
COLOR
G.82P
lo
1 - 10
eo
CANADA1997Model (2-doorHatchbackl
VehicleldentificationNumber
2 H G E J 63 2 * V H 0 0 0 0 0 1
-[
Manufacturer,Make and
]
Type oI Vehicle
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
Line, Body and EngineTYPe
EJ6: ClVlC3-door/D16Y7
Body Type and TransmissionTYPe
3: Hatchbacld5-sPeed
lvlanual
4: HatchbaclV4-speed
Automatic
VehicleGrade
2i CX
3: CX-G
CheckDigit
Model Yeal
V: 1997
FactoryCode
H: AllistonPlant,Ontario,Canada
ao
'1600SOHC16-valves
D16Y7:
SequentialMultiPon
Engine
Fuel-iniected
A4RA:4-speedAutomaticTransmission
B4RA:4-speedAutomaticTransmission
S 4 O : s - s p e e dM a n u a l T r a n s m i s s i o n
A4RA:600000184RA;6000001S40 :1000001'
Selial Number
VehicleldentificationNumbel
and CanadianMotor Vehicle
Safety Standard Certification
NH-503P
NH.583M
PB.14P
R-97
GranadaBlackPearl
New VogueSilverMetallic
DarkAmethystPearl
RomaRed
PaintCode
COLOR
NH.5O3P
e o
1-11
Chassisand Paint Godes
CANADA1997Modet(4-doorSedan)
]l
l H G E J 65 3 * V L 8 0 0 o o l
D16Y7 2750001
1600SOHC16-vatves
SequentialMultiport
Fuel-injected
Engine
Line, Body and EngineType
EJ6: ClvtC4-door/D16y7
Body Typ€ and TransmissionType
5; Sedan/5-speed
Manual
4: LX with ABS
5; LX with ABS and A,/C
7: EX with ABS
8: EX with ABS and Ay'C
Ch.ck Digit
Model Year
V: '1997
,A4RA:4-speedAutomaticTransmission
B4RA:4 speedAutomaticTransmission
S40 :s-speedManualTransmission
44RA:6000001B4RA:6000001S40 :1000001-
0 0
B-73M
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification
NH-503P
NH-538
NH-583M
CycloneBlueMetallic
CypressGreenPearl
GranadaBlackPearl
FrostWhite
New VogueSilverMetallic
Paint Code
COLOR
B.73M
ea
1-12
Downloaded from www.Manualslib.com manuals search engine
E-
ao
CANADA1997Model (2-doorCouPel
EngineNumber
D16Y7 2750001
1 H GE J 6 1 2 * V L 8 0 0 0 0 1
1 H G : H O N D AO FA M E R I C A
Line, Body and EngineTYPe
EJ6: ClvlC2-door/D16Y7
EJ8: ClVlC2-door/D16Y8
Body Type and Tr8nsmissionTYP8
Engins Typs
D16Y7:1600SOHC16-valves
SequentialMultiPort
Engine
Fuel-injected
D16Y8:l600 SOHCVTEC16-valves
SequentialMultiPort
Engine
Fuel-iniected
SerialNumber
A4RA- 6000001
0 0
Vehicle Grado
2 : D X ,S i
3: Si with ABS
5: DX with ABS
6: DX with ABS and l'lc
7: Siwith ABS and A,/C
CheckDigit
Model Ysar
V:1997
A4RA:4-speedAutomaticTransmission
B4RA:4-speedAutomaticTransmission
S4O : s-speedManualTransmission
A4RA:6000001B4RA:6000001*
S40 :1000001-
L: EastLiberty,Ohio Plant,U.S.A.
Vehicle ldentification Number
and CanadianMotor Vehicle
Safety Standard Certification
CypressGreenPearl
GranadaBlackPearl
FrostWhite
New VogueSilverMetallic
M i l a n oR e d
G-82P
NH-503P
NH-538
NH-583M
R-81
PaintCode
COLOR
NH-538
a o
1-13
Ghassisand PaintGodes
U.S. 1998Model (2-doorHatchback)
0 a
Vehicleldenti{icationNumber
2 H G E J 63 2 . W H 1 0 0 0 0 1
Manufactursr,Mak€ and
Type of Vehicle
2HG: HONDAOF CANADA
MFG.,INC.
HONDAPassenger
vehicle
Lin€, Body and Engine Type
EJ6: ClvlC3-door/D16y7
Body Type and TransmissionType
3: Hatchbaclds-speed
Manual
4: Hatchbacl/4-speed
Automatic
Vehicle Grade
2i CX
4: DX
CheckDigit
Model Year
W: 1998
FactoryCode
HrAllistonPlant,Ontario,Canada
Deslinations
D16Y7:'1600SOHCl6-valves
SequentialMultiport
Fuel-injected
Engine
B4RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
Serial Numbet
Vehicleldentification Number
and FederalMotor Vehicle
Safety Standard Certification
NH-592P
NH-583M
PB,74P
R-97
FlamencoBlackPearl
New VogueSilverMetallic
DarkAmethystPearl
RomaRed
0 0
PaintCode
COLOR
NH.583M
ao
1-14
eo
U.S. 1998Model (4'doorSedan)
VehicleldentificationNumber
EngineNumber
D 1 6 Y 7 3300001
J H M E J 65 2 * W S O O O O O 1
Manufacturer,Make and
Type of Vehicle
J H M : H O N D AM O T O RC O .
LTD.
Passenger
HONDA
vehicle
HONDAOFAMERICA
M F G . I, N C .
HONDAPassenger
vehicle
HONDAOF CANADA
M F G , I, N C ,
HONDAPassenger
vehicle
Line, Body and Engine TYPe
ro
EJ6: ClVlC4-door/D16Y7
EJ8: ClVlC4-door/D16Y8
Body Type and TransmissionTYPe
Manual
5: Sedan/5-sPeed
Sedan/4-speed
6r
Automatic
vehicle Grade
2i DX
4: EX
7: LX with IVC
Check Digit
Model Yeal
W: 1998
FactoryCode
L: EastLiberty,Ohio Plant,U S.A
Japan
S: SuzukaPlant,Mie Prefecture,
H: AllistonPlant.Ontario,Canada
SerialNumber
000001:JAPAN,U.S.A.
500001:CANADA
EngineType
Sequential
D16Y7:1600SOHC16-valves
Engine
MultiportFuel'injected
Sequential
D l6Y8: 1600SOHCVTEC16-valves
Engine
Fuel-injected
Multiport
Serial Number
JAPAN:D16Y7.D16Y8- 3300001U.S.A : D16Y7,D16Y8- 3500001^
B4RA 700000' I
84RA: 4-speedAutomaticTransmission
M4RA:4-speedAutomaticTransmission
S4O :s-speedManualTransmission
B4RA(U.S.A.): 7000001M4RA(JAPAN):3000001"
S40(JAPAN) : 1000001-
CycloneBlueMetallic
CypressGreenPearl
TaffetaWhite
FlamencoBlackPearl
New VogueSilverMetallic
lnzaRedPearl
B-73M
G 82P
NH-578
NH-592P
NH-583M
R-96P
PaintCode
VehicleldentificationNumber
and FederalMotor Vehicle
Sa{ety Standard Certification
COLOR
B-73M
e o
1-15
Ghassisand Paint Codes
U.S. 1998Model (2,doorCoupel
ea
EngineNumber
l H G E J 61 2 * W L 0 0 0 0 0 1
Line, Body and Enginc Type
EJ6: ClVlC2-door/D16y7
EJ7: ClVtC2-door/D16ys
EJ8: ClvlC2-door/D16y8
Body Type and TransmissionType
5: EX with ABS and IVC
ChockDigir
Model Year
W: 1998
L: EastLiberty,Ohio ptant.U.S.A.
Vehicleldentification Number
and FederalMotor Vehicle
Safety Standard Certification
D16Y5 3300001
EngineType
D16Y5:1600SOHCWEC-El6,vatves
SequentialMultiport
Fuel-injected
Engine
D16Y7:1600SOHC16-valves
SequentialMultiport
Fuel-in.iected
Engine
Dl6Y8: 1600SOHCWEC 16-vatves
SequentialMultiport
Fuel-injected
Engine
Serial Number
JAPAN:D16Y5- 3300OOtU.S.A.: D16Y7,D'16y8- 3500001-
84RA: 4-speedAutomaticTransmissron
S40 :s-speedManualTransmission
M4VA:ContinuouslyVariable
Transmission(CVT)
0 a
B4RA:7000001S40 :1000001M4VA:4000001-
NH-592P
NH-578
NH-583M
R-81
CypressGreenPearl
FlamencoBlackPearl
TaffetaWhite
New VogueSilverMetaltic
MilanoRed
PaintCode
COLOR
G.82P
aa
1-16
trO
CANADA 1998Model (2-door Hatchback)
VehicleldentificationNumber
2 H G E J 63 2 + W H 0 0 0 0 0 1
Manulacturet, Make and
Type of Vehicle
2HG: HONDAOF CANADA
HONDAPassenger
vehicle
Line,Body and EngineTYPe
EJ6: ClVlC3-door/D16Y7
Body Type and TransmissionTYPe
3: Hatchbacld5-sPeed
M a nu a l
4: Hatchbacld4-sPeed
Automatic
Vehicle Grade
2t CX
3:CXG
CheckDigit
Model Year
W: 1998
FactoryCode
H: AllistonPlant,Ontario,Canada
SerialNumber
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety StandardCertification
1600SOHC16-valves
SequentiallvlultiPort
Edn g i n e
Fuel-injecte
B4RA:4-speedAutomaticTransmission
S40 :s-speedManualTransmission
84RA:7000001S40 :1000001'
NH-592P
NH-583M
PB-74P
R-97
FlamencoBlackPearl
New VogueSilverMetallic
DarkAmethystPearl
BomaRed
Paint Code
COLOR
NH.592P
1-17
Chassisand Paint Codes
CANADA1998Model (4-doorSedanl
A O
VehicleldentificationNumber
2HG .I
Manufacturer,Make and
Type of Vehicte
2HG: HONDAOF CANADA
M F G , I, N C .
HONDApassenger
vehicle
JHM: HONDA|\4OTOR
CO.,
r_rD
H 900001
I
]
l
I
D16Y7:1600SOHC16-valves
SequentialMultiport
Fuel-injected
Engine
3 7 5 0 0 0 1 -U: . S . A .
370000'l-:JAPAN
]
HONDApassenger
I
vehicte
I
Line, Body and EngineType
EJ6: ClVlC4-door/D16y7
Body Type and TransmissionType
5: Sedan/5speedManual
6: Sedan/4-speed
Automatic
VehicleGrade
0: EX
3: LX
4: LX WithABS
5: LX with ABS and A"/C
7: EX with ABS
8: EX with ABS and A"/C
CheckDigit
Model Year
W: 1998
FastoryCode
H :A l l i s t o nPlant,Ontario,Canada
S : S u z u k aPlant,N4iePrefecture,
Japan
SerialNumber
800001^:JAPAN
900001-:CANADA
VehicleldentificationNumber
and CanadianMotor Vehicle
SafetyStandardCertification
B4RA{U.S.A,): 700000.1M4RA(JAPAN):
3000001S40(JAPAN) : 'tOO0OO1-
0 0
B-73M
NH-592P
NH-578
NH-583M
CycloneBluef\4etallic
CypressGreenPearl
FlamencoBlackpearl
TaffetaWhite
New VogueSilverMetallic
Paint Code
COLOR
8.73M
ao
1-18
aa
CANADA1998Model (2-doorCouPe)
Vehicleldentification Numbel
EngineNumber
D16Y7
1 H GE J 61 2 * W
1 H G : H O N D AO FA M E R I C A
M F G , I, N C ,
HONDAPassenger
vehicle
Line, Body and Engine TYPe
EJ6: CIVIC2 door/D16Y7
EJ8: CIVIC2 dootD16Y8
Body Type and TransmissionTYPe
EngineType
1600SOHC16-valves
D'16Y7:
SequentiallvlultiPort
FueliniectedEngine
D16Y8:1600SOHCVTEC16-valves
SequentialMultiPon
Engine
Fuel-iniected
Serial Numbel
D16Y7:375000'l'
D16Y8:3780001-
Vehicle Grade
2: DX, Si
tio
3: Si with ABS
5: DX with ABS
6: DX with ABS and A,/C
7: Si with ABS and A,/C
CheckDigit
ModelYear
W:1998
B4RA:4-speedAutomaticTransmissron
S40 : s-speedManualTransmission
84RA:7000001S40 :1000001-
L: EasrLiberty,Ohio Plant,U.SA.
Vehicleldentification Number
and CanadianMotor Vehicle
safety StandardCertification
Cypress Green Pearl
Flamenco Black Pearl
Taffeta White
N e w V o g u e S i l v e rM e t a l l i c
MilanoRed
G-82P
NH-592P
NH-578
NH-583M
R,81
Paint Code
COLOR
NH-578
t a
1-19
Chassisand Paint Codes
U.S. 1999Model (2-doorHatchbackl
aa
Vehicleldentification Number
2HGEJ632*XH100001
Manufacturer,
Makeand
Typeof Vehicte
T
2HG: HONDAOF CANADA
M F G .t.N C .
HONDApassenger
I
I
vehicle
Line,Body and EngineType - _ r
EJ6: CIVIC3-door/Dt6y7
Body Type and TransmissionType
3: Hatchback/b-speed
M an u aI
4: Hatchbacl/4-speed
Automatic
Vehicle Grade
2: CX
4: DX
Check Digit
Model Year
X: 1999
FactoryCode
H: AllistonPlant,Ontario,Canada
Destinations
D'16Y7:
1600SOHCl6-vatves
SequentialMultipon
Fuel-injected
Engine
84RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
B4RA:8000001S40 | 1000001-
Serial Numbel
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
NH.592P
NH.583M
PB-14P
R-97
FlamencoBIackPearl
New VogueSilverMetallic
DarkAmethystPearl
RomaRed
1a
PaintCode
COLOR
NH-583M
a a
1-20
ro
U.S. 1999Model (4'doorSedan)
Vehicleldentification Number
-f
J H ME J 6 5 2 * X S 0 0 0 0 0 1
Manufacturel,Make and
Type ol vehicle
1 H G : H O N D AO FA M E R I C A
ro
HONDAPassenger
vehicle
HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
HONDAMOTORCO.,
LTD.
HONDAPassenger
vehicle
Line. Body and EngineTYPe
EJ6: CIVIC4 door/D16Y7
EJ8: ClVlC4-door/D16Y8
Body Type and TransmissionTYPe
Manual
5: Sedan/S-speed
6: Sedan/4-speed
Automatic
Vehicle Grade
'l: DX-V
2t DX
4: EX
7: LX
Check Digit
Model Year
X: 1999
FactoryCode
L: EastLiberty,Ohio Plant,U S.A
H: AllistonPlant,Ontario,Canada
Japan
S: SuzukaPlant,Mie Prefecture,
Serial Numbel
U.S.A.
000001:JAPAN.
500001:CANADA
EngineType
Sequential
1600SOHC16-valves
D,]6Y7:
Engine
MultiportFuel-injected
D16Y8:
U.S.A : D16Y7.D16Y8- 4500001-
B4RA: 4-speedAutomaticTransmission
S40 :s-speedManualTransmission
B4RA(U.S.A.): 8000001M4RA{JAPAN):4000001'1000001S40(JAPAN) :
lcedTealPearl
CloverGreenPearl
TaffetaWhite
FlamencoBlackPearl
New VogueSilverMetallic
lnzaRedPearl
BG.41P
NH-578
NH-592P
NH.583M
R-96P
Paint Code
COLOR
NH-s78
Vehicleldentification Number
and FederalMotor Vehicle
Safety Standard Certification
t a
1-21
Chassisand Paint Codes
U.S. 1999Model (2-doorCoupe)
VehicleldentificationNumber
aa
EngineNumber
1 H GE J 61 2 * X L 0 0 0 0 0 1
Manutacturer,Make and
Type of Vehicle
'1HG:
HONDAOF AMERTCA
M F G . I, N C .
HONDAPassenger
vehicle
Line, Body and EngineType
EJ6: ClVlC2-door/D16y7
EJ7: ClVlC2-door/D16y5
EJ8: ClvlC2-door/D16y8
EM1: CIVIC2-doorlB'1642
Body Type and TransmissionType
1:Coupe/s-speed
Manual
2: Coupe/4-speed
Automatic,
CVT
VehicleGrade
2: DX, HX
4: EX
5: EX WithABS,Si
CheckDigit
Model Year
X:1999
FactoryCode
L: EastLiberty,Ohio Plant,U.S.A.
SerialNumber
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
EngineType
81642:'1600
DOHCVTEC16 vatves
SequentialMultiport
Fuel-injected
Engine
Dl6Y5: 1600SOHCWEC-E16 vatves
SequentialMultipon
FuelinjectedEngine
D16Y7:1600SOHCt6-vatves
SequentialMultiport
Fuel,injected
Engine
D16Y8:1600SOHCVTEC16-vatves
SequentialMultipon
Fuel-injected
Engine
Serial Numbel
JAPAN:816A2,Dl6Y5 - 4300001U.S.A.: D16Y7,D16Y8- 4SO000t
-
B4RA : 4-speedAutomaticTransmission
S40,S4C:5-speedManuatTransmission
M4VA : Continuously
Variable
(CVT)
Transmission
ta
B4RA : 8000001S 4 0 ,S 4 C : 1 0 0 0 0 0 1 M4VA : 5000001-
B-95P
G-95P
NH-592P
NH-578
NH-583M
R-97
ElectronBluePearl
CloverGreenPearl
FlamencoBlackPearl
TaffetaWhite
New VogueSilverMetallic
RomaRed
PaintCode
COLOR
NH.592P
1-22
ea
CANADA1999Model (2-doorHatchback)
Vehicleldentification Number
E n g r n eN u
-rl
2 H GE J 6 3 2 * X H 0 0 0 0 0 1
ro
Manufacturer,Make and
Type of Vehicl€
2HG: HONDAOF CANADA
lNC.
l\4FG.,
HONDAPassenger
vehicle
Line,Bodyand EngineType
EJ6: ClVlC3-door/D16Y7
Body Type and TransmissionType
speed
3r Hatchbaclds
M an u aI
4r Hatchbacld4-speed
Automatic
VehicleGrade
2: CX
3: DX
CheckDigit
Model Year
X: 1999
FactoryCode
H: AllistonPlant,Ontario,Canada
Serial Number
Vehicleldentification Number
and CanadianMotor Vehicle
Safety Standard Certification
EngineType
D16Y7:1600SOHC16-valves
SequentialMultiport
Engine
Fuel-injected
B4RA 8000001
T
t
TransmissionType
B4RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
SerialNumber
84RA:800000'lS40 :1000001-
NH-592P
NH-583M
PB.74P
R,97
FlamencoBlackPearl
New VogueSilverMetallic
DarkAmethystPearl
RomaRed
PaintCode
COLOR
NH.592P
t a
1-23
Ghassisand Paint Codes
CANADA1999Model (4-doorSedanl
eo
Vehicleldentification Number
J H ME J 6 5 3 * X S 8 O O O O 1
Manufaclurer,Make and
Type ot Vehicle
JHM: HONDAMOTORCO.,
LTD.
HONDAPassenger
vehicle
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
vehicle
Line, Body and EngineType
EJ6: ClVlC4-door/D16Y7
Body Type and TransmissionType
5: Sedan/s-speed
Manual
6: Sedan/4-speed
Automatic
VehicleGrade
0: EX
3: LX
4: LX with ABS
5: LX with ABS and lVC
7: EX with ABS
8: EX with ABS and Ay'C
Ch6ckDigit
Model Year
X: 1999
FactoryCode
S: SuzukaPlant,Mie Prefecture,
Japan
H: AllistonPlant,Ontario,Canada
SerialNumber
800001:JAPAN
900001:CANADA
D16Y7 4700001
EngineType
D 16Y7:1 600SOHC16-valves
Sequential
MultiportFuel-injected
Engine
JAPAN:D16Y7- 4700001- 4750001U.S.A : D'16Y7
B4RA: 4-speedAutomaticTransmission
M4RA:4-speedAutomaticTransmission
S40 rs-speedManualTransmission
B4RA(U.S.A.): 8000001M4RA(JAPAN);400000'lS40(JAPAN) : 1000001-
ro
BG.41P
G-95P
NH-578
NH-592P
NH-583M
R-97
lcedTealPearl
CloverGreenPearl
TaffetaWhite
FlamencoBlackPearl
New VogueSilverMetallic
RomaRed
PaintGode
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification
COLOR
BG.41P
ta
1-24
CANADA1999Model (2-doorCouPel
VehicleldentificationNumber
EngineNumber
D 1 6 Y 7 4750001
1 H GE J 61 2 * X L 8 0 0 0 0 1
Manufacturer,Make and
Type of Vehicle
l H G r H O N D AO FA M E R I C A I
M F G , I, N C .
HONDAPassenger
vehicle
i
Line. Body and EngineTyPe EJ6: ClVlC2-door/D16Y7
EJ8: ClVlC2-door/D16Y8
EMlr CIVIC2'doorlB'16,42
Body Type and TransmissionTYPe
1:Coupe/s-speed
M a nu a l
2: Coupe/4-speed
Automatic
Vehicle Grade
2: DX,Si
4 :S i R
5: SiRwith ABS
6: DX with ABS and IVC
7: Si with ABS and A,,/C
CheckDigit
Model Year
X:1999
FactoryCode
L: EastLiberty,Ohio Plant,U.S.A.
SerialNumbel
Vehicleldentification Number
and CanadianMotor Vehicle
Safety Standard Certification
EngineType
816,42:1 600DOHCVTEC16-valves
SequentialMultiport
FuelinjectedEngine
D16Y7:1600SOHC16'valves
SequentialMultiPort
Engine
Fuel-injected
D16Y8:1600SOHCVTECl6-valves
SequentialMultiPort
Engine
Fuel'injected
SerialNumber
8 1 6 4 21: 7 0 0 0 0 1 D16Y7:
47500014780001'
D16Y8:
TransmissionNumber
B4RA
T
Type
Transmission
B4RA : 4-soeedAutomaticTransmission
S40.S4C:5-sgeedManualTransmission
SerialNumber
B4RA : 8000001S40,S4C:1000001-
C ol o r
B.95P
G-95P
NH-592P
NH 578
NH-583M
R97
ElectronBluePearl
CloverGreenPearl
F l a m e n cB
o l a c kP e a r l
TaffetaWhite
N e wV o g u eS i l v e rM e t a l l i c
R o m aR e d
PaintCode
COLOR
NH-592P
t o
1-25
Chassisand PaintCodes
U.S.2000Model (2-doorHatchback)
0 0
VehicleldentificationNumber
2 H G E J 6 3 2 *H 1 0 0 0 0 1
Manufacturer,Make and
Type of Vehicle
2HG: HONDAOF CANADA
M F G , I, N C .
HONDAPassenger
Vehicle
Line, Body and EngineType
EJ6: ClVlC3-door/D16Y7
Body Type and T.ansmissionType
3: Hatchbaclds-speed
Manual
4: Hatchbacld4-speed
Automatic
Vohicle Grade
2: CX
4: DX
Check Digit
Model Yeal
Y: 2000
D16Y7 -[
5500001
Dl6Y7: 1600SOHCI6-valvesSequenlal
MultiportFuel-injected
Engine
84RA:4 speedAutomaticTransmissron
S40 :s-speedManualTransmissiorr
84RA:900000'lS40 | 100000'l-
FastoryCode
H: AllistonPlant,Ontario.Canada
SerialNumber
VehicleldentificationNumbeI
and FederalMotor Vehicle
Safety Standard Certification
NH-578
NH.583M
NH-592P
R-97
TaffetaWhite
New VogueSilverlr4etallic
FlamencoBlackPearl
RomaRed
to
PaintCode
COLOR
NH.583M
ro
1-26
t
U.S.2000Model {4-doorSedan)
VehicleldentificationNumber
EngineNumber
Dl6Y7, 5300001
J H ME J 6 5 2 * Y S 0 0 0 0 0 1
Manufacturer,Makg and
Type of Vehicle
JHM: HONDAMOTORCO.,
LTD.
HONDAPassenger
Vehicle
HONDAOFAMERICA
MFG.,INC.
HONDAPassenger
Vehicle
2 H G : HONDAOF CANADA
IVIFG.,
INC,
HONDAPassenger
Vehicle
Line, Body and EngineType
EJ6: ClVlC4-door/D16Y7
EJ8: ClVlC4-door/D16Y8
Body Type and TransmissionTyPe
Manual
5: Sedan/5-speed
Automatic
6: Sedan/4-speed
Vshicle Grade
2: DX
4: EX
7: LX
CheckDigit
Model Year
Y: 2000
FactoryCode
Japan
S: SuzukaPlant,Mie Pretecture,
L: EastLiberty,Ohio Plant,U.S.A.
H: AllistonPlant,Ontario,Canada
Serial Number
JapanU
, .S.A.:000001500001Canada:
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
EngineType
Sequential
D16Y7:1600SOHC16-valves
Engine
MultiportFuel-iniected
D16Y8:1600SOHCVTEC16-valves
SequentialMultiportFuel-iniected
Engine
Sorial Numbsr
Japan:5300001U.S.A.r5500001-
AutomaticTransmission
: 4-sDeed
S4RA
: 4-speedAutomaticTransmission
B4RA
S40,S4C : s-speedManualTransmission
S4RA{Japan)
B4RA(U.S.A.)
S40,S4C(Japan)
lcedTealPearl
CloverGreenPearl
TaffetaWhite
FlamencoBlackPearl
TitaniumMetallic
VintagePlum Pearl
BG-41P
G.95P
NH-578
NH-592P
YR.525M
RP.32P
Paint Code
COLOR
NH-578
t o
1-27
Chassisand Paint Codes
U.S.2000Model (2-doorCoupe)
VehicleldentificationNumber
ta
EngineNumber
l H GE J 61 2* Y 1 0 0 0 0 0 1
Manufacturer.Make and
Type ol Vehicle
'1HG:
HONDAOF AMERICA
t\4FG.,
tNC.
HONDAPassenger
Vehicle
Line,Body and EngineType
EJ6: ClvlC2-door/Dt6Y7
EJ7: ClVlC2,door/D16y5
EJ8: ClVlC2-door/D16Y8
EM1: CIVIC2-doorlB1642
Body Type and TransmissionType
1: Coupe/s-speed
Manual
2: Coupe/4-speed
Automatic,CVT
Vehicle Grade
2: DX, HX
4: EX
5: EX with ABS,Si
CheckDigit
Model Year
D16Y5- 5300001
EnginoType
Bl642; 1600DOHCWEC '16-vatves
SequentialMultiportFuel-injected
Engine
D'I6Y5:1600SOHCWEC-E16.vatves
SequentialMultiportFuel-injected
Engine
D16Y7:1600SOHC16-valves
Sequenlal
MultiportFuel-injected
Engine
D16Y8:1600SOHCWEC 16-vatves
SequentialMultipon Fuel-injected
Engine
Serial Number
81642,D16Y5:5300001Dl6Y7,Dl6Y8:5500001-
Y: 2000
FactoryCode
L: EastLiberty,Ohio Plant,U.S.A.
Serial Number
VehicleldentificationNumber
and FederalMotor Vehicle
Safety Standard Certification
B4RA : 4-speedAutomaticTransmission
S40,S4C:5-speedManualTransmissron
M4VA :ContinuouslyVariable
(CVT)
Transmission
to
B4RA : 9000001*
S40.S4C:1000001M4VA :6000001-
B-95P
NH-578
NH.583M
NH-592P
R-81
ElectronBluePearl
CloverGreenPearl
TaffetaWhite
New VogueSilverMetallic
FlamencoBlackPearl
M i l a n oR e d
PaintCode
COLOR
NH.592P
to
1-28
ro
CANADA2000 Model (2-door Hatchbackl
Vehicle ldentification Number
D16Y7 -
2 H GE J 6 3 2 * Y H 0 0 0 0 0 1
Manufaqturor,Make and
Type of Vehicle
2HG: HONDAOF CANADA
HONDAPassenger
Vehicle
Line, Body and EngineType
EJ6: ClVlC3-door/Dl6Yt
Body Type and TransmissionType
Manual
3: HatchbacUs-sDeed
Automatic
4; Hatchbacld4-speed
Vehicle Glade
2t CX
3: OX
5r SE
CheckDigit
Model Yoal
Y: 2000
FactoryCode
H: AllistonPlant.Ontario,Canada
Serial Numb€r
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification
Sequential
D16Y7:1600SOHC16-valves
Engine
MultiportFuel-injected
Number
Se1i8l
B4RA:4-speedAutomaticTransmission
S40 : s-speedManualTransmission
84RA:9000001S40 :1000001-
NH.583M
NH.592P
R-97
RP-32P
New VogueSilverMetallic
FlamencoBlackPearl
RomaRed
VintagePlum Pearl
Paint Code
COLOR
NH.592P
1-29
Chassisand Paint Codes
CANADA2000Model (4-doorSedanl
ro
VehicleldentificationNumber
J H M E J 65 2 * Y S 8 0 0 0 0 1
Manufaqturer, Makg and
Type ot Vehicle
JHM: HONDAMOTORCO.,
LTD.
HONDAPassenger
Vehicle
2HG: HONDAOF CANADA
M F G . I, N C .
HONDAPassenger
Vehicle
Line, Body and EngineType
EJ6: ClVlC4-door/D16Y7
Body Type and TransmissionTyp€
5: Sedan/s-speed
Manual
6: Sedan/4-speed
Automatic
Vehicle Grade
0: EX
1: LX-V
2: LX-Vwith ABS
3: LX
4: LX with ABS
5: LX with ABS and ly'C
7: EX with ABS
8; EX with ABS and A,,/C
Check Digit
Model Y€ar
Y: 2000
Fac'tory
Code
S: SuzukaPlant,Mie Prefecture,
Japan
H: AllistonPlant,Ontario,Canada
Serial Number
Japan :800001Canada:900001-
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification
D16Y7
EngineType
D't6Y7| 1600SOHC16-valves
Sequential
MultiportFuel-injected
Engine
J a p a n5
: 700001U.S.A.:5750001-
Transmission
Number
--t
S4RA- 5000001
TransmissionType
54RA: 4-speedAutomaticTransmissron
B4RA: 4-speedAutomaticTransmissron
S 4 0 : s - s p e e dM a n u aT
l ransmission
SerialNumber
54RAlJapan)
: 500000'1B4RA(U.S.A,);
900000
1S40(Japan) : '1000001,
ro
Paint Code
Paint Code
G-95P
NH,583M
NH.592P
YR-525M
RP.32P
CloverGreenPearl
New VogueSilverMetallic
FlamencoBlackPearl
TitaniumMetallic
VintagePlum Pearl
PaintCode
COLOR
NH.583M
ro
1-30
CANADA2000 Model (2-doorCoupel
VehicleldentificationNumber
l H G E J 6 ' l2 * Y 1 8 0 0 0 0 1
L
Manufacturer,Make and
Type of Vehicle
1 H G : H O N D AO FA M E R I C A
M F G , I, N C .
HONDAPassenger
Vehicle
Line, Body and EngineType
EJ6r ClVlC2-door/D16Y7
EJ8: ClVlC2-door/D'16Y8
EM1: CIVIC2-door/B1642
Body Type and TransmissionType
Manual
1: Coupe/s-speed
Automatic
2: Coupe/4-speed
Vehicle Grade
2: DX,Si
4 :S i R
5: SiRwith ABS
6: DX with ABS and A,/C
7:DXG
Check Digit
Model Year
Y: 2000
FactoryCode
L: EastLibertv,Ohio Plant.U.S.A.
SerialNumber
81642 5700001
816A2:1600DOHCVTEC16-valves
SequentialMultiportFuel-iniected
Engine
'1600SOHC16-valves
Sequential
Dl6Y7:
Engine
MultiportFuel-injected
D16Y8:1600SOHCWEC 16-valves
SequentialMultiponFuel-injected
En gi n e
81642:5700001D16Y7:575000'lD16Y8:578000'l-
B4RA :4-speedAutomaticTransmission
S40,S4C:s-speedManualTransmissron
B4RA :9000001S40,S4C:1000001-
VehicleldentificationNumber
and CanadianMotor Vehicle
Safety Standard Certification
8.95P
G.95P
NH-583M
NH.592P
R-81
ElectronBlue Pearl
CloverGreenPearl
New VogueSilverMetallic
FlamencoBlackPearl
M i l a n oR e d
PaintCode
COLOR
NH-592P
ra
1-31
ldentification Number Locations
t,
Vehicle ld6ntification
Numbsr(VlN)
ta
Number
1-32
t a
Warning/CautionLabelLocations
A: CABLEREELCAUTIONA:
'96 -99 model
TO SERVICEMANUAL FOR DETAILEDINSTRUC.
TtoNs.
'00 model
ALLATIONOF THE SRS CAELEREELIS CRITICALTO
THE PROPEROPERATIONOF THE SRSSYSTEM.REFERTO
T H E S E R V I C E M A N U A L D E T A I L E DI N S T A L L A T I O N
INSTRUCTIONS.
Br oRIVERMODULEWARNING
WARNING
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIOENHURTOR KILLYOU.
CAN SERIOUSLY
TALLYDEPLOYEO,
TESTEoUIPMENToR PROB. DO NOT USE ELECTRICAL
ING OEVICES.
DEPLOYMENT.
THEYCAN CAUSEACCIDENTAL
o N O S E R V I C E A B L EP A R T S l N S l D E . D O N O T
DISASSEMBLE.
. PLACEAIRBAGUPRIGHTWHENREMOVED.
CAFEFULLY.
. FOLLOWSERVICE
MANUALNSTBUCTIONS
C: DRIVERMODULEOANGER
DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACIO.WATER OR HEAVY METALS SUCH
I.EADOR MERCURYMAY PRODUCEHARMFUL
AS COPPER.
AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS,
MUST NOT EXCEED2OO'F
STOBAGETEMPERATURES
I1(x}"CI.FOR PROPERHANDLING.STORAGEAND DISPOS.
REFERTO SERVICEMANUAL. SRS SUP.
AL PROCEDURES
PLEMENT.
POTSON
CONTAINSPOISONOUSSODIUM AZIOEAND POTASSIUM
NITRATE.
FIRSTAID:
IF CONTENTSARE SWALLOWED,INDUCEVOMITING,FOB
EYECONTACT.FLUSHEYESWTTHWATERFOR15 MINUTES.
IF GASES{FNOMACIOORWATEBCONTACTIAREINHALED,
SEEKFRESHAIR. IN EVERYCASE,GET PBOMPTMEDICAL
ATTET,ITION.
KEEPOUT OF REACHOF CHILDREN.
(cont'd)
1-33
Warning/GautionLabelLocations
to
(cont'dl
-==-J
_)
F
v7777m7na
ro
D: DRIVERINFORMATION:
CANADAmod6l l'96 - gtt modell
.
.
ALWAYSWEARYOURSEATBELT
THIS CAR IS EOUIPPED
WITH A DRIVERAIRBAGAND A
FRONTSEAT PASSENGER
AIRBAG' AS A SUPPLEMENTAL RESTRAINTSYSTEMISRSI.
IT IS OESIGNED
TO SUPPLEMENT
THESEATBELT,
* Except CANADA CX
E: SBSINFORMATION:U.S. model ('96.'97 model)
CAUTION
TO AVOIDSERIOUSINJURY:
. FORMAXIMUM SAFEW PROTECTION
IN ALL TYPESOF
CBASHES,YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.
. DO NOT INSTALLREARWARD-FACING
CHILDSEATSlN
ANY FRONTPASSENGER
SEATPOSITION.
. DO NOT SIT OR LEAN UNNECESSARILY
CLOSETO THE
AIRBAG.
. DO NOT PLACEANY OBJECTSOVERTHE AIRBAGOR
BETWEENTHEAIRSAGAND YOURSELF.
o SEE THE OWNER,S MANUAL FOB FURTHER
INFORMATION
AND EXPLANATIONS.
. THESRS MUST BE INSPECTED
TEN YEASSAFTERIT IS
INSTALLED,
. THE DATEOF INSTALI-ATION
I S S H O W NO F T H E
DRIVER'SDOORJAMB.
1-34
U.S. model l'98, 39 model)
WARNING
OEATHOR SERIOUSINJURYCAN OCCUR.
. CHILDREN
1 2 A N D U N O E RC A N B E K I L L E DB Y T H E
AIREAG.
. THEBACKSEATIS THESAFESTPLACEFORCHILDREN.
o N E V E RP U T A B E A R . F A C I N G
C H I L DS E A T I N T H E
FRONT.
. SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
. ALWAYSUSESEATBELTSAND CHILDRESTRAINTS.
. THE SRSMUST BE INSPECTED
TEN YEARSAFTERIT IS
INSTALLED,
. T H E D A T E O F I N S T A L L A T I O NI S S H O W N O N T H E
DRIVER'SDOORJAMB.
U.S. model ('00 modelI
WARNING
DEATHOR SERIOUSINJURYCAN OCCUR,
. CHILDREN12 AND UNDER CAN BE KILLEDBY THE
AIRBAG.
. THEBACKSEATIS THESAFESTPLACEFORCHILOREN.
. N E V E RP U T A R E A R - F A C I N G
C H I L DS E A T l N T H E
FRONT.
o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG.
o ALWAYSUSESEATBELTSAND CHILDRESTRAINTS.
ro
Llo
MOOULEDANGER
I: FRONTSEATPASSENGER
CANADAmodel ('00 model)
CAUTION
TO AVOIDSERIOUSINJURYT
lN ALL TYPESOF
. FORMAXIMUM SAFETYPROTECTION
CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY
BELT.
CHILDSEATSlN
. DO NOT INSTALLREARWARD-FACING
SEATPOSITION.
ANY FRONI PASSENGER
. DO NOT PLACEANY OBJECTSOVER THE AIRBAGOR
BETWEENTHEAIRBAGAND YOURSELF.
. SEE THE OWNER'S MANUAL FOR FURTHER
ANDEXPLANATIONS.
INFORMATION
ExceptCx tor passengerside
F: ASSISTANTINFoRMATION:US MODEL('96.
'97 mod€l)
AIRBAGSEEOTHERSIDE,
U.S. model l'98 - 00 modell
AIRBAGWARNING
FLIPVISOROVER
G: STEERINGCOLUMNNOTICE
Llo
NOTICE
TO PBEVENTSRS DAMAGE, REMOVESTEERINGWHEEL
BEFOREREMOVINGSTEERINGSHAFT CONNECTING
BOLT.
ll: MONITORCAUTION
NOTICE
. NO SERVICEABIfPABTSlNSlDE.
. REFERTO SERVICEMANUAL FORDETAILEDINSTRUC'
TtoNs.
DANGER
EXPLOSIVE/FLAMMABLE
CONTACTWITH ACID, WATEROR HEAVY METALS SUCH
LEADOR MERCURYMAY PRODUCEHARM.
AS COPPER,
F U L A N D I R R I T A T I N GG A S E S O R E X P L O S I V EC O M MUST NOT EXCEED
POUNDS,STORAGETEMPERATURES
FOR PROPERHANOLING,STORAGEAND
2OO'FI1OO"C}.
REFERTO SERVICEMANUAL'
DISPOSALPNOCEDURES
SRSSUPPLEMENT.
POISON
CONTAINSPOISONOUSSODIUM AZIDEAND POTASSIUM
NITRATE.
FIRSTAID
IF CONTENTSARE SWALLOWEO,INDUCEVOMITING.FOR
EYE CONTACT,FLUSH EYES WITH WATEB FOR 15 MINUTES. IF GASESIFROM ACID OB WATER CONTACT)ABE
INHALED.SEEKFRESHAIR. IN EVERYCASE,GET PROMPT
MEDICALATTENTION.
KEEPOUT OF REACHOF CHILDREN,
WARNING
THE AIRBAG INFLATORIS EXPLOSIVEAND, IF ACCIDENHUBTOR KILLYOU.
CAN SERIOUSLY
TALLYOEPLOYED,
. D O N O T U S E E L E C T R I C ATL E S T E O U I P M E N TO R
PROBINGDEVICES.
DEPLOYMENT'
TH€YCAN CAUSEACCIDENTAL
. N O S E R V I C E A B L EP A B T S l N S l D E . o O N o T
DISASSEMBLE.
. PLACEAIRBAGUPRIGHTWHENREMOVED
CAREFULLY
MANUALINSTRUCTIONS
. FOLTOWSERVICE
Jr SRSWARNINGIHOOD)
SYSTEMISRS}
RESTRAINT
SUPPLEMENTAL
THIS VEHICLEIS EOUIPPEDWITH DBIVERAND FRONT
AIRBAGS'.
SEATPASSENGER
ABE
WIRINGAND CONNECTORS
ALL SRS ELECTRICAL
COLOREDYELLOW.
T A M P E R I N G W I T H , D I S C O N N E C T I N GO R U S I N G
TEST EOUIPMENTON THE SRS WIRINGCAN
ELECTRICAL
OR CAUSEACCIDENTAL
MAKETHESYSTEMINOPERATIVE
FIRINGOF THEINFLATOR.
WARNING
AND, IF ACCIDEN.
THE AIRBAGINFLATORIS EXPLOSIVE
CAN SERIOUSLYHURT YOU. FOLLOW
TALLY DEPLOYED,
CAFEFULLY'
SERVICEMANUAL INSTRUCTIONS
' ExceotCANADACX
AIRBAGCAUTION
K: PASSENGER
u.S. model l'98 - 00 model)
WARNING
CAN 8E KILLEDOR INJUREOBY PASSENGER
CHILDREN
AIRBAG,
THE BACKSEAT IS THE SAFESTPLACEFORCHILDREN12
USESEATBELTS
AND UNDER.MAKESUREALLCHILDREN
OR CHILDSEATS.
(cont'd)
1-35
Warning/CautionLabelLocations
(cont'd)
t,
191t7CANADAMod6l
t,
t,
1-36
Under-hoodEmissionsControl Label (1996,1997model)
EmissionGroupldentification
Families
Engineand EvaPorative
Example:
EngineFamily:
Model Year
T: 1996
V: 1997
Manufacturer
H N :H o n d a
Displacem€nt
T|I
V H Nl . 6 V J G K G K
TI
VACUUMHOSEROUTINGDIAGRAM
-VEHICLE
INFORMATION
CONTROL
Ei/ISSION
E \ G \ . r r M r r v t s N r s \ J L K 6 \ D s p - A ( . M5F9N0 ( - - , . O
!APOF!]V4-AV.t' !-rirorrSrMAc
CATALYST
CIVIC
fa:n
\Y:/
IwcN02S{2)sFr
F l . t a r o s t q ! t M A \ u A t t o a a o o T o \ a -\ ' o F M ^ r o \
E q lA
r . \ F J o ( O \ D' O \ S E \ G r \ lA I N O n M A - O o l q l l N C T M oU
rS r-F\Eo0F C00ll\G-A\ 0(
a-LACCESSoT
N NEUTFAI
TRANSM1SSION
NEEDEO.
NOOTHERAOJUSIMENTS
rt
Tl
lH
i
\-!-lJ
O8D IICERTIFIED
IDLESPEEO
ATDC
NDr(Jl6CR.L1l
U S.EPAANDSTATE
THSVEHCLECONfOFMSTO
1997
RECULAI
ONSAPPLICA8IElO
OFCALfORNIA
VEHCL'S
NEWMOTOR
MOOET
YEAR
4q!sq+HT-q4E!rL
Er!4#_"E!!ifl
N US€
.?2EAO2
11211
r.r-i,"
ilil]]lrl
TIEB
l FULL
HONDA
MoTOR
C0, tTD
50ST{50 States):
TO U.S,EPAAND STATEOF
CONFORMS
THISVEHICLE
TO 1996AND
APPLICABLE
REGULATIONS
CALIFORNIA
VEHICLES.
1997MODELYEARNEWMOTOR
/$ST (49 States/Federall:
TO U.S.EPA REGULATIONS
CONFORMS
THISVEHICLE
' 1 9 9 6A N D 1 9 9 7M O D E LY E A RN E W
A P P L I C A B LTEO
MOTOBVEHICLES,
CAL (Calitornis):
TO U.S.EPAAND STATEOF
CONFORMS
THISVEHICLE
TO 1996AND
APPLICABLE
REGULATIONS
CALIFORNIA
,1997MODELYEARNEW PASSENGER
CARSPROVIDED
INTOCOMIS ONLYINTROOUCED
THATTHISVEHICLE
MERCEFORSALEIN THESTATEOF CALIFORNIA.
Car
V: Light DutyVehicle/Passenger
Fuel Systsm and Number of valves
J: ElectronicSequentialMultiportInjection
(threeor more valvesper cylinder)
Fuel Type
G:Gasoline
Standard
F: 49 or 50 StatesTier 1
K: 49 or 50 StatesTier 1
1 : C a l i f o r n iTai e r 1
2: CaliforniaTLEV
3: CaliforniaLEV
4; CaliforniaULEV
Catalyst
E, F, G. H: ThreeWay Catalyst
OBD
K - T: OBDEquipped
Family:
Evaporative
'|T
v HN1077BYMAc
Model Year
T:1996
|
V:1997
l
Manufacturel
H N :H o n d a
Storage System
1:Canister
CanisterWorking Capacity (grams)
CanisterConfigulation
A: PlasticHousing(ClosedBottom)
B: PlasticHousing(oPenBottom)
Fuel Systsm
Y: FuelInjection
Fuel Tank
M: Metal
Standard
A: CurrentEvap
E: EnhancedEvap
Wild Card
1-37
Under-hoodEmissionsControl Label(lggg model)
EmissionGroup ldentification
Engineand EvaporativeFamilies
Example:
EngineFamily:
oR3.'@M|LES|3,@|frlw!cs
rf
H N X v 0 ' t . 6J L 2
Model Year
W: 1998
Manufacturer
H N X :H o n d a
Type
VEHICLE
EI\4ISSION
CONTROL
INFORIVATION
rH SVEHCLECONFOFMS
IO U S EPAAND
STA1EOFCALIFORNIA
RE6ULAIIONS
APPLICABLE
IO 199AMODELYEARNEWTIEVPASSENGER
CA8SPFOVOEOTI]AI 'HIS VEI CLE S OILY
INIBODUCEDINTOCOMMEfiCE
FORSALE N TNC
CATALYST
IWCINO?S]2)EGR6F
/OBO] CEFT]F
ED
VALVE
LASH
1C0L0l
EX 0 r51002mm
NOOTHTR
AO.]USIMI\ISNI'TOEO
I]ONDA
MOTOB
CO.,ITD
OE
V: Light DutyVehicle/Passenger
Car
Displacement
SequenceCharacters
EvaporativeFamily:
Model Year
W: 1998
Manufacturel
H N X :H o n d a
Type
E :EVAP
CanisterWork C.pacity (glamsl
SequenceCharacters
W HNX E 0065A A D
T
50ST (50 Statosl:
THISVEHICLE
CONFORMS
TO U,S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8
MODELYEARNEWMOTORVEHICLES,
ilgsT 149States/Federal):
THISVEHICLE
CONFORMS
TO U.S.EPAREGULATIONS
APPLICABLE
TO 1998MODELYEARNEWMOTORVEHI.
CLES.
LO
CAL (California):
THISVEHICLE
CONFORMS
TO U.S.EPAAND STATEOF
C A L I F O R N IR
A E G U L A T I O NASP P L I C A B LTEO 1 9 9 8
M O D E LY E A R N E W P A S S E N G E C
R A R SP R O V I D E D
THATTHISVEHICLE
IS ONLYINTRODUCED
INTOCOM.
MERCEFORSALEIN THESTATEOF CALIFORNIA.
ro
1-38
(1999modell
EmissionGroupldentification
Example:
Families
Engineand Evaporative
EngineFamily:
Model Yeal
X:1999
X HNX V 0 t . 6J F 1
T rT T
r l
Manutacturer
H N X :H o n d a
Tvpe
INFOEMATION
CONTROL
EMISSION
VEHICLE
IO U S E
13 S VEHCLECONFORMS
NEWPASSENCER
APPLCABLETOI999MOOELYEAR
Car
V: Light DutyVehicle/Passenger
Disolacement
SequenceCharacters
FamilY:
Evaporative
ModelYear
X:1999
CATALYST
IAIV€L{SH
COLD
SPARTPLU6CAP
E v
@o
MOTOECOLTD
HONDA
Manufacturer
H N X :H o n d a
Type
R: ORVR
CanisterWork CaPacitY(gramsl
SequenceCharacters
_T
R 0090AAD
++
T_
I
l
TIER1:
FEDERAL
TO U.S,EPAREGULATIONS
CONFORMS
THISVEHICLE
'1999MODELYEARNEW PASSENGER
TO
APPLICABLE
CARS.
TLEV:
CALIFORNIA+ NLEV{RESTRICTEDI
REGULATO
CALIFORNIA
THIS VEHICLECONFORIVIS
TLEV
NEW
YEAR
1999
MODEL
TO
APPLICABLE
TIONS
CARSAND TO U.S.EPA NLEVPROGRAM
PASSENGER
TO 1999NEW TLEV PASAPPLICABLE
REGULATIONS
CARS.
SENGER
INTOCOMMAY ONLYBE INTRODUCED
THISVEHICLE
A STATETHAT HAS
MERCEFORSALEIN CALIFORNIA,
THE CALIFORNIASTANDARDSIN EFFECTTO WHICH
A , S T A T ET H A T
H A S B E E NC E R T I F I E D
T H I SV E H I C L E
OR A STATE
PROGRAM,
NLEV
HAS OPTEDINTOTHE
THERETO.
CONTIGUOUS
50 STATELEV+ CFFV+ NLEV {UNRESTRICTED}:
C O N F O R MT
SO U . S .E P A N L E VA N D
T H I SV E H I C L E
A
N
D
C A L I F O R N IR
AE G U L A '
V
E
H
I
C
L
E
CLEAN-FUEL
E O G A S O L I N EF U E L E D1 9 9 9
T I O N SA P P L I C A B LT
CARS/LIGHT
M O D E LY E A R N E W L E V I P A S S E N G E R
DUW TRUCKS].
50 STATETLEV + NLEV (UNRESTRICTED):
TO U.S.EPANLEVREGULA'
CONFORMS
THISVEHICLE
1999
MODELYEARNEW TLEV
TO
TIONSAPPLICABLE
A
N
D
C
A
L
I F O R N IR
AE G U L A T I O N S
C
A
R
S
PASSENGER
TO 1999 MODELYEAR NEW TLEV IPAS'
APPLICABLE
DUW TRUCKS].
SENGERCARS/LIGHT
1-39
Under-hoodEmissionControl Label (2000model)
EmissionGroupldentification
Engineand Evaporative
Families
Example:
EngineFamily:
Y H N X V 0 1 , 6J F 1
ro
Model Yeal
oRs'MM|LESt4,0oorml,wtscN
Y; 2000
Manufaqturer
HNX:Honda
Type
VEHICLE
EMISSION
CONTROL
INFOBI\4ATION
T8ISVEHCLECONFOfiMS
TO U,S EPARECIJLATIONS
APPLICABLE
IO 'OOOMODELYEASNEWPASSENGER
V: Light DutyVehicle/passenger
Car
Displacoment
SequenceCharaqtgrs
EvaporativeFamily:
CATALYST
vAtw LcsH
rN0.20:0
0?nn
lcorDr
EX025:00?mh
SPAAKPIIJGCAP
NOOTNER
AD.IUSIMENIS
NE€OTO
(0. Lro
t0N0aM0T08
Y HNX R OO99
AAD
Model Year
Y: 2000
Manufaeturer
HNX: Honda
Type
R: ORVR
CanisterWork Capacity (grams)
SsquenceCharacters
FEDERAL
TIER1:
THISVEHICLE
CONFORMS
TO U,S.EPA REGULATIONS
APPLICABLE
TO 2OOO
MODELYEARNEW PASSENGER
CARS.
CALIFORNIA+ NLEV (RESTR|CTEDt
TLEV:
T H I SV E H I C L E
CONFORMS
T O C A L I F O R N IR
AE G U L A TIONSAPPLICABLE
TO 2OOO
MODELYEARNEW TLEV
PASSENGER
CARSAND TO U,S.EPA NLEVPROGRAM
REGULATIONS
APPLICABLE
TO 2OOO
NEW TLEV PASSENGERCARS.
THISVEHICLE
MAY ONLYBE INTRODUCED
INTOCOM.
MERCEFORSALEIN CALIFORNIA.
A STATETHATHAS
THE CALIFORNIASTANDARDSIN EFFECTTO WHICH
THIS VEHICLEHAS BEENCERTIFIED,
A STATETHAT
HAS OPTEDINTOTHE NLEVPROGRAM,OR A STATE
CONTIGUOUS
THERETO.
LO
50 STATELEV + CFFV+ NLEV {UNRESTRTCTED):
T H I S V E H I C L EC O N F O R M ST O U . S , E P A N L E VA N D
C L E A N . F U EVLE H I C L E
A N D C A L I F O R N IR
AE G U L A ,
T I O N SA P P L I C A B L T
E O G A S O L I N EF U E L E D2 O O O
MODELYEARNEWLEVPASSENGER
CARS.
E P A C E R T I F I C A T I OTNE S T F U E L :E P A U N L E A D E D
GASOLINE
50 STATETLEV+ NLEV (UNRESTRICTED}:
THISVEHICLE
CONFORMS
TO U.S.EPANLEVREGULA.
TIONSAPPLICABLE
TO 2OOO
MODELYEARNEW TLEV
P A S S E N G EC
RA R SA N D C A L I F O R N IR
AE G U L A T I O N S
APPLICABLE
TO 2OOO
MODELYEAR NEW TLEV PASSENGERCARS.
L,
1-40
Lift and SupPort Points
L,O
Lift and SafetYStands
t!ffi
-aE
hatch' and trunk lid are to be
when heavv rear componentssuch as suspension'fuel tank' spare tire'
rear
before hoisting. when substantial weight is lemoved from the
removed, place additional wetght Inihe luggage arga
vehicle to tip tolward on the hoisi
of the vehicls. the center of gravity may change and can cause the
NOTE:
30 lbs (14kg)'placingthefrontwheelsin the luggageareacan
weighsapproximately
assembly
. Sinceeachtire/wheel
assistwiththeweightdistribution
. Usethesamesupportpointsto supponthevehicleon safetystands'
1 . Placethe lift blocksas shown.
and rockthe vehicleto be sure it is firmly supported'
2 . Raisethe hoista lew inches(centrmeters)
3 . Raisethe hoistto full height,and inspectlift pointsfor solidsupport
REARSUPPORTPOINT
1-41
Lift and Support Points
FloorJack
1.
Apply the parkingbrakeand blockthe wheetsthat
are not being lifted.
When liftingthe rearof the vehicle,put the gearshift
lever in reverse(Automatictransmission/Cwin E
position).
t,
Always use safety stands whon working on or undel
any vehicle that is supported by only a iack.
Never attempt to use a bumper jack for lifting or
supporting the vehicle.
Raisethe vehicle high enough to insert the safety
stands.
4.
Adjust and place the safety stands so the vehicle
will be approxlmatelylevel,then lower the vehicle
onto them.
FRONT:
LIFT PLA
Centerthe jacking
bracketin the middle
of the iack lift platform.
REAR:
LIFT PLATFORM
1-42
Centerthe iack
bracketin the middle
of the jack lift ptatform.
L,
Towing
towlf the vehicleneedsto be towed,call a professional
ing service.Nevertow the vehiclebehindanothervehi
cle with iust a rope or chain lt is very dangerous'
Front:
EmergencyTowing
Thereare three popularmethodsof towing a vehicle:
Flat-bedEquipment- The operator loads the vehicle on
the
the backof a truck.Thisis the bestway of transporting
vehicle.
Wheel Lift Equipment- The tow truck usest\ivopivoting
armsthat go underthe tires {frontor rear}and liftsthem
o f f t h e g r o u n d .T h e o t h e r t w o w h e e l s r e m a i no n t h e
ground.
Sling-type Equipment- The tow truck uses metal cables
with hookson the ends.Thesehooksgo aroundpartsof
the frame or suspension,and the cableslift that end of
the vehicleoff the ground The vehicle'ssuspensionand
body can be seriouslydamagedif this methodof towing
is attemDted.
TIE DOWN HOOKS
lf the vehiclecannotbe transportedby flat-bed.it should
be towed with the front wheelsoff the ground lf due to
d a m a g e ,t h e v e h i c l e m u s t b e t o w e d w i t h t h e f r o n t
wheelson the ground,do the following:
lvlanualTransmissionand CW
. Releasethe parkingbrake
. Shiftthe transmissionto neutral(CW to E position)'
AutomaticTransmission
the Parkingbrake.
. Release
. Start the engine.
. Shiftto LDllposition,then E position.
. Turn oif the engine
CAUTION;
o lmploper towing preparation will damage ihe tfansmission. Follow the above procedute exaqtly lf you
cannot shift the tlansmission or start the engino
laulomatic transmissionl,yout vehicle must be transported on a flat-bed.
. lt is best to tow the vehicle no farther than 50 mil€s
(80 km), and ksop thE speedbelow 35 mph (55 km/hl
. Trying to lift 01 tow your vehicle by tho bump€F will
caus€setious damagg.Ths bumpers are not dEigned
to supportthe vshicle'sweigh.
Rear:
TOWINGHOOK
tJO
1-43
The Special Tools Section of this manual has
been omitted intentionally. Each section in the
manual that requires the use of special tools has
them listed separately for that section.
Specifications
StandardsandServiceLimits "'.".'.""' 3-2
"...""' 3-20
ications,..'....,.'..'....
DesignSpecif
"'."'." 3-23
BodySpecifications
Standardsand ServiceLimits
CylinderHead/ValveTrain (Dt6y5,
( u r b Y 5 , Dt6y7,
u l 6 Y 7 , D l 6 Y g e n lSines)
-Section6 MEASUREMENT
Compression
Cylinderhead
Camshaft
D16Y5
EX
IN
Secondary
EX
D16Y8
IN
Primary
Mid
Secondary
EX
Valveclearanca
{Cold)
IN
EX
ValvestemO.D.
IN
EX
IN
EX
IN
EX
Stem-toguideclearance
Valveseat
width
Steminsta ed height
Valvespring
Freelengrh
IN
EX
Dt6y7
D16Y5
IN
D16Y8
IN
EX
Valveguide
t.D.
I n s t a l l e dh e i g h t
Rockerarm
Arm-toshaftclearance
L,
STANDARD INFWT
250rpm and wide openthroftle
kPa{kgf/cm,,psi)
Nominal
Minimum
Maximumvariation
Warpage
Height
Endplay
Camshaftto-holderoil clearance
Totalrunout
Cam lobeheight
D16y7
IN
EX
IN
EX
IN
EX
IN
EX
930{9.5,135)
200 120 ?R\
92.95- 93.05{3.659 3.663)
0 . 0 5 , 0 . 1 5( 0 . 0 0 2 0 . 0 0 6 )
0.050- 0.089(0.002_ o.oo4)
0 . 0 3( 0 . 0 0 1 ) m a x .
35.299(1.38971
31.241/.1.4678)
38.427(1.5129)
32.19311.2674l
38.784(1.5269)
36.778(1.4479)
38.274(1.5068)
37.065 .4592)
38.008(1.4964)
- 0.009)
0.18- 0.2210.007
0.23 0.27(0.009 0.011)
5.48- 5.49(0.2157 0.2161)
_ 0.2150}
5.45- 5.46{0.2146
0.02- 0.05(0.001_ o.oo2)
0.05-008lono2-nnn?l
0.85- 1.15(0.033- 0.045)
- 0.061i
1.25- 1.5510.049
5 3 . 1 7- 5 3 . 6 4{ 2 . 0 9 _3 2 . 1 1 2 )
53.17- 53.64(2.093_ 2.112)
57.9 (2.2a)
56.5\2.221
57.9 t2.29l
58.0 (2.2a)
58.7{2.31i
5 . 5 1- 5 . 5 3( 0 . 2 1 -7 0 . 2 1 8 )
5.51- 5.53(0.217_ 0.218)
17.85- 18.35\0.103- 0.722)
18.65 19.t5 (0.734_ 0.754)
0.017- 0.050(0.0007 0.0020)
- 0.0021)
0.018- 0.054(0.0007
0.05{0.002)
0.5(0.02)
0.15(0.006)
0.04(0.002)
=
5.45(0.2146)
5.42 tO.21341
0.08(0.003)
0 . 1 1( 0 . 0 0 4 )
1.6(0.063)
2.0(0.079)
53.a9\2.122|j
$.a9 Q.122)
5.55t0.219)
5.5s{0.219)
ra
0.08(0.003)
0.08(0.003)
LO
3-2
U n i t o f i e n g t h :m m ( ! n )
CylinderHead/ValveTrain (816A2engine)- Section
STANDARD
INEW)
MEASUREMENT
Nominal
2 5 0r p m ( m i n r i a n d
930(9.5,135)
Minimum
wide openthrottle
20012.0,zal
variation
Maximum
(kqf/cm'
psi)
,
kPa
Endplay
holderoil clea€nce
Camshaft-to
Totalrunout
lN
Cam lobe height
EX
Valveclearance
ValvestemO.D.
Stem-to-guideclearance
width
Stem installedheight
free t*gth
LD.
Installedheight
lN
0.05- 0.15(0.002- 0.006)
0.050- 0.089(0.002- 0.004)
0.0310.001)max.
33.088(1.3027i
Primary
36.261{1.4278)
Mid
Secondary 3 4 . 9 7 (81 . 3 7 7 1 )
32.785{1.2907)
Primary
35.720(1.4063)
Mid
Secondary 34.691(1.3658)
I N 0.15- 0.19(0.006- 0.007)*
EX 0.17- 0.21(0.007- 0.008)*
- 0.2159)
I N 5.475- 5.48510.2156
EX 5.450- 5.460(0.2146- 0.2150)
0.025- 0.055(0.0010 0.0022)
IN
EX 0.050-0.080(0.0020- 0.0031)
1.25- 1.55{0.049- 0.061)
IN
r.25- 1.55(0.049- 0.061)
EX
- 1.4935)
37.465- 37.935(1.4750
IN
- 1.4817)
37.165- 37.635(1.4632
EX
OUTER 4 0 . 9 2( 1 . 6 1 1 ) * '
4 0 . 9 1( 1 . 6 1 1 1 "
36.71(1.415)
4 1 . 9 6( 1 . 6 5 2 ) * r
4 r.94(1.651)*'
lN
5.51- 5.53(0.217- 0.218)
EX 5.51- 5.53(0.217- 0.218i
lN
12.55- 13.05(0.494 0.5' j4)
12.55- 13.05(0.494- 0.514)
EX
SERVICELIMIT
u*u lo.r,ool
5.420(0.2134)
0.08(0.003)
0 . 1 1( 0 . 0 0 4 )
2.0(0.08)
2.0(0.08)
3 8 . 1 8 (51 . 5 0 3 3 )
3 7 . 8 8 (51 . 4 9 1 5 )
- 0.052(0.00100.0020)
0.025
{0.00100.0020)
o.o2s- 0.052
*: Measuringpoint betweencamshaftand rockerarm'
valvespnng.
*1: NTHON
vatvespring. *2: CHUOHATSUJOmanutactured
H;TSUJOmanufactured
3-3
Standardsand ServiceLimits
EngineBlock {Dl6Y5,D16Y7,Dt6y8 enginesl- Section
,n7 _-MEASUREMENT
Cylinderblock
Piston
Pistonring
Pistonpin
Connecting
rod
Crankshaft
Bea.ings
Warpageof decksurface
Borediameter
Boretaper
Reboringlimit
SkirtO.D. at 5 mm (0.2in)
from bottomof skin
Clearance
in cylinder
Groovewidth {for ring)
Top
Second
oil
Ringto-grooveclearance Top
Second
Ring end gap
Top
Second
oil
o.D.
STANDAFOINEW}
0.0710.003)
max.
75.00 75.02(2.953- 2.954)
SERVICE
LIMIT
0.10(0.004)
75.07(2.956)
0.05(0.002)
0.5(0.02)
74.9A0 74.990t2.9520 2.95241
74.970(2.9516)
0.010- 0.040(0.0004 0.0016)
_ 0.0406)
1.020- 1.03010.0402
- 0.0484)
1.220 1.230(0.0480
2 . 8 0 5- 2 . 8 2 0{ 0 . 11 0 4_ 0 . 1 1t O )
0.035- 0.060(0.0014 0.0024)
0.030- 0.055{0.0012 0.0022)_
0.15 0.30{0.006_ 0.012)
0 . 3 0- 0 . 4 5( 0 . 0 1 -2 0 . 0 1 8 )
0.20- 0.7010.008 0.028)
_ 0.7480)
18.994- 19.000(0.7478
0.010- 0 0?2 lo oona-n dn^ol
_ 0.ool6)
0.014- 0.040(0.0006
18.96- 18.98(0.746 0.747)
48.011.89)
0.15- 0.30(0.006- 0.012)
- 2.1654)
54.976- s5.000(2.1644
44.91
6 - 45.0001'1.17
01 _ 1.71111
0.002510.0001)
max.
0.0025(0.0001)max.
0.10- 0.35(0.004 0.014)
0.03(0.001)max.
Pin-topistonclearance
Pin-torod interference
Smallend borediameter
Largeend borediameterNominal
Endplay installedon crankshaft
M a i nj o u r n a l d i a m e t e r
R o di o u r n a l d i a m e t e r
Taper
Out of-round
Endplay
Totalrunout
Main bearingto-lournalo't clearanceN o _l a n d5 j o u r n a l s
0.018- 0.036(0.0007 0.0014)
N o .2 , 3 a n d4 j o u r n a t s 0.024 0.042(0.0009
- 0.0017)
_
Bodbearingto,journatoil ctearance
_ o.oo.t5)
0.020- 0.038(0.0008
L,
0.05(0.002)
1 . 0 5( 0 . 0 4 1 )
1.2510.049)
2.85(0.112)
0 . 1 3{ 0 . 0 0 5 )
0.13(0.005)
0.60(0.024)
0.70(0.028)
ljqql)
_
oroto.o',ur
0.005(0.0002)
0.005(0.0002)
0.4510.018)
0.04(0.002)
0.05(0.002)
0.05{0.002)
0.05(0.002)
LO
LO
3-4
Unlt of length: rnm ( n)
EngineBlock (816A2engine)- Section7
STANOARD{NEW)
0.05(0.002)
8 L 0 0 8 1 . 0 2( 3 . 1 8 9 3 . 1 9 0 )
MEASUREMENT
Cylinder block
Piston
Piston ring
Warpageof decksurface
Borediameter
Boretaper
Reboringlimit
Skin O D. At 15mm (0.6in)
{rom bottomof skirt
in cylinder
Clearance
Groovewidth (for ring)
ToP
Second
oil
Second
Top
Ring end gap
Second
oil
Piston pin
Connectingrod
o.D.
Pin to-pistonclearance
Pin'torod interference
Smallend borediameter
Largeend borediameter
Endplayinstalledon crankshaft
Nominal
Mainjournaldiameter
No. 1, 2, 4 and 5 iournals
No. 3 journal
Rodjournaldiameter
Taper
Out of round
Endplay
Totalrunout
oil clearance
Main bearingto_journal
Eearing
N o .1 ,2 , 4 a n d5 j o u r n a l s
N o .3 j o u r n a l
Bod bearing'toiournaloil clearance
*1: RIKENmanutactured
prstonrrng
pistonring
*2:TEIKOKU
PISTONRINGmanufactured
Crankshaft
0.08{0.03)
8 1 . 0 7( 3 . 1 9 2 )
0.05(0.002)
0 . 2 5( 0 . 0 1 )
80.980- 80.990(3.lUUz 3. rUubl
du Y/u lJ. ro/o,
- 0.0016'
0.010 0.040(o.ooo4
- 0.04091
I O3O 1.04010.0406
. 0.04881
1.230- 1.?40{0.0484
0 05 r0 002)
1 060{0 0417)
1.26010.04961
I
I
|
1
'*: ?:::i?l:91'::ll:l
I::::::=
u . u 4 5- u . u / u l u . u u r o
R i n g - t o - g r o o v ec l e a r a n c e
LIMIT
SERVICE
0.040- 0.065(0.0016 0.0026)*l
0.045- 0.070(0.0018 0.0028)*'
0.20- 0.35(0.008- 0.014)*1
o.20- 0.30(0.008- 0.012)*'
0.40 0.55(0.016 0.022)
0.20- 0.50(0.008- 0.020)*'
0.20- 0.45(0.008- 0.018)"
- 0.8268)
20.994- 21.000{0.8265
0.010- 0.022(0.0004 0.0009)
- 0.0013)
0.013- 0.032(0.0005
- 0.8260)
20.968 20.981(0.8255
0.13(0.005)
0.1310.005)
0.60(0.024)
0.60t0.024)
0.7010.028)
0.70(0.028)
o.o''r,
lliSlto?,o.oou
o.rotoo'ut
- 2.1654)
54.976 55.000(2.1644
54.970- 54.994(2.1642 2.1651)
- 1.1711|
- 45.00011.'1707
44.976
max.
0.005(0.0002)
max.
0.004(0.0002)
0.10 0.35(0.004- 0.014)
0.020(0.0008imax.
0.010(0.0004)
0.006(0.0002)
0 . 4 5( 0 . 0 1 8 )
0.030(0.0012)
- 0.042(0.00090.0017)
0.024
- 0.048
{0.00120.0019)
o.o3o
- 0.0020)
- 0.050(0.0013
0.032
0.06(0.002)
0.06(0.002)
0.06(0.002)
l
l
,rr]q!4l
-
ginesl- Section 8
EngineLubri,cation(Dl6Y5,Dl5Y7' Dl6Y8 enginesl
STANOARD(NEW)
MEASUREMENT
E n g i n eo i l
O i lp u m p
R e l i e fv a l v e
S€RVICELIMIT
4.3(4.5,3.8)Iorengineoverhaul
3.6(3.8,3.2)for oil change,includingfilter
3.3(3.5,2.9)for oil change,withoutfilter
D16Y5D16Y8 3 . 7( 3 . 9 , 3 . 3 ) f oern g i n eo v e r h a u l
3.3(3.5,2.9)for oil change,includingfilter
3.0{3.2,2.6}for oil change,withoutfilter
- 0.006)
0.20{0 008)
0.02- 0.14(O.OO1
rotorradialclearance
lnner-to-outer
(0 008)
- 0.007)
0.20
(o.oo4
0.18
0.10
i
Pumphousingto_outerrotor radialclearance
(0
006)
(qool!.oo3l
o 03 !.08
rotora)rialclearance
_
Pumohousrnq_to
settingwith oil temperature176'F(80'Ci
Pressure
7 0 ( 0 . 7 1, 0 )m i n .
at idle
,
kPa(kgf/cm'PsiI
) in
3 4 0( 3 . 5 , 5 0m
at 3,000rpm
Capacity | (USqt, lmp qt)
D16Y7
-
(cont'd)
3-5
Standardsand ServiceLimits
EngineLubrication(B16A2engine)(cont,d)- Section8
E n g i n eo i l
O i lp u m p
R e l i e fv a l v e
MEASUREMENT
Capacity f (uS qt, lmp qt)
STANDARD INFWI
4.8(5.1,4.2)for eng;neoverhaul
4.0(4.2,3.5)for oil change,;ncludin
g oilfilter
3.7 (3.9.3 3)for dil .h,nde
Inner-toouterrotorradialclearance
Pumpbody-toouterrotorradialclearance
Pumpbody to-rotoraxialclearance
Pressure
setting176"F(80.C)
kPa(kgflcm,,psi)
at;dte
at 3,000rpm
L,
'^,irh^,,r
0.04- 0.16{0.002- 0.006)
0 . 1 0- 0 . 1 9( 0 . 0 0 4 - 0 . 0 0 7 )
,0.003)
0.02 0.0710.001
0.20(0.008)
0.20{0.008)
0 15 {OOO6i
70 (0.7,10)min.
340(3.5,50)min.
Cooling- Section 10
Radrator
MEASUREMENT
Coolantcapacity t 1USqt, tmp qt)
includingengine,heater,coolinglineand
reservotr
Beservoircapacity:
0.4f {0.42US qt, 0.35lmp qt)
R a d i a t o rc a p
Thermostat
Cooling fan
Openingpressure
kPa(kgl/cm,,psi)
Start to open .F (.C)
Fully open "F ('C)
Valve lift at fulty open
Thermoswilch 'ON" temperature
Thermoswitch "OFF' lemperature
F r.C,
.F (
C)
STANOARO{NEW)
81642engine
5.0{5.3,4.4)for overhaul
4.5(4.8,4.0)for cootantchange
D16Y5,D16Y7,D16Y8engines:
M/T: 4.2(4.4,3.7)foroverhaul
3.1(3.3,2.7)for coolantchange
A"/T:016Y7
4.1(4.3,3.6)for overhaul
3.0(3.2,2.6)for cootantchange
Dl6Y8
4.3{4.5,3.8)foroverhaul
3.2(3.3,2.8)for cootantchange
CW: 4.3(4.5,3.8)foroverhaul
3.2(3.3,2.8)forcootantchanqe
9 3 1 2 3( 0 . 9 5 -1 . 2 51, 4 1 8 )
1 6 9- 1 7 6( 7 6 8 0 )
194(90)
8 . 0( 0 . 3 1 ) m i n .
196- 203191 95)
Subtract5 - 15{3 - 8) from actual,,ON,,temperature
L.
L,
3-6
Unit of length: mm (in)
Fueland Emission - Section
STANOARO(NEW)
MEASUREMENT
Fuelpaessure
regulator
wilh fuel pressureregulatorvacuumhose
Pressure
,
disconnected kPa(kgvcm' Psi)
D16Y5
D16Y7
D16Y8
81642
260
260260210-
Fueltank
Capacity I (USgal,lmp gal)
ldlespeed rpm
4 5 { 1 1 . 99, . 9 )
M/T (neutral)
En g i n e
016Y5
D16Y7
D16Y8
816A2
310(2.7310(2.7310(2.7320 Q.A-
3.2,38 3.2,38 3.2,38 3.3, 40 -
46)
46i
46)
471
u.s.A.
Canada
670 1 50
6701 50
670150
700t 50
7 5 0 15 0
7 5 0 15 0
7 5 0 15 0
I A/T or C\.T (lE or fd positioni
Canada
U,S,A.
700t 50
700I 50
7 0 0 15 0
750150
750r 50
0.1max.
ldleCO %
Clutch- Serr tion12
STANDARD{NEWI
MEASUREMENT
Clutchpedal
Flywheel
Clutch disc
plate
Pressure
Pedalheight
Stroke
Pedalplay
D i s e n g a g e m e n th e i g h t
Clutchsurfaceruoout
Rivetheaddepth
Thickness
Warpage
Diaphragmspringfingersalignment
to floor
to floor
to carpet
I
SERVICELIMIT
16s(6 1/2)
130 140(5 1/8 5 1/2)
12 -21 t1l2- 13/161
83 (3 1/4)
44 (1 3/4)min. Reference
max.
0.05(0.002)
1 . 3 -1 . 9( 0 . 0-50 . 0 7 )
- 0.36)
8.5- 9.1(0.33
0.15(0.006)
0 . 2{ 0 . 0 1 )
5.5(0.22)
0.03(0.001)max
0.6(0.02)max
0.15(0.006)
1.0(0.04)
Lro
3-7
Standardsand ServiceLimits
ManualTransmissionS40- Section 13
MEASUREMENT
Capacity | (USqt, tmp qt)
Mainshaft
End play
Diameter of ball bearing contact area A
( T r a n s m i s s i o nh o u s i n g s i d e )
Diameterof 4th, 5th gear contact area B
Diameter of 3rd gear contact area C
Diameterof ball bearing contact area D
( C l u t c hh o u s i n g s i d e )
Bunout
Countershaft
Diameterof needlebearingcontactareaA
Djameterof lst gear contact area g
Diameter of ball bearing contactarea C
Runout
E n d p l a y ( W h e n t i g h t e n e d b y t h e s p e c i f i e dt o r q u e )
Thickness
gear
Endptay(Whentightenedby the specifiedtorque)
t.D.
o .D .
Length
Spacercollar
(Mainshaft4th
and 5th gear)
Beverserdlergear
LD.
Shift arm A
MBS Shiftprece
D i f f e r e n l i a lc a r r i e r
3- 8
Adjust
2 1 . 9 3 (00 . 8 6 3 4 )
_ 1.0627)
26.980 26.993(1.0622
33.984 34.000(1.3380 1.3386)
25.917- 25.99011.02271.0232)
26.930('1.0602i
33.930(1.3358)
25.92011.0205)
0 . 0 2( 0 . 0 0 1m) a x .
39.009 39.025(1.5358 1.5364)
0.06 0.21(0.002 0.008)
0.06 0.19(0.002 0.007)
30.22 30.21(1.190 1.192)
3 0 . 1 2- 3 0 . 1 7( 1 . 1 8 6 1 . 1 8 8 )
0.05(0.002)
39.07('r.538)
0 . 3 3{ 0 . 0 1 3 )
0 . 3 1( 0 . 0 1 2 )
3 0 . 1 5( 1 . 1 8 7 )
3 0 . 0 5( 1 . 1 8 3 )
SEBVICE
LIMIT
ro
(1.4570
_ 1.4577) 3 7 . 0{71 . 4 5 9 )
37.00937.025
- 0.007)
0.06- 0.19(0.002
0 . 3 1( 0 . 0 ' 1 2 )
- 2a.4711.119,1.1211
28.42
2 8 . 3(51 . 1 1 6 )
3 0 . 0 0 03
- 0 . 0 1 {51 . 1 811- 1 . 1 8 1 7 ) 2 9 . 9 5 (01 . 1 7 9 1 )
3 5 . 9 8 -4 3 6 . 0 0 (01 . 4 1 6 71 . 4 1 7 3 ) 3 s . 9 3 r0. 4 1 4 6 )
- 0.9840) 24.930(0.9815)
24.980 24.993(0.9835
0 . 0 2( 0 . 0 0 1 ) m a x .
0.0s(0.002)
4 1 . 0 0-9 4 1 . 0 2 (5' t . 6 1 4 51 . 6 1 5 2 ) 41.0111.617J
0.03 0.10(0.001_ 0.004)
0.22(0.009)
3 0 . 4 1 3 0 . 4 4( 1 . 1 9-7 1 1 9 8 )
3 0 . 3 6( 1 . 1 9 5 )
- 44.025
44.009
(1.73261.7333) 44.0111.t35)
- 0 005)
0.04- 0.12(0.002
0.24(0.009)
3 1 . 9 13 1 . 9(61 . 2 5 61 . 2 5 8 )
3 1 . 8 5( 1 . 2 s 4 )
33.000- 33.010(1.2992 1.2996)
38.989 39.00011.53s0_
1.53s4)
32.03- 32.06tl.261 - 1.2621
3 3 . 0 4{ 1 . 3 0 1 )
38.93(1.533)
3 2 . 0 1( 1 . 2 6 0 )
2 7 . 0 0 22 7 . 0 1(21 . 0 6 3_ 11 . 0 6 3 5 )
- 34.000
- 1.3386)
(1.3381
33.989
(1.25941.2598)
3r.989- 32.000
- 22.86
(0.8990.900)
22.83
- 0.928)
23.53 23.56(0.926
2 7 . 0(61 . 0 6 5 )
(1.336)
33.93
3 r . 9 3{ 1 . 2 5 7 )
(0.898)
22.81
2 3 . 5(10 . 9 2 6 )
r s . 0 1 6 1 5 . 0 4(30 . 5 9 1_20 . 5 9 2 2 )
_ 0.0030)
0.032 0.077(0.0013
R i n g - t o g e a r c l e a r a n c e{ R i n g p u s h e d a g a i n s t g e a r )
0 . 7 3- 1 . l 8( 0 0 2 9- 0 . 0 4 6 )
Forkfinger thickness
lsv2nd/sth I 6.2- 6.410.244
- O.ZS2)
3rdl4th
7.4 i.6lO 2g1 O 2ggt
Fork to-synchrosleeveclearance
0.35- 0.65(0.014- 0.026)
Forkpawl groovewidth
1 2 . 7- 1 3 . 0( 0 . 5 0_ 0 . 5 1 )
Forkto-reverseidlergearclearance
0.5 1.t (0.020 0.043)
L groovewidth
- 0.2851
7.05- 7.25tO.21A
Fork'to-5th/reverse
shiftpiecepin clearance
0.05 0.35(0.002 0.014)
tnnerdiameterof shift arm C contactffi
(0.5140.517)
13.05 13.13
Shift arr14-go "L;L ".m C clearance
0.05- 0.23(0.002_ 0.009)
Innerdiameterof shiftarm B shaftcontactpoint
13.973- 14.000(0.5501 0.5512)
Shiftarm 8-to shaftclearance
_ 0.0028)
0.013 0.070(0.0005
Shiftarm B to-shiftpiececlearance
0.2- 0.5{0.008 0.020)
Diameterof shiftpiececontactpoint
1 2 . 9 1 3 . 0( 0 . 5 0 -8 0 . 5 1 2 )
Diameterof pin
6.9 7.1 \O.27 0 2A)
Pinion shaft bore diameter
_ 0.7098)
18.010 18.028(0.7091
C a r r i e r - t op i n i o n s h a f t c l e a r a n c e
- 0.0022)
0.023 0.057(0.0009
D r i v e s h a f tb o r e d i a m e t e r
26.025 26.04s{1.0246_1.0254)
C a r r i e r t o , d r i v e s h a f tc l e a r a n c e
0.045- 0.086(0.0018 0.0034)
Backlash
0.05 0.15(0.002 0.006)
Piniongearborediameter
1 8 . 0 4-2 1 8 . 0 6(60 . 7 1 0_30 . 7 1 1 3 )
Piniongear-topinionshaftclearance
_ o.oo37)
0.055- 0.095{0.0021
0 0.110- 0.004)
G e a r t o r e v e r s eg e a r s h a f t c j e a r a n c e
Beverseshittfork
STANDARDINEW}
' 1 . 9( 2 . 0 ,
1 . 7 ) f oo
r verhaul
1 . 8( 1 . 9 1, . 6 )f o r o i t c h a n g e
0 . 1 1 0 . 1 8( 0 . 0 0_4 0 . 0 0 7 )
21.987- 22.000(0.8656 0.8661)
LrO
15.08(0.594)
0 . 1 4( 0 . 0 0 6 )
0 . 4( 0 . 0 1 6 )
0.16(0.006)
o.6210.02441
(0.5031)
12.78
0.095(0.004)
0 . 1 4( 0 . 0 0 6 )
Adjust with shim
LO
U n i t o f l e n g t h :m m ( i n )
ManualTransmissionS4C- Section 13
T r a n s m i s s i ooni l
Mainshaft
Mainshaft 3rd and
4th gears
STANDARD{NEW)
M€ASUREMENT
Capacity | (US qt, lmp qt)
Fnd plaV
Diameterof ball bearingcontactareaC
(Clutchhousingside)
Diameterof 3rd gearcontactareaB
Diameterof ballbearingcontactarea'q
( T r a n s m i s s ihoonu s i n gs i d e )
Runout
LD.
Endplay
Thickness
3rd
4th
t.D.
Endplay
Thickness
Diameterof ball bearingcontactareaA
Diameterof lst gearcontactareaI
Diameterof needlebearingcontactareaC
Runout
LD.
torque)
Endplay{Whentightenedby the specified
Thickness
S p a c ecr o l l a r
(CoLrntershaft
2nd
LD.
gear)
Length
S p a c e rc o l l a r
( M a i n s h a f t4 t h
and 5th gear)
LD.
o.D.
o.D.
Lengtn
LIMIT
SERVICE
2 . 3( 2 . 4 , 2 . 0f o) r o v e r h a u l
r i lc h a n g e
2 . 2( 2 . 3 1, . 9 ) f o o
0 . 1 1- 0 . 1 8( 0 . 0 0-4 0 . 0 0 7 )
- 1.10201
21.917- 21.990 11.1015
Adtust
2 7 . 9 3 (01 . 0 9 9 6 )
37.984 38.000(1.4954 1.4960)
2 7 . 9 8-7 2 8 . 0 0 (01 . 1 0 1 81 . 1 0 2 4 )
37 930 (1.4933)
2 7 . 9 4 (01 . 1 0 0 0 )
0 . 0 2( 0 . 0 0 1 ) m a x .
43.009- 43.025(1.6933 1.6939)
0.06- 0.21(0.002 0.008)
34.92- 34.91\1.315 1.311)
31.42- 31.41(1.237 1.239)
0.05(0.002)
4 3 . 0 8( 1 . 6 9 6 )
0 . 3( 0 . 0 1 )
34.3(' t.350)
31.3 11.232)
- 1.6939) 4 3 . 0(81 . 6 9 6 )
(1.6933
43.00943.025
- 0.008)
0 . 3( 0 . 0 1 )
0.06 0.21(0.002
- 31.41
31.311.232)
31.42
\1.231 1.2391
24.980 24.993(0.9835 0.9840)
- 1.4567)
36.984 37.000(1.4561
- 1.2998)
33.000- 33.015(1.2992
max.
0.02(0.0008)
4 1 . 0 0-9 4 1 . 0 2 (51 . 6 1 4-51 . 6 1 5 2 )
0.045- 0.205(0.0018 0.0081)
24.940(0.9818)
36.930(1.4539)
3 2 . 9 5 (01 . 2 9 7 0 )
0.05(0.002)
4 1 . 0 7( 1 . 6 1 7 )
0 . 2 5( 0 . 0 1 )
- 1.7333) 4 4 . 0 7( 1 . 7 3 5 )
44.00944.025
{1.7326
- 0.006)
0.24(0.009)
0.07 0.14(0.003
-' j.1405)
- 28.97
(1.1386
2 8 . 8( 1 . 1 3 4 )
28.92
36.521- 36.531(1.4378 1.4382)
4 1 . 9 8 94
- 2 . 0 0 (01 . 6 5 3-11 . 6 5 3 5 )
- 1.1453)
29.07- 29.0911.1444
31.0O2 31.01211.2205- 1.2209'l
- 1.4570)
36.989- 37.000{1.4563
- 2.22641
56.45- 56.551'2.2224
26.03- 26.0A11.025- 1.021|
3 6 . 5 4( 1 . 4 3 9 )
4 1 . 9 3( 1 . 6 5 1 )
3 1 . 0 6( 1 . 2 2 3 )
3 6 . 9 4( 1 . 4 5 4 )
(cont'd)
3-9
Standardsand ServiceLimits
ManualTransmissionS4C(cont'd) - Section 13
MEASUREMENT
Reverseidlergear
t.D.
Gear-toreversegearshaftclearance
(Ringpushedagainstgear)
Ringto-gearclearance
(Ringpushedagainstgead
Clearance
Outersynchroring to gear
Inner synchroring to-gear
Outersynchroring-to-synchro
cone
Shiftfork
Fork{ingerthickness
Fork-tosynchrosleeveclearance
Beverseshiftfork
Forkpawl groovewidth
Fork-to-reverse
idlergearclearance
L-groovewidth
At 5th gearside
At reverseside
Fork'to-5th/reverse
shift piecepin clearance
At 5th gearside
At reverseside
Shiftpiece
Shiftpiece-to-shift
arm clearance
Groovewidth of shiftarm contactarea
Shilt'piece-to-shiftfork shaft clearance
Width of shift lork contactarea
Selectarm
Selectarm-to-interlock
clearance
Selectarm to-shimclearance
Interlock
Width of selectarm contactarea
Changepiece
Changepiece-to-shilt
arm holderclearance
Groovewidth ot shittarm holdercontactarea
Changepiece-toselectarm clearance
Groovewidth of selectarm contactarea
Final driven gear
Backlash
Differentialcarrier Pinionshattborediameter
Carrierto-pinionshaftclearance
Driveshaft
borediameter
Carrier-to
driveshaftclearance
Carrier-to-int6rmediate
shattclearance
pinion Backlash
Differential
gear
Piniongearborediameter
Piniongear-to-pinion
shaftclearance
Setring to bearingouterrace
Synchroring
Doublecone
STANDARD(NEW)
-0.7891)
20.016- 20.043(0.7880
- 0.0033)
0.036- 0.084{0.0014
0.73- 1.18(0.029 0.046)
SERVICELIMIT
20.09(0.7909)
0.16(0.006)
0 . 4( 0 . 0 1 6 )
- 0.066)
0.9s- 1.6810.037
0.5- 1.0(0.02- 0.04)
0.5 1.0(0.02- 0.04)
- .299i
7 . 4- 7 . 6( 0 . 2 9 1 0
0.35- 0.65(0.015 0.026)
- 0.524)
13.0- 13.310.512
0.5- 1.0(0.02- 0.04)
7.4 t.1 10.29-O.30)
7.O5- 7.25 (0.21A- 0.2A5i'
0.6(0.024)
0 . 3{ 0 . 0 1 )
0 . 3( 0 . 0 1 )
0.4 0.9(0.02 0.04)
0.05 0.45(0.002- 0.018)
0.1- 0.3(0.004- 0.012)
8 . 1 - 8 . 2( 0 . 3 1-9 0 . 3 2 3 i
0.2- 0.5 (0.008 0.020)
- 0.472)
11.9- 12.010.469
0.05- 0.20(0.002- 0.008)
- 0.008)
0.01- 0.210.0004
(0.390
9.9 10.0
0.394)
ua
1.0(0.04)
1 €{ 0 . 0 7 )
0.6(0.02)
0.8(0.03)
0.45(0.018)
- 0.014)
0.05- 0.35(0.002
1 2 . 0-51 2 . 1\50 . 4 7-40 . 4 7 a 1
- 0.010)
0.05- 0.25(0.002
- 12.t5 (0.474
- 0.478)
12.05
0.8{0.03)
- 0.0059)
0.090- 0.149(0.0035
- 0.7093)
18.000 18.01610.7087
0.013- 0.045{0.001 0.002)
24.000- 28.02111.1024 1.1032)
- 0.0024)
0.020,0.062(0.0008
- 0.0034)
0.05- 0.087{0.0020
0.200(0.008)
0.12(0.005)
0.14(0.006)
- 0.006)
0.05-0.15(0.002
1 8 . 0 4 21 8 . 0 6( 60 . 7 1-00 . 7 1 1 )
- 0.095(0.002
- 0.004)
0.055
0 . 1 5( 0 . 0 0 6 )
0 - 0.10(0 - 0.004)
Adjust with shim
0.5(0.02)
0.10{0.004)
.'1
L,O
3-10
U n i t o f l e n g t h im m ( i n )
tssron- Section 14
AutomaticTf ansmtssron
Transmission
fluid
Hydraulic
LIMIT
SERVICE
STANOARD{NEWI
MEASUREMENT
(US
qt,
lmp qti
Capacity f
Linepressureat 2,000rpm in E or E position
5.9(6.2,5.2)Ioroverhaul
2.7(2.9,2.4)for fluid chanse
sgO g8ol85 SO,rzO rSO,
r A o , e ' 0I 0 ,
800- 850(8.2-8.7, 120- 124)
8 1 0 - 8 6 0( 8 . 3- 8 . 8 ,1 1 8- 1 2 5 )
7 6 0( 7 . 7 1, 1 0 )
7 6 0( 7 . 81, l 1 )
2,100
28
1 s tc l u l c h p r e s s u r ea l 2 , O 0 O r p m i n D . p o s i t i o n
kPa
(kgf/cm',psa)
2nd clutchpressureat 2,000rpm in El position
3rd and 4th clutchpressureat 2,000rpm in lFl position
Stallspeedrpm (Checkwith vehicleon levelground)
1st,2nd
Clutchinitialclearance
Clutch
3rd,4th
Clutchreturnspringfree length
1st
(A4RA,B4RATransmission)
2nd,3rd,4th
lst
lM4RATransmission)
2nd,3rd,4th
Clutchdiscthickness
1st
Clutchplatethickness
2nd,3rd,4th
Mark1
Ctrt"h ""d pl"t" thl"t**
Mark2
(A4RA,B4RATransmission)
Mark3
Mark4
Mark5
Mark6
Mark7
M a r kI
MarkI
Clutch end plate thickness
(M4RA Transmassioni
M"*l
Mark2
Mark3
Mark4
Mark5
Mark6
Mark7
Mark8
Mark9
Mark 10
M a r k1 1
M a r k1 2
M a r kl 3
M a r k1 4
M a r k1 5
M a r k1 6
Mark17
Mark 18
0.65, 0.85(0.026- 0.033)
0.40- 0.60(0.016- 0.024)
3 2 . 0( 1 . 2 6 )
30.s(1.20i
31.1 11.221
3 0 . 5( 1 . 2 0 )
1.88- 2.00{0.074- 0.079)
1 . 5 5- 1 . 6 5 1 0 . 0 -601. 0 6 5 )
1.95- 2.05(0.077 0.081)
2.05 2.10(0.081- 0.083)
2.15- 2.20(0.085- 0.087)
2.25- 2.30{0.089- 0.091i
2.35- 2.40(0.093- 0.094)
2.45- 2.50(0.096- 0.098)
2.55- 2.60(0.100- 0.102)
2.65- 2.70(0.104 0.106)
2 . 7 5- 2 . 8 0( 0 . 1 0 8 0 . 1 1 0 )
2 . 8 5 2 . 9 0( 0 . 1 1 -2 0 . 1 1 4 )
2.3- 2.4{0.091 0.094)
2.4, 2.5{0.094- 0.098)
2.5 2.6(0.098- 0.102)
2.6- 2.7(0.102- 0.106)
2 . 7, 2 . 8( 0 . 1 0 -6 0 . 1 1 0 )
2 . 8- 2 . 91 0 . 1 1 00 . 1 1 4 )
- .118)
2 . 9- 3 . 0( 0 . 1 1 4 0
3 . 0 , 3 . 1( 0 . 1 1 8 - 0 . 1 2 2 )
3.1- 3.2\O.122-0.1261
3 . 2- 3 . 3{ 0 . 1 2 -6 0 . 1 3 0 }
2.0- 2.1(0.079- 0.083)
2.1- 2.2(0.083- 0.087)
2.2- 2.3(0.087- 0.091)
3 . 3- 3 . 4( 0 . 1 3 0 0 . 1 3 4 )
3.4- 3.5(0.134- 0.138)
3.5- 3.6(0.138 0.142)
3 . 6 3 . 7{ 0 . 1 4 2 0
- .146)
3 . 7, 3 . 8 1 0 . 1 4-60 . 1 5 0 i
1_ffi9
3 0 . 0( 1 . 1 8 )
28.5\1.12)
2 9 . 1( 1 . 1 5 )
28.511.121
Untilgroovesworn out
Discoloration
Discoloration
1
I
I
Discoloration
Discoloration
1
I
I
L
I
Discoloration
(cont'd)
3-11
Standardsand ServiceLimits
Automatic Transmission(cont'd)- Section l4
MEASUREMENT
Diameterof needlebearingcontactarea
On mainshaftstatorshaftbearing
On mainshaft2nd gear
On mainshaft4th gearcollar
On mainshaft1stgearcollar
(leftside)
On countershaft
On countershaft
3rd gearcollar
On countershaft
4th gear
On countershaft
reversegearcollar
On countershaft
1stgearcollar
On reverseidlergearshaft
Insidediameterof needlebearingcontactarea
On mainshaft1stgear
On mainshaft2nd gear
On mainshaft4th gear
On countershaft
1stgear
On countershaft
3rd gear
On countershaft
4th gear
On countershaft
reversegear
On reverseidlergear
On statorshaft(ATFpump sidei
On statorshalt(statorside)
Reverseidlergearshaftholderl.D.
Endplay
Mainshaftlst gear
Mainshaft2nd gear
Mainshaft4th gear
Countershaft
lst gear
Countershaft
3rd gear
Countershaft
4th gear
Reverseidlergear
Countershaft
reversegear
Selecto.hub O.D.
Mainshaft4th gearcollarlength
Marnshaft4th gearcollarIlangethickness
Mainshaftlst gearcollarlength
Countershaft
distancecollarlength
,96 97 models
'98 00 modets
Countershaft
reversegearcollarlength
Countershaft
reversegearcollarflange
thackness
Countershaft
1stgearcollarlength
Countershaft
lst gearcollarflangethickness
Countershaft
3rd gearcollarlength
t
L
a.\
STANOARD{NEW)
SERVICE
LIMIT
22.980 22.99310.9047 0.9052|j
3 5 . 9 7 5 3 5 . 9 9 (11 . 4 1 6-31 . 4 1 6 9 )
3 1 . 9 7 5 3 1 . 9 9 (11 . 2 5 8 9 _ , 1 . 2 5 9 5 )
30.975- 30.991t1.2195 1.22011
3 6 . 0 0 4 3 6 . 0 1 (71 . 4 1 7-51 . 4 1 8 0 )
( 1 . 4 1 6-51 . 4 1 7 2 )
3 5 . 9 8 03 5 . 9 9 6
2 7 . 9 8-0 2 7 . 9 9 (31 . 1 0 1-61 . 1 0 2 1 )
3 1 . 9 7 5 3 1 . 9 9 (11 . 2 5 8-91 . 2 5 9 5 )
3 1 . 9 7 s 3 1 . 9 9 (11 . 2 5 8-91 . 2 5 9 5 )
- 14.000{0.5508
- 0.5512)
13.990
3 5 . 0 0 0 , 3 s . 0 1( 61 . 3 7 8-01 . 3 7 8 6 )
4 1 . 0 0-0 4 1 . 0 1 16 1 . 6 1 4- 21 . 6 1 4 8 )
- 1.4967)
38.000- 38.0'16
{1.4961
- 1.4967)
38.000 38.016(1.4961
4 1 . 0 0 0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 )
33.000- 33.016(1.2992 1.2998)
- 1.4967)
38.000- 38.016(1.4961
- 0.7094)
18.007- 18.020(0.7089
-29.O1311.1417
- 1.14221
29.OO0
- 1.0638)
27.O00 27.02111.0630
'14.416
- 14.434(0.5676 0.5683)
0.08 0.19(0.003- 0.007)
0.05- 0.13(0.002 0.005)
0.075- 0.185(0.003 0.007)
0.1- 0.5{0.004- 0.020)
0.05- 0.17{0.002- 0.007)
0.10- 0.18(0.004 0.007)
0.05- 0.18(0.002 0.007)
0.10- 0.25(0.004 0.010)
51.87- 51.90{2.042 2.043)
45.00- 45.03(1.771- 1.773)
- 0.1781)
4.435- 4.525(0.1746
2 7 . 0 0 -2 7 . 1 5( 1 . 0 6-3 1 . 0 6 9 )
38.87- 38.90{1.530- 1.531)
38.92 38.95{1.532- 1.533)
3 8 . 9 7- 3 9 . 0 0( 1 . 5 3 4 , 1 . 5 3 5 i
39.02- 39.05(1.536- 1.537)
39.07- 39.10{1.538- 1.539)
3 9 . r 2- 3 9 . 1 5( 1 . 5 4 -0 1 . 5 4 1 )
3 9 . 1 7- 3 9 . 2 0( 1 . 5 4-2 1 . 5 4 3 )
39.22- 39.25(1.544- ' t.545)
39.27 39.30(1.546- 1.547)
21.15- 21.20(0.833- 0.835)
20.65 20.70(0.813- 0.825)
14.5 r4.6 {0.571- 0.575)
2.4- 2.610.094 0.102)
14.s- 14.6(0.571- 0.575)
2.4 2.6(0.094- 0.102)
Wear or damage
Un;t of length: mm {in)
Automatic Transmtsston Section 14
Transmission
3.97
4.024 . 0 74 . 1 24 . 1 74.224 . 2 74 . 3 24.374.42-
Thrustwasherthickness
Mainshaftball bearingleftside
Mainshaftlst gear
'96 97 models
3rd gearsplinedwasher
Countershaft
'98- 00 models
2 . 9 52.43
4 . 4 54.95-
3 . 0 5{ 0 . 1 1 -6 0 . 1 2 0 )
2.50(0.096- 0.098)
4 . 5 0( 0 . 1 7-5 0 . 1 7 7 i
5.00(0.195 0.197)
Wearor damage
One-wayclutchcontactarea
1stgearLD.
Countershaft
ParkgearO.D.
Mainshaftfeed pipeA, O.D.(at 15 mm (0.59inlfrom
83.339- 83.365(3.2810 3.2821)
- 2.6259)
66.685- 66.698(2.6254
8.97- 8.98(0.353- 0.354)
Wearor damage
Wearor darnage
8.95(0.352J
- 0.2354i
5.97 5.9810.2350
- 0.3142)
7.97- 7.98(0.3138
5 . 9 5( 0 . 2 3 4 )
7 . 9 5( 0 . 3 1 3 )
1.87- 1.97{0.074 0.078)
1 . 8 0( 0 . 0 7 1 )
- 0.2374)
6.0r8 - 6.030{0.2369
9.000- 9.01s10.3543-0.3549)
- 0.3158)
8.000-8.022(0.3150
2.025- 2.015l0.0197-0.0417)
35.000 35.02511.37801.3782)
6.045(0.2380)
9.03(0.356)
8.03{0.316)
2.08(0.082)
35.050(1.3799)
5.90- 6.00(0.232- 0.236)
5.40(0.213)
Mainshaft 2nd gear thrust washer thickness
feedpipeB,O.D.(at30 mm {1.2in)from end)
Mainshaft
feedpipeO.D.lat 15 mm (0 59 in) from
Countershaft
eno)
Mainshaftsealingringthickness
1 2 9m m 1 1 . 1i n i a n d3 5 m m { 1 . 4i n ) )
Mainshaftbushingl.D.
MainshaftbushingLD.
bushingLD.
Countershaft
Mainshaftsealingring goovewidth
Regulator
valve body
Seatingring conlact area l.D.
Shifting device and
park brake control
ReverseshiftforkIingerthickness
Parkbrakepawl
Parkgear
Servobody
Shift fork shaft bore LD.
Shiftfork shaftvalveborel.D.
ATFpump gearsideclearance
clearance
ATFpump gear-to-body
ATFpump
Differential
carrier
Differential
prnrongear
LIMIT
SEBVICE
STANDARDINEW)
- 0.157)
4.0010.156
4.05(0.158 0.159)
4 . 1 0( 0 . 1 6-0 0 . 1 6 1 )
4 . 1 5( 0 . 1 6 2 0 . 1 6 3 )
4 . 2 01 0 . 1 6-40 . 1 6 5 )
4.25(0.166- 0.167)
4 . 3 0( 0 . 1 6 8 - 0 . 1 6 9 )
4 . 3 5( 0 . 1 7 0 0 . 1 7 1 )
- 0.173)
4.4010.172
- 0.175l
4.4510.114
MEASUREMENT
ATFpump drivengearLD.
ATFpump drivengearshaftO.D
PinionshaftcontactareaLD.
Carrierto'pinionclearance
contactare LD.
Driveshaft
clearance
Carrierto-driveshaft
Backlash
t.D.
Pinion gear to-pinion shaft clearance
Set ring-to bearing outer race clearance
1
I
+
Wearor damage
+
I
lWear
- 0.5516)
14.000- 14.010(0.5512
- 1.4582)
37.000- 37.039(1.4567
0.03-0.05 {0.001- 0.002)
- 0.0052)
Drive 0.1050- 0.1325(0.0041
- 0.0025)
Daiven 0.0350- 0.0625(0.0014
- 0.5525i
- 14.034{0.5518
14.0' |6
13.980 13.990(0.5504 0.5508)
18.010 18.028{0.7091 0.7098)
-0.0022)
0.023- 0.057(0.0009
26.025* 26.04511.0246 1.0254)
- 0.0034)
0.045- 0.086(0.0018
0.05- 0.15{0.002- 0.006)
- 0.7113i
18.042- 18.066(0.7103
- 0.0037)
0.055- 0.095(0.0022
0 - 0.15(0 0.006)
or otherdefect
3 7 . 0 4 (51 . 4 5 8 5 )
0.07(0.003)
0.1{0.004)
0 . 1 2{ 0 . 0 0 5 )
ffi.oour
Adjust
(cont'd)
3-13
Standardsand ServiceLimits
Automatic Transmission(cont'd)
Section '14
STANDARD{NEW}
MEASUREMENT
Wire Dia.
Springs
CVT
Hegulator
valvespringA
Regulato.
valvespringB
Statorreactionspring
Modulatorvalvespring
Torqueconvenercheckvalvespring
Coolerreliefvalvespring
Reliefvalvespring
2nd oriticecontrolvalvespring
1-2shiftvalvespring
2-3shift valvespring
3 4 shiftvalvespring
'lst accumulator
spring
4th accumulator
springB
4th accumulator
springA
2nd accumulator
springA
3rd accumulator
springA
2nd accumulator
springB
3rd acc!mulatorspringB
2nd accumulator
springC
Lockup shiftvalvespring
Lockup timing valvespring
Lock-upcontrolvalvespring
3 4 ofificecontrolvalvespring
Servocontrolvalvespring
CPCvalvespring
CPBvalvespring
4th exhaustvalvespring
1 . 8{ 0 . 0 7 1 )
1 . 8{ 0 . 0 7 1 )
4.5\O.117)
1 . 4( 0 . 0 5 5 )
1.010.039)
1.0(0.039)
1 . 1( 0 . 0 4 3 )
0.7 (0.028)
0.9 (0.035)
0.9(0.035)
0.9(0.035)
2.1(0.083)
2.3 (0.091)
2.610.102)
2.4(0.094)
2 . 8( 0 . ' 1 1 0 )
1.6(0.063)
2.2(0.087)
2.2 t0.041)
0.9 (0.035)
0.9(0.035)
0.7(0.028)
0.7(0.028)
1.0(0.039)
0.6(0.024)
0.9{0.035)
0.9(0.035)
MEASUREMENT
Capacity f {USqt, lmp. qt)
No. ol Coils
87.8(3.457)
44.0i.732l'
3 0 . 3( 1 . 1 9 3 )
35.0{1.378)
3 3 . 8( 1 . 3 3 1 )
3 3 . 8( 1 . 3 3 1 )
3 7 . 1( 1 . 4 6 1 )
34.8(1.370)
4 1 . 3( 1 . 6 2 6 )
57.0 (2.2441
51.0 \2.2441
89.1{3.508)
5 1 . 6( 2 . 0 3 1 )
87.0(3.425)
39.011.535)
89.3(3.516)
2 0 . 7( 0 . 8 1 5 )
3 5 . 11 1 . 3 8 2 )
68.012.6711
73.7 12.902)
80.7(3.177)
38.0{1.496)
37.5fi.476)
52.1(2.051)
12.2(0.480)
47.2{1.858}
36.4{1.433)
STANDARDINEWI
Forwardclutchpressureat 1,500rpm in E position
Reversebrakepressureat 1,500rpm in E position
Dr;vepulleypressureat 1,500rpm in E posrtron
1kgflcm,,psi)
Drivenpulleypressureat 1,500rpm in N position
pressureat 3,000rpm in E posrtron
Lubrication
Stallspeedfpm (Checkwith vehicleon levelground)
E position
E, E, El positions
Hydraulic
pressure
Clutchinitialclearance
Clutchreturnspringfree length
Clutchdiscthickness
Clutchplatethickness
3-14
Downloaded from www.Manualslib.com manuals search engine
L.
FreeLongth
16.5
11.0
1.9
10.9
4.2
4.2
13.4
22.0
16.3
26.8
26.a
16.2
13.8
14.2
2.9
15.6
6.1
2.4
13.9
32.0
45.8
14.1
24.6
20.4
18.3
19.5
Section 14
Transmission
fluid
Clutch
o.D.
14.7(0.584)
9.6 (0.381)
3s.4(1.407)
9.4(0.374)
8.4 (0.334)
8.4 (0.334)
8.6{0.342)
6.6(0.262)
7.6 (0.302)
7.6 (0.302)
7.6 (0.302)
16.0(0.636)
10.2lo.402l
17.0{0.676)
2 9 . 0( 1 . 1 5 2 )
1 7 . 5( 0 . 6 9 5 1
9.0 (0.358)
3 1 . 0( 1 . 2 2 0 )
14.5{0.576)
7.6(0.302)
8 . 1( 0 . 3 1 9 )
6.610.262)
6.6(0.262)
8.1 (0.322)
5.6 (0.2231
8.110.322)
6.1 10.242)
Forwardclutch
Start clutch
Reversebrake
Forwardclutch
Start clutch
Reversebrake
Forwardclutch
Startclutch
Reversebrake
Forwardclutch
Start clutch
Reversebrake
SERVICELIMIT
6.4{6.8,5.6)for overhaul
3.9 (4.1,3.4)for fluid change
- 11.A,203
- 2531
1.4- 1.15114.3
1.4 1.75(14.3 11.8,203 2531
-7.1,28- 1011
o . 2- 0 . 7 1 2 . 0
r . 5 2 . 31 1 5 .-3 2 3 . 52, 1 8- 3 3 4 )
A b o v e0 . 2 1 2 , 3 0 )
2,500
3,000
- 2,650
2,350
- 3,r00
2,800
0.6- 0.8(0.024- 0.031)
0.5- 0.7(0.020 0.028)
0.45- 0.75(0.018- 0.030)
3 0 . 5{ 1 . 2 0 1 )
4 0 . 9( 1 . 6 1 0 )
2 9 . 4( 1 . 1 5 7 )
1.88- 2.00(0.074-0.079)
1.88 2.00(0.074- 0.079)
1.94- 2.06(0.076- 0.081)
1.95- 2.05(0.077-0.081)
2.25 2.35(0.089- 0.093)
1.90- 2.00(0.075 0.079)
3 8 . 9( 1 . 5 3 1 )
27.411.019l'
Until groovesworn out
,*x.ar}
Untilgroovesworn out
Discoloration
Discoloration
Discoloration
UO
cw
[Jnit of length: mm (in)
Section 14
STANDARD{NEW}
- 0.138)
3.4 3.510.134
Mark 1 or 15
Forwardclutchend platethickness
M a r k2 o r 1 6
3 . 5- 3 . 6( 0 . 1 3-8 0 . 1 4 2 )
3 . 6- 3 . 7( 0 . 1 4-2 0 . 1 4 6 )
M a r k3 o r 1 7
3.7 3.8(0.146 0.150)
M a r k4 o r 1 8
3 . 8- 3 . 9( 0 . 1 5 -0 0 . 1 5 4 )
M a r k5 o r 1 9
3 . 9- 4 . 0( 0 . 1 5-4 0 . 1 5 7 i
Mark6 or 20
4 . 0- 4 . 1( 0 . 1 5-7 0 . 1 6 1 )
Mark7 or 21
4.1- 4.2(0.161- 0.165)
Mark8 or 22
4.2- 4.3(0.165- 0.169)
MarkI or 23
Mark10or 24 4.3- 4.4(0.169- 0.173)
Mark11or 25 4 . 4- 4 . 51 0 . 1 7-30 . 1 7 7 i
Mark12or 26 4 . 5 4 . 6( 0 . 1 7 7 0 . 1 8 1 )
4.6- 4.7(0.181- 0.185)
Matk 13ot 21
3.55- 3.65(0.140 0.144)
plate
Mark
1
thickness
Reversebrakeend
- 0.152)
3.75- 3.8510.148
Mark2
3.95- 4.05(0.156- 0.159i
Mark3
4 . 1 5- 4 . 2 5( 0 . 1 6 3 0 . 1 6 7 )
Mark4
4.35- 4.45(0.171- 0.175)
\44rk 5
4.55- 4.65(0.179- 0.183)
Mark6
4.75- 4.85(0.187- 0.191)
Mark7
4.95- 5.05(0.195- 0.199)
Mark8
- 9.99(0.3929 0.3933)
9.98
gear
shaftO.D.
ATFpump drive
- 0.3933)
9.98- 9.99{0.3929
ATFpump drivengearshaftO.D.
10.000- 10.015(0.3937 0.3943)
Drivegearshaft
ATFpump body bushingl.D.
Drivengearshaft 10.000- 10.015(0.3937 0.3943)
0.01s- 0.035(0.0006 0.0014)
ATFpump gearsideclearance
0.035- 0.0505(0.0014-0.0020)
ATF pump gear-to-bodyclearance Drive gear
0.035- 0.0505(0.0014- 0.0020)
Drivengear
MEASUBEMENT
ATFpump
Transmission
Diameterof needlebearingcontactarea
Inputshaft- flywheelside
Inputshaft forwardclutchside
Drivepulleyshaft- startclutchside
Drivepulleyshaft- flywheelside
Drivepulleyshaft- forwardclutchside
Thrustclearance
Carrierand ring gear
Drivenpulleyshaftand startclutchhub
Inputshaftand ATFpump drivensprocket
gearshaftand flywheelball bearing
Secondary
- 0.7874)
19.987- 20.000(0.7869
- 0.7874)
19.987- 20.000(0.7869
- 1.7319)
43.981- 43.991(1.7315
24.007- 24.020(0.945- 0.946)
24.007- 24.020(0.945- 0.946)
SERVICELIMIT
Discoloration
Discoloration
Discoloration
1
I
Discoloration
Wear or damaged
Wear or damaged
Wear or damaged
Wear or damaged
Wear or
Wear or
Wear or
Wear or
Wear or
damaged
damaged
damaged
damaged
damaged
- 0.0043)
0.050- 0.110(0.0020
- 0.005)
0.000- 0.13010.000
0.370- 0.650(0.015- 0.026)
0.00 0.15(0.00 0.006)
(cont'd)
3-15
Standardsand ServiceLimits
CW {cont'd)
Transmission
(cont'd)
Section 14
MEASUREMENT
T h r u s st h i m , 2 5x 3 1 m m t h i c k n e s s
Cottersthickness
ATFpump drivesprocketthrustshim,22 x 28 mm
thickness
gearshaftthrustshim,25 x 35 rnm
Secondary
thickness
Input shaft feed pipe O.D.
Drive pulley leed pipe
Forward clutch feed pipe
Input shaft bushing t.D.
Drive pulley feed pipe bushing
Forward clutch feed pipe bushing
Driven shaft feed pipe O.D.
Start clutch feed pipe (right side cover side)
Driven pulley feed pipe
S t a n c l u t c h f e e d p i p e ( f t y w h e e th o u s i n g s i d e )
Driven pulley shaft bushing LD.
Stan clutch feed pipe (right side cover sroer
Drive pulley feed pipe
Start clutch feed pipe (flywheel housing side)
Secondarydriven gear sealing ring groove width
Start clutch end plate l.D.
Input shaft sealing ring groove width
Dnve pullev shaft LD. at sealing ring
Shifting device
ano parK
brakecontrol
3-16
Parkbrake cone
Parkbrake pawl
Parkgear
STANDARD{NEW}
rlz-r-osr-o.o+o
oolrr
1 . 0 9- 1 . 1 2( 0 . 0 4 3 0 . 0 4 4 )
1 . 1 6 1 . 1 9( 0 . 0 4-6 0 . 0 4 7 )
1.23 1.26(0.048 0.050)
1 . 3 0- 1 . 3 3( 0 . 0 5 1 0 . 0 5 2 )
1.37- 1.40(0.054 0.055)
1.44- 1.47(0.057 0.058)
1 . 5 1 1 . 5 4( 0 . 0 5 9 0 . 0 6 1 )
1 . 5 8 1 . 6 1( 0 . 0 6-2 0 . 0 6 3 )
1.65- 1.68(0.065 0.066)
1.72 1.75{0.068 0.069)
- 0.012]}
1.79 1.a2t0.O10
1 . 0 5 5 1 . 0 8 5( 0 . 0 4 1 50 . 0 4 2 7 )
1 . 1 2 -5 1 . 1 5 5( 0 . 0 4 4 30 . 0 4 5 4 )
1.195- ' I.225(0.0470 0.0482)
- 1 . 2 9 s( 0 . 0 4 9 80 . 0 5 1 0 )
1.265
- 0.0537)
1.335 1.365(0.0526
- 0.0565)
1.40s- 1.435(0.0553
r.475 1.505{0.0580 0.0593)
1.545 1.575(0.0608 0.0620)
- 0.0648)
1.615 1.645(0.0636
1 . 6 8 5 1 . 7 1 5 1 0 . 0 6- 603. 0 6 7 5 )
1.755- 1.785{0.0691 0.0703)
2 . 8 7- 2 . 9 0( 0 . 1 3- 0 . 1 1 4 )
2 . 9 7- 3 . 0 0( 0 . 1 1 7 0 . 1 1 8 )
3.07-3.10 \0.121 0.122)
3 . 1 7- 3 . 2 0( 0 . 1 2 5 0 . 1 2 6 )
1 . 1 2 1 . 1 5 1 0 . 0 -4 4
0.045)
1.37 1.40(0.054- 0.055)
1.62- 1.65(0.064 0.065)
1 . 8 7- 1 . 9 0( 0 . 0 7 4 , 0 . 0 7 5 )
2.12 2.15(0.083- 0.08s)
2.37 2.40(0.093 0.094)
2 . 8 0- 2 . 8 5( 0 . 1 ' t-00 . 1 1 2 )
2 . 9 0 2 . 9 5( 0 . 1 1-4 0 . 1 1 6 )
3 . 0 0 3 . 0 5( 0 . 1 1-8 0 . 1 2 0 )
3 . 1 0- 3 . 1 51 0 . 1 2 20 . 1 2 4 )
, .128i
3 . 2 0- 3 . 2 5( 0 . 1 2 6 0
3.30- 3.35(0.130 0.132)
3 . 4 0- 3 . 4 s1 0 . 1 3 40 . 1 3 6 )
3 . 5 0 3 . 5 5( 0 . 1 3-8 0 . 1 4 0 )
3 . 6 0 , 3 . 6 5( 0 . 1 4 2 0 . 1 4 4 )
3 . 7 0- 3 . 7 5( 0 . 1 4 6 0 . 1 4 8 )
3 . 8 0- 3 . 8 5 1 0 . 1 5 0 . 1 5 2 )
SERVICE
LIMIT
I Wr"r - d-"-"g"d
ii
11
ir
Wear,or damaged
I
Wearor damaoed
Wearor damaged
t
{
Wear or damaged
Wearor damaged
w
Wearor damaqed
6.97- 6.98(0.274- 0.27s)
1 1 . 4 -7 1 ' 1 . 4(80 . 4 5 1 60 . 4 5 2 0 )
6.95(0.274)
(0.451)
11.45
- 0.2762]l
7.O0O7.0t510.2156
1 1 . 5 0 0 1 1 . 5 1(80 . 4 5 2 80 . 4 5 3 5 )
7.030(0.277)
1 1 . 5 3(30 . 4 s 4 )
6.97- 6.9A\0.214 0.275:l
- 1 1 . 4 8( 0 . 4 5 1_60 . 4 5 2 0 )
11.47
- 0.354)
8.97 8.9810.353
6.95(0.274)
1 1 . 4 5( 0 . 4 5 1 )
8 95 (0.352)
- 0.2762)
7.000 7.015(0.2756
(0.4528
- 0.4535)
11.500- '11.518
- 0.355)
9.000 9.01510.354
2.50 2.65(0.098 0.104)
88.900,88.935(3.500- 3.501)
- 0.083)
2.00 2.1010.079
t.030l0.2t7l
1 r . 5 3 3( 0 . 4 5 4 )
9.03(0.356)
2.655(0.r05)
Wearor damaged
2 . 1 0 5( 0 . 0 8 3 )
Wearor damaqed
5*
rl
Wear or other defect
Wear or other defect
Wear or other defect
ro
cw
U n i t o f l e n g t h :m m l i n )
Section14
STANDARD{NEW)
1 8 . 0 1 0 1 8 . 0 2 8 ' 0 . 7 0-901. 7 0 9 8 )
- 0.0022)
0.023 0.057(0.0009
26.025- 26.045(.0246 1 0254\
- 0.0034)
0.045 0.086(0.0018
0 0 5 0 . 1 5i 0 0 0 2 0 . 0 0 6 )
1 80 4 2 1 8 . 0 6{60 . 7 1 0 30 . 7 "l 3 )
- 0.0037)
0.055- 0.095(0.0022
(0
0.006)
0.15
0
MEASUREMENT
Differential
Pinion shaft contact area LD.
C a r r i e r - t op i n i o n c l e a r a n c e
Drive shaft contact area l.D.
Carrierto driveshaftclearance
Dtri"*"t"|p'.b"
gear
Backlash
LD.
Pinion gear to-pinion shafl clearance
S"t rrg-t" b""il"s ) u t e r r a c e c l e a r a n c e
MEASUBEMENT
Springs
Steering
PHregulatorvalvespring
PHcontrolvalvespring
PL regulatorvalvespring
PH'PLcontrolvalvespring
c r u t l hr e d u c ' n vs d r v es p n n s
valvespring
LLbrication
Shittvalvespring
Shiftcontrolvalvespring
Stan clutchcontrolvalvespring
Pitotregulatorvalvespring
spring
Startclutchvalveaccumulator
Reversecontrolvalvespring
Shiftinhibitorvalvespring
WireDia
1 2 (0 047)
1 7 {0.067)
0 9 (0.035)
1 0 (0 039)
]I : 1(u
9 9]:l
b ubJr
1 4 (0.055)
1 0 (0.039)
0.4(0 016)
0.6(0 024)
1 2 \0 O47)
1 2 (0.047)
1 3 (0 051)
Gearbox
0.1(0 004)
0.12(0.005)
0.15{0.006)
Adjlrst
O.D.
FreeLength
9.0{0.354)
13.4(0.528)
1.2lO.2A3\
10.0(0.394)
1 6 . 8( 0 . 6 6 1 )
13.4(0.528)
8.2 (0.323)
1.4 t0.2911
4 . 1( 0 . 1 6 1 )
5.7 t0.224)
8.3{0.327)
9.4 (0.370)
1 3 . 2( 0 . 5 2 0 )
2 6 . 7( 1 . 0 5 1 )
3 9 . 4( 1 . 5 5 1 )
1 4 . 6( 0 . 5 7 5 )
3 1 . 4( 1 . 2 3 6 )
44.4\1.14al
5 1 . 6( 2 . 0 3 1 )
3 4 . 1( 1 . 3 4 3 )
1 9 . 3( 0 . 7 6 0 )
1 2 . 1( 0 . 4 7 6 )
9 . 5( 0 . 3 7 4 )
2 9 . 8( 1 . 1 7 3 )
3 1 . 4( 1 . 2 3 6 )
4 8 . 3( 1 . 9 0 2 )
I
No. of Coils
r0.0
8.1
1.2
8.6
8.0
13.0
1.5
6.8
5.0
12.3
11.0
10.6
Section 17
STANDARD
{NEWI
MEASUREMENT
Steeringwheel
SERVICELIMIT
Playat steeringwheel circumference
S t a r t i n g l o a d a t s t e e r i n gw h e e l c i r c u m f e r e n c e
N (ksf, lbf)
Manual steering
Engine running
Power steering
M/S
Angleof rackguidescrewloosened
P/S
from lockedposition
Preloadat piniongearshaftN m (kglcm,lbfin) M/S
P u m p p r e s s u r ew i t h v a l v e c l o s e d
( o i l t e m p . / s p e e d :4 0 ' C ( 1 0 5 " F )m i n . / i d l e
Do not run for more than 5 seconds).
kPa (kgtcm?,psi)
0 - 1 0( 0 0 . 4 )
1 5( 1 . 5 , 3 . 3 )
2 9( 3 . 0 , 6 . 6 )
20!5"
20'Max
0 . 5- 1 . 7( 5- 1 7 , 4 . 3- 1 4 . 8 i
0 . 6 1 . 2( 6- 1 2 ,5 . 2 0- 1 0 . 4 2 )
6,400- 7,400{65- 75,920- 1,070)
HONDAPowerSteeringFluid
at disassembly
0.85(0.90,0.75)
Reservoir 0 . 4{ 0 . 4 2 . 0 . 3 5 }
Power steering
fluid
powersteeringfluid
Recommended
Fluidcapacity | {US qt, lmp q0
Powersteering
belt*
with 98 N (10kgf,22lbf)
Deflection
betweenpulleys'99 modell81642EngineTypeonly
7.5 11.0{0.30- 0.43)withusedbelt
5.0 7.0(0.20 0.28)with new belt
'96 '99 models:OtherEngineTYPes 10.5- 14.010.41
- 0.55)with usedbelt
7.5 10.010.300.39)with new belt
ron.ionffi
81642EngineTvpeonly
N (kgf,lbf) '99 model:
'96 -'99 models:OtherEngineTYPes
'99 modelr
81642EngineTYPeonlY
'96 '99 models:OtherEngineTYPes
390
340740
640
540{40
490(35880(757 8 0( 6 5-
55,88 '120)wrth usedbek
50,77 - 110)with usedbelt
90, 170- 200)with new belt
8 0 ,1 4 3 - 1 7 6 ) w i t hn e w b e l t
M / S : [ , 4 a n u a ls t e e r i n g , P / S l P o w e r s t e e r i n g
*: When using a ne; bett,adjust dellection or tension to new values. Run the engine for 5 minutes then turn it offR e a d j u s tt h e d e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .
3-17
Standardsand ServiceLimits
Suspension- Section 18
MEASUREMENT
STANOAROINEW}
Camber
algnmenl
Caster
Totaltoe
Frontwheelturningangle Inwardwheel
Outwardwheel
B i mr u n o u t
A l u m i n u mw h e e l
Steelwheel
Wheel bearing
Endplay
Front
Rear
Front
Front
Bear
0 " 0 0 ' 11 "
-1.11'
1'40'I 1"
I n ' 1 . 0 12 . 0{ 1 / 1 6t 1 / ' 1 6 )
I n 2 . 0l j B( 1 / 1 6 11 / 1 6 )
39.50'
33'10'(Reference)
Axial
Badial
Axial
R a d l Ia
Front
Rear
0
000-
0.7(00 . 7( 01 . 0( 0
1 . 0( 0
0.03)
0.03)
0.04)
0.04)
SERVICELIMIT
2.0(0.08)
1 . 51 0 . 0 6 )
2.0{0.0B)
1.5(0.06)
0 0.0s(0 - 0.002)
0 0.05(0 0.002)
Brakes- Section 19
MEASUREMENT
STANDAROINEWI
Parklngbrake
Playin strokeat 196N (20kgf,44 lbfi leverforce
To be lockedwhen pulled
6 - I notches
Footbrake
peoal
Pedalheight(withfloor mat removed)
156.5
{6.16)
161(6 5/16)
1 5(1/16-3/16)
0 - 0.4(0 0.02)
20.9- 21.8(0.82- 0.86)
8.9- 9.1(0.350- 0.358)
Mastercvlinder
Freeplay
Pistonto pushrodclearance
Discbrake
Discthickness
Discrunout
Discparallelism
Padthackness
Front
Rear
Front
Rear
Frontand rear
Front
Rear
Rearbrake
LD.
drum
Liningthickness
*1. 5410Stampedon the caliperbody.
*2. 2056Stampedon the caliperbody.
M/T
A/'T, CVT
9.5 10.5*'
8.5- 9.5*'
7 . 0 8 . 0( 0 . 2 8 - 0 . 3 r )
200 17.a7l
4 . 0( 0 . 1 6 )
SERVICELIMIT
19.0(0.75)
8 . 0( 0 . 3 1 )
0 . 1 0( 0 . 0 0 4 )
0.10(0.004)
0.015(0.0006)
1.6(0.06)
1 . 6( 0 . 0 6 )
'r.6(0.06)
201 \7.911
2.0{0.08}
Air Conditioning- Section22
Conditioning
SANDEN
NIPPONDENSO
Compressor
SANDEN
NIPPONDENSO
Compressor
belt*
MEASUREMENT
STANDARDINEWI
Lubricanttype:SP 10 (P/N38897- Pl3 - A01AHor 3889I - P13 A0li lForrefrigerant:
(R,134a))
HFC-134a
Lubricantcapacity
Condenser | 20\2t30.11
mf (floz, lmp oz)
Evaporator I 45(12/3,1.6)
Lineor hose 1 0( 1 / 3 , 0 . 4 )
Receiver
1 0t 1 / 3 , 0 . 4 )
Lubricanttype:ND'O|L8(P/N38899- PR7- 003)(ForRef.igerant:HFC,134a
(R-134a))
Lubricantcapacity
Condenser 25 (s/60.9)
mf (floz, lmp oz)
Evaporator 6 0 ( 2 , 2 . 1 1
Lineor hose 1 0( 1 / 3 , 0 . 4 )
Receiver
1 0( 1 / 3 . 0 . 4 )
Lubricanttype:SP-10
Lubricantcapacity ml lfl oz,lmp oz)
130 150(4 1/3 4.6,5.0- 5.3)
Fieldcoil resistance
at 68'F(20"C) O
plateclearance
Pulley-to-pressure
0.5r 0.1510.020
t 0.006)
Lubricanttype:ND-OlL8{P/N38899- PR7,003 or P/N38899 pR7- AO1)(ForRefrigerant:
HFC134a{R,134a))
L u b r i c a nc ta p a c i t y m { ( f l o z ,l r n p o z )
| 1 4 O ( 4 . 7 , 4 . -91J5 S { 5 . 2 . 5 . 4 )
S t a t o r c o i l r e s i s t a n c ea t 2 0 ' C ( 6 8 . F ) 0
3.4- 3.8
P u l l e y - t o - p r e s s u r ep l a t e c l e a r a n c e
0 . 5 1 0 . 1 5( 0 . 0 2 1 0 . 0 0 6 )
Deffection
with 98 N (1Okgl.22lbll
7.5- 9.5(0.30 0.37)with usedbelt
betweenpulleys
5.0- 6.5(0.20- 0.26)withnew belt
Belttension N (kgf,lbf)
340 490i35 50,77 - 110)with usedbell
Measuredwith belttensiongauge
690- 830(70- 85, 150 190)with new belt
*: When using a new belt,adjust deflectionor tension to new
values.Run the engine for 5 minutes then turn it of{.
R e a d j u s td e f l e c t i o n o r t e n s i o n t o u s e d b e l t v a l u e s .
3-18
U n i t o f e n g l h :m m { n )
Electrical Section 23
STANDARD
{NEW}
MEASUREMENT
Ratedvoltage V
at 68'F(20'C) o
Primarywindingresistance
12
HITACHI
TEC
windingresastance
at 68'F120"C) kO
Secondary
HITACHI
TEC
Resistance
at 68'F(20'C) kf)
F i r i n go r d e r
0.45 0.55
0.63 0.11
Sparkplug
Type
Gap
Seesection23
l g n i t i o nt i m i n g
At idle
' B T D Cl R e d )
Alternator belt+
D e f l e c t i o nw i t h 9 8 N ( 1 0 k g f , 2 2 l b f )
between pulleys
lgnitioncoil
lgnitionwire
Belttension N (kgf,lbf)
Measuredwith belttensiongauge
22.4- 33.6
12.A- 19.2
25 max.
1-3-4 2
1.13,(o.o€-3*.)
8.0- 10.5{0.31- 0.41}with usedbelt
6.0- 8.5{0.26- 0.33)withnew belt
340- 490(35- 50,77 110)with usedbelt
5 4 0- 7 4 0( 5 5- 7 5 ,1 2 1 . 1 6 5 ) w h hn e w b e r t
SERVICELIMIT
STANDARDINEWI
(MITSUBISHI)
Alternator
(DENSOi
Starter
(MITSUEA
1 . 0k w
1.2kW)
Outputl3.5 V at hot A
(rotor)at 68'F(20"C) kO
Coalresistance
S l i pr i n sO . D .
Brushlength
Brushspringtension g (oz)
'13.5V at hot A
Output
(rotor)at 68'F (20'C) k0
Coil resistance
S l i pr i n gO . D .
Erushlength
Brushspringtension g (oz)
75
3.4-3.8
Z2.j \0.A9)
19.0(0.75)
3 4 0 4 2 0( 1 2 . 0 1 4 . 8 )
Tvpe
Commutatormicadepth
Commutatorrunout
CommutatorO.D.
Brushlength
Brushspringtension(new)
N (ksf,lbf)
Gearreduction
0.4- 0.5(0.016- 0.020)
o o.o2(o - 0.000e)
2 8 . 0 - 2 8 . 1( 1 . 1 0 2 1 . 1 0 6 )
1 5 . 8- 1 6 . 21 0 . 6-2 0 . 6 4 )
15.7- 11.1
{1.60- 1.80,3.5- 4.0i
80
2.2- 3.0
14.4(0.57)
10.5(0.41)
3 3 0{ 1 1 . 6 )
I
22.2\0.47)
5.0(0.20)
| 14.0(0.55)
1.5(0.06)
0.15(0.006)
| o.o5(o.oo2)
| 27.5(1.083)
1 1 . 0( 0 . 4 3 )
*: When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off
Readiustdeflectionor tensionto usedbeltvalues
3-19
DesignSpecifications
ITEM
DII/IENSIONS
OverallLength
2 door Coupe/4door Sedan
2 door Hatchback
(,96 98)
('99,' 00)
(,96,,97)
('98- 00)
Overallwidth
Overallheight 2 doorCoupe/2doorHatchback
4-doorSedan
Wheelbase
FronvRear
I Track
GroundClearance
SeatiogCapacity
WEIGHT(USA)
GrossVehicleWeightRaring(GVWR)
2 door Coupe
HX M/T,DX M/T
HX CVI ('96)
HX CVT('97,'98)
HX CVT('99}
DX A,/T(96 98,
DX A"/T('99,'00)
EX
Si
2 door Hatchbacl CX.DX r'96, 97,
cx, DX ('98)
cx (,99,,00)
DXM/Ti'99,00i
DX A/T ( 99, 00,
4 door Sedan
DX, LX,DX-V
EX
WEIGHT(CANADA) GrossVehicleWeightBating(GVWR)
2-doorCoupe
DX ('96)
DX ('97 00)
DX-G
si 1,96)
si ('97- 00)
siR
2 door Hatchback CX,CX,G('96)
cx,cx,G1,97)
cx-G(,98)
cx ('98 00)
4 door Sedan
ENGINE
DX M/T, SE M/I
DX A,/T,SE A,/T
LX,LX V
EX M/I
EX A/T
Type
CylinderArrangement
Boreand Stroke
D16Y5,D16Y7,Dt6y8
B1642
Displacement
D16Y5,D16Y7,Dl6Y8
81642
Compression
Ratio
D16Y5,D16y7
D16Y8
816A2
ValveTrain
Lubrication
System
Oil PumpDisplacement
at 6,800enginerprn
D16Y5,D,l6Y7,D16Y8
81642
WaterPumpDisplacement
at 6,000enginerpm
016Y5,D16Y7,D16y8
816A2
FuelRequired
D16Y5,D16Y7,D16y8
816A2
STARTEB
Type/Make
NormalOutput
NominalVohage
HourRating
Directionof Rotation
METRIC
ENGLISH
4,445mm
4,450mm
4 , 1 7 0m m
4 , 1 8 0m m
1 , 7 0 5m m
1,375
mm
1,390mm
2,620mm
1,475/1,415
mm
1 5 0m m
1 7 5 . 0i n
115.2in
164.2in
1 6 4 . 6i n
6 7 . 1i n
5 4 . 1i n
5 4 . 7i n
1 0 3 . 1i n
58.1/58.1
5.9in
NOTE
3,290tbs
3,320tbs
3,330tbs
3,360rbs
3,290rbs
3 , 3 1 0t b s
3,440tbs
3,480tbs
3,285tbs
3,290tbs
3,290tbs
3,290tbs
3,330lbs
3,330tbs
3,460tbs
1,500ks
1,510
kg
1 , 5 1 0k g
1,560kg
1,570kg
1,590ks
1,495
kg
1,505kg
1 , 5 1 0k s
1 , 5 1 0k s
1,510
kg
1,530kg
1,510
kg
1 , 5 1 0k s
1,540ks
Water-cooled,
4-stroke
SOHC*1,
SOHC
VTEC"',SOHCWEC.E'3,DOHCVTEC{
gasolineengine
Inline4 cylinder,transverse
75.0x 90.0mm
2.95x 3.54in
8 1 . 0x 7 7 . 4m m
3 . 1 9x 3 . 0 5i n
1,590cm3
97.0cu-in
1,595cm3
97.3cu in
9.4
9.6
10.2
Beltdriven,4 valveper cylinder
Forcedand wet sump,trochoidpump
* 1 :D 1 6 Y 7
*': D16Y8
*3:D16Y5
*': 816A2
33.4f (35.3US qt, 29.4lmp qt)/minute
43.8| (46.3US qt, 38.6lmp qt)/minute
125{ {132US qt, 110lmp qt}/minute
140f {148US qt, 123lmp qt}/minute
gasolinewith 86 Pump
UNLEADED
OctaneNumberor higher
PremiumUNLEADED
gasoline91 Pump
OctaneNumberor higher
Gearreduction/MITSUBA
1.0kw, 1.2kw
12V
30 seconds
Clockwise
as viewedfrom gearend
5-Z.V
-
trEM
MllSUBAr.u,l.z kw
SfAnff n i*nt-i-
W"'gf,t
CLUTCH
ClutchType
TRANSMISSION
ClutchFacingArea
Type
Transmission
I
M/T
CVT
M/T
M/T
Arr
CW
PrimaryReduction
5-speedforward,1 reverse
Synchronized
4 speedautomatic,1 reverse
Non stagespeedforward,1 reverse
Direct1 : 1
D16Y5 |
FinalReduction
3.250
1.182
1.112
0.909
0.702
3.153
Gearratio
GeartYPe
3.122 13.122"11.053"
1 4.250 |
'lst
GearRatio
2nd
3rd
4th
Reverse
Gearratio
GeartYPe
FinalReduction
cw
Low - O.D.
Reverse
GearRatio
SecondaryReduction
FinalReductionGearRatio
GearRatio
AIR
CONDITIONING
CoolingCapacity
Type/Make
Compressor
No. of CYlinders
CaPacitY
Max.Speed
LubricantCaPacitY
Compressor
Type/Manufacturer
No. of Cylinder
Capacity
Max.Speed
LubricantCaPacitY
Condenser
Evaporator
LubricantTYPe
Type
TyPe
Elower
Enginetype
D16Y8 I 81642
3.230
3.250
3.250
2.105
1.909
1.182
1.458
1.250
1.112
1.107
0.909
0.909
0.875
0.102
0.702
3.000
3.153
3.153
D16Y7
1st
2nd
3rd
4th
5th
Reverse
Automatictransmission
TyPe
Motor Input
SPeedControl
Max.CaPacity
NorEs
Singleplatedry, diaphragmspring
Torqueconverter
Multi plateswet sanP,hYdraulic
2 5s q i n
160cm,
Manualtransmission
GearRatio
ENGLISH
merntc
r'4 rg
*1:2 door
Hatch back
+ 2 r2 - d o o r C o u p e ,
and 4 door
Sedan
4.266
S i n g l eh e l i c a l g e a r
Enginetype
D16Y8
D16Y7
|
2.122
2.600
1.468
0.975
0.926
0.638
0.638
1.954
1.954
4.357
1.351
2.466 0.449
2.466
1.333
4.357
14,000BTU/h
3,530Kcal/h
Scroll/SANDEN
5.22cu inkev
10,000rpm
41l3tloz.
1 3 0m f
4.6imp oz
|
Swash-plate/DENso
10
9.4cu_in/rev
155.3mf /rev
76,000rpm
4 2l3fl oz,
140mf
|
4 9 l m po z
I
ND'OIL8
85.7 m//rev
sP,10
Corrugatedfin
fin
Corrugated
fan
Sirocco
200w112v
4 speed variable
16,200 cu ft/h
460 m3/h
Temperature Control
Compressor
Clutch
Refrigerant
TyPe
PowerConsumPtion
TyPe
ouantity
drive
Dry,singleplate,PolY-V'belt
40 W max./12V at 68'F(20'C)
HFC134a(R'134a)
22.9 isoz
650 gos
|
( c o n t ' )d
4
.\t
J-Z
I
DesignSpecifications
(cont'd)
ITEM
STEERING
SYSTEM
METRIC
Tvpe
P/s
M/S
p/S
M/S
p/S
M/S
OverallRatio
Turns,Lock-toLock
SUSPENSION
WHEEL
ALIGN|\t4ENT
SteeringWheelDia.
TYPe
Frontand Rear
Frontand Rear
Camber
Front
Rear
F.ont
Front
Rear
Caster
TotalToe
EBAKESYSTEM
Type
Front
Rear
PadSurfaceArea
Front
ParkingBrake
TIRE
WASHER
Type
Sizeand Pressure
Capacity
2door Coupe/4,door
Sedan
2,doorHatchback
ELECTRICAL
Baftery
Starter
Alternator
Fuses
In UnderdashFuse/Felay
Box
In Under-hoodFuse/Belay
8ox
In UnderhoodABS FLrse/Relay
Box
Headlights
FrontTurn Signal/Parking
Lights
RearTurn SignalLaghts
Brake/Taillights
InnerTaillights*,
HighMount BrakeLight
Backup Lights
LicensePlateLights
CeilingLight
TrunkLights
GaugeLights
IndicatorLights
llluminationand PilotLights
HeaterControlPanelLights
P/S:PowerSteering M/S:ManualSteering
*l: 2-doorCoupe *2: 2door Hatchback *3: 4-doorSedan
*4: USA (HAM),Canada(HCM)produced *5: Japanproduced
NOTE
0.00,
- 't'
1.40'
ln 1 mm
In 2 mm
ln 1/16
In 1/16
Powerassisted
selfadjustingventilated
disc
Powerassisted
selfadiustjngsoliddisc
Powerassistedsell adjustingdr!m
37.5cm' x 4
5.8sq in x 4
44.1ctn,x4
Rear
ENGLISH
Powerassisted,
rackand pinion
R a c ka n dp i n i o n
1l.1
20.3
3.6
4..1
380 mm
15.0in
Independent
doublewishbone,coil spring
Telescopic,hydraulicnitrogengas-filled
]
6.84sq-inxa
67.2cmzx 4
to.+ sq in ' I
|
21.2cm, x 4
3.3 sq in x 4
Mechanical
actuating,reartwo wheel
brakes
5410stampedon
the caliperbody
2056stampedon
the caliperbody
Drum
Disc
Seelire intormationlabel
2.5f (2.6LJSqt, 2.2 lmp qt)
4 . 5| ( 4 . 8U S q t , 4 . 0 l m pq t )
2.51 (2.6US qt, 2.2lmp qt)
4.5f (4.8US qt, 4.0lmp qt)
12V 38 AH/5HR
12V 1.0kW, 1.2kW
1 2 V 7 5A , 8 0A
7.5A, t0 A, 15A, 20 A
7.5A, 10A, 15A, 20 A, 30 A, 40A, 80 A
7 . 54 . 2 0 A , 4 0A
12V_60/55W
12V-2115W
1 2 V- 2 1 W
1 2 V- 2 1 / 5 W
12V-5W
1 2V 1 8W * " 2 1W + " * 3
12V 21W
12v-5w
l2V-8W(Withmoonroofl
12V - 5W (Withoutmoonroof)
USAmodel
Canadamodel
DX
ExceptDX
12V-1.4W,3W
' t 2v 1 . 1 2 W 1
. . 4W
1 2 v - 0 . 8 4 w ,1 . 4W
1 2 V 1 . 4W
L'
3-22
Body Specifications
U n i t :m m ( i n )
2-doorCoupe:
lt t9) gtt't
Body Specifications(cont'd)
2-door Hatchback:
Unit:mm (in)
(t t9] gre'r
3-24
Lif
Un i t :m m ( i n )
4-doorSedan:
(r'tsl 06€'l
3-25
Maintenance
.""."".' 4'2
LubricationPoints
MaintenanceSchedulefor 1996Model
'.""" 4-4
Normal Gonditions
."""" 4-6
SevereConditions
MaintenanceSchedulefor 1997Model
."""' 4-8
Normal Conditions
....""' 4-10
SevereConditions
MaintenanceSchedulefor 1998Model
"""" 4'12
Normal Conditions
."""" 4-14
SevereConditions
MaintenanceSchedulefor 1999Model
."""' 4'16
Normal Conditions
."""" 4'18
SevereConditions
MaintenanceSchedulefor 2000Model
."""' 4-2O
Normal Conditions
"'.""' 4-22
SevereConditions
I
LubricationPoints
For the detailsof lubricationpointsand types of lubricantsto be
applied,referto the lllustratedIndexand variouswork
procedures(suchas Assembly/Reassembly,
Replacement,
Overhaul.Installation,
etc.)containedin eachsection.
No.
LUBRICATIONPOINTS
LUBRICANT
I
Engine
"Energy
Conserving"
gradeoil,
The oil containermay also displaythe Apl Certificationmark
shownbelow.Makesureit says,,ForGasoline
Engines.,,
SAEViscosity:Seechart below,
Transmission
Manual
GenuineHondaMTF*1
Automatic
GenuineHondaPremiumFormula
AutomaticTransmission
Fluid(ATF)*,
CVT
GenuineHondaCVTFluid*3
3 BrakeLine
GenuineHondaDOT3BrakeFluid*a
4
ClL,tci t""e
GenuineHondaDOT3BrakeFluid*a
Powersteeringgearbox
Steering greaseP/N 08733- BO70E
Shift leverpivots(manualtransmission)
Greasewith molybdenumdisulfide
7
Releasefork (manualtrancmitzxze
'.:;':;?
trii;i
c< co
NormalConditions
-d
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MaintenanceSchedulefor 1g96Model
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. Make sure
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iacks and salety stands are placedploperly
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Make sure the vehicle will not roll off stands and fall
while you are working underit.
8 x 1 . 2 5m m
24 N.m (2.4kgf.m, 17 lbf ftl
CAUTION:
. Use fender covers to avoid damaging painted surface.
. Unplug the wilin9 connectorscaretully while holding
the conngstor portion to avoid damage,
. Mark all wiring and hososto avoid misconnoction.
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hosesor interferewith other parts,
1.
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the positiveterminal.Removethe battery.
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engine).
8 x 1.25 mm
24 N.m {2.4kgl.m, 17 lbf.ft}
STRUTBRACE
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the connectorsfrom the ECM/pCM.
7.
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MAIN WIRE HARNESS
CONNECTOR
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BATTERYCABLES
UNDER.HOOD
FUSE/RELAY
BOX
ECM/PCM
5-2
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Removethe intakeair duct and air cleanerhousing.
016Y5,Dl6Y& 815A2engin€sl
D16Y, ongino:
a.
a.
Removethe resonatorand intakeair duct.
D i s c o n n e c t h e I A T s e n s o r c o n n e c t o r ,t h e n
removethe intake8ir duct and air cleanerhousIng.
6x1.0mm
9.8 N m {1.0kgtm, 7.2 lbl'ft)
6x1.0mm
9.8 N.m (1.0kgt m, 7.2 lbf.tt)
INTAKE AIR
DUCT
INTAKE AIR
AIR CITANER
HOUSING
Disconnectthe intake air tempsrature (lAT) sensor connector,then r€movethg air cleanerhousIng.
AIR CI."EANER
HOUSING
9.
IAT SENSOR
CONNECTOR
Disconnectthe engine wire harnessconnectoron
the left sideof the enginecompartment.
6x1.0mm
9.EN.m (1.0kgtm, t.2lbtft,
IAT SENSOR
CONNECTOR
(cont'd)
5-3
EngineRemoval/lnstallation
Removal(cont'dl
10. Relievefuel pressure(seesectionl1).
Do not smokewhile working on the fuel
!@
system, Keep open flame or spark away from the
wolk area.Drainfuel only inlo an approvedcontainer.
1 1 . R e m o v et h e e v a p o r a t i v e m i s s i o n( E V A P c) o n t r o l
canisterhoseand fuel feed hose.
12. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose.
D16Y7engine:
VACUUMHOSE
D16Y7engine:
BANJOBOLT
33 N m ( 3.itlgt m, 25 lbt.ft)
FUEI-FEEDHOSE
D16Y5,D16Y8,Bt642 engines:
Dl6Y5, D16Y8,Bl642 enginos:
BRAKEBOOSTER
VACUUMHOSE
I
5-4
13. Removethe throftlecableby looseningthe locknut,
then slip the cable end out of the acceleratorlinkage.
NOTE;
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjustthe throttlecablewhen installing(seesect i o n 11 ) .
the connectorsfrom the PCM.
1 4 , Disconnect
R e m o v et h e g r o m m e t a n d w i r e h a r n e s sc l a m p s ,
then pull out the ECM/PCMconnectors
6x1.0mm
D16Y7engine:
LOCKNUT
16. Removethe mountingboltand lockbolt,then remove
the power steering(P/S)pump belt and pump
NOTE:Do not disconnectthe P/Shoses.
816A2engine:
Removethe adjustingbolt and mountingboits,
then removethe P/Spump belt and pump
D16Y5,D16Y8,B16A2engines:
AOJUSTING
LOCKNUT
(cont'd)
5-5
EngineRemoval/lnstailation
Removal(cont'dl
(
Dl6Y5. DrGYr, D16Y8enginas:
-1. Removethe mounting bolt and lock
bolt, then
removethe P/Spump beltand pump.
'18.
Removethe ransmission ground cable and hose
ct8mo.
HOSECLAMP
6 x '1.0mm
MOUNTING
BOLT
8 x 1.25mm
24N.m{2.4kgl.m,17tbf.ftl
LOCKBOLT
8 x 1.25mm
24 N.m 12.4kgf.m, 17 lbf.ftl
1 9 . R e m o v et h e c l u t c h s l a v e c y l i n d e ra n d l i n e / h o s e
assembty(M/T).
17. Loosenthe idler pulleycenternut and adjusting
bolt, then remove the air conditioning (A[/C)
compressorbelt.
IDI.IR PULLEYCENTER
NUT
10 x 1.25mm
a,l N.m {,1.5kgt.m, 33 lbf.ft)
NOTE:
. Do not disconnectthepipe/hoseassembly.
. Do not operatethe clutch pedal once the slave
cylind€r has been removed.
o Takecarenot to bendthe line.
6x1,0mm
11N.m{1.1kgt.m,
I tbf.ftl
8x1.2Smm
2a N.mt2.4kgf.m,
17tbf.ftl
8 x 1.25mm
2a N'm {2,4 kgt m,
17 tbt.ftl
5- 6
and splashshield.
24. Removethe front tires/wheels
20. Removethe shiftcable(CVT)
CLIP
WASHER
LOCKNUT
29 N.m {3.0 kgf m,22lbf'ft}
Pt-Aslc
6 x 1l.u
. 0mm
mm
u
9.8Nm(10 kqt'm,
7.2lbf.ftl
SHIFTCABLE
2 1 . D i s c o n n e c t h e P o w e r s t e e r i n g p r e s s u r e( P S P )
switch connector, and r e m o v et h e w i r e h a r n e s s
cramp.
l
l
I
SHIELD
25. Drain the engine coolant (see page 10-7).Loosen
the drain plug in the radiator.
26. Drainthe transmissionfluid Reinstallthedrainplug
usinga new washer(seesection13,14).
27. Drainthe engineoil. Reinstallthe drain bolt usinga
new washer(seepage8-6).
28. Removethe shift rod and extension rod (M/T)
SHIFTROD
ER
EXTENSION
ROD
caP.
theradiator
Remove
usa carewhen l€movingthe tadiator
!!!@
by hot coolantor steam'
scalding
Ap to avoid
Raisethe hoist to full height.
8 x 1.25mm
't6lbtft)
22 N.m t2.2 kgf'm,
(cont'd)
EngineRemoval/lnstallation
Removal(cont'dl
{
29. Removethe Ay'Ccompressor.
31. RemoveexhaustpipeA.
NOTE:Do not disconnectthe Ay'Choses.
Dl6Y5. D16Y7engines:
8 x 1.25mm
22 N.m12.2ksl.m.16tbI.fr)
Replace.
8x 1.25mm
24 N.m(2.{ kgf.m,t7 tbtft}
A/C
A/C COMPRESSOR
COMPRESSOR
SELF.LOCKING
8 x 1.25mm
16 N.m (1.6kgtm,
30. Removethe shift cable(IVT).
NOTE:
. Takecare not to bend the cablewhen removing
it. Always replaceany kinkedcable with a new
one.
. Adjust the shift cable when installing(see sec_
tion14).
12tbt.ftl
Replace.
SELF.LOCKING
NUT
10x 1.25mm
33 N.m {3.4kgt.m,
25 lbr'frl
Replace.
D16Y8 ongin6;
8 x 1.25mm
22 N.m (2.2kgf.m. 16 tbf.ftl
Replace.
8 x 1.25
mm
22 N.m(2.2kgf.m,16lbf.frl
GASKET
Replace.
SELF.LOCKING
NUT
8 x 1.25mm
16 N.m 11.6kgf.m,12 lbtft)
Replace.
LOCKWASHER
Beplace.
6x1.0mm
14 N.m (1.4kgf.m, tO tbtft)
SELF-LOCKING
NUT
l 0 x 1 . 2 5m m
54 N.m (5.5kgf.m, 40 lbf.ft)
Replace.
5-8
t
35. Lowerthe hoist.
81642 engine:
HO2SCONNECTOR
,&
36. Remove the upper and lower radiator hoses and
heaterhoses,
8 x 1.25mm
22N,n 122 kdl'rn, 16rbt.ftl
Replace.
GASKETS
Replace.
UPPER
RADIATORHOSE
Replace.
SELF.LOCKING
8 x 1.25mm
16 N.m t1.6 kg{ m, 12 lbl'ft)
Replace.
PIPEA
10 x 1.25 mm
s4 N.m {5.5 kgf m, 40 lbf'ftl
RePlace'
32. Removethe damperforks (seesection18).
D i s c o n n e ctth e s u s p e n s i o nl o w e r a r m b a l l j o i n t s
(seesection18).
34. Removethe driveshafts.
CAUTION:
o Do not pull on th€ drivoshaft. the CV ioint may
com9 apart.
o Use care whgn prying out the assombly.
Pull it straight to avoid damaging the differential
oil seal or intermediate shaft dust seal.
37. Removsthe ATF cooler hoses,then plug the ATF
cooler hosesand PiPes(A,/T)
N o T E : C o a t a l l p r e c i s i o n - f i n i s h esdu r f a c e sw i t h
cleanengineoil. Tie plasticbagsover the driveshaft
enos.
!^.
HOSES
(cont'd)
EngineRemovaUlnstallation
Removal(cont'd)
38. Attachthe chainhoistto the engine.
HOISTINGBRACKET
Installon the cylinderhead
witha8x1.25mmbolt.
5-10
39. Removethe left and rightfront mount and bracket'
41. Removethe uPPsrbracket.
UPPER
4 2 . R e m o v et h e t r a n s m i s s i o nm o u n t b r a c k e t ,t h e n
removethe transmissionmount.
TRANSMISSION
MOUNT/BRACKET
40. Removethe rearmount bracket.
Checkthat the engine/transmissionis completely
free of vacuum hoses,fuel and coolant hosesand
electricalwiring.
(6 in)'
are
disconwires
and
hoses
all
that
again
Checkonce
nectedfrom the engine^ransmission
150mm
44. Slowlyraisethe engineapproximately
45. Raisethe engineall the way, and removeit from the
car.
5-11
EngineRemovaUlnstallation
Installation
Brackei Bolts Torque Specifications:
Dl5Y5,Dl6Y7,Dl6Y8 €nginss
10x 1.25mm
44 N.m {4.5 kgt m,
33 tbr.ftl
10 x 1.25mm
54 N.m {5.5kgf.m,
40 rbf.ftl
D16Y5,D16Y8engines(M/Tl:
REARSTIFFENER
10x 1.25mm
44 N.m 14.5kgf.m,
33 tbf.frt
8 x 1.25mm
2/t N.m 12.4kgf.m, 17 tbf.ftl
ALTERNATOF
BRACKET
EXCEPTD16Y5, Dl6Yg engines lM/T)j
STIFFENER
Tightenthe boltson the stiffener
in the numberedsequenceas shown
li) o).
l3l 10x 1.25mm
44 N.m {1.5kgt.m,
33 tbt.ft)
O8x1.25mm
24 N.m {2.4kg{.m,
17 tbr.ftt
10x 1.25mm
14 N.m 14.5kgt m,
33 tbf.ft)
8 x 1.25mm
24 N.m (2.4 kgf.m,
17 tbf.ft)
o16Ys,D16Y8
enginoslM/T):
FRONT
STIFFENER
8 x 1.25mm
2{ N.m (2.t kgtm,
17 rbtft)
5-12
10x 1.25mm
14 N.m (4.5kgf.m,
33 lbf.ftl
10 x 1.25mm
4,4N.m {4.5kg{.m.
33 tbf.ftl
1 0x 1 . 2 5m m
44 N.m {4.5kg'f.m,
33 tbtftl
816A2engine
P/S PUMP
BRACKET
REAR
STIFFENER
SIDEENGINE
MOUNT BRACKET
t0 x 1.25mm
ia{ N.m (i1.5kgt rn,
33 lbt.tr)
t
1 2x 1 . 2 5n m
57 N.m {5.8 kgf,m,
12 tbl.ttl
8 x 1.25mm
24 N.m (2.4 kgl.m,
17lbf.ft)
10x 1.25mm
54 N m {5.5 kgf m, a0 lbl ft}
10x 1.25mm
4a N,m (4.5kgf.m,
33 tbf.ftt
FRONT
STIFFENER
A/C COMPBESSOR
BRACKET
'12x 1.25mm
57 N.m {5.8 kgt'm,
42 tbt.ft)
8 x 1.25mm
24 N.m {2.4kgf.m,
17 tbtft)
ALTERNATOR
BRACKET
'10x 1.25mm
,14N.m {,1.5kgt.m,
33 rbf.ft)
(cont'd)
5-13
Engine Removal/lnstallation
Installation(cont'd)
Engino Inst!llation:
Installthe engine in the reverseorder of removal.
Beinstallthe mount bolts/nutsin the followingsequence.
Failureto follow these proceduresmay cause excessive
nois€and vibration,and reducebushinglife.
l,
Install the transmissionmount and bracket,then
tightenthe boltson the frame side,
NOTE; Do not tighten the bolts/nutson the trans_
missionside.
CW;
10x 1.25mm
38 N.m {3.9 kgt m. 28 lbt.ftl
I
I
2,
Installthe upper bracket,then tighten the nuts in
the numberedssquenceshown (O _ @).
O t2 x 1.25mm
74 N.m17.5kgf.m,
5-14
O t2 x t.2smm
74N.m17.5
kgtm,
rbrft)
l
a
3.
Installthe rear mount bracket,then tightenthe bolts
in the numberedsequenceshown (O - @).
4.
Tighten the bolvnuts on the transmissionmount
bracketin the numbe.edsequenceshown (O - O).
CVT:
O 12 x 1.25mm
59 N.m (6.0 kgl'm,
ilil lbf ftl
Replace.
12x 1.25mm
59 N.m 16.0kgf'm,
|:r tbf.tt)
Replace.
@ t2 x t.2smm
7,1N.m(7.5kg{m, 54 lbfftl
O 12 x 1.25mm
59 N'm {6.0 kgf'm,
/€ lbf.ftl
Replace.
ExceptCVT:
/
/
\
O 12r 1.25mm
, @ 1 4x ' 1 . 5m m
59 N m 16.0kgt m,
8:t N.m {8.5 kgf.m,
(} tbf.ftt
61 rbr.fr)
Replace.
Replace.
12 x 1,25mm
fl N.m 16.5kgt.m,
47 tbf.ftl
Tightenthe boltson the rightfront mounvbracketin
the numberedsequenceshown(O - @).
GW:
Olax1.5mm
83 N.m 18.5kgf.m,
61 tbf.ftl
Replace.
L
O to x 1.25mm
54 N.m{5.5kgl.m.
/|{}lbf.ftl
10 x 1.25mm
4,1N.m {4.5kgf.m. 33 lbf.ftl
(cont'd)
5-15
EngineRemoval/lnstallation
Installation(cont'd)
ExceptCVT:
7.
Performthe following:
.
.
.
.
.
.
.
.
.
12 x 1.25mm
64 N.m (6.5kgd.m,
.
.
Tightenthe bolts/nuton the left front mount in the
numberedsequenceshown {O - @).
( t 1 2 x 1 . 2 5m m
8 3 N ' m ( 8 . 5k g f . m , 6 1t b t . t r l
/+4 N.m 14.5 kgf.m,
33 lbt.trl
5-16
Cleanthe areaswhere the driveshaft(s)
and the
intermediateshaft contactthe transmission(dif_
ferential)thoroughlywith solvent or carburetor
cteaner,and dry with compressedair.
Checkthat the set rings on the ends of the drive_
shaftand intermediate
shaftclickinto place.
CAUTION: Use new set rings,
Adjustthe shift cable(seesection14).
Adjustthe throttlecable(seesection11).
Adjustthe cruisecontrolcable(seesection23).
Refillthe enginewith engineoil (seepage8-6).
Refillthe transmissionwith fluid (seesection13,
14).
Refillthe radiatorwith enginecoolant(seepage
10-7).
Bleedair from the coolingsystemwith the heater
valveopen (seepagej0-7).
Cleanthe batterypostsand cableterminalswith
sandpaper,assemblethem, then apply greaseto
preventcorrosaon.
Inspectfor fuel leakage(seesectionj l).
After assemblingthe fuel line,turn on l) the igni_
tion switch(do not operatethe starter)so that the
fuel pump runs for approximatelytwo seconds
and the fuel line pressurizes.
Repeatthis opera_
taontwo or three times,then checkfor fuel leak_
age at any point in the fuel line,
O 1 2 r 1 . 2 5m m
59 N.m 16.0kgt.m,
43 tbt.rtl
Seplace.
\
Mount and Brackst Bohs/Nuts Torque Value Spocitications:
A: '10x 1.25mm
64 N.m {6.5 kgl'm, 47 lbf'ft}
B : 1 0i 1 . 2 5m m
44 N.m {4.5kgim,33 lbtft)
C : 1 2x 1 . 2 5m m
83 N.m 18.5kgt'm, 61 lbf'ft)
D : 1 2x 1 . 2 5m m
59 N.m (6.0ks{ m, 43 lb{ft)
Replace.
REARMOUNT
SIDEENGINE
MOUNT
CylinderHead/ValveTrain
Dl6Y5,D16Y7,Dl6Y8engines
.............
G2
SpecialTools
VTECControl System
TroubleshootingFlowchart .........."6-3
VTEGSolenoidValve
............"
6-6
Inspection
VTECRocker Arms
Manuallnspection
(D16Y5engine).............................
6-7
Manual Inspection
(D16Ygenginel................'............
6-7
Inspection Using Special Tools
6-8
{D16Y5engine}.....................""'...
Inspection Using SpecialTools
(D16Y8engine).........................'.'.
6-10
Valve Clearance
..."".....6-12
Adiustment
Valve Seals
Replacement(Cylinderhead removal
6-1tl
not requiredl................................
CrankshaftPulleyand PulleYBolt
."......&16
Replacement
Timing Selt
6-17
lllustratedIndex ...............................
6-18
..............
Inspection
6-1I
TensionAdjustment ........................
6-19
......,,.........
Removal
.............
6-20
lnstallation
CrankshaftSpeedFluctuation(CKF)Sensor
.........6'22
Repfacement
Cylinder Head
6-23
lllustratedIndex ...............................
6-27
.................
Removal
6-40
................
Warpage
.............
6-45
lnstallation
Rocker Arms
6-30
.................
Removal
6-31
...............
Disassembly/Reassambly
RockerArms and Lost Motion Assemblies
Inspection (D16Y5,D16Yg
"..........'5-34
enginesl
Rocker Arms and Shafts
6-35
GlearanceInspection.......................
Camshaft
6-36
..............
Inspection
Valve
Seals
and
Valves, Valve Springs
........"".....
6-38
Removal
Valve Guides
6-39
Valve Movement ..............................
.........6-41
Replacement
.......'......'.'
6-43
Reaming
Valve Seats
.'....6'40
Reconditioning
Valves
lnstallation
Camshaft/RockerArms and
Camshaft Seal/Pulley
lnstallation
.............
6-tt3
.............
6-44
SpecialTools
\
Ref.No.
Tool Number
I
o
o
@
@
o
or@-1
andO-2
@
o
(
OTHAH_ PJTOlOB
0 7 J A A- 0 0 1 0 1 0 A
07JAB- 0010204
OTLAJ_ PR3O2OB
07NAB- 0010404
07NAJ- P07010A
01406 - 0020201
OTMAJ- PY4O'114
07MAJ- PY40120
07406- 0070300
0 7 7 4 2- 0 0 1 0 1 0 0
ValveGuideReamer,5.5 mm
Socket,17 mm
H o l d e rH a n d l e
Air Stopper
HolderAttachment.50 mm
PressureGaugeAdapter
A/f PressureHose
A/T PressureHose,2,210mm
Ay'TPressureAdapter
A,/TLow PressureGaugeWPanel
ValveGuideDriver,5.5 mm
6-43
6-16
o- to
6-8,10
6-16
6-4
6-4
6-4
6-4
6-4
6-4't,42
-rE=-!fT----F
o
@
@
@
g-A\
o
O-r
A-2
@
El
ril
6l
6-2
a
VTECControlSystem
Flowchart
Troubleshooting
tFtrsrl #ilH:::lj1t:"J:T,?ffnostic
circuit
or
A probrem
inthevrEcPressure
switch
rrouble
code(Drc)Pr25e:
Reterto page 1 l-38 th rough 11-55beforetroubleshooting.
The MIL has been reoortedon.
DTCP1259is sto.ed.
Checkthe VTECCont.olSyst6m:
1. Do the enginecontrolmodule
(ECM)/powertrain
control mod
ule lPCM)ResetProcedure(see
section11).
2. Stan the engine.
3. Warm up the engineto normal
operatingtemperature(cooling fan comeson).
4. Do the BoadTest.*
ls OTCP1259indicated?
* Road Test:
A c c e l e r a t ei n 1 s t g e a r t o a n e n g i n es p e e do v e r 3 , 0 0 0r p m
(D16Y5engine)or 6,000rpm (D'16Y8
engine).
Holdthat enginespeedfor at leasttwo seconds.
It DTCP1259is not repeatedduringthe first road test, repeat
thistesttwo moretames.
Intermittont tailura, 3y3t.m is OK
at thia time.
Check for ooor connoctionr o.
loose wirea at VTEC oiassurc
lwitch, VTECsolonoid valvo .nd
ECM/PCM,
SWITCH2P
VTECPRESSURE
CONNECTOR
Test rhe VTECPrensureSwitch:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe VTECPressure
switch2Pconnector.
3. Checkfor continuitybetween
VTECpressureswitch2P connectorterminalNo. 1 and No.
2.
Terminalsideof
maleterminals
ls there continuity?
Replacethe VTECpreasure3witch.
l1
VTM
(BLu/BLK)
f;-)
{Topage6'4i
I
I
Te3t the VTEC Pressure Switch
Wire:
1. Turnthe ignitionswitchON lll).
2. Measurethe voltagebetween
V T E C p r e s su r e s w i t c h 2 P
c o n n e c t o rN o . l a n d b o d y
ground.
ls there batteryvoltage?
|
Y
I
Wire sid6 ol female
rermtnats
In3poct for en opon or shod to
ground in thG wi.. bctwoon tho
VTEC pro$ur6 switch rnd ECM/
PCM l'96 - 9a: C15,'99- 00: C101.
lf tha wiro i3 OK,3ubrtitute a
known-good ECM/PCM and
recheck.
I
VTECControl System
TroubleshootingFlowchart(cont'd)
:
(
VTECPRESSURE
SwlTCH2P
CONNECTOR
(From page 6-3)
t
Test the VTEC Pr6suro Switch
Wiro:
Nleasurevoltage acrossthe VTEC
pressureswitch2P connector.
I
t
:
.
ls there bafteryvoltage?
.
Wire side of female
(€rmrnats
Rcpai. opon in tho wire
brtw.en VTECpr6.urc switch
andG101.
lf th. wir6 b OK, sub.thuto a
lnown-good ECM/PCM !nd
racheck.
VTECSOLENOIDVALVE lP
CONNECTOR
Te3tthe VTECSolonoidV.lve:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the VTECsolenoid
valve1Pconnector.
3. Checkfor continuity between
t h e V T E Cs o l e n o i dv a l v e 1 P
connectorterminalNo. 1 and
bodyground.
'll '- ff---r
'1
I
I-L
ls there 14- 30 0?
ls pressurebelow 49 kPa
(0.5kgflcm,,7 psi)?
(To page6-5)
6-4
I
Ir----'t I
Terminalsideof
maleterminal
Te3ttho WEC SolonoidVatvo:
'1. Remove
the VTEC pressure
swatchand installthe special
tool as shown, then reinstall
the VTECpressureswitch.
2. Reconnoctthe VTECsolenoid
valve 1P connectorand VTEC
pressureswitch 2P connector.
3, Connectthe tachometer(see
section11).
4. Stanthe engine.
5 , W a r m u p e n g i n et o n o r m a l
operatingtemperature(cool,
ing fan comeson).
6. Checkoil pressureat engine
speeds D16Y5engine: 1,000
and 3.000rpm, D16Y8engine:
1,000,3,000
and 5,000rpm.
t
A/T LOWPRESSURE
w/PAt{EL
07406-0070300
N O T E : K e e p m e a s u r i n gt i m e a s s h o r t a s
possiblebecauseengineis runningwith no
load(lessthan one minute).
In.poct the VTEC aolonoid vllvo
ls.c p.g. &6).
PRESSURE
GAUGE
ADAPTER
07NAJ - P07010A
A/T PRESSURE
I{OSE
07406- 0020201
ot
A/T PRESSURE
HOSE.
2,210mm
07MAJ - PY&llA and
A/T PRESSURE
ADAPTER
07MAJ - PY,()120
I
VTECSOLENOIDVALVE
1P CONNECTOR
(Frompage6'4)
Terminalsideof
maleterminal
Testthe VTECSolenoidValve:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the wEC solenoid
valve 1Pconnector.
3 . A t t a c h t h e b a t t e r yp o s i t a v e
terminalto the VTECsolenoid
valveterminal.
4 . S t a r t t h e e n g i n ea n d c h e c k
t h e o i l p r e s s u r ea t e n g i n e
speedof 5,000rpm.
ls the pressureabove390kPa
(4.0kgtcm' ,57psi)?
Inspect lhe VTEC solonoid valve
lseep6gem).
C {31P}
ECM/PCMCONNECTOR
'99 - 00:
'96 - 98:
VTM
Testthe VTECPressureSwitch:
With the battery positiveterminal
connectedto the VTECsolenoid
valve, measurevoltagebetween
connectorterminal
the ECM/PCM
' 9 6 - 9 8 : C l 5 , ' 9 9 - 0 0 : C 1 0a n d
bodyground.
'99 - 00:
ls there batteryvoltage above
5,000rpm?
VTECSOLENOID
VALVE
1PCONNECTOR
'96 - 98:
VTECSOLENOID
VALVE
CONNECTOR
T6st the VTEC Solenoid Valve
wire:
1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
t h e V T E Cs o l e n o i dv a l v e 1 P
c o n n e c t o rt e r m i n a la n d t h e
ECM/PCMconnectorterminal
'96 - 98: A8, '99 00r B'12.
ECM/PCMCONNECTOR
A {32P1
VTS
{GRN/YEL)
wire sideo{ female
terminals
wire sideoI temale
terminals
Repair open in the wire between
the ECM/PCM ('96 - 98: A8, '99 0o: 8l2l and VTEC solenoid v.lv6
connoc{or.
Test the VTEC Solenoid Valve
Check for continuity between the
V T E Cs o l e n o i d v a l v e 1 P c o n n e c t o r
t e r m i n a l€ n d b o d y g r o u n d .
ls therecontinuity?
Substitute a known-good ECM/
PCM and recheck. lf symptom/
indication goes away, replace
the original ECM/PCM.
ECM/PCMCONNECTOR
B {25Pt
ReDair 3hort in the wire between
the ECM/FCM ('96 - 98: A.8,'99 0O:Bl2l and VTECaolenoidvalve
connectot,
VTECSolenoidValve
Inspection
D i s c o n n e ct th e 1 P c o n n e c t o frr o m t h e V T E Cs o l e noid valve.
1.
Measureresistancebetweenthe terminaland body
ground.
(
4.
lf the filter is not clogged,push the VTECsolenoid
valvewith your fingerand checkits movement.
.
lf the VTECsolenoidvalve is normal.checkthe
enganeoil pressure.
I
Resistance:
l4 - 30 O
6x1.0mm
12 N.m {1.2kgt.m,8.7lbf.ft)
lf the resistanceis within specifications,
removethe
V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m t h e c y l i n d e r
head,and checkthe VTECsolenoidvalve filter for
cloggrng.
.
\
.
I
(
lf there is clogging,replacethe engine oil filter
a n dt h e e n g i n eo i l .
VTECSOLENOID
VAI-VEASSEMBLY
;
6x1.0mm
12 N.m 11.2kgf.m,8.7lbtft)
6- 6
..
VTECRockerArms
(D16Y5engine)
ManualInspection
ManualInspection(D16YB
engine)
1 . Setthe No. 1 pistonat TDC.
1.
2.
Setthe No. 1 pistonat TDC.
Removethe cylinderheadcover.
Removethe cylinderheadcover.
NOTE:Referto page 6-46when installingthe cylinder headcover.
NOTE:Reterto page6-46when installingthe cylinder headcover.
'l
Pushthe intakemid rockerarm on the No. 1 cylind e rm a n u a l l y .
3.
Move the intakesecondaryrockerarm on the No.
c y l i n d em
r anually.
4.
Checkthat the intakesecondaryrockerarm moves
independently
of the primaryintakerockerarm,
4.
Checkthat the intakemid rockerarm movesindependently of the primary and secondaryintakerocker
arms.
MID ROCKER
ARM
SECoNDARY
ROCKERARM
. P u s ha n d p u l l .
PRIMARYROCKERARM
Pt
C h e c k t h e i n t a k e s e c o n d a r y r o c k e ra r m o f e a c h
c y l i n d e ra t T D C .
a lf the intakesecondaryrockerarm doesnot move,
removethe primaryand secondaryintakerocker
armsas an assemblyand checkthat the pistonsin
t h e s e c o n d a r ya n d p r i m a r yr o c k e ra r m s m o v e
smoothly.
a lf any rockerarm needsreplacing,replacethe primary and secondaryrockerarmsas an assembly.
5,
Checkthe intakemid rockerarm of eachcylinderat
TDC,
l f t h e i n t a k em i d r o c k e ra r m d o e s n o t m o v e .
remove the mid, primary and secondaryintake
rockerarmsas an assemblyand checkthatthe pist o n s i n t h e m i d a n d p r i m a r yr o c k e ra r m s m o v e
smoothly.
l f a n y r o c k e ra r m n e e d sr e p l a c i n gr,e p l a c et h e
primary,mid, and secondaryrockerarms as an
assemory.
6-7
VTECRockerArms
(Dl6Y5enginel
Inspection
Using SpecialTools
CAUTION:
. Before using th6 Valve Inspection Tool, make 3ure
that ths air pressuregaugo on the air comptsssor
indicatesover iloo kPa 14kgf/cmr, 57 psi).
. Inspecl th6 valv€ clearancebeforo rocker atm insDec"
tion,
Coverthe timing belt with a shop towel to protect tho
belt.
Check ths intakg primaty rocker arm of each cylindqr at
TDC.
'1.
3,
(
Removethe sealing bolt from the inspectionhole
and connectthe an air pressureregulatorwith a 0 100psi gauge.
10x 1.0mm
BOLT
SEALING
20N.m{2.0kgj'm.14lblft}
Removethe cylinderheadcover.
NOTE:Referto page6-46when installingthe cylinder headcover.
Plugthe reliefhole with the specialtool.
l
I
'10x 1.0mm
ADAPTER
YY
OTLAJ- PR3O2OB
o-at
;NSp€CTTONHOLE
(Commercially
available)
P u l l t h de i a a
l nd
turnto adlust,
Loosenthe regulatorvalve on the valve inspection
tool and applythe specifiedair pressure.
SpocifiedAir Pressurei
250 kPa {2.5 kg,t/cm,,36 psi}
l'
5.
With the specifiedair pressureappli€d,push up the
timing plate;the synchronizingpiston will pop out
and engagethe intakesecondaryrockerarm.
Visuallycheckthe engagementof the synchronizing
prston.
NOTE;
pistoncan be seen in the gap
The synchronizing
betweenthe secondaryand primaryrockerarms,
With the timing plate engagedin the groove on
t h e t i m i n g p i s t o n ,t h e p i s t o n i s l o c k e d i n t h e
oushedout Dosition.
6.
Stop applyingair pressureand push up the timing
plate;the synchronizingpistonwill snap backto its
originalposition.
Visuallycheckthe disengagementof the synchronizingpistons.
NOTE:
. When the timing plate is pushedup, it releases
the timing piston,lettingthe returnspring move
pistonto its originalposition.
the synchronizing
7.
Replacethe intake rocker arms as an assemblyif
either does not work correctly,
TIMIT{GPLATE
TIMIiIG
PLATE
SPRIT{C
TIMINGPLATE
oll PASSAGE--!
PRIMARYROCKER
ARM
SECOI{DARY
ARM
ROCKER
TIMII{GSPRII{G
PRIMARYROCKERARM
SECODARY
ARM
ROCKER
RETURI{SPRING
TIMI G PISTOI{
Removethe spscialtools.
AIR PRESSURE
After inspection,checkthat the malfunctionindicator
lamp (MlLl doesnot comeon.
GROOVE
TIMINGSPRING
6-9
VTECRockerArms
InspectionUsing SpecialTools(D16Y8enginel
CAUTION:
o Before using the Valve Inspection Tool. mak6 sure
that the air pressuregauge on the air comprsssor
indicatesovor 400 kPa {4 kgf/cm,, 57 psil.
. Inspectth6 valve clearancobefore rockar arm inspection.
. Cov€r th€ timing belt with a shop towel to protect
the bolt.
. Checktho intake prima.y rockff arm of each cylindel
at TDC.
3.
Removethe sealing bolt from the inspectionhole
anclconnectan air pressureregulatorwith a 0 - 100
psi gauge.
l 0 x 1 . 0m m
SEALINGEOLT
20 N.m (2.0 kgf.m, 14 lbf.ft)
1 . Removethe cylinderheadcover.
NOTE: Referto page6-46when installingthe cylinder
neaocover,
Plugthe reliefhole with the specialtool.
AIR PRESSURE
REGULATOR
{Commercially
available)
. P u l l t h ed i a l a n d
turn to adjust,
OTLAJ- PR3O2OB
I,^
A
IA
o- tu
(
4.
Loosenthe regulatorvalve on the valve inspection
tool and applythe specifiedair pressure.
1.
Removethe specialtools.
8.
U s e a 1 0 m m d i a m e t e rr o d t o d e p r e s se a c h l o s t
motionassemblythroughits full movement.
Replaceany lost motion assemblythat does move
smoothly.
SpecifiedAir Pressure:
250 kPa {2.5 kgf/cm',36 psil
PRIMARY
ROCKER
ARM
MID ROCKER
ARM
SECONDARY
ROCKERARM
SYNCHRONIZING
SYNCHRONIZING
PISTON
A
PISTON
B
5.
Make sure that the intake primary and secondary
connectedby the piston
rockerarmsare mechanically
and that the mid rockerarm does not move when
oushedmanuallY.
ASSEMBLY
9.
After inspection,checkthat the MIL does not come
on.
SECONDARY
ROCKERARM
t
lf any intake mid rockerarm moves independentlyof
the primary and secondaryrocker arms, replacethe
rockerarms as a set.
6-11
Valve Clearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylindsr
headtemperatureis lessthan 100"F(38"C).
. After adjusting,retorquethe crankshaftpulley bolt
(seepage6-16).
1,
Removethe cylinderheadcover.
NOTE; Referto pagee46 when installingthe cytinder
headcover.
2.
Removethe uppercover (seepage6-19).
3.
Set the No. 1 pistonat TDC.The "UP" mark on the
c a m - s h a f tp u l l e y s h o u l d b e a t t o p , a n d t h e T D C
marksshouldalignwith the cylinderheadsurface.
5.
Loosenthe locknut,and turn the adjustmentscrew
until the feeler gauge slides back and forth with a
sliOhtamountof drag,
D16Y7engin.:
CAUTION: Do not oyertighlen the locknuts; tho
rockor arms are made of aluminum.
INTAKE
endEXHAUST
VALVE
LOCKNUTS
18 N.m (1.8kgI.m, 13 tbl.ftl
"UP"MARK
TDCMARKS
tr
Dl6Y5, Dl6Y8 engin€3:
INTAKE.nd EXHAUSTVALVE
LOCKNUTS
20 N.m 12.0kstm, 14lbtft)
4.
Adjustvalveson No, 1 cylinder.
Intako: 0.18- 0.22 mm {0.007- 0.009in}
Exhaust:0.23- 0.27mm (0.009- 0.011inl
Adiusting screw locations:
o.4
IMTAKE
1{o.3
No.2
(
No.4
6- 12
nb.3
No.2
EXHAUST
No. 1
6.
Tightenthe locknut,and checkthe clearanceagain.
Repeatthe adjustmentif necessary.
8.
' 1 8 0 'c o u n t e r c l o c k w i s teo
R o t a t et h e c r a n k s h a f t
b r i n g N o . 4 p i s t o nt o T D C .B o t hT D C g r o o v e sa r e
o n c ea g a i nv i s i b l eA. d j u s tv a l v e so n N o .4 c y l i n d e r .
GAUGE
-UP'MARK
7.
(camRotatethe crankshaft180' counterclockwise
"UP" mark shouldbe on
shaft oullevturns 90'1.The
the exhaustside.Adjustvalveson No. 3 cylinder.
to bring
Rotatethe crankshaft180'counterclockwise
No. 2 piston to TDC.The "UP" mark should be on
the intakeside.Adjustvalveson No. 2 cylinder.
"UP- MARK
t
6-13
Valve Seals
(Cylinderheadremovalnot requiredl
Replacement
N O T E :C y l i n d e rh e a d r e m o v a li s n o t r e q u i r e di n t h i s
procedure.
Intake Valve Seals:
6.
Selectthe 7/8 in diametershort compressorattachment,and fastenthe attachmentto the No. 4 holeof
the leve.arm with the speedpin supplied.
7.
lnsertan air adapto.into the sparkplug hole.pump
air into the cylinderto keepthe valve closedwhile
compressingspringsand removingthe valve keep
ers.
8.
Put shop towels over the oil passagesto prevent
t h e v a l v e k e e p e r sf r o m f a l l i n g i n t o t h e c y l i n d e r
neao.
The procedureshown below applieswhen using the inc a r v a l v e s p r i n g c o m p r e s s o r( S n a p - o nY A 8 8 4 Sw i t h
Y48845- 2 A7/8" attachment).
Alway wear approved eye protection when
!@@
using ihe in-cai valve spring compressor.
1. Turn the crankshaftso that the No. I and the No. 4
pistonsare at top deadcenter(TDC).
2.
Removethe cylinderheadcoverand the rockerarm
assembly.
OIL PASSAGES
NOTE:
. R e f e rt o p a g e 6 - 3 0 f o r r o c k e r a r m a s s e m b l y
removat.
. W h e n r e m o v i n g o r i n s t a l l i n gt h e r o c k e r a r m
assembly,do not remove the camshaft holder
b o l t s .T h e b o l t s w i l l k e e pt h e h o l d e r s ,s p r i n g s
and rockerarms on the shaft.
. Referto page 6-46 when installingthe cylinder
headcover.
,
I
3 . Removethe fuel injectorsand the wire harness.
4.
i
Usingthe 8 mm bolts suppliedwith the tool. mount
t h e t w o u p r i g h t st o t h e c y l i n d e rh e a d a t t h e e n d
c a m s h a f th o l d e r s .T h e u p r i g h t sf i t o v e r t h e c a m shaftas shown.
OILPASSAGES
Positionthe lever arm underthe crossshaft so the
lever is perpendicular
to the shaft and the compressor attachmentrests on top of the retainerfor the
spring being compressed.Use the front position
slot on the leveras shown.
IN-CARSPRINGCOMPRESSOR
lnsert the cross shaft through the top hole of the
two uprights.
SLOT
6- 14
10. Using a downward motion on the lever arm, com.pressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spring.
1 6 . Using a downward motion on the lever arm, compressthe valvespringand removethe keepersfrom
t h e v a l v e s t e m . S l o w l y r e l e a s ep r e s s u r eo n t h e
spnng.
11. Removethe valveseals(seepage6-38).
't7. Removethe valveseals{seepage6-38),
12. Installthe valveseals{seepage6-43).
'18. Installthe valveseals(seepage6-43).
13. Installthe springs,the retainersand the keepersin
reverseorderof removal.
1 9 . Installthe springs,the retainersand the keepersin
reverseorderof removal.
ExhaustValvs Sesls:
20. Repeatsteps6 to 19 on the othercylinders.
'14.
Selectthe 7/8 in. diametershort compressorattachment,and fastenthe attachmentto the No. 2 hole of
the leverarm with the speedpin supplied.
Positionthe lever arm under the cross shaft so the
to the shaftand the compresleveris perpendicular
sor attachmentrests on top of the retainerfor the
s p r i n g b e i n g c o m p r e s s e dU. s e t h e f r o n t p o s i t i o n
slot on the leveras shown.
IN-CARSPRINGCOMPRESSOR
7/8 in SHORTATTACHMENT
L
6-15
CrankshaftPulleyand Pulley Bolt
Replacement
W h e n i n s t a l l i n ga n d t i g h t e n i n gt h e p u l l e y .f o l l o w t h e
procedurebelow,
'1.
Tightenthe pulleybolt to the specifiedtorque.
Torque: 20 N.m {2.0 kgf.m, 14 lbf'ft}
C l e a n ,r e m o v e a n y o i l , a n d l u b r i c a t ep o i n t s s h o w n
below.
O: Clean
x: Bemoveany oil
a: Lubricate
Use I felt tip pen to mark the pulley bolt head and
washer.
MARKING
CRANKSHAFT
TIMINGBELT
GUIOEPLATE
Crankhaft pulley bolt size and torque value:
14 x 1.25mm
20 N.m {2.0 kgl.m, 14 lbf.ft) + 90'
\
EMBOSSINGMARKS
NOTE:Do not usean impactwrenchwhen installing.
3.
HOI.I'ERHANDTI
07JAB- 001020A
HOLDERATTACHMENT.50 mm
07NAB - ootoilllA
Tightenthe pulleybolt an additional90".
EMBOSSINGMABK
MARKING
S(rc(ET,17mm
07JAA-lxtl010Aor
{Co.nm.rci.lly.v.il.bl.}
MARKING
6-16
I
Timing Belt
Illustratedlndex
NOTE:
. Referto page6-20for how to positionthe crankshaftand pulleybeforeinstallingthe belt.
. Markthe directionof rotationon the belt beforeremoving.
a Do not usethe uppercoverand lower coverfor storingremoveditems,
. Cleanthe uppercoverand lowercoverbeforeinstalling.
. Replacethe camshaftsealsand crankshaftseals if there is oil leakage.
. Referto page6-16beforeinstallingthe timing belt.
HEAD
CYLINDER
COVER
Relerto page6-46
wheninstalling.
HEAD COVEBGASKET
Replacowhen l6akin9,
domagedor deteriorated.
Apply liquid gasketat
th€ lour cornersof the
tecessos.
TIMINGBELT
page6-18
Inspection,
Adjustment,page6-18
Removal,page6-19
Installation.page 6-20
d
@
I x 1.25mm
3t N.m {3.8 kgf'm, 27 lbfftl
Applyengineoilto the bolt
thleads.
SPEEDFI.UCTUATION
CRANKSHAFT
lcr(FlsENsoR
Replacement,
Page6-22
COVEB
UPPER
6x1.0mm
9.8 N'm 11.0kgt m,
7.2 tbf.ft)
NUBBERSEALS
Replacewhen damaged
or deledorated.
LOWERCOVER
FUBBER
PLUG
PULLEY
CRANKSHAFT
page6'16
Replacement,
PULLEYBOLT
lil x 1.25mm
20 N.m 12.0kgt.m,
14 lbt'ft) + 90"
page6'16
Replacement,
Do not us6 an impact
wrenchwhen installing.
lnstallwith
surfacefacingin.
\.-,o
TIMINGBELT
DRIVEPULLEY
page6_16
Replacement,
BOLT
o-RING 6 x 1 . 0 m m
10 x 1,25mm
Reolace.t2 N.m 11.2kgf'm,
8.7 tbt f0
14 N.m {,1.5kgt m, 33 lbt ftl
x 1.0mm
9.EN'm (1.0 kgt.m,
?.2 tbf.ftl
6-17
Timing Belt
Inspection
TensionAdjustment
Removethe cylinderheadcover.
1.
.
R e f e tr o p a g e6 4 6 w h e n i n s t a l l i n g .
2.
Removethe uppercover(seepage6 19).
3.
I n s p e ctth e t i m i n gb e l tf o r c r a c k sa n d o i l o r c o o l a n t
soakrng.
NOTE:
. Replacethe belt if oil or coolantsoaKeo.
. Removeany oil or solventthat gets on the belt.
CAUTION:lt*ays aa;j"t the timing bett rension with
the enginecold.
NOTE:
. The tensioneris spring loadedto applytensionto the
belt automaticallyafter makingthe following adjust
ment.
. Always rotatethe crankshaftcounterclockwise
when
v i e w e d f r o m t h e p u l l e ys i d e . R o t a t i n gi t c l o c k w i s e
m a y r e s u l ti n i m p r o p e ra d j u s t m e not f t h e b e l t t e n sion.
. lnspectthe timing belt beforeadjustingthe belt tenston.
1.
Removethe cylinderheadcover.
.
Referto page6,46when installing.
2.
Removethe uppercover(seepage6,'19).
3.
Rotatethe crankshaftfive or six revolutionsto set
the belt.
4.
Setthe No. 'l pistonat TDC(seepage6-21).
5.
Loosenthe adjustingbolt 180'.
\
ADJUSTINGBOLT
44 N.m {4.5kgt m,
33 rbf.ft)
Rotatepulley
and inspectbelt.
After inspecting,retorquethe crankshaftpullevbolt
{seepage6- 16).
Rotatethe crankshaftcounterclockwise
three teeth
on the camshaftpulley.
7 . Tightenthe adjustingbolt.
8 . After inspecting,retorquethe crankshaftpulleybolt
(seepage6-16).
o- I6
I
Removal
NOTE:
km)
. Replacethe timing belt at 105,000miles (168.000
(normal
conschedule
accordingto the maintenance
conditions).
ditions/severe
lf the vehicleis regularlydrivenin one or more of the
followlngconditions,replacethe timing belt at 60.000
miles(U.S.A.)100,000km {Canada).
. I n v e r yh i g ht e m p e r a t u r e( so v e r1 1 0 ' F . 4 3 ' C )
. In very low temperatures(under-20'F, -29"C)'
! Turn the crankshaftpulley so the No. 1 piston is at
top dead center(TDC)beforeremovingthe belt (see
page6'21).
. Inspectthe water pump before installingthe timing
belt {seePage10-14).
1.
Removethe splashshield(seepage5-7).
2.
Loosenthe mountingbolt and lockbolt.then remove
the powersteering(P/S)pump beltand pump
5.
Removethe dipstick,then removethe upper cover
and idler PulleYbracket
NOTE: Do not use the upper cover to store removed
items.
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2
IDLER
BRACKET
MOUNTINGBOLT
8 x 1.25mm
2il N m 12.4kgl m, 17 lbf'ft)
6.
I x 1.25mm
24 N.m (2.4kgl.m, 17 lbf'ft)
Removethe upperbracket{seepage6-29)
NOTE:
. Usea jackto supportthe enginebeforethe upper
bracketis removed
. Make sure to place a cushion between the oil
pan and the jack.
P/S PUMP
BELT
I x 1.25mm
24 N m (2.4kgfm, 17lbtft)
1.
Removethe crankshaftpulley(seepage6-16).
.'.
Removethe lowercoverand dipsticktube
NOTE; Do not use the lower cover to store removed
items.
DIPSTICKTUBE
3.
L o o s e nt h e i d l e r p u l l e yc e n t e rn u t a n d a d j u s t i n g
bolt, then remove the air conditioning(AVC)compressorbelt (seePage5-6).
LOWER
Loosenthe mountingnut and lockbolt,then remove
the alternatorbelt.
ALTERNATOR
BELT
LOCKBOLT
I x 1.25mm
24 N.m 12.4kgf.m,
r? tbI.ft)
6x1.0mm
9.8 N.m (1.0kgf m,
7.2 rbt.ft)
Replace.
MOUNTING NUT
1 0 x 1 . 2 5m m
44 N.m 14.5kgl m,
33 rb{ ft)
(cont'd)
6-19
Timing Belt
Removal (cont'd)
lnstallation
9. Removethe CKFsensorfrom the oI pump.
Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere.
l.
set rhe timing belt drive pulleyso that the No. 1 piston asat top deadcenter(TDC),Align the grooveon
the timing belt drive pulleyto the pointeron the oil
pump.
TDC MARK
POINTER
I
12 N.m 11.2kgt.m,
8.7 rbf.ftl
t
I
10. Loosenthe adjustingbott lgO.. Push the tensioner
t o r e m o v e t e n s i o n f r o m t h e t i m i n g b el t . t h e n
retightenthe adjustingbolt.
AD.'USNNG BOLT
4{ N.m 14.5kgt m,
33 tbtftl
1 1 . R e m o v et h e t i m i n gb e l t .
6-20
TIMING BELT
DBIVEPULLEY
Clean.
2.
S e t t h e c a m s h a f tp u l l e y t o T D C .A l i g n t h e T D C
marks on the camshaftpulleyto the cylinderhead
surface.
I
3.
Installthe timing belttightlyin the sequenceshown'
)@Adjusting
OTiming beltdrive pullev(crankshaft)
pulley-towater pump pulleyJ@Camshattpulley'
9. Checkthat the crankshaftpulleyand camshaftpulley are both at TDC.
CRANKSHAFTPULLEY:
NOTE: Make sure the timing belt drive pulley and
camshaftPulleYare at TDC
(wHrTE)
CAMSHAFTPULLEY:
"UP" MARK
Loosenand retightenthe adiustingbolt to tension
the timing belt.
lnstallthe lowercoverand uppercover.
N O T E :C l e a nt h e u p p e r a n d l o w e r c o v e r sb e f o r e
installation.
lnstallthe crankshaftpulley,then tightenthe pulley
bolt (seepage&16)
7.
Rotatethe crankshaftpulley about five or six turns
so that the timing belt positions
counterclockwise
on the Pulleys.
8.
Adjustthe timing belttension(seepage6-18).
TDC MARK
lf the camshaftand crankshaftpulleysare not positioned at TDC, remove the timing belt and adjust
the positionfollowingthe procedureon page 6-20'
Then reinstallthe timing belt.
adjustthe tensionof eachbelt
1 1 . After installation,
See section23 for alternatorbelt tensionadjustment.
a See section22 tot NC compressorbelt tension
adjustment.
. See section17 for P/Spump belt tensionadjust
ment,
.
L
6-21
CrankshaftSpeed Fluctuation(CKF)Sensor
Replacement
1 . Removethe cylinderheadcover.
NOTE:Referto page6-46when installing.
2. Removethe crankshaftpulley(seepage6_16),
3 . R e m o v et h e u p p e r c o v e r a n d d i p s t i c k / t u b e{ s e e
p a g e6 - 1 9 ) .
4.
Removethe lower cover and idler pulley bracket
(seepage6-19).
5.
Disconnectthe CKFsensorconnector,then remove
the CKFsensor.
CKFSENSOR
CONNECTOR
:
I
6x1.0mm
'12N.m
{1.2kgt.m,
8.7 tbf.ft)
6.
InstalltheCKFsensorin reverseorderof removal.
6-22
(
GylinderHead
lllustratedIndex
CAUTION:
(38'C)beforeremovingthe cylinder
. To avoid damage,wait until the enginecoolanttemperatuledrops below 100"F
head.
. When handlinga metal gasket,take carenot to fold it or damagethe contactsurface'
NOTErUsenew O-ringsand gasketswhen reassembling'
WASHER
when damaged
Replace
or deteriorated.
HEAD
CYLINDER
COVER
Referto page6 46, when
installingcylinderheadcover.
6x1.0mm
9.8 N.m 11.0kgf.m,7.2lbfft)
Applysoapsudsto threadsand cylinderhead
contactsurfacewhen replacingthe rubber
seal,then temoveany soapsudsafterinstall
ing rubberseal.
RUBBERSEAL
Replacewhen damaged
or deteriorated.
CYLINDERHEADBOI-T
10 x 1.25mm
67 N.m 16.8kgf m, a9 lbt'ft)
Tightening,Page6-46
Applyengineoilto the threads.
HEADCOVEBGASKET
when leaking,
Replace
damagedor deteriorated.
Apply liquidgasketat
the four cornersol the
recesses,
DISTRIBUTOR
Seesection23.
8 x 1.25 mm
24 N.m (2.4kgf.m,
17 tbt.ft)
O.RING
Replace.
CYLINDERHEAD
GASKET
Replace.
8 x 1.25mm
24 N.m {2.4kgf m, 17 lbf ftl
t
PINS
(cont'd)
6-23
CylinderHead
lllustratedIndex(cont'dl
-/)
-
(
_.
"or to reassembring,
creanat thepartsin sorvent,
drythemandappryrubricant
E
to anvcontactoarts.
D16Y7 engine:
8 x 1.25mm
20 N.m (2.0kgt.m, 14 tbt.ftl
Applyengineoil to the
ROCK€RARM
ASSEMBLY
Removal,page6 30
Inspection,
page6-35
6x1.0mm
12 N.m (1.2kst.m, 8.7 tbf.ft)
Applyengineoit to the
threads.
VALVEKEEPERS
CAMSHAFT
nspectron,
page6-36
SPRINGRETAINER
H
B
INTAKEVALVE
SPRING
OILCONTROL
ORIFICE
Clean.
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
O-RING
Replace.
:a
INTAKEVALVE
GUIDE
VALVEKEEPERS
ti
\
SPRING
RETAINER
EXHAUST
VAL
SPRING
EXHAUST
VALVE
SEAL
8 x 1.25mm
37 N m (3.8kgt m,
27 tbtftl
A p p l ye n g i n eo i l t o
the threads.
VALVESPRING
SEAT
EXHAUSTVALVE
GUIDE
rnspectron,
page6,39
Beplacement,
page6 4l
Aeaming,page6-43
VALVE
INTAKEVALVE
Removal,page6-38
lnstallation,
page6-43
Removal,page6,27
Warpage,page6 40
Valveseatreconditioning,
page6-40
Installation,
page6-45
t
t
t
c
- A
9-2.+
L
D16Y5 engine:
I x 1.25mm
20 N.m (2,0 kgf m, 14 lbf ft)
Applyengineoilto the
threads.
ROCKEBARM
ASSEMBLY
Femoval,page6-30
Inspection,
Page6-34
6x1.0mm
12 N.m 11.2kgf m, 8.7 lbf'ftl
Apply engineoilto the
threads.
CAMSHAFT
page6-36
Inspection,
VALVEKCEPERS
6x1.0mm
12 N,m 11.2
8.7 tbf.ft)
SPRINGRETAINER
INTAKE VALVE
SPRING
B
WEC SOLENOID
VALVE
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
INTAKE VALVE
GUIDE
VTECSOLENOID
VALVE FILTER
Replace.
OIL CONTROL
ORIFICE
Clean.
CAMSHAFT
PUL|'IY
VALVE
SPRINGRETAINEB
EXHAUSTV VE
SPRING
EXHAUSTVALVE
SEAL
8 x 1.25mm
37 N.m 13.8kgf.m,
27 tbf.frl
Apply engineoilto
the lhreads.
t"o'""".uoau,
SEAT
Replace.
GUIDE
page6-39
Inspection,
Replacement,
Page6-41
Reaming,page6-43
EXHAUST
VALVE
INTAKEVALVE
Removal, page 6 38
I n s t a l l a l i o n ,P a g e 6 4 3
OIL SEAL
Replace.
HEAD
Removal,page6-27
Warpage,Page6 40
Valveseatreconditioning'
page6-40
page6_45
lnstallation,
(cont'd)
6-25
CylinderHead
lllustratedIndex(cont'dl
-vp
e,.io"o reassembring,
creanat the partsin sorvent,dry them and appryrubricantto
any contactparts.
D16Y8engine:
LOSTMOTION
ASSEMgLY
LOSTMOTION
ASSEMBLY
HOLDER
ROCKERARM
ASSEMBLY
Removal,page6 30
Inspection,
page6-34
20 N.m 12.0kgl.m, 14 tbf.ft)
Applyengineoit to the
threads.
6x1.0mm
12 N.m (1.2kgt.m,8.7lbf.ftl
\
Apply engineoil to the
threads,
\
si l 9l l
CAMSHAFT
Inspection,
page6-36
5xl.0mm
12 N.m {1.2
8.7 tbf.ft)
VALVEKEEPERS
SPRINGRETAINER
INTAKEVALVE
INTAKEVALVESEAL
Replace.
VALVESPRING
SEAT
VTECSOLENOID
VALVEFILTEB
Replace.
INTAKEVAI.VE
GUIOE
OILCONTROL
ORIFICE
Clean.
VALVEKEEPERS
CAMSHAFT
PULLEY
SPRINGRET
EXHAUSTVALVE
SPRING
@
EXHAUSTVALVE
SEAL
VALVESPRING
Replace.
SEAT
EXHAUSTVALVE
O.RING
GUIDE
Replace.
Inspection,
page6 39
Replacement,
page6 41
Reaming,page6 43
8 x 1.25mm
37 N.m 13.8kgt m,
27 tbfitl
A p p l ye n g i n eo i l t o
the threads.
OIL SEAL
Beplace.
INTAKEVALVE
EXHAUST CYLINDERHEAD
Bemoval,page6 38 VALVE
Removal,page6 27
Installation,
page6 43
Warpage,page6-40
Valveseatreconditioning,
page6 40
Installation,
page6-45
I
I
Removal
Engineremovalis not requiredfor this procedure
Make sure iacks and salety stands are
!!!s@
propetty
and hoist brackets are attached to the
ta"eata"ea
f
correct positions on the engine.
CAUTION:
. Use tender covels to avoid damaging painted sulfaces.
o T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s
carefully while holding the connector portion to
avoiddamage.
. To avoid damagingthe cylinderhead,wait until the
e n g i n e c o o l a n t t e m p e r a t u r ed r o p s b e l o w 1 0 0 " F
{38"C}before loossning the tetaining bolts.
8.
Removethe throttlecableby looseningthe locknut,
then slip the cableend out of the throttlelinkage
NOTE:
. Takecarenot to bendthe cablewhen removingit
Alwaysreplaceany kinkedcablewith a new one
. Adjustthe throttlecablewhen installing(seesect i o n 11 ) .
D16Y7engine:
LOCKNUT
NOTE:
o M a r k a l l w i r i n g a n d h o s e st o a v o i d m i s c o n n e c t l o n
Also, be surethat they do not contactother wiring or
hoses,or interferewith other parts.
. Inspectthe timing belt before removingthe cylinder
he a d .
T u r n t h ec r a n k s h apf tul l e ys o t h a tt h e N o . l p i s t o n i s a t
top deadcenter(seePage6-21)
.
'1. Disconnect
the negativeterminalfrom the battery'
2.
D r a i nt h e e n g i n ec o o l a n (t s e ep a g e ' 1 0 - 7 ) .
a Removethe radiatorcapto speeddraining.
3.
Removethe intakeair duct and air cleanerhousing
(seepage5 3).
4.
R e m o v et h e m o u n t i n g b o l t a n d l o c k b o l t . t h e n
r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d
pump (seepage5'5).
CABLE
Dl6Y5, Dl6Y8 engines:
THFOTTLE
CABLE
L o o s e nt h e i d l e r p u l l e y c e n t e rn u t a n d a d j u s t i n g
bolt' then removethe air conditioning(A'lc)compressorbelt (seePage5-6).
6.
L o o s e nt h e m o u n t i n g n u t a n d l o c k b o l t . t h e n
removethe alternatorbelt (seepage6-19).
1.
Removethe P/Spump bracket(seepage5-12).
(cont'd)
6-27
CylinderHead
Removal (cont'd)
(
9. Relievefuel pressure(seesection11),
Do not smokewhile working on tho fuel
E@E
system. Ke6p opgn flame or gpark away from lhe
work area, Drain fuel only into an app.oved containgr.
10. Removethe evaporativeemission (EVAP)control
canisterhose,fuel feed hoseand breatherhose.
1 1. Removethe brakeboostervacuumhose.fuel return
hoseand vacuumhose(seepageS_4).
12. Removethe water bypasshose and positivecrank_
caseventilation(pCV)hose.
016V7engine:
WATEREYPASS
D16Y7engine:
BANJOBOLT
33 N.m{3.4kgtm,
25 tbf.ftt
a
\
BREATHER
HOSE
PCVHOSE
D16Y5, D16Y8 engines:
D15Y5, Dl6YB engines:
BANJOAOLT
33 N.m (3.4kgf.rn,
25 tbf.ftt
PCVHOSE
EVAP CONTROL
CANISTERHOSE
I
6- 28
13. Remove the upper radiator hose' heater hose and
water bYPasshose
1 5 . Removethe spark plug caps and distributorfrom
the cylinderhead.
Removethe uPPerbracket.
WATER
EYPASS
HOSE
UPPER
RADIATOR
HOSE
NOTE:
. U s e a j a c k t o s u p p o r tt h e e n g i n e b e f o r et h e
upperbracketis removed.
. Make sure to place a cushion between the oil
pan and the jack.
12 x 1.25mm
74 N.m {7.5 kgf m.
sil lbl.ftl
UPPER
BRACKET
HEATER
HOSE
1 4 . Remove the engine wire harnessconnectorsand
wire harness clamps from the cylinder head and the
intake manifold.
o Fourfuel injectorconnectors
. Engine coolant temperature(ECT)sensor connector
a ECTswitch connector
ECTgaugesendingunit connector
a Throttlepositionsensorconnector
a Manitold absolute pressure(MAP) sensor con-
'17. Removethe cylinderheadcover'
CYLINDER
HEADCOVER
nector
Primary heatedoxygen sensor (primary HO2S)
connector
S e c o n d a r yh e a t e do x y g e n s e n s o r ( s e c o n d a r y
HO2S)connector(D16Y7engine)
Exhaustgas recirculation(EGR)valve lift sensor
connector(D16Y5engine)
. VTECsolenoid valve connector(Dl6Y5, D16Y8
engrnes)
. VTECpressureswitch connector(D16Y5.D16Y8
engrnes,
. ldle air control(lAC)valveconnector
(cont'd)
6-29
Cylinder Head
RockerArms
Removal(cont'd)
Removal
1 8 . Removethe timing belt {seepage6-19).
\
1.
1 9 . Removethe camshaftpulleyand backcover,
Loosenthe adjustingscrews.
ADJUSTINGSCREWS
CAMSHAFT
PULLEY
Cleanwhen installing.
6x1.0mm
8 x 1.25mm
37 N.m (3.8 kgf.m,
21 tbtlrl
Applyengineoilto the
bolt threads.
Removethe exhaustmanifold{seepages9-6and 9_7).
2 1 . Removethe intakemanifold(seepages9-2thru 4).
22. Removethe cylinder head bolts, then remove the
cylinderhead.
CAUTION:To pr€vent warpage, unsclew lhe bohs
in sequonce1/3 turn at a time; rgpeat tho sequence
until all bolts are loosened.
CYLINDERHEADBOLTSLOOSENINGSEOUENGE:
6-30
2.
Unscrew the camshaft holder bolts, then,remove
the rockerarm assembly.
NOTE:
a Unscrewthe camshaftholderboltstwo turns at a
t,me, in a crisscrosspattern,to preventdamao_
ing the valvesor rockerarm assembly.
. When removingthe rockerarm assembly,do not
removethe camshaftholder bolts.The bolts will
keep the camshaftholders,the springs and the
rockerarms on the shaft.
CAMSHAFTHOLDERBOLTSLOOSENING
SEOUENCE:
(
Disassembly/Reassembly
NOTE:
in originallocations'
. ldentifypartsas they are removedto ensurereinstallation
(see
page
6-35).
arms
and
rocker
. lnsDectrockershafts
. Rockerarms must be installedin the same positionif reused.
. h e b o l t s w i l lk e e p t h e
r r m a s s e m b l y , d o n orte m o v et h e c a m s h a fht o l d e rb o l t s T
. w h e n r e m o v i n go r i n s t a l l i n g t h reo c k e a
holders,springsand rockerarms on the shaft.
-Zl
contactpoints.
prio, ,o reassemblinq,
- cleanall the pans in solvent,dry them and apply lubricantto any
|
RocKER
TNTAKE
RocKER
TNTAKE
ARM B
ARM A
D16Y7engine:
14places)
(4 placesl
INTAXEROCKER
"8" is stamped
Lefter
on rockerarm.
I
I
I
ROCKERSHAFT
COLLAR
14plac.3l
B
A
fift
\
'
A
L$\ft
:l o ol ) l[ * o
:
l .
I
Jol----t
No.3CAMSHAFT
| | ruo.z cltusxerr 1i
T-* l=Bl-* d
I
qJ?[l'-qJ'Ll
,", 'l l=^ ^l
' I ^
B A
EI
[ilH
l"\
9
ROCKERSHAFT
SPRING
{4 places)
t
(cont'd)
6-31
RockerArms
Disassembly/Reassembly
(cont'dl
\
(
NOTE:
. ldentifypans as they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms (seepage6-34).
. Rockerarms must be installedin the samepositionif reused.
t when removingor installingthe rockerarmassembly,do not remove
the camshaftholderbolts.The boltswill keepthe
holders,springsand rockerarms on the shaft.
I
erior to reassembring,
creana the partsin sorvent,dry them and appryrubricantto any contactpoints.
II{TAKEROCKERSHAFT
D16Y5engine:
ROCKER
ARMS
TIMINGPLATE
RUBBER
BANO
-]-
-P'g,rp
t+.t't ll
\--,?|, \2i
No.5 CAMSHAFT
_ l
HOLDER
l
No. 4 CAMSHAFT
HOLDER
l
No. 3 CAMSHAFI
HOLDER
\ ra
I
No.2
HOLDER
!-r I
?h'ffi*ffi'
EXHAUSTROCKER
ARM B
/^
IOCKERSHAFT
{,1plac€s)
--
EXHAUSTROCKEESHAFT
Letter "8" is stamped
6-32
Letter "A" is slamped
D16Y8engine:
INTAKESOCKERSHAFT
ROCKER
SI{AFT
ROCKERARMS
COLLAR
No. 4 CAMSHAFT
HOLOER
BAND
NUBBER
No. 3 CAMSHAFT
HOLDER
No. 2 CAMSHAFT
HOLDER
COLLAR
No. 'l CAMSHAFT
HOLDER
No. 5 CAMSHAFT
HOLDER
SHAFT
R(rcKER
SPRING
ARMB
EXHAUSTROCKERSHAFT
Letter
"B"
is stamped
Letter"A" is stamped
L
6-33
RockerArms and Lost Motion Assemblies
(D16Y5,
Inspection
Dt6Y8enginesl
N O T E rW h e n r e a s s e m b l i n gt h e p r i m a r y r o c k e ra r m ,
c a r e f u l l ya p p l y a i r p r e s s u r et o t h e o i l p a s s a g eo f t h e
rockerarm.
1.
Inspectthe rockerarm piston.push it manually.
- lf it does not move smoothly,replacethe rocker
a r ma s s e m b t y .
\
(
DI6YSengine:
NOTE:Set the timing plate and returnspring as shown
oerow.
RETURN
Dl6Y5 engine:
ROCKERARM
TIMINGPISTON
TIMINGSPRING
SYNCHRONTZING
PISTON
CAMSHAFTHOLDER
Dl6Yg engine:
SECONDARY
ROCKERARM
MID ROCKERARM
PRIMARYROCKER
SYNCHRONIZING
PISTON A
NOTE:
. Apply oil to the pistonswhen reassembling.
o Bundlethe rockerarms with a rubberbandto prevent
them from separating.
6-34
2.
Removethe lost motion assemblyfrom the holder
and inspectit. Test it by pushingthe plungerwith
your finger.
- l f t h e l o s t m o t i o n a s s e m b l yp l u n g e rd o e s
not
move smoothly,replaceit.
Pu3h
I
LOSTMOTION
ASSEMBLY
\
a
RockerArms and Shafts
ClearanceInspection
Measureboth the intakerockershaftand exhaustrocker
shaft.
1.
Measurethe diameterof the shaft at the first rocker
locatron.
2.
Zerothe gaugeto the shaftdiameter'
3.
M e a s u r et h e i n s i d ed i a m e t e or f t h e r o c k e ra r m a n d
checkfor an out of-roundcondition.
RockelArm-to-ShaftClearance
Standard(Newl:
0.017- 0.050mm
lntake:
{0.0007- 0.0020inl
Exhaust: 0.018- 0.054mm
(0 0007- 0 0021 in)
ServiceLimit:0.08mm {0.003inl
on all the rockers.
Repeatthesemeasurements
- lf the clearance
is overthe servicelimit,replacethe
rockershaftand all overtolerancerockerarms.
I
6-35
Gamshaft
Inspection
(
\
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removethe rockerarms and rockershafts.
1.
2.
Seatthe camshaftby pushingit toward the rear of
the cylinderhead.
3,
Zerothe dial indicatoragainstthe end ofthe camshaft.
Push the camshaft back and fonh, and read the end
ptav.
Put the camshaftand the camshaftholderson the
cylinderhead.then tightenthe boltsto the specified
toroue.
Camshaft End Play:
Standard{New):0.05- 0.15mm
10.002- 0.006inl
SorviceLimit
0.5 mm (0.02in,
Spocifiedtorqu€:
8 mm bolts; 20 N.m (2.0kgf.m t4 lbf.ft)
Apply engin6 oil to tho throads,
6 mm bohs: t2 N.m (1.2 kgf'm 8.7 tbf.ft)
Apply oogine oil to the thleads.
6 mm bolts: @, @ @, @
I
Removethe bolts,then removethe camshaftholders from the cylinderhead.
- Liftthe camshaftout of the cylinderhead,wipe it
clean, then inspect the liit ramps, Replacethe
c a m s h a f ti f a n y l o b e s a r e p i t t e d . s c o r e d ,o r
excessively
worn,
- Cleanthe camshaftbearingsurfacesin the cylinder head,then setthe camshaftbackin place.
- Placea plastigagestrip acrosseachIournal.
5.
Installthe camshaftholders,and tightenthe boltsto
the soecifiedtoroue.
\,l
6- 36
E
6,
Removethe camshaft holders. then measure the
widest ponion of the plastigageon eachjournal.
Camshaft-to-HolderOil Clearance:
Standard lNew):0.050- 0.08!tmm
{0.002- 0.004in}
ServiceLimit : 0.15 mm {0.006in)
8.
Checkthe cam lobe heightwear.
Cam lobe heightstandard(New)
O16Y/engine
D16Y5
engrne
PRI
U n i tm m ( i n )
INTAKE
EXHAUST
35.299(1.3897)
37.281(1.4678)
38.427 11.51291
38.784(1.5269)
3 2 . 1 9 3( 1 . 2 6 7 4 )
SEC
36.77811.44791
PRI
D l6Y8
MID
engrne
38.274(1.5068)
38.008(1.4964)
37.065(1.4592)
sEu
PRI;Primarycam lobe,SEC:Secondarycam lobe
MtD:Mid cam lobe.T/B:Timing belt
lN: Intake,EX:Exhaust
PRI
-7.
oil clearanceis out ot tollf the camshaft-to-holder
erance:
- A n d t h e c a m s h a f th a s a l r e a d yb e e n r e p l a c e d ,
you must replacethe cylinderhead.
- lf the camshafthas not beenreplaced,first check
the total runout with the camshaftsupportedon
V-blocks.
sEc
a*
rN
Ex
t/g
- D16Y5engine
MIDSEC
rts
- Dl6YE ongine
CamshaftTotal Runout:
Standard (New): 0.03 mm (0.001inl max.
ServiceLimit: 0.04 mm {0.(X)2in)
Checkthis area{or wear.
Rotatecamshatt
while measuring.
-
L
lf the total runout of the camshaftis within tolerance,replacethe cylinderhead.
lf the total runout is out of tolerance,replacethe
oil
camshaftand recheckthe camshaft-to-holder
clearance.lf the oil clearanceis still out of tolerance.replacethe cylinderhead.
6-37
Valves,Valve Springs and Valve Seals
Removal
(
N O T E : l d e n t i f yv a l v e sa n d v a l v e s p r i n g sa s t h e y a r e
removedso that each item can be reinstalledin its orioinal oosition.
'1.
3.
Install the valve guide seal remover.
SEAL REMOVER
Using an appropriate-sized
socketand plasticmallet. lightlytap the valve retainerto loosenthe valve
keepersbeforeinstallingthe valve spring compressor.
vat
vF GI
nF !SEALREMOVER
VALVE
GUIDE
LISLEP/N 57900or KD3350
PLASTICMALLET
I
SOCKET
4.
Removethe valveseal.
Installthe spring compressor.Compressthe spring
and removethe valvekeeper.
VALVE SPRII{GCOMPRESSOR
Snlp-onCF711or KD-383
whh #32 JAWS
L
6-38
Valve Guides
ValveMovement
Measurethe guide-to-stemclearancewith a dial indicator while rockingthe stem in the directionof normal
thrust (wobblemethod).
lniake Valve Stem-to-GuideClearance:
St8ndardlNew): 0.04- 0.10mm
- 0.004in)
10.002
0.16 mm 10.006in)
ServiceLimit:
ExhaustValvs Stem-to-GuideGlearance:
Standard{New}: 0.10- 0.16mm
10.004- 0.006in)
0.22 mm (0.009in)
SorviceLimit
Valveextended10 mm out from seat.
lntake Valve Dimensions
A StandsrdlNewl: 29.9- 30.1mm
1 1 . 1-8 1 . 1 9i n l
(New):
117.42- 117.72mm
B Standard
(4.523- 4.635inl
C Standald{Newl: 5.'18- 5.49 mm
{0.2r57- 0.2r61in)
5.,[5mm (0.21,16in]
C ServiceLimit:
D Standard (New): 0.85- 1.15mm
(0.033- 0.0'15in)
0.65mm (0.026in)
D ServiceLimit:
ExhaustValve Dimensions
A StandardlNew): 25.9- 26.1mm
(1.02- 1.03in)
B Standard {Newl: 114.60- 114.90mm
11.512- 4.521in1
C Standard {New): 5.i[5 - 5.46 mm
- 0.2150inl
10.21lt6
5.,12mm 10.213'lin)
C ServiceLimit:
D Standard {New): 1.05- 1.35mm
{0.041- 0.053in)
0.95mm {0.037in}
D ServiceLimit:
O
/'-_)
.
.
.
l f t h e m e a s u r e m e net x c e e d st h e s e r v i c el i m i t ,
recheckusinga new valve.
lf the measurementis now within the service
limit, reassembleusinga new valve.
l f t h e m e a s u r e m e n st t i l l e x c e e d st h e l i m i t ,
recheckusing the alternatemethod below,then
replacethe valveand guide,if necessary.
NOTE: An alternatemethod of checkingguide to
stem clearanceis to subtractthe O.D. of the valve
stem, measuredwith a micrometer,from the l.D.of
the valve guide, measuredwith an inside
micrometeror ball gauge.Takethe measurements
i n t h r e e p l a c e sa l o n g t h e v a l v e s t e m a n d t h r e e
places inside the valve guide. The differencebet w e e n t h e l a r g e s t g u i d e m e a s u r e m e n ta n d t h e
smalleststem measurementshould not exceedthe
servicelimit.
lntake Valve Stgm-to-Guidgclearance:
Standard {Newl: 0.02- 0.05 mm
{0.001- 0.002in)
0.08
mm (0.003in)
Limit
Ssrvico
ExhaustValvo Stem-to-GuideClearance:
Standard {New): 0.05- 0.OBmm
{0.002- 0.003in)
0.11 mm (o'Ooilin)
S€rviceLimit
6-39
Cylinder Head
Valve Seats
Warpage
Reconditioning
N O T E : l f t h e c a m s h a f t - t o - h o l d eori l c l e a r a n c e s( s e e
page6-36)are not within specification,
the cylinderhead
cannotbe resurfaced.
'1. Renew
the valve seatsin the cylinderhead using a
valveseatcutter.
NOTE: lf the guides are worn (see page 6-39).
r e p l a c et h e m ( s e e p a g e 6 - 4 1 )b e l o r e c u t t i n g t h e
valveseats.
lf the camshaft-to-holder
oil clearancesare within sDeci,
fications,checkthe cylinderheadlor warpage.
lf warpageis lessthan 0.05mm (0.002in), cylinder headresurfacingis not required.
lf warpage is between 0.05 mm (0.002in) and
0.2 mm {0.008in), resurfacethe cylinderhead.
M a x i m u m r e s u r f a c el i m i t i s 0 , 2 m m ( 0 . 0 0 8i n )
basedon a heightof 93 mm (3.66in).
VALVESEAT
CUTTER
(Commercially
available)
2.
C a r e f u l l yc u t a 4 5 ' s e a t , r e m o v i n g o n l y e n o u g h
materialto ensurea smoothand concentricseat.
?
Bevelthe upperedge of the seatwith the 30. cutter
and the lower edge of the seat with the 60' cutter.
Checkthe width of the seatand adjustaccordingly.
4.
Makeone more very light passwith the 45"cutterto
removeany possibleburrs causedby the other cutIers.
Valve Seat Width:
Standard (N€w):
- 0.045in)
Intake:
0.85- 1.15mm 10.033
Exhaust:
1.25- 1.55mm {0.049- 0.061in}
SorviceLimit:
Intake:
1.6mm (0.063inl
Exhausl:
2.0 mm (0.079in)
Measurealongedges,and threeways acrosscenter.
Seat Width
Cylinder Head Height:
Standard{Newl: 92.95- 93.05mm
{3.659- 3.66:}in)
6-40
5.
After resurfacing the seat, inspect for even valve
s e a t i n g r A p p l y P r u s s i a nB l u e c o m p o u n d t o t h e
valve face, and insert the valve in its original location in the head, then liit and snap it closed against
the seat several times.
\
ValveGuides
Replacement
1 . As illustratedbelow, use a commercially-available
air-impactvalve guide driver attachmentmodified
to fit the diameterof the valveguides.In most cases.
the same procedurecan be done using the special
tool and a conventionalhammer.
VALVE
SEAT
VALVEGUIDEDRIVER
lCommerciallv
available)
PFUSSIANBTUECOMPOUNO
The actual valve seatingsurface.as shown by the
blue comDound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve stem), you
must make a second cut with the 60'cutter to
move it down, then one more cut with the 45'
cutter to restoreseat width,
. lf it is too low (closerto the vslve edge), you
must make a second cut with the 30" cutter to
move it uD,then one more cut with the 45'cutter
to restoreseat width.
NOTE:The final cut shouldalwaysbe madewith
the 45" cutter.
7.
lnsertthe intakeand exhaustvalvesin the headand
measurethe valvestem installedheight.
Intake. Exhau3tSiem Installsd Height:
Standard (New): 53.17- 53.6,4mm
- 2.112in)
12.093
53.89mm (2.122in)
SorviceLimit:
8.
87 mm +t3.43in) |
57 mft
1224 inl
5.3 mm
tr-r
'10.8mm
(0.42 inl
or
VALVEGUIDEDRIVER,5.5 mm
07742- 0010100
guides.and chill them
Selectthe properreplacement
in the freezersectionof a refrigeratorfor about an
nour.
Use a hot plate or oven to evenlyheat the cylinder
headto 300"F(150'C).Monitorthe temperaturewith
a cookingthermometer.
lf the valve stem installed height is over the service
limit. reDlacethe valve and recheck.lf its still over
t h e s e r v i c el i m i t , r e p l a c et h e c y l i n d e r h e a d ;t h e
valveseat in the headis too deep.
VALVESTEM
INSTALLEDHEIGHT
CAUTION:
. Do not use a torch; it may warp the head.
Do not got the head hottel than 300"F (150"C1;
excessiveheat may loosen thg valve seats.
To avoid burns. use heayy gloves whon handling
the heated cylinder h€ad.
\-
{cont'd)
6-41
Valve Guides
Replacement(cont'd)
Workingfrom the camshaftside,use the driver and
a n a i r h a m m e tr o d r i v et h e g u i d ea b o u t2 m m ( 0 . 1i n )
towardsthe combustionchamber.This will knockoff
some of the carbonand makeremovaleasier.
CAUTION:
. Always wear satety gogglesor a face shield when
driving valve guides.
. Hold the air hammer directly in line with the
valve guide to prevent damaging the driver.
7.
Apply a thin coat of cleanengineoil to the outside
of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to
drivethe guide in to the specifiedinsralledheight.lf
you haveall 16 guidesto do, you may haveto reheat
thehead.
I
Turn the headover, and drive the guide out toward
the camshaftside of the head.
VALVEGUIOE
DRIVER,5.5
mm
07742- 0010100
ll
VALVE GUIOEORIVER,
5.5 mm
07742 - 001 01 00
Valve Guide lnstalled Height:
Intake: 17.85- 18.35mm (0.703- 0.722inl
Exhausi:18.65- 19.15mm (0.734- 0.754in)
VALVEGUIDE
It a valve guide still won't move, drill it out with a
8 mm {5/16in) bit, then try again.
CAUTION: Drill guides only in extreme cases; you
could damagethe cylinder head it the guide breaks.
6.
Removethe new guidesfrom the freezer,one at a
time, as you needthem.
6-42
Valves
Reaming
lnstallation
NOTE:For new valveguidesonly.
1 . Coat valve stems with engine oil. Insertthe valves
in the valveguides.
1.
Coat both the reamerand valve guide with cufting
orl.
2.
Rotatethe reamer clockwisethe full length of the
valveguide bore.
3.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore.
4.
Thoroughlywash the guide in detergentand water
to removeany cuttingresidue.
5.
Checkthe clearancewith a valve(seepage6-391.
Verifythat the valve slidesin the valve guide without exertingPressure.
T u r nr e a m e irn
clockwisedireclion
o nl y .
NOTE: Make sure lhe valves move up and clown
smoothly.
2.
lnstallthespringseatson the cylinderhead.
3.
I n s t a l lt h e v a l v e s e a l su s i n gt h e v a l v e g u i d e s e a l
installer.
NOTE:Exhaustand intakevalvesealsare not interchangeable.
WHITE
SPRING
INTAKEVALVESEAL
BLACK
SPRING
EXHAUST
VALVESEAL
VALVEGUIDESEAL
INSTALLER
REAMER
K D 2 8 9 9 ( C o m m e r c i a l l ya v a i l a b l e )
NOTE: Use small lD end of
o a)
o ,
o
o
REAMER,5.5 mm
O7HAH.PJ'O'IOB
P
I
(cont'd)
6-43
Valves
Camshaft/RockerArms and
CamshaftSeal/Pulley
Installation(cont'd)
Installation
4.
CAUTION:
. Make sure that all tockers are in alignment with their
valvgs when torquing the rocket assemblybolts,
. Valve locknuls should be loosened and adiusting
screws backed off bofore installation.
. To prevont tho rocker arm a$smbly from coming
apad, l6av€the camshaft holder bohs in the holdeB.
I n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r .t h e n
installthe valve spring compressor.Compressthe
springand installthevalvekeepers.
NOTE:Placethe end of the valvespringwith closely wound coilstoward the cylinderhead.
1.
After wiping down the camshaft,camshaftseal and
j o u r n a l si n t h e c y l i n d e rh e a d ,l u b r i c a t eb o t h s u r facesand installthe camshaft.
2.
Cleanand installthe oil control orificewith a new
O-ring.
OIL CONTROLORIFICE
available)
lCornmercially
Snap-onCFrll or KD- 3tX'
with #32JAWS
Lightlytap the end of eachvalve stem two or three
times with a plasticmalletto ensureproperseating
of the valveand valvekeepers.
NOTE:Tap the valvestem only along its axisso you
do not bendthe stem.
CAMSHAFTSEAL
Sealhousingsurfaceshouldbe dry.
Applya lightcoat of oil to camshaft
a n d i n n e rl i p o f s e a l .
3.
' 6-44
Turn the camshaft until its keyway is facing up (No.
piston TDC).
CylinderHead
lnstallation
4.
Apply liquidgasket(PartNo. 08718- 0001or 087180003)to the head mating surfacesof the No. 1 and
No.5 camshaftholders.
- Apply liquidgasketto the shadedareas
lnstallthecylinderheadin the reverseorderof removal:
NOTE:
. Alwaysuse a new headgasket.
. C y l i n d e rh e a d a n d c y l i n d e rb l o c ks u r f a c em u s t b e
clean.
. "UP" markon the camshaftpulleyshouldbe at the top
. Turn the crankshaftso the No. 1 pistonis at TDC(see
page6-20).
. Cleanthe oil controlorificebeforeinstalling.
a Do not use the upper cover and lower cover to store
removeorlems.
Cleanthe upper cover and lower cover beforeinstaltaUon.
1.
Cylinderheaddowel pins must be aligned.
CYUNOERHEAD
Set the rockerarm assemblYin place and loosely
installthebolts.
- Makesurethat the rockerarms are properlypositionedon the valvestems.
Tighteneachbolttwo turnsat a time in the sequence
shown belowto ensurethat the rockersdo not bind
on the valves.
Specitiedtorquo:
8 mm bolts: 20 N.m (2.0 kgt'm, l/t lbf'ft)
Apply engine oil to the threads.
6 mm bolts: 12 N.m {1.2 kgif'm,8.7 lbf'ft)
Apply engine oil to the thresds.
6 mm bolts:O, @. @, @
PINS
!
7.
Installthe backcover.then installthe camshaftpul-
(cont'd)
6-45
Cylinder Head
Installation(cont'dl
(
Positionthe camshaftcorrectly(seepage6-20).
7 . Installthetiming belt (seepage6-20).
Tightenthe cylinderhead bolts sequentiallyin four
steps.
8 . Adjustthe valveclearance(seepageel2),
rsr st.p: O - @ 20 N.m (2.0 kgf.m, 14 lbf'ft|
2nd srep: O - @ 49 N.m (5.0kgf.m, 36 tbtft)
3rd stop; O - @ 67 N.m {6.8 kgf.m, /r9 lbl'ft}
4th st6p: O, O 67 N.m 16.8kgf.m, 49 tbf.ftl
NOTE:
. W e r e c o m m e n du s i n g a b e a m - t y p et o r q u e
wrench, When using a preset-typetorque wrench.
be sure to tighten slowly and not to overtighten.
. If a bolt makesanynoisewhileyouaretorquingit,
loosenthe bolt, and retightenit from the 1ststep,
9. Installthe head cover gasketin the groove of the
c y l i n d e r h e a d c o v e r , S e a t t h e r e c e s s e sf o r t h e
camshaftfirst, then work it into the groove around
the outsideedges.
NOTE:
. B e f o r ei n s t a l l i n gt h e h e a d c o v e r g a s k e t ,t h o r oughlycleanthe sealand the groove.
. When installing,make sure the head cover gask e t i s s e a t e d s e c u r e l yi n t h e c o r n e r s o f t h e
recesses
wathno gap.
COBNERS
OF
THERECESS
CYLINDERHEADBOLTSTOROUESEOUENCE:
I
CORNERS
OF
THEREcEss
covEB
1 0 . Apply liquid gasketto the head cover gasketat the
four cornersof the recesses.
4.
Installthe intakemanifoldand tightenthe nuts in a
crisscrosspatternin two or three steps,beginning
with the innernuts (seepages9-2thru 9-4).
.
Alwaysusea new intakemanifoldgasket.
NOTE:
. Use liquid gasket,Pan No. 08718- 0001or 08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket.
. Do not installthe parts if five minutesor more
h a v e e l a p s e ds i n c e a p p l y i n gl i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingold
residue.
. After assembly,wait at least 30 minutes before
fillingthe enginewith oil.
Installthe exhaustmanifoldand tightenthe nuts in
a crisscrosspatternin two or threesteps,beginning
with the inner nut {seepages9-6 and g-7).
.
Always usea new exhaustmanifoldgasket.
I n s t a l lt h e e x h a u s tm a n i f o l d b r a c k e t .l n s t a l l t h e
exhaustpipe A and the bracket,then installthe cover.
6-46
\-
1 1 . W h e n i n s t a l l i n gt h e c y l i n d e rh e a d c o v e r ,h o l d t h e
headcovergasketin the grooveby placingyour fingers on the camshaft holder contacting surfaces
(top of the semicircles)
Setthe sparkplug sealon the sparkplug tube.
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the headcovergasket.
12. Tightenthe nuts in two or thre€ steps.In the final
step,tighten all bolts, in sequence,to 9 8 N'm (1.0
kgf.m,7.2 lbf.ft).
NOTE: After assemblv, wait at least 30 minutes
beforefillingthe enginewith oil
NOTE:
. Before installingthe cylinder head cover, clean
t h e c y l i n d e r h e a d c o n t a c t i n gs u r f a c e sw i t h a
shop towel.
. Do not touch the parts where liquid gasketwas
aDolied.
. T a k ec a r e n o t t o d a m a g et h e s p a r k p l u g s e a l s
when installingthe cylinderheadcover,
. Visuallycheckthe sparkplug sealsfor damage.
. Replaceany washerthat is damagedor deteriorated.
6x1.0mm
9.8 N.m 11.0ksf.m,7.2lbfftl
1?
After installation,check that all tubes, hosss and
connectorsare installedcorrectlY
\g-----*o""t'
Ptl
vE eE
\_
6-47
GylinderHead/ValveTrain
816A2 engine
SpecialTools
.............
6'50
VTECContlol System
6-51
TroubfeshootingFlowchart ............
VTECSolenoid Valve
...""'......5-54
Inspection
VTEC RockerArms
6-54
ManualInspection...........................
InspectionUsing SpecialTools .....'6-55
ValveClearance
.
.^
t
.........."
6-57
Adiustment
PulleyandPulleyBolt
Crankshaft
..".....6-59
Replacement
Timing Belt
CylinderHead
RockerArms
...............6'72
Disassembly/Reassembly
Rocker Arms and Lost Motion Assemblies
.........""'6-73
Inspection
Rocker Arms and Shafts
6-74
Inspection..'..."'..............
Clearance
Camshafts
SpringsandValveSeals
Valves'Valve
""""""""' 6-77
Removal
ValveSeats
......6'78
Reconditioning
lnstallation
6-82
'............
SpecialTools
\
Ref.No.
q
g
g
Tool Number
I
o T H A HP J 7 0 1 0 B
07JAA-001020A
07JAB-0010204
07JAB- 0010404
07LAJ- PR3020A
07MAA- PR70100
I
I
I
g
|6)
g
g
g
(!D
Description
I
I
V a l v eG u i d eR e a m e r , 5 .m
5m
Socket,19 mm
H o l d e rH a n d l e
PulleyHolderAttachment.50 mm
Air Stopper
TappetAdjuster
- enu
ozvu,r
orzo TappetLocknutWrench
07MAF- PR9010A ValveSpringCompressorAttachmentExtension
0 7 7 4-2 0 0 1 0 1 0 0
ValveGuideDriver,5.5 mm
0 7 7 5 7 - P J 1 0 1 0 4 ValveSpringCompressorAttachment
t
Oty
1
1
1
1
1
1
1
1
1
1
(
PageRelerence
6-81
659
6-59
6-5s
]
I 6-55
6-57
6-57
J 6-77
6-80,81
6-71
I
a;
aL)
'n
-=<-,,LE;;
(D
\-
6- 50
a
VTECControl SYstem
TroubleshootingFlowchart
problemin the WEC PressureSwitchcircuitor
The scantool indicatesDiagnosticTroubleCode{DTC)Pl259:A
VTECSolenoidValvecircuit
Referto page 1'l-38through 11 55 beforetroubleshooting
The MIL has beenteported on.
DTCP1259is siored.
Checkthe VTECControl SYsiem:
1. Do the enginecontrolmodule
( E C M) R e s e tP r o c e d u r e( s e e
section11).
2. Startthe engine
3. Warm uP the engineto normal
operatingtemPerature(cool
ing fan comeson).
4. Do the RoadTest.*
ls DTCP1259indicated?
* Road Test:
in 1stgearto an enginespeedover 6,000rp '
Accelerate
Holdthat enginespeedfor at leasttwoseconos'
lf the DTC P1259is not repeatedduring the first road test'
repeatthis testtwo moretimes
lntermittent failure, sYstemis OK
at this time.
Check for Poor connectlons or
loose wires at VTEC Pressure
swilch. VTECaolenoid valvo and
ECM.
SWITCH2P
VTECPRESSURE
CONNECTOR
Test the VTECPressureSwitch:
1. Turnthe ignitionswitchOFF.
the VTECPressure
2. Disconnect
switch2P connector.
3. Checkfor continuitybetween
VTECpressureswitch2P con
n e c t o rt e l m i n a l N o 1 a n d
No.2.
T e r m i n a l s i d eo f
male termtnals
Reolacethe VTECPre3sureswitch.
/1
WM
IBLU/BLKI
/ 1 Y------r
t--------- l
\1-/
|
I
I
Test the VTEC Pressure Switch
Wire:
1. Turnthe ignitionswitchON (ll).
the voltagebetween
2. N4easure
V T E C p r e s su r e s w i t c h 2 P
c o n n e c t o rN o . 1 a n d b o d y
ground,
YES
I
I
1
Wiresideof female
terminals
Inspectlor an open or short to
ground in the wire between the
VTEC orassure swilch and ECM
{c101.
lf the wire i3 OK, substitute a
known-good ECMand recheck.
{To page6 52)
(cont'd)
6-51
VTECControl System
TroubleshootingFlowchart(cont,d)
(
VTECPRESSURE
SWITCH2P
CONNECTOR
(Frompage6-5ll
Test tha VTEC P.es3uro Switch
Wi.e:
Measurevoltage acrossthe VTEC
pressureswitch2P connector.
ls there batteryvoltage?
Wiresideof temale
terminals
Ropairopon in the wiro batwoen
VIEC pr...urc switch and Glot .
lf the wiro is OK, 3ubltitutr a
known-good ECMand rochack.
VTECSOLENOID
VALVElP
CONNECTOF
Ir------rI
lLl.ll-r
I
I
Test the VTECSolenoidV.tve:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the VTECsolenoid
valve1Pconnector.
3. Checkfor continuitybetween
t h e V T E Cs o l e n o i dv a l v e 1 P
connectorterminalNo, I and
bodyground.
It
Terminalsideof
maleterminal
I
ls there14- 30 O?
OIL PRESSURE
GAUGE
(Comm.rciallyavail.bte)
Te3tthe VTECSotonoidVatve:
'1. Remove
the VTEC pressure
switch and installthe special
tool as shown. then reinstall
the VTECpressureswitch.
2. Reconnectthe VTECsolenoid
valve 1P connectorand VTEC
pressureswitch2P connector,
3. Connectthe tachometer(see
sectio1
nl).
4. Startthe engine.
5 . W a r m u p e n g i n et o n o r m a l
operatrngtemperature(cooling fan comeson).
6. Checkoil pressureat engine
s p e e do f 1 , 0 0 0 , 3 , 0 0 0
and
5,000rpm.
ls pressurebelow 49 kPa
(0.5kgflcm,,7psi)?
GAUGEJOINT ADAPTER
SNAP.ONMT26.17
10 x 1.0ftm
. Usenew washerwhen
installingthe sealingbott.
N O T E : K e e p m e a s u r i n gt i m e a s s h o r r a s
possiblebecauseengineis runningwitn no
loadllessthan one minute).
Inipoct thg VTEC aolenoid valve
l3ee P8go6-54).
(To page 6-53)
6-52
I
VTECSOLENOIDVALVE
1PCONNECTOR
(Frompage6-52)
Terminal side of
male terminal
Test the VTECSolenoid Valve:
1. Turnthe ignitionswitchOFF
the VTECsolenoid
2. Disconnect
valve 1Pconnector,
3 . A t t a c h t h e b a t t e r YP o s r t r v e
terminalto the VTECsolenoid
valveterminal.
4 . S t a r t t h e e n g i n ea n d c h e c k
t h e o i l P r e s s u r ea t e n g i n e
speedol5,000rPm
ls the pressureabove390 kPa
(4.0kgt/cm?,57 Psi)?
lrcoect the VTEC solenoid valve
(seepageS54)
C (31PI
ECMCONNECTOR
WM
Testthe VTECPressureSwitch:
With the battery Positiveterminal
connectedto the VTECsolenoid
valve,measurevoltagebetween
the ECMconnectorterminalC10
and bodyground.
ls there battery voltage above
5 , 0 0 0r p m ?
VIECSOLENOID
VALVE
1PCONNECIOR
Test the VTEC Solenoid Valve
Wire:
1. Turnthe ignitionswitchOFF
2. Checkfor continuitvbetween
t h e V T E Cs o l e n o i dv a l v e 1 P
c o nn e c t o rt e r m i n a la n d t h e
terminal812
ECMconnector
ECMCONNECTOR
B l2sP)
Wire sideot female
termrnals
Repairopen in the wire between
the ECMlB12| and VTECaolenoid
VTECSOLENOIDVALVE
1P CONNECTOR
Test lhe VTEC Solenoid Valve
Wire:
Checkfor continuitybetweenthe
VTECsolenoidvalve'lPconnector
terminalandbodyground.
I'ft
Repair short in the wiro b€'tween
the ECM( 812)and VTECaolenoid
I
I
Wire sideof female
termanal
Substitute a known'good ECM
and recheck. lI sYmptom/indica'
tion goes away. repleca the original ECM.
6-53
VTECSolenoid Valve
Inspection
ManualInspection
1 . R e m o v et h e V T E Cs o l e n o i dv a l v e a s s e m b l yf r o m
t h e c y l i n d e rh e a d .a n d c h e c kt h e V T E Cs o l e n o i d
valvefilter for clogging.
.
VTECRockerArms
lf thereis clogging,replacethe engineoilfilter and
engineoil.
\
1.
Set the No. 1 pistonat TDC.
2.
Removethe ignitionwire coverand the wires.
3.
Removethe ignitionclampswhile pullingup on the
Iock.
a
6xl.0mm
9.8 N.m (1.0kgl.m,7.2tbtftl
IGNITION
WIRECOVER
IGNITION
WIRE
SOLENOID
6x1.0mm
12N.m(1.2kgf.m,B,7tbf.ftl
I
lf the filter is not clogged.push the VTECsolenoid
valvewith your fingerand checkits movemenr.
.
lf the VTECsolenoidvalve is normal,checkthe
engineoil pressure.
6x1.0mm
12 N.m (1.2kgtm,8.7 lbt.ft)
LOCK
(
6- 54
L
InspectionUsingSPecialTools
Removethe cylinderheadcover.
NOTE:Referto page6-88when installingthe cylinder head cover.
Pushthe mid rockerarm on the No. 1 cylindermanually.
Checkthat the mid rockerarm movesindependently
of the primary and secondaryrockerarms.
CAUTION:
. B€fore using tho Yalvo inspeciion tool, mako suro
that ths air pre3sure gauge on the air comprossor
indicatos ovor /rco kPa (,1kgf/cm', 57 psi)
. In3poct ths valve closranca bafore rock$ arm impoc'
tion.
. Cover the timing beh whh I shop towel to prcvenl
gstting oil on the bolt'
. Chock ths mid rocker arm of each cylindll at TDC'
1.
Removethe cYlinderhead cover.
NOTE: Rsfer to page 6-86 when installing the cylinder headcover.
2.
Plug the relief hole with the special tool (Air Stopper).
OTLA'- PRSO2OA
3.
7.
Checkthe mid rockerarm ot eachcylinderat TDC'
.
.
Removethe bolt and washer from the inspection
hole and connoct the an air pressureregulator with
a 0 - 100psi gauge.
AIF STOPPEB
OTLA' - PR3O2OA
lf the mid rockerarm does not move, removs the
mid, primary and secondaryrockerarms as an
assemblyand checkthat the pistonsin the mid
and primaryrockerarms move smoothly.
lf any rocker arm needs replacing,replacethe
primary.mid, and secondaryrockerarms as an
assembly.
TNSPECTIONHOIE
t0 x 1.0mrn
20 N.m{2.0kgfm,
14tbt'fr)
BEGULATORVALVE
. Pullthe leverand
turn to adjust.
AIRPRESSURE
REGULATOR
avril.bl.l
{Cornm.rcirlly
{cont'd}
6-55
VTECRockerArms
InspectionUsingSpecialTools(cont,dl
4.
L o o s e nt h e v a l v e o n t h e r e g u l a t o ra n d a p p l y t h e
specifiedair pressure.
I
SpecifiedAir Pressuro:
250 kPa {2.5 kgtlcm,, 36 psil
- 490 kPa {5.0 kgtcm,, 7t psil
Make sure that the primary and secondaryrocker
a r m s a r e m e c h a n i c a l l cy o n n e c t e db y t h e p i s t o n s
and that the mid rocker arms do no. move wnen
pushedmanually.
SECONDARY
ROCKER
ARM
.
lf any mid rocker arm moves independentlyof
the primaryand secondaryrockerarms, replace
the rockerarms as a set.
ll
Removethe tools.
7.
Checkthe operationof the lost motion assemblyby
p u s h i n go n t h e m i d r o c k e ra r m . T h e l o s t m o t i o n
a s s e m b l ys h o u l d c o m p r e s sf u l l y a n d o p e r a t e
smoothlythroughits full stroke.Replacethe assem_
bly if it does not work smoothly.
After inspection.check that the Malfunction Indi_
catorLamp{MlL)does not come on.
;l
6-56
ValveGlearance
Adjustment
NOTE:
. Valves should be adjusted only when the cylinder
head temperaturs is lessthan 100'F (38'C)'
. After adjusting,retorquethe crankshaftpulleybolt to
177N.m (18.0kgf'm,130lbt'ft)
1.
Removethe cylinderheadcover'
Adjustvalveson No. 1 cylinder.
lntako: 0.15- 0.19 mm {0'006- 0.007in)
ExhaGt 0.17- 0.21 mm {0'007- 0 008 inl
4.
Loosenthe locknut, and turn the adjusting screw
until the feeler gauge slides back and forth with a
slightamountof drag.
NOTE:Referto pageG86 when installingthe cylinder headcover.
2.
TAPPETADJUSTER
WFENCHSET
07MM - PR70110
"UP" mark on the pullsy
Set No. 1 pi$on at TDC.The
should be at the top, and TDC grooves on the pulley
should align with the pointer on the backcover' TDC
grooves{white paint) on the crankshaftpulley should
align with the pointeron the timing belt lower cover'
Number I Pistonat TDC:
TAPPETLOCKNUT
WRENCH
07MAA - PR70120
LOCKNUT
20 N.m {2.0 kgf'm, lil lbt'ftl
Adiusting sclaw location:
(cont'd)
6-57
Valve Clearance
Adjustment{cont'd)
5.
Tightenthe locknutand recheckclearance.
Repeatadjustmentif necessary.
FE€LER
GAUGE
R o t a t et h e c r a n k s h a f t1 8 0 . c o u n t e r c l o c k w i s e
(camshaftpulleyturns 90'). The "Up" mark should
be on the exhaustside.Adjustvalveson No. 3 cylinder.
Number 3 piston at TDC:
"UP-
7.
I
R o t a t et h e c r a n k s h a f t' 1 8 0 .c o u n t e r c l o c k w i s teo
bring No. 4 piston to TDC.The ,,Up,.mark should
be pointing straightdown. Adjust valves on No. 4
cylinder.
Number 4 piston at TDC:
8,
R o t a t et h e c r a n k s h a f t1 8 0 . c o u n t e r c l o c k w i s teo
bring No. 2 pistonto TDC.The "Up., marksshould
be on the intakeside.Adjust valveson No. 2 cylin_
der.
L
I
Number 2 piston at TDC:
MARKS
I
6- 58
CrankshaftPulleYand PulleYBolt
Replacement
When installingand tighteningthe pulley,follow the procedurebelow'
Clean,removeany oil, and lubricatepointsshown below
a: Clean
x : BemoveanYoll
a: Lubricate
CRANKSHAFT
PULLEYBOLT
XXX
X
x
X X
x
X
X
X
X
I i
XXXXX
x
WASHER
TIMII
GUID
BELT
GUIOEPLATE
Crankshaftpulley bolt size and torque value:
1 4 x 1 . 2 5m m
177 N.m t18.0kgtm, 130 lbf'ftl
NOTE:Do not usean impactwrenchwhen installing'
PULLEYHOLO€RATTACHMENT,
50 mm
07JAB- 0O10,OA
6-59
Timing Belt
lllustratedIndex
I
NOTE:
. Referto page6-59for positioningcrankshaftand pulleybeforeinstalling
belt.
. Markthe directionof rotationon the belt beforeremovino.
a Do not usethe middlecoverand lowercoverfor storingr'emoveditems.
. Cleanthe middlecoverand lowercoverbeforeinstallation.
WASHER
Replace
when damaged
or deteriorated.
CAPNUT
x 1,0mm
9.8 N.m lr.0 kgf.m,7.2lbtftl
CYLINDER
HEADCOVER
Referto page6-86
when installing.
HEADCOVERGASKET
Replacewhen leaking,
damagedor deteriorated.
Apply liquidgasketat
the four cornersol the
recesses,
- -o
TIMINGBELT
page6-61
Inspection,
Adjustment,page6-61
Replacement,page 6-62
MIDDTECOVER
6 x 1.0mrn
9.8 N.m {1.0 kgf.m,
7.2 tbt-ltl
8 x 1.25mm
N.m {5.7 kgt.m,
6 x '1.0mm
9.8 N.m {1.0kgf.m, 7.2 lbt.ftl
41tbtfr)
6x1.0mm
N.m 11.0kgf.m,
7.2 tbt.ft'l
l0 x 1.25mm
5a N.m {5.5 kgl.m,
40 tbt ftt
TIMINGBELT
DRIVEPULLEY
Replacement,
page6-59
6- 60
Installwithconcave
surtacefacing out.
Removeany oil and clean.
LOWER
COVER
PULLEYBOLT
14x 1.25mm
CRANKSHAFT
PULLEY 177 N.m {18.0kgf.m. 130tbt.ft}
page6-59
Replacement,
page6-59 Beplacement,
Do not usean impact
wrenchwhen installing.
I
Inspection
TensionAdiustment
'L
CAUTION: Always adiust timing belt tension with the
engine cold.
Removethe cylinderheadcover.
NOTE:Referto page6-86when installingthe cylinder headcover.
Inspectthe timing belt for cracksand oil or coolant
soakrng.
NOTE:
. Replacethe belt if oil or coolant soaked.
. Removeany oil or solventthat gets on the belt'
NOTE:
. The tensioneris spring-loadedto apply proper ten
after makingthe followsion to the belt automatically
ing adjustment.
when
. Always rotatethe crankshaftcounterclockwise
it
clockw'se
Rotating
pulley
side.
the
from
viewed
may result in improper adjustmentof the belt tension.
1,
Removethe cylinderheadcover.
NOTE;Referto page6-86when installingthe cylinder headcover.
lnspectthrs area
2.
Setthe No. 1 pistonat TDC(seepage6-64)
3.
Rotatethe crankshaftlive or six revolutionsto set
the belt.
4.
Setthe No. 1 Pistonat TDC
ADJUSTINGBOLT
54 N.m
(5.5kgt.m, a0 lbtftl
I
Rotate PUlleY
and inspect belt-
5.
Loosenthe adjustingbolt 180'.
three teeth
Rotatethe crankshaftcounterclockwise
on the camshaftPulleY.
After inspecting,retorquethe crankshaftpulley bolt
to 177N.m (18.0kgf'm,130lbf'ft)
7.
Tightenthe adjustingbolt.
8.
After adjusting,retorquethe crankshaftpulley bolt
to 177N.m (18.0kgf'm,130lbnft)
6-61
Timing Belt
Removal
\
NOTE:
. Replacethe timing belt at 105,000mites(168,000
km)
accordingto the maintenanceschedule(normalconditions/severe
conditions).
lf the vehicleis regularlydrivenin one or more of the
followingconditions,replacethe timing beltat 60,OOO
miles(U.S.A.)100,000km {Canada).
. In very high temperatures(over 110"F,43"C).
. In very low temperatures(under-20.F, 29.C).
. Turn the crankshaftpulley so the No. 1 piston is at
top dead center(TDC)beforeremovingthe belt (see
page6-57).
. Inspectthe water pump before installingthe timing
belt {seepage 10-14).
1.
4.
Loosenthe mountingnut and lockbolt,then remove
the alternatorbelt.
a
LOCKBOLT
8 x 1.25mm
24 N.m {2.4 kgt.m.
17 rb{.ftl
Removethe splashshield(seepage5-9).
Removethe adjustingbolt and mountingbolts,then
r e m o v et h e p o w e r s t e e r i n g( P / S )p u m p b e l t a n d
pump.
MOUNTING
10x 1.25mm
44 N.m (4.5kgf.m.
33 rbf.ftt
5.
BELT
Removethe upperbracket(seepage6-69).
NOTE:
. Use a jack to support the engine before removing
the upper bracket.
o Placea cushionbetweenthe oil pan and the jack.
Removethe P/Spump lower bracket
8xL25mm
24 N m {2.{kgf.m,17lbf.ft)
Loosenthe idler pulley bracketbolt and adjustingbolt,
then removethe air conditioning(A,/C)compressor
belt
aDJUsnNG
IOLERPULLEYBRACKET
EOLT
10x 1.25mm
44 N.m 14.5kgf.m, 33 bnft)
6-62
HEATSHIELD
8 x 1.25mm
24 N.m 12.,1
kgf.m,
17 tbf.ftl
P/S PUMP LOWERARACKET
l 0 x 1 . 2 5m m
44 N.m 14.5kgt.m, 33 lbf.ft)
'-f
lnstallation
7 . Removethe crankshaftpulley(seepage6-59).
8 . Removethe cylinderheadcover'
Installthe timing belt in the reverseorderof removal;
Only key pointsare describedhere.
1.
NOTE:Referto page6-86when installingthe cylinder headcover.
Set the timing beltdrive pulleyso that the No. 1 pis'
ton is at top deadcenter(TDC).Align the grooveon
the timing belt drive pulleyto the V pointeron the
oil pumP.
9 . Removethe middlecoverand lower cover.
NOTE:Do not use the middle and lower coversfor
storingremoveditems.
COVER
MIDDLE
POINTER
LOWERCOVER
9.8N.mlt.o kgfm,
7.2lw'ftl
1 0 . Loosenthe adjustingbolt 180'. Pushthe tensioner
t o r e m o v e t e n s i o nf r o m t h e t i m i n g b e l t , t h e n
retightenthe adjustingbolt.
set the camshaftpulleysso that the No. 1 piston is at
TDC.
Align the TDC marks on the intakeand exhaustcamshaft pulleys.
N.m (5.5kgt'm,
TDC MARK
11. Remove the timing belt.
(cont'd)
6-63
TimingBelt
a
lnstallation(cont'dl
3.
Installthe timing belttightlyin the sequenceshown.
@ T i m i n g b e l t d r i v e p u l l e y ( c r a n k s h a f t )+ @
Adjusting pulley* @ Water pump pu ey + @ Intake
camshaftpulley+ @ Exhaustcamshaftpulley,
9. Checkthat the crankshaftpulley and camshaftpulleys are both at TDC.
CRANKSHAFT
PULLEY
NOTE: Make sure the timing belt drive pulley and
camshaftpullevsare at TDC,
CAMSHAFT
PULLEY:
"UP" MARKS
'l
Loosenand retightenthe adjustingbolt to tension
the timing belt.
Installthe lower coverand middlecover.
NOTE: Cleanthe middle and lower covers before
installing.
Installthe crankshaftpulley,then tighten the pulley
bolt (seepage459).
7.
Rotate the crankshaft pulley about five or six turns
counterclockwiseso that the timing belt positionson
the pulleys.
Adjustthe timing belttension(seepageA611.
1 0 . lf the camshaftand crankshaftpulleysare not positioned at TDC, remove the timing belt, adjust the
positionfollowingthe procedureon page&63, then
reinstallthe timing belt.
1 1 . After installation,
adjustthe tensionof eachbelt.
.
.
.
See section 23 for alternator belt tension adjustment.
See section22lor NC compressorbelt tension
adiustment,
See section 17 for P/S pump belt tension adjustment.
I
6-64
CylinderHead
lllustratedIndex
CAUTION:
(38"C1bofote
. To avoid damaging the cylinder head, wait until the engine coolant tempsraturo drops below 100"F
removing it,
gasket.
. when handling a metal gasket,take caro not to fold the gaskot or damagethe contact surfaceof the
NOTE:Use new O-ringsand gasketswhen reassembling.
8 x 1,25 mm
27 N.m P.E kgl m.
20 tbf.fo
Applyengineoil to
the threads.
6x1.0mm
9.8 N.m (1.0 kgf'm,
7.2rbnftl
6 x l,omm
ft)
9.8N'mtl.0 kgt'm,7.2lbf
IGNMON
WIRECOVER
cr.rMp.S
CAMSHAFT
fi
"o''*t*';
\
A
wes@
CYLINOERHEAD
COVER
Referto page 6-86
when installing
%
CYLINDERHEAO
PLUG
Replace.
)@
DISTRIBUTOR
8 x 1,25mm
24 N.m {2.4 kgf'm,
1? tbf.ftl
OIL SEAL
Replace.
EXHAUST
HEADCOVERGASKET
when leaking,damaged
Replace
or deteriorated.
Apply liquidgasketat the
cornersof the recesses,Page6-86
SEAL
RUBBER
whendamaged
Replace
or detedorated.
10 x 1.25mm
56 N.m (5.7 kgf m,
,r1 lbl.ft)
(cont'd)
6-65
CylinderHead
lllustratedIndex(cont'dl
CYLINDERHEAD
BOLTS
1 1x 1 . 5m m
83 N.m {8.5kg{.m,61
Applyengineoil
to threads.
INTAKEVALVESPRINGINNER
VALVEKEEPERS
SPRINGRETAINER
INTAKEVAI.VESPRINGOUTER
valvEKEEPEBS\:""j"*'
SPRINGRETAINER
EXHAUST
VALVE
SPRING
VALVESEAL
Replace.
SPRINGSEAT
VALVEGUIDE
INTAKEVALVE
VALVESEAL
Replace.
VALVE
t il
LOSTMOTION
ASSEMBLY
ROCKERSHAFT
EXHAUSTVAL
SEALINGAOLTS.20mm
64 N.m (6.5kgt.m, 47 tbf.ft)
HEAOOIL CONTROL
ORIFICE
C l e an .
a
6- 66
Removal
Engineremovalis not requiredfor this procedure.
6.
Make surejacks and safetystandsare placed
!@@
properly and hoist brackels are attachedto correst position on the engine,
CAUTION:
o Use fender covers to avoid damaging painted surfaces.
T o a v o i d d a m a g e ,u n p l u g t h e w i l i n g c o n n e c t o r s
carelully while holding the connector portion.
To avoid damaging the cylinder head, wait until the
engine coolant temperature drops below 100"F{38'Cl
before looseningthe retaining bolt.
NOTE:
. Unspecifieditemsare common.
. Markall wiring and hosesto avoid misconnection.
AIso,be surethat they do not contactother wiring or
hosesor interferewith other parts.
o Inspectthe timing belt beforeremovingthe cylinder
ne a o .
. Turn the crankshaftpulleyso that the No. 1 piston is
at top deadcenter(seepage6-64).
1.
the negativeterminalfrom the battery.
Disconnect
2.
Drainthe enginecoolant{seepage 10-7).
.
Removethe radiatorcapto speeddraining.
3.
Removethe strut brace(seepage5-2).
4.
r ousing
R e m o v et h e i n t a k ea i r d u c t a n d a i r c l e a n e h
(seepage5-3).
Loosenthe idler pulley bracketbolt and adjusting
b o l t ,t h e n r e m o v et h e a i r c o n d i t i o n i n g( A / C )c o m pressorbelt.
ADJUSTING
IDLERPULLEYBRACKET
BOLT
10x 1.25mm
33 lbt.ft}
44N.m{4.5kg,l.m,
7.
Loosenthe mountingnut and lockbolt,then remove
the alternatorbelt.
LOCKBOLT
8 x 1.25mm
24 N.m {2.4 kgf.m,
17 tbtftl
Removethe adjustingbolt and mountingbolt,then
removethe powersteering(P/S)pump beltand pump
(seepage5 5).
10 x 1.25mm
,l,l N.m {4.5 kgf.m,
33 tbf.ft,
\
ALTERNATOR
BELT
(cont'd)
6-67
Cylinder Head
Removal(cont'd)
8. Removethe P/Spump lower bracket.
8 x 1.25mm
24 N.m 12.4kgf.m,
17 tbtftl
11. Removethe brakeboostervacuumhose,fuel return
hoseand vacuumhose(seepage5 4).
T SHIELD
12. Removethe water bypasshoseand positivecrankcase
ventilation(PCV)hose.
PCVHOSE
10x 1.25mm
44N.m{4.5kgf.m,
33 tbf.frl
P/S PUMPLOWER
BRACKET
WATERBYPASS
HOSE
1a
9 . Relievefuel pressure(seesectionl1).
Do not smok6 while working on fuel
@
system, keep open flam€ or spark away lrom work
ar€a,Drainfuelonly into an approvedcortain€r.
1 0 . Removethe evaporativeemission (EVAP)control
canisterhose,fuel feed hoseand breatherhose.
BANJOBOLT
33 N.m(3.4kgl.m.25lbf.ftl
WATEREYPASS
HOSE
Removethe throttlecableand throttlecontrolcable
by looseningthe locknut,then slip the cableend out
of the throftlelinkage.
NOTE;
. Takecare not to bend the cableswhen removing
them.Alwaysreplaceany kinkedcablewith a new
one.
. Adjustthe throttlecablewhen installing(seesectionI I ),
. Adjust the throttle control cablewhen installing
(seesection14).
WASHERS
BREATHER
HOSE
CONTROL
CABLE
6- 68
\.
14. Removethe upper radiatorhose, heater hose and
water bvpasshose.
1 6 . Removethe spark plug caps and distributorform
the cylinderhead.
1 7 . Removethe upperbracket.
WATERBYPASS
HEATER
NOTE:
. Use a jack to supportthe engine before removing
the upp€r bracketis removed.
. Placea cushionbetweenthe oil panandthejack.
12x 1.25fin
kgtm,
74N.m17.5
UPPERBRACKET
HOSE
andwlre
1 5 . Removethe enginewire harnessconnectors
harnessclampsfrom the cylinderheadand the intake
manifold.
a
a
a
a
a
\
Fourfuel injectorconnector
Enginecoolanttemperature(ECT)sensorconnector
ECTgaugesendingunit connector
ECTswitchconnector
ldle air control(lAC)valveconnector
Manifold absolutepressure(MAP) sensor connector
Throttlepositionsensorconnector
Primary Heatedoxygen sensor (PrimaryHO2S)
connecror
VTECsolenoidvalveconnector
18. Removethe cylinderheadcover.
{cont'd)
6-69
CylinderHead
Removal(cont'dl
1 9 . Removethe timing belt {seepage6-62).
24. Removethe camshaftholderplates,camshaftholders and camshafts.
20. Removethe backcoverand camshaftpulleys.
CYLINDERHEAD
PLUG
Replace.
t
BACKCOVER
\
\
CAMSHAFT
HOLDERPLATE
1
€
i
\
b4
CAMSIIAFTS-
6xl.0mm
9.8 N,m (1.0kgf.m, 7.2 lbf.ft)
56 N.m (5.7kgf m,
41 tbt.f0
21, Removethe exhaustmanifold(seepage9-8).
22. Removethe intakemanifold(seepageg-5).
23. Loosenthe adjustingscrews.
Removethe cylinder head bolts, then remove the
c y l i n d e hr e a d .
CAUTION: To prevsnt warpage. unscrew the bolts
in sequonc€1/3 turn at a tim€; lepeat lh6 sequence
until all bolts aro loosened.
CYLINDERHEADBOLTSLOOSENINGSEOUENCE:
No.4
INTAKE
No.3 No.2
N o .1
6-70
Downloaded from www.Manualslib.com manuals search engine
RockerArms
Removal
'1. Holdthe rockerarmstogetherwith a rubberbandto
preventthem from separating.
3.
S c r e w 1 2 m m b o l t s i n t o t h e r o c k e ra r m s h a f t s .
Removeeach rocker arm set while slowly pulling
out the intakeand exhaustrockerarm shafts.
RUEBERBAND
12 mm BOLTS
2.
Removethe intakeand exhaustrockershaftoil control orifices,then removethe VTECsolenoidvalve
and the sealingbolts.
ROCKERARM SHAFTS
NOTE:The shapesofthe intakeand exhaustoil control orificesare different,ldentifythe parts as they
in the original
are removedto ensurereinstallation
locauons.
EXHAUSTROCKER
SHAFTORIFICE
Clean.
O.RING
Replace.
O.RING
R e p l a c e ._
r
(lX
-dJ'v-l-<
-Y^\
INTAKE ROCKER
ORIFIGE
Clean.
/
/.
I
\
6-71
RockerArms
Disassembly/Reassembly
CAUTION: After installing the rocker shaft oritice, make suro thot the orifics is correctly installed in the hole of rocker
shaft by trying to turn the rocker shaft. ll the orifice is in place, it should not turn.
NOTE:
. ldentifypartsas they are removedto ensurereinstallation
in originallocations.
. Inspectrockershaftsand rockerarms(seepage6-73).
o Rockerarms must be installedin the samepositionif reused.
. Cleanthe rockershaftorificeswhen installino.
I
erior.to ,"installing,cleanarrthe partsin sorvent,dry them, and appryrubricantto any contactsurfaces.
INTAKEROCKERARM ASSEMBLIES
CYLTNDERNUMBER
y'///
SEALINGBOLTS20 mm
64 N m {6.5kg{.m,/t7 lbf.ftl
k
r ROCKEN
a
RockerArms and Lost Motion Assemblies
Inspection
the primaryrockerarm,careNOTE:When reassembling
fully apply air pressureto the oil passageof the rocker
arm.
2.
Removethe lost motion assemblyfrom the cylinder
head and inspectit. Test it by pushingthe plunger
with your finger,
-
l f t h e l o s t m o t i o n a s s e m b l yd o e s n o t m o v e
smoothly,replaceit.
PRIMARYROCKERARM
MID ROCKERARM
Push
I
LOSTMOTIONASSEMBLY
PISTONS
1.
Inspecteachrockerarm piston.Pushit manually
-
lf it does not move smoothly. replacethe rocker
arm assemDly.
PRIMARY
SECONDARY
Check prstonmovement
\
NOTE:
. Apply oilto the pistonswhen reassembling.
. Bundle the rocker arms with a rubber band to
keepthem togetheras a set.
6-73
RockerArms and Shafts
ClearanceInspection
Measureboth the intakerockershaft and exhaustrocker
shaft.
1.
Measurediameterof shaft at the first rockerlocatron.
3.
Measurethe insidediameterof eachrockerarm and
checkfor out-of-roundcondition
RockerArm-to-Shaft Clearance:
Intakeand Exhaust
Standard{Newl:0.025- 0.052mm
{0.0010- 0.0020in)
ServiceLimit: 0.08 mm {0.003in)
Surlaceshor/ldbe smooth.
Inspectrockerarm
facefor wear.
2.
Zerogaugeto shaftdiameter.
Repeatfor all rockers.
- lf over limit, replacerockershaft and all overtolerancerockerarms.
MICROMETER
6-74
NOTE:lf any rockerarm needsreplacement,
replace
all three rockerarms in that set {primary,mid, and
seconoary).
Camshafts
Inspection
NOTE:
. Do not rotatethe camshaftduringinspection.
. Removgthe rockerarms and rockershafts.
'L
Putthe camshaftsand camshaftholderson the cylinder head.and then tightenthe boltsto the specified
torque.
SpecifiedTorque:
O -@: 8 mm botts27 N.m {2.8kgf.m,20lbt'ft)
Apply engineoil to the threads,
O - @: 6 mm bolts 9.8 N.m (1.0 kgf m, 7.2 lbf'ft)
o o
o
o
o
oo
4.
o o
o
o o
Removethe bolts.then removethe camshaftholders from the cylinderhead.
-
Lift the camshaftout of the cylinderhead,wipe
c l e a n ,t h e n i n s p e c t h e l i f t r a m p s .R e p l a c et h e
camshaftif lobes are pitted, scored,or excessively
-
Cleanthe camshaftbearingsurfacesin the cylin
der head,then setthe camshaftbackin place,
Inserta plastigagestrip acrosseachiournal.
-
Put the camshafton the cylinderhead.then install
the camshaftholders,and then tighten the bolts to
the specifiedtorque as shown in the left column on
this page.
R e m o v et h e c a m s h a f th o l d e r s ,t h e n m e a s u r et h e
widestportionof the plastigageon eachjournal.
Seatthe camshaftby pushingit toward the distributor end of the cylinderhead.
Zerothe dial indicatoragainstthe end of the distributor drive. then push the camshaftback and fonh
and readthe end play.
Camshaft-to-Hold€1Oil Clearsnce:
Standard {Newl: 0.050- 0.089mm
{0.002- 0.004inl
S6rviceLimit: 0.15 mm 10,006inl
PLASTIGAGE
STRIP
CamshaftEnd Play:
Standard{New}:0.05- 0.15mm
{0.002- 0.006inl
0.5 mm (0.02in)
Servicelimil:
\-
(cont'd)
6-75
Gamshafts
Inspection(cont'dl
7.
lf the camshaft-to-holder
oil clearanceis out of tolerance:
8.
Checkthe cam lobe height.
Cam lobe height standard (New):
-
And the camshafthas alreadybeenreplaced,
you
must replacethe cylinderhead.
- lf the camshafthas not been replaced,first check
the total runoutwith the camshaftsupportedon
V-blocks.
CamshaftTotal Runout:
Standard(New):0.03mm {0.001in} max.
ServiceLimit: 0.04 mm (0.002inl
INTAKE
EXHAUST
PRIMARY
33.088mm
{1.3027in)
32.785mm
(1.2907inl
MID
36.267mm
(1.4278in)
35.720mm
{1.4063in)
SECONDARY
34.978mm
( 1 . 3 7 7i1n l
3i1.691mm
(1.3658in)
I
Check thrs area lor wear.
-
lf the total runout of the camshaftis within toler,
ance,replacethe cylinderhead.
lf the total runout is out of tolerance.replacethe
camshaftand recheckthe camshaftto,holderoil
clearance.lf the oil clearanceis still out of tolerance,replacethe cylinderhead.
Cam Position
INTAKE
MID
TIB
T/B: TIMINGBELT
PRI: PRIMARY
MID: MID
EXHAUST
SEC
MID
PRI
Valves,Valve Springs and Valve Seals
Removal
NOTE: ldentify valves and valve springs as they are
removedso that eachitem can be reinstalledin its original Dosition.
l.
3.
Installthe valve guide seal remover.
VALVEGUIDESEALREMOVER
COMMERCIALLY
AVAILABLE
()R KD3350
Ltst-EP/N 571100
socketand plasticmalUsing an appropriate-sized
retainer
to loosenthe valve
let, lightlytap the valve
keeoers.
PLASTIC
4.
Installthe valve spring compressor.Compressthe
spring and removethe vSlvekeepers.
VALVESPRING
COMPRESSOR
ATTACHMENT
07757- PJ1010A
Removethe valveguideseal.
Valve Dimensions
VALVESPRING
ATTACHMENT
COMPRESSOR
EXTENSION
OTMAF- PRgOIOA
lntake Valvo
A Standsrd {Newl; 32.90- 33.10mm (1.295- 1.303in}
B St ndard {New}: 101.00- 101.30mm (3.976- 3'988 in}
C Stsndard (Nowl: 5./t5 - 5.,185mm (0.2156- 0.2159in)
5.445{0.21/l| in)
C ServicoLimit
D Siandard (N!w): 1.05- 1.35mm (0.041- O.05ilinl
0.85 mm {0.033inl
D S€.vice Limit:
I
COMPRESSOR
Sn.p-onCFr1l
ExhaustValve
A StandardlNewli 27.90- 28.10mm (1.098- 1.106in)
B Stlndard {Nowl: 100.m - 1qr,90 mm {3.961- 3.972in)
- 0.2150in)
C Stsndard {Now}: 5.450- 5.,[60mm {0.21,16
inl
5.42010.213,0
C ServiceLimit
D Standard {New): 1.65- 1.95mm (0.065- 0.077in)
l.ils mm 10.057inl
D SorvicoLimit:
6-77
Valve Seats
Reconditioning
1.
Renewthe valve seats in the cylinder head with a
valveseatcutter.
5.
NOTE:lf any guidesare worn (seepage6-79),
r e p l a c et h e m ( s e e p a g e 6 - 8 0 )b e f o r ec u t t i n g t h e
valveseats,
After resufacingthe seat. inspect for even valve
s e a t i n g :A p p l y P r u s s i a nB l u e C o m p o u n dt o t h e
valve face, and insertthe valve in its originallocat i o n i n t h e h e a d .t h e n l i f t i t a n d s n a p i t c l o s e d
againstthe seatseveraltimes.
PRUSSIANBLUECOMPOUND
The actualvalve seatingsurface,as shown by the
bluecompound,shouldbe centeredon the seat.
. lf it is too high (closerto the valve stem),you must
make a second cut with the 60. cutter to move it
down, then one more cut with the 45. cutter to
restoreseatwidth.
. lf it is too low (closerto the valve edge),you must
make a second cut with the 30. cutter to move it
up. then one more cut with the 45. cutterto restore
seatwidth.
NOTE:The final cut should always be made with
the 45"cutter,
Carefullycut a 45oseat, removing only enough material to ensurea smooth and concentricseat.
Bevel the upper edge of the seat with the 30" cutter
and the lower edge of the seat with the 60. cutter.
Checkwidth of seatand adjustaccordingly,
Makeone more very light passwith the 45"cutterto
removeany possibleburrs causedbv the other cutters.
Valve Seat Width:
Standard(Newl: 1.25- 1.55mm {0.0't9- 0.061in)
ServiceLimii: 2.0 mm 10,08inl
7.
Insenthe intakeand exhaustvalvesin the headand
measurevalvestem installedheioht.
Intaka Valve Stem Installed Height:
Standsrd lNaw): 37.465- 37.935mm
(1./P50- r.4935inl
SorviceLimit: 38.185mm 0.5033 in)
Exhau3tValv€ Stem Installed Height:
Standard (New): 37.165- 37.6i|5mm
- 1.i1817
(1.46:t2
inl
ServicoLimit
37.885(1.4915inl
SearWidrh
lf valve stem installedheight is over the servicelimit,
replacethe valve and recheck.lf it is still over the service limit,replacethe cylinderhead;the valveseatin
the h6ad is too deep.
6-78
(
CylinderHead
Valve Guides
Warpage
ValveMovement
oil clearances(seepage 475)
NOTE:lf camshaft-to-holder
the headcannotbe resurfaced.
are not within specification,
clearancewith a dial indicaMeasurethe guide-to-stem
t o r w h i l e r o c k i n gt h e s t e m i n t h e d i r e c t i o no f n o r m a l
thrust (wobblemethod).
are within specificaoil clearances
lf camshaft-to-holder
tions,checkthe headfor warPage.
.
.
.
lf warpage is less than 0.05 mm (0.002in) cylinder
headresurfacingis not required.
lf warpageis between0.05mm (0.002in) and 0 2 mm
(0.008in), resurfacecylinderhead
Maximum resurfacelimit is 0.2 mm (0.008in) based
o n a h e i g h to f 1 4 2m m ( 5 . 5 9i n ) .
EDGE
STRAIGHT
PRECISION
lntake Valve Stem-to-GuideCl6arance:
Standard(Newl:0.05- 0.11mm
(0.0020- 0.0043inl
ServiceLimit: 0.15 mm {0.0059inl
ExhaustValve Stem-to-GuideClealance:
StandardlNewl: 0.10- 0.16mm
(0.0039- 0.0063inl
ServiceLimit: 0.24 {0.0094in)
Valveextended10 mm out from seat.
lf the measurementexceedsthe service limit, recheck
usinga new valve.
lf the measurementis now within the servicelimit.
reassembleusingthe new valve
lf the measurementstill exceedsthe limit. recheckusing
the alternatemethod below.then replacethe valve and
guide,if necessary.
Measurealongedges,and threeways acrosscenter'
Cylinder Head Height:
- 142.05mm
StandardlNewl: 1i11.95
15.589- 5.593in)
NOTE:An alternatemethod of checkingguide to stem
clearanceis to subtractthe o.D. of the valve stem, measured with a micrometer,from the l.D. of the valve guide,
measuredwith an insidemicrometeror ball gauge.
Takethe measurementsin three placesalong the valve
stem and three placesinsidethe valveguide.
The differencebetweenthe largestguide measurement
and the smalleststem measurementshould not exceed
the servicelimit.
lntake Valv€ Stem-to-GuideClsarance:
Standard lNswl: 0.025- 0.055mm
- 0.0022inl
10.0010
service Limit: 0.08 mm (0.003in)
ExhaustValve Stem-to Guide Cl€arance:
Standard {Newl: 0.050- 0.080mm
{0.0020- 0.0031inl
0.ll mm (0.004in)
ServiceLimit
6-79
t
Valve Guides
Replacement
1.
As illustratedbelow, use a commerciallvavailable
air-impactvalve guide driver attachmentmodified
t o f i t t h e d i a m e t e ro f t h e v a l v e g u i d e s .l n m o s t
cases,the same procedurecan be done using the
sDecialtool and a conventionalhammer.
CAUTION:
. Always wsar safety gogglesor a faceshield whsn
driving valve guides.
. Hold the air hammer dir€ctly in line with the
valve guide to prevont damaging thg dtiver.
COMMERCIALLY
AVAILABLE
VALVEGUIDEDRIVER
rE-
87mm -L(3.43
inl I
sz mm
tz.zrint
Workingfrom the camshaftside,use the driverand
an air hammerto drivethe guideabout2 mm (0.1in)
towardsthe combustionchamber.This will knockoff
someofthe carbonand makeremovaleasier.
t
Turn the head over and drive the guide out toward
the camshaftsideof the head.
t
10.8mm
10.42inl
ol
VALVEGUIOEDRIVER,
5.5mm
077,P- 0010100
S e l e c tt h e p r o p e r r e p l a c e m e n g
t uidesand chill
t h e m i n t h e f r e e z e rs e c t i o no f a r e f r i g e r a t o rf o r
aboutan hour.
Use a hot plate or oven to evenlyheat the cylinder
headto 300"F(150"C).
Monitorthe temperaturewith
a cookingthermometer.
VALVEGUIOEDRIVER,
5.5mm
077{2- 0010100
-:^-,65i^q
NNSp-<
CAUTION:
. Do not use a torch; it may warp tho head.
. Do not get tho head hotter than 300"F {150"C};
excesgiveheat may loosenthg valve seats.
. To avoid burns. use haaw gloves whon handling
the heatod cylinder head.
6-80
lf a valve guide still won't move. drill it out with a
8.0 mm (5/16in) bit,then try again.
CAUTION: Drill guides only in extreme cases; you
could damagothe cylinder head if ths guide br6aks.
Removethe new guide(s)from the freezer,one at a
time, as vou needthem.
Reaming
7.
Apply a thin coat of cleanengineoil to the outside
of the new valve guide. Installthe guide from the
camshaftside of the head; use the specialtool to
drive the guide in to the specifiedinstalledheight.lf
you haveall l6 guidesto do, you may haveto reheat
thehead,
VALVEGUIDEDRIVER,
5.5mm
- (x)l01(x)
077i12
NOTE:For new valveguidesonlY.
1.
Coatboth reamerand valveguidewith cuftingoil.
2.
Rotatethe reamer clockwisethe full length of the
valveguide bore.
C o n t i n u et o r o t a t e t h e r e a m e r c l o c k w i s ew h i l e
removingit from the bore
Thoroughlywash the guide in detergentand water
to removeany cuttingresidue.
Checkclearancewith a valvelsee page6-73)
.
V e r i f y t h a t t h e v a l v e s l i d e s i n t h e i n t a k ea n d
exhaustvalveguideswithout exertlngpressure.
REAMERHANDLE
tr
A\
Turn r6amerin
clockwisedirection
Valve Guide Installed Hoight:
lntake: 12.55- 13.05mm {0.,194- 0.514in)
- 0.51'lin)
Exhaust:12.55- 13.05mm 10.494
a
VALVEGUIDE
VALVEGUIOEREAMER.5.5 mm
OTHAH- PJTO1IIB
\
6-81
Valves
Installation
(
1.
Coatthe valve stemswith oil. lnsertthe valvesinto
the valveguides.
4.
NOTE: Checkthat the valves move up and down
smoothly.
2.
l n s t a l lt h e v a l v e s p r i n g a n d v a l v e r e t a i n e r ,t h e n
installthe valve spring compressor.Compressthe
spring,and installthe valvekeepers.
NOTE:Placethe end of the valvespringwith closely
wound coilstowardthe cylinderhead.
Installthespringseatson the cylinderhead.
VALVESpRtNG
COMpRESSOR
ATTACHMENT
0775?_ pJlOl0A
Installthe valvesealsusingthe specialtool.
VALVESPRTNG
COMPRESSORATTACHMENT
EXTENSTON
o?MAF- PR9010A
NOTE:Exhaustand intakevalvesealsare not interchangeable.
WHITE
SPRING
BRACK
SPRING
VALVEGUIDESEALINSTALLER
KD-28)g(Commercially
available)
NOTE:UsesmalllD
end of tool,
5.
VALVESPRINGCOMPRESSOR
lCommercially
available)
Snap-onCF711or KD-3tXl
with #32JAWS
Lightly tap the end of each valve stem two or three
times with the wooden handle of a hammer to ensure
proper seating of the valve and valve keepers.
NOTE: Tap the valve stem only along its axis so
you do not bend the stem.
VALVESEAL
Replace.
VALVEGUIDESEALtNsTALLER
KD-2899
NOTE:UsesmalllD
end of tool
I
RockerArms
lnstallation
1.
2.
l n s t a l l t h e r o c k e r a r m s i n t h e r e v e r s eo r d e r o f
removal:
. Valveadjustinglocknutsshouldbe loosenedand
the adiustingscrew, backedoff before installatron.
. The componentparts must be reinstalledin the
originallocations.
lnstallthe lost motion assemblies.
4.
Cleanand installthe rockershaft orificeswith new
O - r i n g s .l f t h e h o l e s i n t h e r o c k e ra r m s h a f t a n d
cylinderheadare not in line with each other,screw
a 12 mm bolt into the rockerarm shaft and rotate
the shaft.
NOTE: The shapesof the rockershaft orificestor
the intake and exhaust are different.The orific'
must be installedin the properlocations.
3 . l n s t a l lt h e r o c k e ra r m s w h i l e i n s e r t i n gt h e r o c k e r
arm shaft into the cylinderhead
NOTE:Removethe rubber band after installingthe
rockerarms.
ROCKER
EXHAUST
ROCKER
INTAKE
SHAFTORIFICE
Clean
SHAFTORIFICE
O.RING
O
12 mm BOLT
\
6-83
I
Cylinder Head
Installation
lnstallthe cylinderheadin the reverseorderof removal:
2,
NOTE:
. Alwaysusea new headand manifoldgasket.
. The cylinderheadgasketis a metal gasket,Takecare
not to bend it.
. Rotatethe crankshaft,
setthe No. 1 pistonat TDC(see
page6-63).
. D o n o t u s e t h e m i d d l ec o v e r a n d l o w e r c o v e rf o r
storangremoveditems.
. Cleanthe middlecoverand lowercover beforeinstal_
lation.
o Replaceany washersthat are damagedor deteriorated.
1.
Tightenthe cylinderhead bolts in two steps.In the
first step, tighten all bolts in sequenceto about 29
N.m (3.0 kgf.m, 22 tbf.ftl. ln the final step, tighten in
the samesequenceto 83 N.m (8.Skgf.m,6t lbf.ft).
NOTE:
. Apply clean engine oil to the bolt threads and
underthe bolt head.
. W e r e c o m m e n d u s i n g a b e a m - t y p et o r q u e
wrench. When using a preset-typetorque wrench,
be sure to tighten slowly and not to overtighten.
. lf a bolt makesany noisewhile you are torquing it,
loosenthe bolt, and retightenit from the 1ststep.
Installthe cylinderheadgasket,dowel pins and the
headoil controlorificeon the cylinderhead.
CYLINDERHEADBOLTTOROUESEOUENCE
NOTE:Cleanthe oil controlorificewhen installing.
1 1 x1 . 5m m
83 N.m18.5kgf.m,61 tbf.ftl
DOWELPIN
Installthe intakemanifoldand tightenthe nuts in a
cflsscrosspatternin two or three steps,beginning
with the innernuts.
. Alwaysusea new intakemanifoldgasket.
4.
6-84
Install the exhaust manifold and tighten the new
self-lockingnuts in a crisscrosspattern in two or
threesteps.beginningwith the innernuts.
. Alwaysusea new exhaustmanifoldgasket.
5.
lnstallthe camshaftsand camshaftoil seals.
NOTE:
. lnstallthecamshaftswith the keywayfacingup.
. lnstallthe oil sealwiththespring sidefacingin.
. The oil sealhousingsurfaceshouldbe dry'
. Set the O-ringand dowel pin in the oil passage
of the No, 3 camshaftholder'
7-
lnstall the camshaftholders and camshaft holder
plaIe.
NOTE:The arrowsmarkedon the camshaftholders
shouldpointto the timing belt.
CAMSHAFT
CAMSHAFT
OIL SEAL
Replace.
Apply liquid gasket (P/N 08718- 0001 or 08718
1
and
No.
to the head mating surfacesof the
0OO3)
N o . 5 c a m s h a f th o l d e r s o n b o t h t h e i n t a k e a n d
exhaustside.
Tighteneach bolt two turns at a time in the sequence
shown below.
NOTE:Wipe off the excessliquid gasketfrom the No.
1 and No. 5 camshaftholderswith a shop towel
(D - @: 8 x 1.25mm 27 N.|n (2.8ksf'm, 20 lbf'ft)
Apply ongine oil to the throads.
O O: 6 x 1.0 mm 9.8 N'm (1.0 kgfrm,7.2 lbf'ft)
INTAKE
( Do
oo
o
o
o
NOTE:Cleanand dry the cylinderhead mating surfacesbeforeapplyingliquidgasket.
- Apply liquidgasketto the shadedareas'
@
o
0
o
o o o
EXHAUST
and camshaftpulleys.
back
cover
lnstallthe
{cont'd)
6-85
CylinderHead
Installation(cont'dl
\
1 0 . A l i g n t h e m a r k so n t h e c y l i n d e rh e a d p l u g t o t h e
cylinder head upper surface,then installthe cylin,
der headplug in the cylinderhead.
14. Apply liquid gasketto the headcover gasketat the
eight cornersof the recesses.
NOTE:
. Use liquidgasket,PartNo. 08718- 0001or 08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket
. Do not installthe parts if five minutes or more
h a v e e l a p s e ds i n c e a p p l y i n g t i q u i d g a s k e t .
Instead,reapplyliquid gasketafter removingold
restdue.
. After assembly.wait at least 30 minutesbefore
f i l l i n gt h e e n g i n ew i t h o i l .
CYLINDEB
HEAD
PLUG
Replace.
1 1 . Installthe timing belt (seepage6-63).
1'
Adjustthe valveclearance(seepage6-61).
1 3 . Installthe head cover gasketin the groove of the
c y l i n d e r h e a d c o v e r . S e a t t h e r e c e s s e sf o r t h e
camshaftfirst, then work it into the groove around
the outsideedges,
NOTE:
. Beforeinstallingthe headcovergasket,thoroughly cleanthe head cover gasketand the groove.
. When installing,makesurethe headcovergasket
is seatedsecurelyin the cornersof the recesses
wrrn no gap.
HEADCOVEB
6-86
(
15. When installingthe cylinder head cover, hold the
headcovergasketin the grooveby placingyour fingers on the camshaft holder contacting surfaces
(toDof the semicircles).
O n c e t h e c y l i n d e rh e a d c o v e r i s o n t h e c y l i n d e r
head,slidethe cover slightlybackand forth to seat
the headcovergasket.
16. Tightenthe nuts in two or three steps.In the final
step, tighten all nuts, in sequence,to 9 8 N'm {1 0
kgf.m,7.2 lbf.ft).
NOTE: After assembly,wait at least 30 minutes
beforefillingthe enginewith oil.
NOTE:
. Be{oreinstallingthe cylinder head cover, clean
the cvlinder head contacting surfaces using a
shoPtowel.
. Oo not touch the parts where liquid gasket was
applied.
. Replaceany washertaht is damagedor deter'orated.
t
1 7 . After installing,checkthat all tubes' hosesand connectorsare installedcorrectly.
\
6-A7
EngineBlock
CylinderBlock
..............7-16
lnspec'tion
..........7-17
BoreHoning
PistonPins
...,...........'.7-17
Removal
.............7-18
lnstallation
.'............7-19
Inspection
ConnectingRods
................7-18
Selection
Piston Rings
7'2O
..........".."'
EndGap
.........7-2O
Repfacement
7 -21
...........'.'.
Ring-to-GrooveClearance
7'21
.......""'..
Afignment
7 -12
.................
CrankshaftOil Seal
.............7-22
fnstaffation
."".........7-14
Crankshaft
..-.-..'.".'7'23
fnstaffation
......"'.....7-15
.............7-23 Oil Pan
.............7-26
lnstallation
7-2
..........."
SpeciafTools
7-3
lllustlatedIndex ...................."..'..........
Flywheeland Drive Plate
"""'.' 7-7
Repfacement
ConnectingRod and Crankshaft
..........."....7-8
End Play
Main Bearings
7-9
...............
Clearance
................7-10
Selection
ConnectingRod Bearings
7-11
....'..........
clearance
7-11
................
Selection
Pistonsand Crankshaft
Removaf
Crankshaft
Inspection
Pistons
Inspection
fnstaffation
Oil Seals
fnstaffation
r - f
....""""' 7-29
SpecialTools
Ref. No.
Tool Numbel
I
o
07LAB- PV00100
07749- 0010000
07947- SB00200
07948- SB00'101
07973- PE00200
07973- PE00310
07973- PE00320
07973- PE00400
07973- S800100
07973- 6s70500
07973- 6570600
aal
@
o
@
6'
@
o
R i n gG e a rH o l d e r
Driver
SealDriver
DriverAttachment
P i l o tC o l l a r
PistonPin DriverShaft
PistonPin DriverHead
PistonPin BaseInsert
PistonBaseHead
PistonBase
PistonBaseSpring
1-7
7-22,29
7.29
7-22,29
7-17,18
' 7- 1 7 ,
1a
7 - 1 1 ,1 A
7- 1 7 ,1 8
1 - 1 7 1, 8
7-17,18
7-17,18
Y(\!
a.:
ai
C
a
Eg
o
t0
arll
\
7-2
a
lllustrated Index
I
runricateatt internalpartswith engineoil during reassembly'
NOTE:
pumpcasebeforeinstallingthem'
o Apply liquidgaskettothe matingsurfacesofthe right sidecoverand oil
o
r
0
8
7
1
8
0
0
0
3
'
. U s el i q u i dg a s k e tp, a r tN o 0 8 7 1 8 - 0 0 0 1
pan
. Cleanthe oil pan gasketmatingsurfacesbetoreinstallingthe oil
81642 engine:
DRAIN BOLT
44 N,m {4.5 kgf'm,33 lbt'ft)
OILPAN
Reterto page7 27
when installing.
6 r 1 . Om m
12 N.m t1.2 kgl'm, 8 7 lbf'lt)
OIL PAN GASKET
6 x 1.0 mm
' 1 1N . m ( 1 . 1 k g I ' m ,
I tbl.ft)
BUFFLEPLA
6 x 1.0 mm
1 1 N . m ( 1. 1 k g f . m ,
8 tbI.fr)
12 x 1.0mm
103 N.m {10.5kgf'm,
76 tbr.ft)
FLYWHEEL
(M/TI
GASKET
Replace.
1 1 x 1 . 5m m
76 N.m (7.9 kgf'm, 56 lbf'ft)
Apply engineoil to the bolt
threads.
NOTE:After torqurng
each cap, turn crankshaft
to check for binding.
FLYWHEELCOVER
IM/T)
12 x 1.0mm
74 N.m (7.5
kof.m, 54 lbf'ft)
d#*
MAIN EEARINGCAP
1^
c{Eb
\%^
t*^
MAIN BEARINGS
Selection,page 7_10
NOTE:New main bearingsmusl
be selectedbY matchingcrank
and block identificationmarkrngs
*o"rr^--(Wffi
oa*,trto2,.w
CRANKSHAFT
Installation,
Page7'23
Check for cracks
DRIVE PLATE
COVER(AiT)
6x1.0mm
l
b
f
'
f
t
}
I
k
g
f
'
m
,
11 N.m {1.1
OIL JET BOLT
16 N.m 11.6 kgf'm, 12 lbl'ft)
OIL JET
Inspection,
Page8_10
DOWEL PIN
OIL SEAL
CRANKSHAFT
Installation,
pagesl22andl 29
ReplaceRIGHTSIDECOVER
Apply liquidgasket
to mating surface.
OILPUMP
Overhaul,page8-'l1
Removal/lnspection,
page8-13.
Apply liquidgasket
to matingsurlace.
8 x 1.25mm
24 N.m {2.4 kgf.m, 17 lbf'ft)
THRUSTWASHERS
Groovedsidesface outward
NOTE:Thrusr washer thickness
is tixed and must not be changed
by grindingor shimming
SEAL
CRANKSHAFT
O-RING
Replace
11 N.m {1.1 kgf'm,
a lbt.ltl
l n s t a l l a t i o n ,p a g e s 7 ' 2 9 a n d I 1 4
(cont'd)
Heplace.
lllustrated Index
(cont'dl
I
,
Luoricateatt internalpartswith engineoil during reassembly.
NOTE:
' Apply liquidgasketto the matingsurfacesofthe rightside
coverandoil pumpcasebeforeinstallingthem.
. Use liquidgasket,part No. 08718- 0001or 087,18
_ OOO3.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstallingit.
D16Y7engine:
6 x 1.0mm
DRAIN BOLT
12 N.m (1.2kgt.m.
44 N.m {4.5 kgt.m.33 tbt.ttl
8.7 tbf.tr)
OIL PAN GASKET
Replace.
6 x 1 . 0m m
12 N.m ('l .2 kgt.m, 8.7 tbt.trl
WASHER
Replace.
OIL PAN
Referto page7-27
FLYWHEEL
COVER
IM/T)
1 2 x ' 1 . 0m m
1 1 8N . m
{12.0 kgt.m, 87 tbf.tr}
Apply liquidgaskerto
these points.
1 1x 1 . 5m m
51 N.m
15.2kgl.m,38lbtftl
Applyengineoilto the bolt
threads.
NOTE:Aftertorquing
each cap, turn the crankshaft
to checkfor binding.
MAIN BEARINGCAP
MAIN BEARINGS
Selection,
page7-10
NOTE:New main bearingsmust
be selectedby matchingcrank
and blockidentification
markings.
CRANKSHAFT
Installation,
page7 23
6 r 1.0mm
1 1 N . m { 1 . 1 ksI.m, 8 lbt.ft)
Check for cracks.
CRANKSHAFT
OIL SEAL
Installation,
pages1 22 a^d 7-29
OILSCREEN
6 x 1.0 mm
1 1 N . m 1 1 . 1kgt.m, 8 lbf.trl
\:eprace'
6 x 1 . Om m
11 N.m {1.1kgt.m,
8 rbt.frl
GASKET
Replace.
OILPUMP
Overhaul,page8-12
Bemoval/lnspection,
page8-13
DOWEL PIN
RIGHTSIDECOVER
Apply liquidgasker
1o matrngsurface,
WASHERS
CRANKSHAFT
SEAL
l.j"Ji:l"^
pages
--.S)
z.2e
Replace.
6 x 1.0 mm
1 1 N . m{ 1 . 1
8 tbt.fr)
7-4
DOWELPIN
BREATHING
PORTCOVER
MOUNT BOLTS
6 x 1.0mm
1 1 N . m { 1 . 1 k g t . m ,8 t b f . f r }
Apply liquidgaskerto
the boh threads.
Grooved sides face outward.
NOTE: Thrust washer thickness
is fixed and must not be changed
by grinding or shimming.
I
I
(
D16Y5,D16Y8engines:
DRAIN BOLT
39 N.m 14.0 kgt'm,
29 lbl.tt)
\
\^
6 x 1 . 0m m
WASHER
Replace.
Apply liquidgasketto
these points.
q%
t 2 N . m 1 1 . 2k g f ' m ,
8.7 lbl.ftl
OIL PAN
Referto page7-25
when installing.
FLYWHEELCOVER
(M/T}
P
12 x 1.0mm
1 1 8N . m
(12.0 kgt.m, 87 lbt'ft)
I
1 1x 1 . 5m m
51 N.m
(5.2kgf'm, 38 lbf ftl
Applyengineoiltothe bolt
threads.
NOTE:Aftertorquing
eachcap,turn crankshaft
to checkfor binding.
(M/TI
FLYWHEEL
OII PAN GASKET
Replace.
DRIVEPLATECOVER
{A/T or CVT)
MAIN
BEARING
12 r 1.0mm
74 N.m
17.5 kgl.m, 54 lbf'ft)
MAIN BEARINGS
page7-10
Selection,
NOTE:New main bearingsmust
be selectedby matchingcrank --------*-i6{\
DBIVEPLATE{A/T or CVTI
Checkfor cracks
"nJ lr."i io"irriti"",ion-markings.
CRANKSHAFT
page7-23
Installation,
6 x 1 . Om m
11 N.m {1.1kgl'm,
8 tbl.ftl
6 r 1.0mm
11 N.m (1 1 kgf'm, I lbf'ttl
OIL SEAL
CRANKSHAFT
lnstallation, '1
pages7'?1 and '28
Replace.
OIL SCREEN
RIGHTSIDECOVER
Apply liquid gasket
to mating surface.
GASKET
Replace.
OIL PUMP
Overhaul,page8_12
Removal/lnspection,
page8-13
Apply liquidgasket
to mating surface.
OOWELPIN
SEAL
CRANKSHAFT
pages7 29
Installation,
O.RING
and 8-14
Replace.
Replace.
m
m
6 x 1.0
11 N.m (1 1 kgl'm,
8 tbr.ftl
\
DOWEL PIN
WASHEFS
Groovedsidestace outward
NOTE:Thrust washerthickness
is fixed and must not be changed
bV grindingor shimming.
BREATHINGPORT COVER
MOUNT BOLTS
6 x 1 . Om m
11 f{..n (1.1 kgf'm, 8 lbf'fl)
Apply liquidgasketto
the bolt threads.
(cont'd)
7-5
lllustrated Index
(cont'd)
NOTE:New rod bearingsmust be selectedby matchingconnectingrod
assemblyand crankshaftidentificationmarkings
( s e ep a g e7 , 1 1 ) .
Lubricateall internalpartswith engineoil during
reassembtv.
PISTONINSTALLATION
DIRECTION:
EXHAUST
4\/=\6\z\
\e/!rqrf/
INTAKE
PISTONRINGS
Replacement.
page7-20
Measurement,
pages7 20 andj-21
Alignment,page7-21
PISTONPIN
Removal,page7,17
Installation,
page7-18
Inspection,
page7,19
CONNECTING
ROD
Endplay,page7-8
page7,18
Selection,
PISTON
page7-15
Inspectron,
NOTE:Betoreremovingthe piston,inspectthe
top of the cylinderborefor carbonbuild-upor
ridge.Bemoveridgeif necessary,
page7-13
ENGINEBLOCK
Cylinderboreinspection,
page7-16
Warpageinspection,
page7,'16
Cylinderbore honing,page7,17
CONNECTING
ROD
BEARINGS
C l e a r a n c e ,p a g e 7 1 1
S e l e c t i o n ,p a g e 7 - 1 1
Inspecttop of eachcylinderbore
for carbonbuild-upor ridge
before removing piston.
Removeridgeif necessary,
page7-13
CONNECTING
RODBEARINGCAP
page7-23
Installation,
NOTE:lnstallcapsso the
bearing recessis on the
samesideas the recess
in the rod.
7-6
CONNECTING
RODCAPNUT
816A2€ngin6:
9 x 0.75mm
{0 N.m (4.1 kgt m, 30 tbf.ftl
D16Y5,Dl6Y7. D16Y8engines:
8 x 0.75mm
3l N.m {3.2kg{.m,
23 tbt.fr)
Applyengineoilto
the bolt threads.
NOTE:Aftertorquingeachbearing
cap, rotate crankshaftto
checkfor binding.
Flywheel and Drive Plate
Replacement
ManualTransmission:
816A2engine:
Removethe eight flywheel bolts,then separatethe flyw h e e l f r o m t h e c r a n k s h a f ft l a n g e .A f t e r i n s t a l l a t i o n '
tiohtenthe bolts in the sequenceshown
Automatic Transmission:
Removethe six drive platebolts,then separatethe drive
tighten
flange.Atter installation,
olatefrom the crankshaft
the bolts in a crisscrossPattern.
RINGGEARHOLDER"-i
OTLAB PVOOlOO
rurS;u'.\
$..3s'
RINGGEAB
Inspectring gear
teeth lor wear or
damage.
12 x 1.0mm
74 N.m
t7.5 kgl.m, 54 lbl'ltl
1 2 x 1 . 0m m
103 N.m
(10.5 kgf.m, 76 lbf.tt)
D16Y5,D16Y7,D16Y8engines:
Removethe six flywheel bolts,then separatethe flywheel
tightenthe
from the crankshaftflange.After installation,
bolts in a crisscrossPattern.
RINGGEAR
Inspectring gear
wear or
teeth
teetn lor wea(
/
danase.
\
,///.'
1 2 x 1 . om m
11 8 N , m
(12.0kgI.m,87 lbf.ftl
L
7-7
ConnectingRod and Crankshaft
EndPlay
\
Connecling Bod End Play:
Standard(Newl:0.15- 0.30mm
- 0.012inl
10.006
ServiceLimit: 0.40mm (0.016inl
a lf out-of-tolerance.
installa new connectingrod.
a lf still out-of-tolerance,replacethe crankshaft(see
pages7-12and 7-23).
Pushthe crankshaftfirmly away from the dial indicator,
and zerothe dial againstthe end of the crankshaft.
Then
pull the crankshaftfirmly backtoward the indicator;dial
readingshouldnot exceedservicelimtr.
GrankshaftEnd Play:
Standard (Newl: 0.10- 0.35 mm
(0.00,f- 0.01,tinl
Servic€Limit
0.it5 mm (0.018in)
.
lf end play is excessive,inspectthe thrust washers
and thrustsurfaceon the crankshaft.ReplaceDartsas
necessary.
NOTE:Thrustwasherthicknessis fixed and must not be
changedeitherby grindingor shimmrng.
Thrust washersare installedwith groovedsidesfacing
outward.
7-8
Main Bearings
Glearance
1 . T o c h e c k m a i n b e a r i n g - t o - j o u r n aoli l c l e a r a n c e .
removethe main capsand bearinghalves.
C l e a ne a c h m a i n j o u r n a l a n d b e a r i n gh a l f w i t h a
cleanshop towel.
Placeone strip of plastigageacrosseach main journ al .
NOTE:lf the engineis still in the car when you bolt
the main cap down to checkclearance,the weight
of the crankshaftand flvwheelwill flaftenthe plastigage further than just the torque on the cap bolt.
and give you an incorrectreading.For an accurate
r e a d i n g ,s u p p o r tt h e c r a n kw i t h a j a c k u n d e r t h e
c o u n t e r w e i g h t as n d c h e c ko n l y o n e b e a r i n ga t a
time,
4.
lf the plastigagemeasurestoo wide or too narrow,
(removethe engineif it's still in the car),removethe
crankshaft,and removethe upper half of the bearing. Installa new. completebearingwith the same
color code {selectthe color as shown on the next
page),and rechsckthe clearance.
R e i n s t a ltlh e b e a r i n g sa n d c a p s ,t h e n t o r q u e t h e
bolts.
lst step: 25 N'm (2.5kgl'm. 18 lbf'ft)
FinalsteD:
B16A2engine:
76 N.m (7.8 kgf.m, 56 lbf'ft)
D16Y5,Dl6Y7, D16Y8engines:
51 N.m (5.2kgf'm, 38 lbf'ft)
NOTE:Do not rotatethe crankshaftduring inspectron.
Removethe cap and bearingagain,and measurethe
widestpartot the plastigage.
CAUTION: Do nol fil€, shim, or scrapethe bearings
or tho cap3to adiust cleatanc€.
7.
lf the plastigageshows the clearanceis still incorrect,try the next largeror smallerbearing(thecolor
listedaboveor belowthat one),and checkagain
NOTE: lf the proper clearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
replacethe crankshaftand start over.
Main Boaring-toJournal Oil Clearance:
816A2 engine:
Standald {New}:
No. l, 2, 4, 5 Journals:
O.O2,l- 0.042mm 10'00(B- 0.0017in)
No. 3 Journals:
0.030- 0.048mm {0'0012- 0'0019in)
ServicoLimit: 0.06 mm {0.002in,
Dl6Y5, Dl6\rr, Dl6Y8 engines:
Standard (Nsw):
No. 1,5 Journals:
0.018- 0.035mm {0.0007- 0'001'[ in)
No. 2. 3, 4 Journals:
0.02,1- 0.0,(2mm {0'0009- 0.0017in}
ServiceLimit: 0.05 mm (0.002in)
\
7-9
Main Bearing
Selection
CAUTION: lf the codes are indecipherablebecauseof an
accumulationof dirt and dust, do not scrub them with a
wire brush or scraper.Clean them only with solvent ol
deiergent.
D16Y5,D16Y7,D16Y8engines:
Lettershave beenstampedon the end of the blockas a
codefor the sizeof eachof the 5 mainjournalbores.
Use them, and the numbersstampedon the crankshaft
(codesfor main journalsize),to choosethe correctbearIngs.
Crankshaft Bore Code Location
81642engine:
Lettershave beenstampedon the end of the blockas a
codefor the sizeof eachof the 5 mainjournalbores.
U s e t h e m , a n d t h e n u m b e r so r b a r s s t a m p e do n t h e
crank{codesfor main journalsize),to choosethe correct
beaflngs.
\
Main Journal Code Location(Numbers)
Main JournalCode Locations {Nombers or Barc)
Bearing ldentification
Eearing ldentification
C o l o rc o d e r s
on lhe edgeof
the bear ng.
B
Larger crank bore
c
a
-----------""'
D
Smallerbeanngtlhrcker)
lr-l
tt +#, t ll
l
f '-
9""1
B':""
Black
Alack
Alue
c
D
Smaller bea ng {th'cker)
f
7-10
Ldrger crank bore
Color code
on the
edge of
the bearing-
Smaller
maan
journal
4
Red
Pink
Pink
't t l
Green
Green
Green
Green
Brown
Brown
Brown
Black
Black
Elue
Smaller
bearing
{thicker)
\
I
ConnectingRod Bearings
Clearance
Selection
'1. Removethe connectingrod cap and bearinghalf
C l e a nt h e c r a n k s h a frto d i o u r n a la n d b e a r i n gh a l f
with a cleanshop towel.
CAUTION: lf the codes are indecipherable because of
an accumulationof dirt and dust, do not sclub them
with a wile brush or scraper.Cleanthem only with solvent or detergent,
Placeplastigageacrossthe rod journal.
ConnectingRod Code Location
the bearinghalfandcap,andtorquethe nuts.
Reinstall
Numbershave been stampedon the side of each con
necting rod as a code for the size of the big end Use
them, and the lettersstampedon the crankshaft(codes
for rod journalsize),to choosethe correctbearlngs
4.
Torque
Bl6A2 engine:
40 N.m (4.1 kgl.m, 30 lbf'ft)
Dr6Y5,D16Y7,D16Y8enginss:
31 N'm (3.2 kgf.m, 23 lbf ftl
NOTE| Do not rotatethe crankshaftduring inspection.
Half of numberls
stampedon bearing
cap and the other
half is stampedon
rod.
Removethe rod cap and bearinghalf and measure
the widest part of the plastigage.
ConnectingRod Bearing-to.JournalOil Glearance:
816A2engine:
Standard lNewl: 0.032- 0.050mm
- 0.0020in)
10.0013
inl
ServiceLimit: 0.06mm 10.002
D16Y5,D16Y7,D16Y8engines:
Standard lNew): 0.020- 0.038mm
(0.0008- 0.0015in)
0.05 mm 10.002inl
ServiceLimit
ConnectingRod Journal Code Locations(Lettels)
PLASTIGAGESTRIP
lf the plastigagemeasurestoo wide or too narrow'
removethe upper half of the bearing,installa new,
completebearingwith the same color code (select
t h e c o l o r a s s h o w n i n t h e r i g h t c o l u m n ) ,a n d
recheckthe clearance.
CAUTION: Do not lile, shim, or scrapethe bearings
or the caps to adiust clgarance.
7.
\
lf the plastigageshows the clearanceis still incorrect.
try the next largeror smallerbearing(thecolor listed
again.
aboveor belowthat one),andcheckclearance
NOTE: lf the Droperclearancecannot be obtained
by usingthe appropriatelargeror smallerbearings,
replacethe crankshaftand startover.
Bearing ldentilication
Color code is on the
edge of
the bearing.
lfA--;T] |
l l e " ' tl t;
Largerbrg end bore
----------------
l l c o r l l ll l
I lD;;ilril |
l - l
Smaller
rod
journal
2
1
Smaller
bearlng
(thicker)
Red
4
Smallerbearing{thrcker)
Pink
Pink
Green
3
Green
Brown
Green
Green
Erown
Black
Black
Blue
7-11
Pistonsand Crankshaft
Removal
\
1.
Removethe oil pan assembly.
3.
Removethe oil screen.
2.
Removethe right sidecover.
4.
R€movethe oil pump.
816A2 engine
816A2engin€
OIL SCREEN
OILPUMP
D16Y5,Dl6Y7,D16Y8ongines
D16Y5,D1oyr, D16Y8engin.s
RIGHT SIDE
O-RING
Replace.
5,
7-12
Remove the baffle plate (816A2 engine).
6.
Removethe boltsand the bearingcaps.
CAUTION: To prevenl warpago unscrow lhe bolts
in s€quence1/3 turn at a tims, r€paat the soquence
until all bolts ar€ loo3ened.
q
Removethe upperbearinghalvesfrom the connecting rods and set them aside with their respective
caos.
1 0 . Reinstallthe main caps and bearingson the engine
in proper order,
MAIN BEARINGCAPBOLTSLOOSENINGSEOUENCE
1 1 . lf you can feel ridgeof metalor hard carbonaround
t h e t o p o f e a c h c y l i n d e r ,r e m o v ei t w i t h a r i d g e
reamer.Follow the reamer manufacturer'sinstrucI|ons.
CAUTION; lf the ridge is not removed, it may damage tho pistons as they are pushod out.
RIOGEREAMER
S:_]ILOJLOAO
7.
and main capvbearRemovethe rod caps/bearings
in order.
ings.Keepall caps/bearing
12. Use the wooden handle of a hammer to drive the
Lift the crankshaftout of the engine,being careful
not to damagejournals.
pastonsout.
1 3 . Reinstallthe connectingrod bearingsand capsafter
rod assembly.
removingeachpiston/connecting
CRANKSHAFT
rod assemblywith its
1 4 . Mark each piston/connecting
cylindernumberto avoid mixup on reassembly.
NOTE:The existingnumber on the connectingrod
does not indicateits positionin the engine,it indicatesthe rod bore size.
7-13
Crankshaft
Inspection
.
Cleanthe crankshaftoil passageswith pipe cleaners
or a suitablebrush.
.
Checkthe keywayand threads.
Out-of-Roundand Tapet
.
Alignment
.
.
M e a s u r er u n o u t o n a l l m a i n j o u r n a l st o m a k e
surethe crankis not bent.
The differencebetweenmeasurementson each
journalmust not be more than the servicelimit.
CrankshaftTotal IndicatedRunout:
Measureout-of-roundat the middle of each rod
and main journalin two places.
a The differencebetweenmeasurementson each
journalmust not be morethan the servicelimit.
Joulnal Out-of-Round:
81642engine:
Standard (New): 0.0004mm {0.0002in) max.
ServiceLimit: 0.006mm {0.0002in)
Dr6Y5, Dl6Y7, D16Y8engines:
Standard (Newl: 0.0025mm (0.0001inl max.
ServiceLimh: 0.005mm (0.0002inl
Bl6A2 engine:
Standard (Newl: 0.020mm {0.0008in} max.
ServiceLimit: 0.030mm {0.0012inl
D16Y5,D15Y7,D15Y8engines:
Standsrd{New):0.03mm (0.001in} max.
ServiceLimit; 0.0i1mm 10.002in)
round at middle.
\
Support with lathe
type tool or V blocks.
.
Measuretaper at the edgesof eachrod and main
journal.
. The differencebetweenmeasurementson each
journalmust not be more than the servicelimit.
JournalTaDer:
B16A2ongine:
Standard lNewl: 0.005mm (0.0002inl max.
ServiceLimit: 0.010mm (0.00i1inl
D16Y5,D16Y7,Dl6YBengines:
Standard (New): 0.0025mm {0.0001in) max.
ServiceLimit: 0.005mm (0.0002in)
7-14
Pistons
Inspection
1 . Checkthe pistonfor distortionor cracks,
N O T E :l f a c y l i n d e ri s b o r e d .a n o v e r s i z e dp i s t o n
must be used.
Measurethe piston diameterat a distanceA from
bottom of the skirt.
3.
Calculatethe differencebetweenthe cylinder bore
diameter(seepage7-16)and the pistondiameter.
Piston-to-CylinderClsarance
StandardlNewl: 0.010- 0.0,10mm
- 0.0016inl
(0.0004
0.05 mm {0.002in}
ServicoLimit:
816A2engino:
A: 15 mm 10.6in)
D16Y5,D16Y7,D16Y8engines:
A: 5 mm (0.2inl
Piston Diameter:
816A2engine:
Standard lNewl: 80.980- 80.990mm
- 3.1886in)
13.1882
(3.1878in)
mm
ServiceLimit: 80.970
D16Y5,D16Y7,D16Y8engines:
Standard {New): 7,f.980- 7i1.990mm
- 2.9521in!
|.2.9520
ServiceLimit: 74.970mm {2.9516inl
lf the clearanceis near or exceedsthe servicelimit,
inspectthe piston and cylinderblockfor excessive
wear.
SKIRTDIAMETER
OversizoPiston Diametor
816A2ongine:
0.25t81.23- 81.21mm (3.1980- 3.1984inl
D16Y5.D16Y7,D16Y8engines:
O.25t75.23- 75.21mm (2.9618- 2.9622in)
0.50:75.i18- 75.49mm {2.9716- 2.9720in}
7 - 15
Cylinder Block
Inspection
'L
Measurewearand taperin directions
X andy at three
levelsin eachcvlinderas shown.
lf the measurementsin any cylinderare beyond
the OversizeBore ServiceLimit, replacethe block.
lf the block is to be rebored.refer to piston ClearanceInspection(seepage7-15)after reboring.
NOTE:Scoredor scratchedcylinderboresmust be
honed.
ReboringLimit:
Bl642 enginc:
0.25mm (0.01in)
Dl6Y5,D16Y7,D16Y8engin€s:
0.50 mm (0.02in)
Checkthe top of the blockfor warpage,
Measurealong the edges and acrossthe centeras
shown.
SURFACES
TO BEMEASUREO
Cylinder Boro Size
816A2engine:
Standard(Newl:81.00- 81.02mm
{3.1t|:l- 3.190int
ServiceLimit: 81.07mm {3.192in)
D16Y5,D16Y7,D16Y8engines:
Standard lNew): 75.00- 75.02mm
(2.9s3- 2.954in)
SarviceLimit: 75.07mm (2.956in)
Oversize
816A2 engiDe:
0.25t41.25- A1.27mm {3.199- 3.200in)
D16Y5,D16Y7,D16Y8Engines:
0.25t75.25-15.27 mm (2.9626- 2.963,0in)
0.50:75.50- 75.52mm 12.9721-2.9i32 inl
Bore TaDet
Limit: (Differencebetween first and third measure"
ment) 0.05 mm (0.002inl
7-16
EngineBlockWarpage:
Bl6A2 engine:
Standard (Now):0.05 mm {0.002inl max.
ServiceLimh: 0.08 mm (0.003in)
DtOYs,D16Y7,D16Y8€nginas:
Standard (N€w):0.07 mm l0.OO3inl max.
ServicaLimit; 0.10 mm {0.00itin)
PRECISION
STRAIGHTEDGE
PistonPins
Cylinder Block
Removal
BoreHoning
1.
Measurecylinderboresas shownon page7-16.lf the
block is to be reused,hone the cylindersand remeasurethe bores.
l.
Assemble the special tool as shown.
PISTONBASEHEAD
07973 - SBtx)too
f t
Honecylinderboreswith honingoil 8nd a fine (400
grit) stone in a 60 degreecross-hatchpattern.
PISTONPINBASE
INSERT
01973- PE00'0)
NOTE:
. Use only a rigid hone with 400grit or finer stone
suchas Sunnen,Ammco,or equivalent.
. Do not usestoneslhat are worn or broken.
rg\g
lj*N*,""
W h e n h o n i n g i s c o m p l e t e ,t h o r o u g h l yc l e a n t h e
engine blockof all metal particles.Wash the cylinder bores with hot soapYwater, then dry and oil
immediatelyto preventrusting.
NOTE: Never use solvent.it will only redistributethe
grit on the cylinderwalls.
2.
PISTONPINDRIVERHEAD
07973- PE00320
Proat
0
lf scoring or scratchesare still presentin cylinder
bores after honing to the servicelimit, rebore the
cylinderblock.
PISTON PIN
DRIVERSHAFT
0t973 - PEqr310
NOTE:Some light verticalscoringand scratchingis
acceptableif it is not deep enough to catch your fingernailand does not run the full lengthof the bore.
PILOTCOLLAR
07973 - PE00200
CYLINOESBLOCK
Emboss6dmark facing up
CYLINDER
NOTEi Us6 a hydraulic press.
When pressingthe pin in or out.
make sure that the recesssd
portion of the piston aligns
with the lips on the collar.
NOTE:
.
.
After honing,cleanthe cylinderthoroughlywith
soapy warer.
Onlv a scoredor scratchedcylinderbore must be
noneo.
Assembleand adjust the length of the piston p t n
driverand shaftto 53 mm (2.1inl as shown.
3.
Placethe piston on the sp€cialtool and press the
pin out with the specialtools and a hydraulicpress.
7-17
ConnectingRods
PistonPins
Selection
Installation
Eachrod fallsinto one of four toleranceranges{fromOto
+ 0.024mm (0 to + 0.0009in), in 0.006mm (0.0002in)
increments)
dependingon the sizeof its big end bore.lt,s
then stampedwith a number{1, 2,3, or 4) indicatingthe
range.
Y o u m a y f i n d a n y c o m b i n a t i o no t l , 2 , 3 , o r 4 i n a n y
engrne.
1.
,
(
Usea hydraulicpressfor installation.
.
Whenpressingthe pin in or out, be sureyou posi
tion the recessed
flat on the pistonagainstthe lugs
on the baseattachment.
816A2engine
D16Y5,D16Y7,O16Y8engines
The arrowmustfacethe
timing beltsideo{ the
engineand the connecting
rod oil holemustfacethe
rearof the engine.
NormalEoreSize:48.0mm (1.89in)
NOTE:
o Referencenumbersare for big end bore sizeand do
NOTindicatethe positionof the rod in the engine.
. Inspectconnectingrod for cracksand heatdamage.
The arrow must face the
timing belt side of the
e n gI n e .
ROD AORE
CONNECTING
REFERENCE
NUMBER
Half of numberis stampedon
bearingcap, the other half on
connectrngrod.
The markmustface
the timing beltside
o f t h ee n g i n e .
a
PISTONPIN DRIVERHEAD
Adjustthe lengthof the
pistonpin driverto
53 mm (2.094n)
PISTONPINDRIVERSHAFT
07973-PEOo3r0
il--Z
P,"roNPrN
PILOTCOLLAR
07973-PE00200
PISTONPINBASE INSERT
07973 PEO0400
PISTONEASE HEAO
07973-5800100
7-18
lnspection
1.
Measurethe diameterof the pistonpin.
3.
NOTE:Checkthe pistonfor distortionor cracks.
Piston Pin Diametel:
B16A2engine:
Standard{New):20.994- 21.000mm
Oversize:
clearance.
Measurethe pistonpin-to-piston
lf the pistonpin clearanceis greaterthan 0.024mm
( 0 . 0 0 0 9j n ) , r e m e a s u r eu s i n g a n o v e r s i z e dp i s t o n
pin.
- 0.8268in)
(0.8265
20.997- 21.003
- 0.8269inl
10.8267
Piston Pin-to-PistonClearance:
Standard(New):0.010- 0.022mm
(0.0004- 0.0009in)
D16Y5,Dl6Y7,Dl6YBengines:
StandardlNewl: 18.99,1-19.000mm
(0.7478- 0.7480inl
18.997- 19.003
Oversize:
{0.7479- 0.7481in)
pistonpins are overslze.
NOTE;All replacement
4.
2.
Zerothe dial indicatorto the pistonpin diameter'
Checkthe differencebetweenthe pistonpin diameter and the connectingrod smallend diameter'
Piston Pin-to-ConnestingRod Interterence:
816A2engine:
Standard(New):0.013- 0.032mm
(0.0005- 0.0013in)
D16Y5,D16Y7,Dl6YBengines:
SiandardlNewl; 0.014- 0.040mm
- 0.0016
inl
10.0006
7-19
PistonRings
EndGap
Replacement
1 . Using a piston, push a new ring into the cylinder
bore 15- 20 mm (0.6- 0.8 in) from the bottom.
1.
Cleanall ring groovesthoroughly.
Measurethe pistonring end-gapwith a feelergauge:
.
.
Socond Ring
816A2 ongina
Standard (Nowl: 0.40- 0.55 mm
- 0.022inl
10.016
ServiceLimit: 0.70 mm (0.028inl
D16Y5,D16Y7,Dt6Y8 engines
Standard (New): 0.30- 0.ia5mm
{0.012- 0.018in)
SorviceLimit
0.70 mm 10.028inl
Oil Ring
81642 ongine
Standard {Now): 0.20- 0.50 mm
(0.008- 0.020inl
SorvicoLimit: 0.70 mm (0.028in)
Dl6Y5. Dl6Y7, D16Y8€nginos
Standard (Nowli 0.20- 0.70 mm
(0.008- 0.028inl
ServicaLimit: 0.80 mm 10.031in)
7-20
NOTE:
. U s e a s q u a r e d - o fbf r o k e nr i n g o r r i n g g r o o v e
cleanerwith bladeto fit pistongrooves.
o Top ring grooveis 1.0mm (0.039in)wide.
. Secondring grooveis 1.2mm (0.047in) wide.
. Oil ring grooveis 2,8 mm (0.11in) wide.
. Filedown the bladeif necessary.
lf the gap is too small,checkto see if you have
the properringsfor your engine.
lf the gap is too large.recheckthe cylinderbore
diameteragainstthe wear limits on page7-16,
lf the bore is over the servicelimit, the cvlinder
blockmust be rebored.
Pkton Ring End-cap:
Top Ring
81642 engino
Siandtrd (New): 0.20- 0.35 mm
{0.008- 0.01,1in)
ServiceLimit: 0.60 mm l0-02i1inl
D16Y5.Dl6Y7, D16Y8enginos
Standard lNewl: 0.15- 0.30 mm
{0.006- 0.012in)
Ssrvic€ Limit
0.60 mm {0.024inl
Usinga ring expander.removethe old pistonrings.
CAUTION: Do noi use a wire blush to clean ring
lands. or cut ring lands deepol with cleaning tool.
NOTE:lfthe pistonis to be separatedfrom the connectingrod, do not installnew ringsyet.
3.
Installnew rings in the proper sequenceand positaon(seepage7-22).
NOTE:Do not reuseold pistonrings.
(Commercially
available)
Clearance
Ring-to-Groove
Alignment
After installing a new set of rings, measure ring-togrooveclearances:
1.
Top Ring Clearance
Standard (New):
B16A2angine:
in)
0.045- 0.070mm (0.0018- 0.(X128
Dl6Y5, Dt6Y7, Dl6Y8 engin€s:
0.035- 0.060mm {0.0014- 0.002'lin)
service Limit: 0.13 mm (o.fixi in)
Installtheringsas shown.
NOTE: The manufacturingmarks must be facing
upward.
TOP RING(Chrome)
SecondRing Clearance
Standard lNow):
B16A2engine:
0.0/t0- 0.065mm (0.0016- 0.0026in)
Dl6Y5, D16Y7,D16Y8onginos:
0.030- 0.055mm (0.(X)12- 0.0022in)
Sewica Limh: 0.13 mm (0.005io)
SECONDRING(Darkl
Piston Ring Dimsnsions:
t----T
l
f
B
t---f_-L
A
U n i tm m ( i n )
Top Ring (Standard)
B
Bl642 engine
3 . 1( 0 . 1 2 )
1.0(0.04)
D16Y5,D16Y7,
D16Y8engines
2 . 6( 0 . 1 0 )
1.0(0.04)
U n i tm m ( i n )
SecondRing(Standard)
B
.,o
816A2engine
3 . 3( 0 . 1 3 )
1.2(0.05)
D16Y5,D16Y/.
D16Y8engines
3 . 0( 0 . 1 2 )
1.2{0.05t
(cont'd)
7-21
PistonRings
CrankshaftOil Seal
Alignment(cont'dl
Installation
,
The sealsurfaceon the blockshouldbe dry.
Apply a light coat of oil to the c.ankshaftand to
t h el i po f t h es e a l .
MARK
TOP RING ---.>
1.
SECONDRING>
Drivethe crankshaftoil seal squarelyinto the right
sidecover usingthe specialtools.
HANDLEDRIVER
07749 0010000
,a-)
/\_4
o,.r^o( qffi<--sPACER
\Z-.
v
Rotatethe rings in their groovesto makesure they
do not bind.
Positionthe ring end gapsas shown:
seal with the
SECONDRINGGAP
DO NOTpositionany ring gap
at pistonthrustsurfaces.
pan numberside
facing out.
C o n f i r m t h a t t h e c l e a r a n c ei s e q u a l a l l t h e w a y
aroundwith a feelergauge.
- 0.8 mm (0.02- 0.03inl
Clearance:0.5
Approx.90
TOP RINGGAP
DO NOTpositionany ring gap
in linewith the pistonpin hole.
OIL RINGGAP
NOTE:Referto page 8-14 for installationof the oil
pumo sidecrankshaftoil seal.
7-22
\
(
Grankshaft
Pistons
lnstallation
lnstallation
Beforeinstallingthe crankshaft,apply a coat of
engineoil to the main bearingsand rod bearings.
B e f o r ei n s t a l l i n gt h e p i s t o n s ,a p p l y a c o a t o f
e n g i n eo i l t o t h e r i n g g r o o v e sa n d c y l i n d e r
bores.
Insertthe bearinghalvesinto the cylinderblockand
connectingrods.
2 . Holdthe crankshaftso the rod journalsfor cylinders
No.2 and No. 3 are straightdown.
3 . Lowerthe crankshaftinto the block,seatingthe rod
journalsinto connectingrods No. 2 and No. 3, and
installthe rod capsand nutsfinger-tight.
1.
1.
2.
lf the crankshaftis alreadyinstalled:
. Setthe crankshaftto BDCfor eachcylinder.
. Removethe connectingrod caps,and slip short
sectionsof rubber hose over the threadedends
of the connectingrod bolts.
. lnstallthe ring compressor.checkthat the bearing is securelyin place,then positionthe piston
in the cylinder,and tap it in using the wooden
h a n d l eo f a h a m m e r .
o Stop after the ring compressorpops free, and
journal aligncheckthe connectingrod-to-crank
ment beforepushingthe pistoninto place
. Apply engine oil to the bolt threads.Installthe
rod capswith bearings,and torquethe nuts to:
815A2engine:
40 N.m {,1.1kgf.m, 30 lbf'ft|
D16Y5,D16Y7,D16Y8engines:
31 N.m (3.2kgf'm,23lbf'ft)
lf the crankshaftis not installed:
installthe ring
. Removethe rod capsand bearings,
then positionthe pistonin the cylincompressor,
der, and tap it in using the wooden handleof a
hammer.
. Positionall Distonsat top deadcenter.
Groovedsidesface
oulward.
Botatethe crankshaftclockwise,seat journals into
connectingrods No, 1 and No.4, and installthe rod
capsand nutsfinger-tight.
NOTE:Installcaps so the bearingrecessis on the
sameside as the recessin the rod.
5.
The arrcw must face
the tamingbelt side
of the engine.
Checkrod bearingclearancewith plastigage(see
p a g e7 - 1 1 )t,h e n t o r q u et h e c a p n u t sA. p p l y e n g i n e
oil to the bolt threads.
Torque:
816A2 sngine:
/l{, N.m {a.l kgf.m, 30 lbf'ftl
D16Y5,D16Y7,Dl6Y8 engines:
31 N.m (3.2 kgf.m, 23 lbf'ft|
ROO
CONNECTING
OILHOLElD16Y5,D16Y7,D16YBongines)
NOTE: Referencenumbers on connectingrod are
for big-endbore toleranceand do not indicatethe
positionof pistonin the engine.
RUBBER
NOTE:Maintaindownwardforce on the ring compressorto preventthe rings from expandingbefore
enteringthe cylinderbore.
,lll
Lineup the markswhen
i n s t a l l i n gt h e c o n n e c t r n g r o d
cap.
6.
Installthe thrust washerson the No. 4 journal.Oil
(cont'd)
the thrustwashersurfaces,
7-23
Crankshaft
Installation(cont'd)
7.
I n s t a l l t h em a i nb e a r i n gc a p s .
Checkclearancewith plastigage(seepage7-9),then
tightenthe bearingcap boltsin 2 steps.
NOTE:
. Useliquidgasket,part No.08718- 0001or087180003.
. Checkthat the mating surfacesare cleanand dry
beforeapptyingliquidgasket.
. Apply liquidgasketevenly,beingcarefulto cover
all the matingsurface.
. To preventoil leakage,apply liquidgasketto the
innerthreadsof the bolt holes.
. Do not installthe parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket.
Insteadreapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least30 minutesbefore
f i l l i n gt h e e n g i n ew i t h o i l .
First step: 25 N.m {2.5 kgf.m, 18 lbf.ft)
Secondstop:
B1642engine:
76 N.m {7.8 kgf.m, 56 lbf.ft)
D16Y5,D16Y7,D16Y8engines:
51 N.m (5.2 kgf.m, 38 lbf.ft)
NOTE: Coat the thrust washer surfacesand bolt
threadswith oil.
MAIN BEARING
CAPBOLTSTIGHTENING
SEOUENCE
o
o
c
o
o
L
Apply liquid gasketto the block mating surfaceof
the right side cover,then install it on the cylinder
block.
Bl6A2 engine;
:V
fr\-/.---\-/.-
CAUTION:Whenever any crankshaft or connecting
rod bearing is replaced,it is necGssaryafter reassombly to run the engine at idling spe6d until it reaches
normal operating temperature,than continue to run
it for approximately15 minutos.
Apply tiquid gaslet along
the broken line.
D16Y5,D16Y7,D16Y8engines:
RIGHTSIDECOVER
7-24
9.
81642ongin€:
RIGHTSIDE
Apply liquid gasketto the oil pump mating surtace
of the block,then installthe oil pump on the cylinder block.
Apply greaseto the lips of the oil seals.
Thgn, align the inner rotor with the crankshaftand
i n s t a l lt h e o i l p u m p . W h e n t h e p u m p i s i n p l a c e ,
clean any excessgreaseoff the crankshaft.Check
that the oil seallips are not distorted.
B16A2ongino:
DOWELPINS
D16Y5,Dl6fr, Dl6Y8 engines:
Apply liquidgasketalong
the brokenline,
Dl6Y5,Dl6Y7,Dt6Y8ongino3:
Apply liquid gasket
alongthe broken
6 x 1.0 mm
1 1 N . m { 1 . 1 k9l.m,
a rbf.ft)
OIL PUMP }{OUSING
OOWEL PIN
{cont'd)
7-25
Crankshaft
Oil Pan
(cont'd)
Installation
Installation
NOTE:
. Apply a light coat of oil to the crankshaftand io
t h e l i po f s e a l .
. U s e n e w O - r i n g sa n d a p p l y o i l w h e n i n s t a l l i n g
them.
1 0 . l n s t a l l t h eo i l s c r e e n .
D16Y5,Dl6Yg engines:
1.
I n s t a ltlh e o i l p a ng a s k eot n t h e o i l p a n .
OIL PAN
816A2engine:
6 x 1 . Om m
l l N ' m ( 1. 1 k g l . m ,
8 tbt.Irl
,.//
{
(..ao
/
cor*rt
Replace.
t(^^
1 1 N . m 1 1. 1 k g f . m ,
a lbl'ltl
tbt4tl ,/
.rB
/
*P/
OIL PAN
GASKET
Replace.
& ^/t
I
O.RING
Replace.
OtL PutitP
24 N.m (2.4kgf.m,
'17
lbl.fr)
D16Y5, D16Y7, D16Y8 engines:
6x1.0mm
1 1 N . m { 1 . 1k g f . m ,
6 x 1.0mm
1 1 N . m { 1. 1 k g f . m ,
a lbf.fr)
DOWELPIN
rl l Te
OIL PUMP
/
6 x 1.0mm
11 N.m
l l.1 kgf'm, a lbf.frl
7-26
8 tbt.rr)
I
I
OIL SCREEN
2.
Apply liquid gasketto the blockmating surfacesof
the oil pan,then installit. Apply liquid gasketto the
shadedareas.
NOTEI
. U s e l i q u i d g a s k e tp a r t N o . 0 8 71 8 - 0 0 0 1 o r
08718- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapPlyingliquidgasket.
. Apply liquid gasketas an even bead, centered
betweenthe edgesol the matingsurface'
. To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes
. Do not installthe parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket
lnstead,reapplyliquid gasketafter removingthe
.
old residue
After assembly,wait at least 30 minutes before
f i l l i n gt h e e n g i n ew i t h o i l .
816A2, D16Y7engines:
t n t h e o i l p u m p a n d r i g h ts i d e
1 . A p p l y l i q u i dg a s k e o
covermatingareasas shown below.
NOTE:
. U s e l i q u i d g a s k e t ,p a r t N o . 0 8 7 1 8- 0 0 0 1o r
08718- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgasket
. Apply liquid gasket as an even bead, centered
betweenthe edgesol the matingsurface'
. To preventoil leakage,apply liquid gasketto the
innerthreadsof the bolt holes
. Do not install the parts if five minutes or more
haveelapsedsinceapplyingthe liquidgasket
Instead,reapplyliquid gasketafter removingthe
old residue.
. Aftel assembly,wait at least30 minutes before
filling the enginewith oil.
CYLINDER
ELOCK
Apply liquid gasket
to these pornts-
OIL PAN
3.
T i g h t e nn u t s f i n g e r - t i g h ta t s i x p o i n t s a s s h o w n
below.
Apply liquid gasket
to these pornts.
4.
I
Tighten all bolts and nuts, startingfrom nut @, clockwisein threesteps.
tighteningcan causedistortionof
NOTE:Excessive
gasket
oil leakage.
pan
and
the oil
Torque:12 N'm {1.2kgt'm,8.7lbf'ft|
(cont'd)
7 -27
Oil Pan
lnstallation(cont'dl
\
Installthe oil pan gasketand oil pan
3,
NOTE:
a Usea new oil pan gasket.
. I n s t a l lt h e o i l p a n n o m o r e t h a n f i v e m i n u t e s
afterapplyingliquidgasket.
Tightenthe bolts and nuts finger tight at six points
as shown below.
816A2 engine:
4.
OIL PAN
GASKET
R€place.
T i g h t e na l l b o l t s a n d n u t s , s t a r t i n gf r o m n u t O .
clockwise in threesteps.
NOTE:Excessive
tighteningcan causedistortionof
the oil pan gasketand oil leakage.
Torque: 12 N.m {1.2 kgf.m, 8.7 lbf.ft)
Apply liquid
gasKet to
these points.
Apply liquid gasker
to these points.
7-28
OIL PAN
GASKET
Beplace.
Oil Seals
lnstallation
NOTE:
. Engineremovalis not required.
. The crankshaftoil sealhousingshouldbe dry.
Apply a light coat of greaseto the crankshaftand to
the lips of the seals.
1.
U s i n gt h e s p e c i atl o o l , d r i v e i n t h e t i m i n g p u l l e y e n d s e a l u n t i l t h e d r i v e r b o t t o m sa g a i n s tt h e o i l
pump.
When the seal is in place,clean any excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
2.
Measurethe flvwheel-endsealthicknessand the oil
sealhousingdepth.Usingthe specialtool. drive the
flywheel-endseal into the rear cover to the point
where the clearancebetweenthe bottom of the oil
sealand the right side cover is 0.5- 0.8 mm (0.02
(see
page
7-23).
0.03in)
NOTE:Align the hole in the driver attachmentwith
the Dinon the crankshaft.
DRIVER
07749-0010000
07947 -S800200
lnstallseal with the
part numbersade
facing out.
DRIVERATTACHMENT
0794a-s800101
lnslall seal with the
part number side
facing out.
I
7 -29
EngineLubrication
"'.""".8'2
..........
SpecialTools
.'..'8-3
lllustratedIndex...........
EngineOil
8-6
.....'......"....."'.
Inspection
8-7
Replacement........'......".'.'..."...."......"
OilFilter
8-8
Rep1acement...............".'...'..'.....'.'...".
Oil Pressure
'.....'8-9
Testing
engine)
OilJet (B16A2
...'.'......"...."'..8-10
Inspection
OilPump
8-11
.....'...'..'."""'
overhaul.'...
..'....8-13
Removal/lnspection/lnstallation
SpecialTools
\
Ref. No.
Toot Number
I
07746- 0010400
07749- 0010000
0 7 9 1 2- 6 1 1 0 0 0 1
o
Attachment,52 x 55 mm
Driver
Oil FilterWrench
6\
,6
\ ll
\
8-2
a
lllustrated Index
CAUTION: Do not overiighten the drain bolt.
NOTE:
. Usenew O-ringswhen reassembling
. Apply oil to O-ringsbeforeinstallation
. Use liquid gasket,Part No 08718- 0001or 087180003.
. Cleanthe oil pan gasketmating surlacesbefore installWASHER
Ing.
RePlace'
6x1.0mm
12 N.m (1.2kqtm,8.7 lbl.ftl
B1642 engine:
DRAINBOLT
44 N.m (4.5kgl'm,33 lbt'ft)
Do not overtrghten.
OIL PAN
Relerto page 7'27
when installing.
OIL PAN
GASKET
Replace-
6x1.0mm
11 N.m (1.1kgtm,
8
OIL BREATHER
CHAMEER
6x1.0mm
11 N'm (1.1 kgl.m,8 lbf.ft)
otL
SCREEN
GASKET
Replace.
BAFFLEPLATE
OIL JET BOLT
16 N'm 11.6kgf.m, 12lbt'ttl
€!
fl
OIL JET
page8-10
Inspection,
[50
8x1+5mm
24 N.d\l2.il kgf.ft,
t7 tbtft)
Replace.
OIL FILTER
R e p l a c e m e n l ,p a g e 8 - 8
Replace.
SWITCH
ENGINEOIL PRESSURE
PipeTaper)28 Threads/inch
Useproperliquidsealant.
Clean
6x1.0mm
11 N.m 11.1kgt m,
8 tbt.frl
Overhaul.page8'11
Removal/lnspection,
Page8-13
Apply liquidgasketto
matingsurfaceof engineblock
(cont,d)
8-3
lllustrated Index
(cont'dl
NOTE:
. Usenew O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstaltal|on.
. Use liquid gasket,Part No. 08718 0001 or 0e719
0003.
. Cleanthe oil pan gasketmatingsurfacesbeforeinstall_
ing.
. Apply liquid gasketto the recessesof the oil pan gas
ket (seepage7-27).
CAUTION: Do not overtighten the drain bolt.
ENGINEOILPBESSURE
SWITCH
18 N.m (1.8kgtm, 13 tbt.trl
1/8in. BSPT(British
StandardPipeTaper)
28 threads/inch.
Use
properliquidsealant.
D16Y7€ngine:
OILPUMP
Overhaul,page8-12
Inspection,
page8 13
Apply liquidgasker
to the matingsurface
of the block.
O-BING OILBREATHER
Replace. CHAMBER
6x1.0mm
'11N.m 1.1ksnm,
{
8 tbtft)
DOWELPIN
ll
6x1.0mm
1l N.m {1.1kgf-m,
8 tbf.ftl
OIL PAN
GASKET
Bepiace.
OIL PAN
R e f e rt o p a g e 7 - 2 7
when installing.
6x1.0mm
1 1N m ( 1 . 1k g t . m , A p p l y l i q u i d g a s k e t t o
8 tbl.ftl
6 x 1 . 0m m
l2 N.m {1.2kgtm, 8.7tbf.ft)
DRAINBOLT
44 N.m {4.5kgtm, 33 tbf.ft}
Do not ovenighten.
8-4
a
NOTE:
. Use new O-ringswhen reassembling.
. Apply oil to O-ringsbeforeinstallation.
. Use liquid gasket,Part No 08718- 0001 or 08718
.
CAUTION: Do not overtightsn the drain bolt.
SWITCH
ENGINEOIL PRESSURE
18 N,m l'1.8kgf.m, 13 lbf.ftl
1/8in. ESPT(British
StandardPipeTaper)
use
28 Threads/inch.
properliquidsealant.
0003.
Cleanthe oil pan gasketmatingsurfacesbeforeinstallIng.
D16Y5,D16Y8engines:
O.RING
Replace.
O-RING
OIL BREATHER
CHAMBER
OILPUMP
Overhaul,Page8 12
Inspection,
Page8 13 OOWELPIN
Apply liquidgasket
to the matingsurface
of the block.
6x1.0mm
11 N.m {1.1kgf.m,
I tbt'ftl
FILTER
page8_8
Replacement,
6 x ' 1 . 0m m
11 N.m ('1.1|
8 tbf.ft)
BAFFL€PLATE
GASKET
Replace.
6x1.0mm
11N.m 11.1kgl.m,
8 tbf.ftl
OILPAN
GASKET
Feplace.
6x1.0mm
11 N.m 11.1kg{'m,
8 rbf.ftl
OIL PAN
Relerto page7 26
when installing.
\3
BOLT
39 N.m (4.0kgf.m.29lbtftl
Do not overtighten.
\
6x1.0mm
12 N.m {1.2kg{.m,8.7lbf ftl
8-5
EngineOil
Inspection
Replacement
1 . Parkthe vehicle on level ground, and turn off
the
engine.Allow the oil a few minutes to drain back
into the oil pan so the dipstickwill show the actual
level.
Make certainthat the oil level indicatedon the dip_
stick is betweenthe upper and lower marks.
lf the level has dropped close to the lower mark.
add oil until it reachesthe uppermark.
CAUTION:Removothe drain boli carefully while
lho
engine is hot; the hot oil may causoscalding.
:1. Warm up the engine.
2.
Drainthe engineoil.
81642,D16Y7engin€s:
CAUTION: lmert thc dipstick car€fully to avoid b€nd_
ing it.
Bl6A2 angin.:
,,7.fp--)*,".
rowrn-u
l
DRAINBOLT
{rl N.m (4.5 kgf.m,33 tbt ft}
Do not overtighten.
D16Y5, Dl6Y8 6ngin93:
WASHER
D16Y5,D16Y7,Dt6y8 ongines:
DRAINBOLT
39 N.m 14.0kgfm, 29 tbf,f0
uo not overtighten.
8-6
3.
Reinstallthe drain bolt with a new washer.and rbfill
the enginewith the recommendedoil.
"Energy
Requirement API ServiceGrade:Use an
Conserving"SJ gradeoil or an
"EnergyConservingll" SH gradeoil,
SAE5W - 30 preferred
You canalsousean oil that bearsthe
mark.
APICERTIFICATION
Capacity
engine:
[atolz
3.7f (3.9US qt,3.3 lmp qtl
I at oil change.
qtl
J 4.0r 9.2 US qt, 3.5 lmp
filter'
including
change,
at
oil
I
( 5 . 1U s q t , 4 . 2l m p q t )
| 4 . 8f
overhaul
engine
after
I
I Dl6Y7 engine:
3.6f (3.8US qt, 3.2 lmP qt)
filter.
I at change.including
(3.5US qt,2.9 lmP qtl
f
3.3
I
filter.
I at change,without
( 4 . 5u s q t , 3 . 8l m p q t l
4
.
3
f
I
I afterengineoverhaul.
J D16Y5,D16Y8engines:
L 3.3{ {3.5US qt,2.9 lmp qt}
filter.
I at change,including
(
3
.
2
q
t
,
2
.
6
l
m pq t )
U
S
3.01
withoutfilter.
at
change,
I
3.7{ (3.9US qt,3.3 lmp qt}
- '1.€fter
engineoverhaul.
MARK
API CERTIFICATION
API SERVICELABEL
Every7,500miles(12,000km) or
12months(NormalConditions).
Every3,750miles(6,000kml or
6 months (SevereConditions).
Change
Run the engine tor more than three minutes,then
checkfor oii leakage
NOTE:Under normalconditions,the oil filter should be
replacedat every other oil change Under severeconditions,the oilfilter shouldbe replacedat eachoil change'
The numbersin the middle of the API Servicelabeltell
you the oil's SAE viscosityor weight Selectthe oil for
vour car accordingto this chart:
Ambient Temoerature
30
20
-10
0
10
20
30
4OoC
A n o i l w i t h a v i s c o s i t y o f 5 W - 3 0 i s p r e f e r r e df o r
improvedtuel economyand year-roundprotectionin the
car.You may usea 10W- 30 oil if the climatein your area
is limitedto the temperaturerangeshownon the chart'
8-7
Oil Filter
Replacement
After the engine has been run, the exhaust pipe will
be hot; be careful when working around ihe exhaust
pipe.
Be careful when loosening the drain bolt whils the
engine is hot. Burns can resuh becausethe oil temperatu16is very high.
l.
Installthe oil filter by hand.
Afterthe rubbersealseats,tightenthe oil filterclock_
wise with the oil filterwrench.
Tighten: 7/8 tu.n clockwise.
Tightening tolque: 22 N.m (2.2kgt.m, 16lbf.ft)
Removethe oil filter with the oil filter wrencn.
Inspectthe threadsand rubbersealon the new filter.
Wipe off the seat on the engineblock,then apply a
lightcoatof oil to the new filter,srubberseal.
NOTE: Use onty fitters with a built-in bypasssys,
tem.
Applyoil to rubberseal
beforeinstalling.
OIL FILTERWRENCH
07912- 6110001
I n s p e c tt h r e a d s a n d
rubber seal surface.
8-8
Oil Pressure
Testing
Usethis procedureto tightenthe filter if eight numbers(1 to 8) are printedon the surfaceof the filter.
lf the oil pressurewarningIightstayson with the engine
running,checkthe engineoil level.It the oil level is correct:
1) Makea markon the oil filterbaseunderthe number that shows at the bottom of the filter when
the rubbersealis seated.
1.
Connecta tachometer'
2.
Removethe engineoil pressureswitch,and installan
oalpressuregauge.
2l
Tightenthe filter by turning it clockwiseseven
numbersfrom the markedpoint. For example,if a
markis madeunderthe number2 when the rub
ber seal is seated,the filter should be tightened
untilthe number1 comesup to the markedpoint'
SWITCH
OtLPRESSURE
ENGINE
HOLE
MOUNTING
7/8 turn
MARK
Numberwhen rubDer
sealis seated
Numberaftertightening.
Numberwhen rubber
sealis seated
Numberaftertightening 8
7
5
1
5
GAUGE
OIL PRESSURE
(Commerciallv
available)
1
CAUTION:Using any procedureother than those
shown could rosult in serious engins damage due
to oil leakage
5.
ADAPTER
(1/8\28. BSPTI
availablei
{CommerciallY
8
fill the enginewith oil up to the specAfterinstallation.
run
the
enginefor more than three minutes,
level,
ified
then checkfor oil leakage
Startthe engine.Shut it off immediatelyif the gauge
registersno oil pr€ssure.Repairthe problembefore
continuing.
Allow the engineto reachoperatingtemperature(tan
The pressureshouldbe;
comeson at leasttlivice).
EngineOil Temperature:176"F(80"C1
EngineOil Pressulo:
69 kPa (0.7 kgf/Gm'.10 Psi)
At ldle:
minimum
At 3.000rpm: 3/UtkPa (3.5 kgt/cm', 50 psi)
minimum
replace
lf the oil Dressureis within specifications,
recheck.
and
pressure
switch
the oil
. lf the oil pressureis NOT within specifications,
inspectthe oil pump (seepage8-10).
.
8-9
OilJet (B1642engine)
Inspection
1 . Removethe oil jet (seepage 8-3) and inspectit as
follows.
M a k es u r et h a t a 1 . 1m m ( 0 . 0 4i n ) d i a m e t e dr r i l l
will go throughthe nozztehole (j.2 mm (0.05in)
diameter).
Insertthe other end of the same 1.1mm (0.04in)
d r i l l i n t o r h e o i l i n t a k e( i . 2 m m ( 0 . 0 5i n ) d i a m e _
ter).
M a k e s u r e t h e c h e c kb a l l m o v e ss m o o t h l ya n d
hasa strokeof approximately4.0 mm (0.16in).
Checkthe oil jet operationwith an air nozzle.lt
shouldtake at least200 kPa (2.0kgf/cm,,28 psi)
to unseatthe checkball.
NOTE: Replacethe oil jet assemblyif the nozzle
rs damagedor bent.
1.2 mm (0.05inl
1 6 N . m1 1 . 6k g f , m ,t 2 t b f . f i l
CHECKBALL
SPRING
Mounting torque is critical.Be very precisewhen
installing.
Torque:16 N.m (1.6kgt.m,12 tbt.ft)
8-10
Oil Pump
Overhaul
NOTE:
. Use new O ringswhen reassembllng.
. Apply oil to O-ringsbeforeinstallation.
. Useliquidgasket,PartNo. 08718- 0001or 08718 0003
. The rotorsmust be installedto the samedirectionin order'
checkthat the rolors move without binding'
o After reassembly,
B15A2engine:
6x1.0mm
7 N.m (0.7 kgf m, 5 lbf ft)
ROTOR
OUTER
page8-13
Inspection,
INNERROTOR
page8-13
O-RING
Replace.
OOWEL
PIN
6x1.0mm
1 1 N . m( 1 . 1kgf.m,
8 tbtfrl
PUMPHOUSING
page8-13
Inspection,
Applyliquidgasket
to the matingsurfaceof
the cylinderblock
when installing.
RELIEFVALVE
Valve mlst slide freeiy
in housingbore.
Replaceif scored.
SEALINGBOLT
39 N.m l4Okgt'm,
29 tbt frl
\
8 x 1.25mm
24 N,m {2.i1kgl.m.
17 tbf.ft)
OIL SEAL
Replace.
p a g e8 - 1 4
lnstallation,
SPRING
(cont'd)
8-11
O il P u mp
Overhaul(cont'dl
(
NOIE:
. U s en e w O r i n g sw h e n r e a s s e m b l i n g .
. Apply oil to O rings beforeinstalraUon.
. U s el i q u i dg a s k e tP, a r rN o .0 8 7 1 8- 0 0 0 1o r 0 8 7 1 8 _ 0 0 0 3 .
. The rotorsmust be installedto the samedirection.
. After reassembly,
checkthat the rotorsmove without binding.
6x1.0mm
7 N.m (0.7kgI.m, 5 lbf ftl
D16Y5,D16Y7,D16Y8engines:
PUMP HOUSING
I n s p e c t i o n ,p a g e 8 1 3
Apply liquid gasket
to mating surfaceof
the cylinder biock
when installing.
INNERROTOR
Inspectron,
page8 13
DOWELPIN
PUMPCOVEB
O-RING
_.feor,""
\
6x1.0mm
11 N.m {1.1kgf.m,8lbl.ft)
OIL SEAL
[".?li;:;"".
*,",,.rg
R E L I E FV A L V E
Valve must slide freely
i n h o u s i n gb o r e .
R e p l a c ei f s c o r e d
""rc
@.-*or"."
9''ggttt*
8- 12
Removal/lnspection/lnstallation
1.
D r a i nt h e e n g i n eo i l .
2 . Turn the crankshaftand align the white groove on
the crankshaftpulleywith the pointeron the lower
cover.
3.
Removethe cylinderheadcoverand uppercover'
4.
Removethe power steeringpump belt, air conditioner beit and the alternatorbelt
5.
Removethe crankshaftpulleyand removethe lower
cover.
6.
Removethe timing belt.
1.
Removethe drive pulley.
8.
Removethe oil pan and oil screen.
OOWELPIN
1 0 . R e m o v et h e s c r e w sf r o m t h e p u m p h o u s i n g t, h e n
separatethe housingand cover'
1 1 . Checkthe inner-to-outerrotor radial clearanceon
the pump rotor.lf the inner-toouter rotor clearance
e x c e e d st h e s e r v i c el i m i t , r e p l a c et h e i n n e r a n d
outer rotors.
lnner Rotor-to-OuterRotor RadialClearance
Standard{New}:815A2engine0.04- 0.16mm
(0 002 - 0'006 in)
D16Y5,D16Y7,D16Y8engines
- 0.006in)
0.02- 0.14mm 10.001
ServiceLimit: 0.20 mm (0 008 inl
ROTOR
OUTER
O.RING
Replace
INNERROTOR
' t 2 . Checkthe housing-to-rotoraxial clearanceon the
pump rotor. lf the housing-torotor axial clearance
exceedsthe servicelimit, replacethe set of inner
and outer rotorsand/orthe pump housing
OILSCREEN
9.
! ' a
Housing-to-RotorAxial Clearance
Standard (N€w): 816A2 engine 0.02- 0.07 mm
(0.001- 0.003inl
D16Y5,D16Y7,D16Y8engines
0.03- 0.08mm (0.001- 0.003inl
in)
S€rviceLimit: 0.15mm 10.006
Removethe oil PumP.
(cont'd)
8-13
Oil Pump
RemovaUlnspection/lnstallation
(cont'dl
13. Checkthe housing-to-outer
rotor radialclearance.
l f t h e h o u s i n g - t o - o u t erro t o r r a d i a l c l e a r a n c e
exceedsthe service limit, replacethe set of inner
and outer rotorsand/orthe pump housing.
Housing-to-OuterRotor Badial Clearanco:
Standard{Newl:816A2sngine0.10- 0.19mm
(0.004- 0.007in)
D16y5,Di6y7, Dt6y8 engines
0.10- 0.18mm {0.00it_ 0.007in)
ServiceLimit: 0.20 mm (0.008in)
17. Reassemblethe oil pump, applyingthread lock to
the pump housingscrews.
18. Checkthat the oil pump turnsfreely.
19. Apply a light coatof oilto the seallip.
20. Installthe two dowel pins and new O-ringon the oil
pump.
21. Apply liquidgasketto the cylinderblockmatingsur_
faceof the oil pump.
NOTE:
. Use liquidgasket,PartNo.08718- oOOjor 08718
- 0003.
. Checkthat the matingsurfacesare cleanand dry
beforeapplyingliquidgaskel
. Apply liquidgasketevenly,in a narrowbeadcenteredon the matingsurface.
o To preventleakageof oil, apply liquid gasketto
the innerthreadsof the bolt holes.
. Do not installthe parts if five mtnuresor more
h a v e e l a p s e ds i n c e a p p l y i n g l i q u i d g a s k e t .
Instead.reapplyliquid gasketafter removingthe
old residue.
. After assembly,wait at least30 minutesbefore
fillingthe enginewith oil.
1 4 . lnspectboth rotors and pump housingfor scoring
or otherdamage.Replacepartsif necessary.
81642engine:
1 5 . Removethe old oil sealfromthe oil pump.
1 6 . Usingthe specialtool, gentlytap in the new oil seal
untilthe driverbottomsagainstthe pump.
NOTE:The oil seal alone can be replacedwithout
removingthe oil pump.
D16Y5,D16Y7,D16Y8engines:
alongthe brokenline.
DRIVERATT
52x55mm
077a6- 0010ao0
8-14
PUMP HOUSING
\
22. Installtheoil pump on the cylinderblock.
Apply greaseto the lip ot the oil pump seal.
Then.installthe oil pump onto the crankshaft.
Whenthe pump is in place,cleanany excessgrease
off the crankshaftand checkthat the oil seal lip is
not distorted.
lnstallthe oil screen.
Installthe oil pan (seepages7-26or 7-27).
NOTE:Cleanthe oil pan gasketmatingsurfaces.
81642engine:
8 x 1.25mm
24 N.m (2.i4kg[.m,
17 tbl.trl
6x1.Omm
11 N.m {1.1 kg{.m,
8 rbt ft)
O.RI G
Replace.
DOWELPINS
GASKET
Replace.
OIL SCREEN
6x1.0mm
rl N.m {1.1kgf'm,
I tbf.ftl
D16Y5, D16Y7. D16Y8 enginos:
6x1.0mm
1 1 N ' m( 1 . 1k g fm '
OOWELPIN
DOW€LPIN
GASKET
Replace.
O.RING
Replace.
6 x 1.0 mm
11 N.m (1.1kgf.m,
8 lbf.ft)
6x1.0mm
'11N'm {1 1 kgf'm,
I lbf ftl
! o
8-15
lntakeManifold/ExhaustSystem
lntakeManifold
9-2
.......................................
Replacement
ExhaustManifold
9-6
....................................".
Rep|acement
ExhaustPipeand Muffler
9-9
...............................'.'."..
Replacement
ThreeWay CatalyticConverter{TWCI
9-12
.................."'.
Inspection
HeatedOxygenSensor(HO2SI
9-12
...........................'.."....."
Rep|acement
r fo
L_s
IntakeManifold
Replacement
NOTE:Usenew O-ringsand gasketswhen reassemblinq.
CAUTION:
. Checktor folds or scratchoson the surfaceof tbe gasket.
. Replacewith a now gasket if damaged.
D16Y7engine:
8 x 1.25mm
22 N.m 12.2kgtm, 16 tbtftl
INTAKEMANIFOLD
Replaceif crackedor
if mating surfacesare
damaged.
8 x 1.25mm
23 N.m {2,3 kgt m.
17 rbf.ftl
INTAKEMANIFOLD
BRACKET
8 x 1.25mm
24 N.m {2.4kgf.m, 17 tbf.ftl
9-2
D16Y5engine:
6x1.0mm
12 N'm (1.2kgl.m,8.? lbf'ft)
EGRCHAMBER
INIAKE MANIFOLD
Replaceif crackedor
if mating surfacesare
8 x 1.25mm
21 N m (2.1kgf.m,
15 tbtft)
damageo,
GAS
EXHAUST
RECIRCULATION
(EGRIVALVE
INTAKEAIB CONTROL
(IAC)VALVE(M/TI
8 x'1,25mm
22 N.m (2.2kst m, 16lblftl
8 r 1.25mm
2a N.m (2.4kgt m,
17 rbt.ft)
INTAKEMANIFOLD
BRACKET
8 x 1.25mm
23 N.m 12.3kgf'm,
17 tbt fr)
I
8 x 1,25mm
22 N.n 12.2kol'm,
16tbftr)
(cont'd)
9-3
lntake Manifold
Replacement(cont'dl
NOTE:Usenew O,ringsand gasketswhen reassembling.
CAUTION:
. Checklor folds or scratcheson the surfaceof the gasket.
. Replacewith a new gasket il damaged.
D16Y8engine:
INTAKEMANIFOLD
Replaceif crackedor
if matingsurfacesare
oamageo,
INTAKEAIR CONTROL
{ract vAt_vE {M/Tl
GASKET
Replace.
THROTTLE
BODY
8 x 1.25mm
24 N.m {2.{ kgtm.
17 tbtftt
9-4
INTAKEMANIFOLD
BRACKET
8 x 1.25mm
22 N.rn |.2.2kgl.rn,
16 tbtft)
816A2engine:
INTAKEMANIFOLD
Replaceif crackedor
if matingsurfacesare
oamageo,
o
t_-l
8 x 1.25mm
22 N.rA 12.2kgl.trr,
16 tbtftt
UH
E
n ""\--
VlCd>-^
M\G
INTAKEAIR CONTROL
IIACIVALVE
8 x 1.25mm
24 N.m 12.4kgf.m,
17 tbtftl
MANIFOLD
BRACKET
8 x 1.25mm
23 N.m {2.3 kg{.m,
17 tbt.ftl
Al N-m 12.2kgt.m,
16 tbt.ftl
yo
9-5
ExhaustManifold
Replacement
NOTE:Use new gasketsand self-locking
nuts when reassembling.
CAUTION:
. Checkfor folds or scratch€son the surfaceof the gasket.
. Replacewith a new gasket it damaged.
D16Y5.D16Y7engines:
I x 1.25mm
24 N.m {2.4kgt.m, 17 tbtft}
PRIMARYHEATED
OXYGENSENSOR
IPRIMAFYHO2SI
44 N.m {4.5kgf m, 33 lbtft)
page9-12
Replacement,
GASKET
Replace.
I x 1.25mm
31 N.m (3.2kgf.m,
23 tbf.ft)
Beplace.
WAY CATALYTIC
CONVERTER
{TWCI
page9'12
lnspection,
6x1.0mm
11 N.m {1.1kgt m,8 lbf.ft)
9- 6
MANIFOLD
BRACKET
SECONDARYHEATED
OXYGENSENSOR
(SECONDARY
HO2S}
44 N.m 14.5kgf.m,33 lbf.ft)
page9-13
Replacement,
D15Y8engine:
8 x 1.25mm
2,1N.m (2.akgf'm,
17 tbf.ftl
GASKET
Replace.
8 x 1.25mm
31 N.m 13.2kgf'm,
23 lbf.ftl
Replace.
PRIMARYHO2S
44 N.m (4.5kgf.m,33 lbtft)
page9-13
Replacement,
EXHAUSTMANIFOLD
BRACKET
10 x 1.25rnm
/r4 N.m {4.5kgf.m,33 lbf.ft)
v
(cont'd)
9-7
ExhaustManifold
(cont'dl
Replacement
NOTE:Usenew gasketsand self-lockingnutswhen reassembljng.
CAUTION:
. Checkfor folds or scratcheson the surfaceot the gask€t.
. R€placewith a new gaskot if damagod,
B16A2engine:
GASKET
Replace.
SELF.LOCKING
NUT
8 x 1.25 mm
31 N.m (3.2 kg{.m,23 lbf.ft)
Replace-
10 x 1.25mm
44 N.m {4.4kgt.m,
33 tbl.ft)
EXHAUSTMANIFOLD
BRACKET
10x 1.25mm
4{ N.m (4.5 kgf.m.33 tbt.fil
9- 8
Exhaust Pipe and Muffler
Replacement
nutswhen reassembling
NOTE:Use new gasketsand self-locking
D16Y5,D16Y7engines:
PIPE
TIP
EXHAUST
MUFFLER
/
O
6x1.0mm
9.8 N.m 11.0kgt m, 7.2 lbf'ftl
HEATSHIELO
6x1.0mm
9.8 N.m tl.0 kgf'm,7.2lbf'ft)
oP----------------
8 x 1.25mm
22 N.m 12.2kg .m,
16 tbf.f
Replace.
Tighlenthe boltsin
steps,alternating
sideto-side.
EXHAUSTPIPEB
8 x 1.25mm
22 N.m 12.2kgl'm, 16lbl'ttl
Replace.
Tighten the bolts in steps,
alternatingside-to-side
----------"+@
neOlace.
NUT
SELF.LOCKING
10 x 1.25mm
33 N.m (3.4ksd.m,
25 lbf.frl
Replace.
\
GASKET
Replace.
NUT
SELF-LOCKING
8 x 1.25mm
16 N.m 11.6kgt m, 12 lbt'ftl
Replace.
(cont'd)
9-9
ExhaustPipe and Muffler
Replacement{cont'dl
NOTE:Use new gasketsand self-locking
nuts when reassembling.
D16Y8engine:
MUFFLER
d'*'ou"'"'""'
6x1.0mm
9.8N.m (1.0ksf m,7.2lbf ft)
8 x 1.25mm
22 N.rn 12.2kgl.m,
16 tbt.ft)
Replace.
Tightenthe boltsin
steps,alternatrng
side-to-side.
HEATSHIELD
6x1.0mm
9.8 N.m (1.0kgl m, 7.2 lbf.ft)
NUT
SELF.LOCKING
10 x 1.25mm
33 N.m {3.4kgf.m,
25 tbtftl
Replace.
EXHAUSTPIPE
SECONDARY
HO25
44 N.m {4.5kgl.m, 33 lbtftl
page9-10
Replacement,
TWC
page9-12
inspection,
GASKETS
Replace.
I x 1 - 2 5m m
22 N m (2.2 kgf.m. 16 lbfft)
EXHAUSTPIPEA
e)
SELF-LOCKING
NUT
1 0x 1 . 2 5m m
54 N.m {5.5kgl.m, 40 lbtft}
Replace.
9-10
1 6 N . m { 1 . 6k g l . m , 1 2 l b f . f t }
Replace-
GASKET
Heplace.
Tighten the bolts in steps,
a l t e r n a t i n gs i d e ' t o s a d e .
816A2 engino:
MUFFLER
-/-
_.,. EXHAUSTPIPE
tlP
g
GASKET
Replace.
\6r1.omm
9.8N m 11.0kgf'm,7.2lbl'ttl
8 x 1.25mm
2. N'm 12.2kgl-m,
t6 tbtf0
Replace.
Tighten the bolts in
steps,alternatrng
side-to-side.
6x1,0mm
9,8 N.m 11.0
7.2lbl4rl
NUT
SELF-LOCKING
l0 x 1.25mm
3:t N.m {3.4 kgf m,24lbf'ftl
ReDlace.
PRIMARYIIEATED
OXYGENSENSOR
{PRIMARYHO2S)
ll N.m (4.5kgl.m,
33 tbt f0
SECONDARY
HEATED
OXYGENSENSOR
HO2SI
{SECONDARY
lrt N.m 14.5kgf.m,
33 rbl.ft)
page9-13
Replacement,
Replacement,
GASKET
R€place.
twc
page9-12
Inspection,
GASKEIS
Replace.
NUT
SELF.L(rcKNG
10x 1.25mm
5,r N.m 15.5kgf.m, ,|{} lbf.ft)
ReDlace.
8 x 1.25mm
16 N.m 11.6kgt.m,
12 rbf.ft)
F€pl8ce.
Replaca.
8x1.25mm
22 N.m {2.2 kgt m, 16 lbf.ftl
Replsce.
Tight6n the bolts in st6ps,
alternatingside-to-side.
I
9-11
TWC
HO2S
Inspection
Replacement
l.
PrimaryHO2S:
Usinga flashlight,makea visualcheckfor plugging,
meltingand crackingof the catalyst.
1.
D16Y5,D16Y7engines:
Removethe primaryHO2S.
D16Y5,D15Y7engines:
a.
a
D i s c o n n e ct ht e p r i m a r yH O 2 Sc o n n e c t o rt ,h e n
removethe cover.
8 x ' 1 . 2m
5m
24 N.m{2.4kgl.m,
A
PRIMARYH02S
CONNECTOR
816A2,D16Y8engines:
FLASHLIGI{T
b.
-\
6{
-)\
lT
Removethe primaryHO2S.
| \l,l(
I bK/l
l llw.
(
/\\
PBIMARYHO2S
44 N m (4.5kgf.m,33 tbI.ft)
9- 12
Bt6A2, Dl6Y8 engines:
a.
Disconnectthe primary HO2Sconnectorthen
removethe primaryHO2S.
816A2engine
Secondsry H02S:
1.
Removethe secondaryHO2S
Dl6Y5, Dt6Y7 engines:
a.
D i s c o n n e c t h e s e c o n d a r yH O 2 Sc o n n e c t o r .
then remove the secondaryHO2S'
02 SENSOR
PRIMARY
H02S CONNECTOR
D16Y8engine
816A2, Dt6Y8 ongin6s:
a.
Removethe grommet,and pull out the secondary
HO2Sconnector,then disconnectthe secondary
HO25connector'
H()2S
SECONOARY
CONNECTOR
PRIMARYHO2S
44 N.m {4.5kgt'm.33 lbf'ft)
L
2.
Installthe primary HO2Sin reverseorder of removal'
{cont'd)
9-13
HO2S
(cont'd)
Replacement
b,
Removethe secondarvHO2S.
02 SENSORWRENCH
SECONOARY
HO2S
4,r N.m (4.5kgf.m, 33 tbf.ft)
I n s t a l lt h e s e c o n d a r yH O 2 S i n r e v e r s eo r d e r o f
removat.
9- 14
w a
Cooling
""' 10-2
fllustratedIndex."..."...
Radiator
10-6
.'....'...."..."
Replacement
EngineCoolantRefillingand
10-7
Bleeding
10-9
CapTesting
10-9
Testing
Thermostat
10-10
.............'....
Replacement
10-10
Testing
EngineGoolantTemPerature
(ECT)Switch
""" 10-11
Testing
WaterPumP
" 10-12
Index ......'...
fffustrated
' 10'14
Inspection
10-14
..'..'...."...'.'....'..'.....'."""
Replacement
!
lllustrated Index
system is under high pressure when the
@@
engine is hot. To avoid dangsr of rsleasing scalding
engine coolant, removo the cap only when the engine is
coot.
Total Cooling System Capacityflncluding heater and
foservoir (0.4f (0.42US qt, 0.35 tmp qt)ll:
Mt-|-
4 . 2 f ( 4 . 4U S q t , 3 . 7 t m p q t ) * j
5.0 / (5.3 U$ q1, 4.4 16p q11*z
CAUTION:lf any engine coolant spills on painted portions of the body, rinse it off immediately.
NOTE:
. Checkall cooling systemhosesfor damage,leaksor
deterioration
and replaceif necessary.
. Checkall hoseclampsand retightenif necessary.
. Usenew O-ringswhen reassembling.
4 . 1f ( 4 . 3U S q t , 3 . 6l m p q 0 * 3
4.31 (4.5US qt, 3.8 tmp qt)*a
CVT
4 . 3f ( 4 . 5U S q t , 3 . 8I m p q t )
*1i D16Y5,D16Y7,D16Y8engines
*2: 81642engine
*3: D16Y7engine
* 4 : D 1 6 Y 8e n g i n e
UPPER
RADIATOR
HOSE
5x0.8mm
A: ,1.4N.m {0.45kgf.m, 3.3 tbtftl
g: 5.4N.m (0.55kgtm.4.0 tbf.ft)
RADIATORCAP
Pressure
test,page'108
RAOIATOR
Enginecoolantrefillingand bleeding,
p a g e1 07
Leaktest,page10-9
Inspectsolderedjointsand
seamsfor leaks,
Blow out dirt Irom between
6x1.0mm
9.8 N.m {1.0kgtm,
7.2 tbt.ltl
UPPERBRACKET
AND CUSHION
COOLANT
RESERVOIR
core fins with compressed air.
l f i n s e c t s ,e t c , , a r e c l o g g i n g
r a d i a t o r ,w a s h t h e m o f f w i t h
r o w p r e s s u r ew a t e r .
iil
6x1.0mm
7.2 N.m (0.73kgt.m,
5.3 tbtftl
RADIATORFAN
FAN MOTOR SHROUD
BADIATOR
FAN
DRAIN
PLUG
Referto section14
when installing.
Ar TOYORADIATOR
manufacturedradiator
B: NIPPONDENSO
manufacfared
raoraror
10-2
O-RING
Replace.
LOWEB
RADIATOR
HOSE
LOWER
CUSHION
Engine HoseConnections:
D15Y7engine:
IAC VALVE
WATEFBYPASS
THERMOSTAT
HOUSING
lv
CONNECTING
PIPE
HEATER
HOSES
VALVE
{cont'd)
10-3
lllustrated Index
(cont'd)
EngineHoseConnections:
D16Y5,D16Y8engines:
IACVALVE
{A/T)
Replace.
WATERBYPASS
HOSE
IAC VALVE
(M/TI
THERMOSTAT
HOUSING
O.RING
Replace.
\
\
\
\
h
CONNECTING
PIPE
HEATER
VALVE
HEATER
HOS€S
10-4
Engine Hose Conneqtions:
81642engine:
THERMOSTAT
HOUSING
CONNECTING
PIPE
O-RING
Replace.
b
WATERBYPASS
HOSE
ENGINEOILCOOLER
HEATER
VALVE
HEATER
HOSES
10-5
Radiator
Replacement
1 . Drainthe enginecoolant.
2.
5.
R e m o v et h e u p p e r a n d l o w e r r a d i a t o rh o s e s ,a n d
ATFcoolerhoses.
3. Disconnectthe fan motor connector.
Removethe radiatorupper bracket,then pull up the
raotator,
RADIA
CAP
Removethe fan shroud assembliesand other parts
from the radiator.
Installthe radiatorin the reverseorderof removal:
NOTE:
. Setthe upperand lower cushionssecurely.
. F i l l t h e r a d i a t o rw i t h e n g i n ec o o l a n ta n d b l e e d
the air.
Y|lT,PS:|"
AND
CUSHION
6x1.0mm
i.i ru-ii brgr.-,
7.2tbr.ftl
ATF COOLER
HOSES(A/T)
Referto section1 4
when installing.
UPPERRAOIATORHOSE
6x1.0mm
7.2 N.m (0.73kgf.m.
5.3 tbf.ft)
,iiiiii
(
RESEBVOIR
TANK
I
RADIATOR
RAOIATORFAN/SHROUD
ASSEMBLY
LOWERCUSHION
DRAINPLUG
O-RING
Replace.
LOWER RAOIATOR HOSE
ATFCOOLER
PIPES{A/T)
10-6
EngineCoolantRefillingand Bleeding
B1642 engin€:
CAUTION:when pouring engine coolant, be sure to
shut the relay box lid and not to lst coolant spill on the
eleqtricalparts or the paint. lf any coolant spills, rinse it
off immediately.
1.
WASHER
Replace.
Slide the heatertemperaturecontrol leverto maxlmum heat. Make sure the engine and radiatorare
cool to the touch.
Removethe radiatorcaP.
Loosenthe drain plug,and drainthe coolant'
DRAINPLUG
DRAINBOLT
78N m (80 kgfm' 58lbfft)
Apply liquid gasketto the drain bolt threads,then
reinstallthe bolt with a new washer and tighten 't
securely.
tl
6.
Tightenthe radiatordrain plug securely
1.
Remove,drain and reinstallthe reservoir'Fill the
tank halfwayto the MAX mark with water, then up
to the MAX mark with antitreeze.
Removethe drain bolt from the cylinderblock'
D16Y5.D16Y7,Dl6Yg sngines:
0d
78 N.m {8.0kgl m.58lbt'ft)
I ro
MAX MARK
(cont'd)
10-7
Radiator
EngineCoolantRefiltingand Bleeding(cont,dl
\.8.
M i x t h e r e c o m m e n d e da n t i f r e e z ew i t h a n e o u a l
amountof water in a cleancontainer.
9. Pourcoolantinto the radiatorup to the baseof the
filler neck.and installthe radiatorcap looselv.
NOTE:
o Useonly genuineHondaantifreeze/coolant.
. For best corrosion protection.the coolant con_
c e n t r a t i o nm u s t b e m a i n t a i n e dy e a r _ r o u n da t
50% minimum.Coolantconcentrations
lessthan
50% may not provide sufficient protection
againstcorrosionor freezing.
. C o o l a n tc o n c e n t r a t i o n gs r e a t e rt h a n 6 0 0 1w0i l l
i m p a i r c o o l i n g e f f i c i e n c ya n d a r e n o t r e c o m _
mended.
CAUTION:
. Do not mix difforont brands ofar ilreeze/coolants.
. Do not use additional rust inhibiiors or anti_rust
produqt3; they may not be compatible with the
coolant.
Engine Coolent Refi Capacity Iincluding reservoir
{0.4f 10.42US qr, 0.35 lmp qt),I;
M/r
Att
CW
3.8f {4.0US qt, 3.3 lmp qt)*1
4.5/ (4.8US qt. 4.0 tmp qt)*,
3 . 7 , ( 3 . 9U S q r , 3 . 3t m p q t ) . 3
3 . 9/ ( 4 . 1U S q t , 3 . 4 l m pq t ) * .
3 . 9/ ( 4 . 1U S q t , 3 . 4t m pq t l
*1: D16Y5,D16Y/,O16Y8
engines
*2: 81642engine
*3; Dl6Y7 engine
*4: Dl6Y8 engine
10-8
1 0 . Startthe engineand let it run until it warms up (the
radiatorfan comeson at leasttwicer.
1 1 .Turn off the engine.Checkthe level in the radiator.
add coolantif needed.
Put the radiatorcap on tightly,then run the engine
againand checkfor leaks.
I
Testing
CapTesting
1.
Removethe radiatorcap, wet its seal with engine
coolant,then installit on the pressuretester'
TESTER
PR€SSURE
RADIATOR
(CommerciallY
available)
RAOIATOR
L
Wait until the engineis cool, then carefullyremove
t h e r a d i a t o rc a p a n d f i l l t h e r a d i a t o rw i t h e n g i n e
coolantto the top of the tiller neck
Attachthe pressuretesterto the radiatorand apply
'123kPa(0.95- 1.25kgflcm' ,14 a pressureof 93 1 8p s i l .
ADAPTOR
(for32 mm neck,low Profile)
PRESSURE
RADIATOR
TESTER
available)
lCommerciallY
ADAPTOR
(for32mm neck'lowPro{ile)
Apply a pressureof 93 - 123kPa (0.95
1 4 1 8p s i ) .
'l 25 kgflcm''
Checkfor a drop in Pressure.
lf the pressuredrops,replacethe cap
Inspectfor enginecoolantleaksand a drop In pressure.
Removethe testerand reinstallthe radiatorcap
NOTE: Checkfor engine oil in the coolant and/or
coolantin the engineoil.
I
t
10-9
Thermostat
Replacement
NOTE:Usea new O-ringwhen reassemblinq.
THERMOSTAT
Install
withpinup.
THERMOSTAT
THERMOSTAT
HOUSING
ENGINECOOLANT
TEMPERATURE
{ECT)
swtTcH
24 N.m {2.4kgf.m, t7 tbf.ft)
10-10
6x1.0mm
12 N.m {1.2kgf.m,8.7tbf.frl
EGTSwitch
Testing
Testing
Replacethe thermostatif it is openat room temperature'
To test a closedthermostat:
1,
Suspendthe thermostatin a containerof water as
shown.
Romovingthe EcT swhch while lhs engine
!!@
i!-ot can causethe coolant to sPrayout, seriouslyscalding you. Always lst th€ ongine and rediator cool down
before removing ihe ECTswitch.
NOTE:Bleedair from the coolingsystemafter installing
the ECTswitch (see Page10-7)
1.
Removethe ECTswitchfrom the thermostathousing (seePage'10-10).
2.
Suspendthe ECTswitch in a containerof water as
shown.
THEBMOMETER
THERMOSTAT
-f
Heat the water, and checkthe temperaturewith a
thermometer.Checkthe temperatureat which the
thermostatfirst opens,and at which it is fully open
Heat the water, and checkthe temperaturewith a
thermometer.
CAUTION: Do not let the thermometer touch the
bottom of the hot Gonlainel.
CAUTION: Do not let the thermomoter touch tho
bottom of the hot container'
Measure lift height of the thermostat when fully
open.
STANDARDTHERMOSTAT
above 8.0 mm (0.31inl
Lift height
Starts opsning: 169' - 176'F (76' - 80'Cl
194'F {90"C1
Fully open:
4.
Measurethe resistancebetweenthe A and B terminalsaccordingto the table.
Terminal
Oo"rffi
196' - 203"F
ON (91"- 95'C)
swlTcH
o- -o
5" - 15'F{3" - 8'C)
OFF lower than the temPerature when t goeson
! ' o
1 0 - 11
Water Pump
lllustratedIndex
NOTE:
. Use new O-ringswhen reassembrrng.
. Use liquidgasket,PartNo. 08718- 0OOlor 087t8 _ 0003.
O16Y5,D16Y7,D16Y8engines:
ECTGAUGE
SENDINGUNIT
9 N.m {0.9 kgI.m,
7 tbnftl
Apply liquidgasket
to the threads.
ENGINECOOLANT
TEMPERATURE(ECT)
SENSOR
1E N.m (1,8 kgf.m,
13 rbttt)
6 x 1 . 0m m
9.8N.m {1.0kgf.m,
7.2 tbt.ft'|
O.RING
Replace.
WATEROUTLET
COVER
Apply liquidgasket
to matingsurface.
ECTSW1TCH
24 N.m 12.4kgf.m,
17 rbf.ftl
6xl.0mm
12 N.m {1.2kgf.m,
8.7 tbf.ft)
6x1.0mm
'12N.m
{1.2 kgt m,
8.7 lbt fr)
10 x 1.25mm
itl N.m 14.5kgt m,
33 rbf.ftl
O.RING
Replace.
10-1 2
815A2 engine:
WATEROUTLET
COVER
Apply liquidgasket
to matingsurface.
6x1.0mm
9.8 N.m {1.0 kgl'm,
7,2 tbl.ftt
ECTGAUGE
SENDINGUNIT
9 N.m (0,9 kgf.m,
7 rbf.ft)
Apply liquidgasket
to the threads.
r
ENGINE
COOLANT
(ECT)
TEMPERATURE
SENSOR
18 N.m {1.8 kgf.m,
13 tbtftl
6x1.0mm
12 N.m (1,2kgdm,
8.7 tbf.ftl
16@
aY@
t"
\lo
S X 1.0 Mrf
iiil:i'iij
WATENPUMP
rnr..,
pase10'1'r
Inspection,
8.7 tbf.ftl
10-13
Water Pump
Inspection
Replacement
't. Remove
the timing belt (seesection6).
1.
Removethe timing belt (seesection6).
2. T u r n t h e w a t e r p u m p p u l l e yc o u n t e r c l o c k w i s e .
Removethe water pump by removingfive bolts.
Checkthat it tarnsfreely.
Checkfor signsof sealleakage.
NOTE:Inspect,repairand cleanthe O-ringgroove
and matingsurfacewith the cylinderblock.
NOTE:A smallamountof "weeping,,fromthe bleed
h o l ei s n o r m a l .
D16Y5,D16Y7,D16Y8engines:
Dl6Y5, Dl6Y7,D16Y8engines:
BLEED
HOLE
6x1.0mm
l0 x 1.25mm
{4 N.m14.5kg{.m.
33 tbt.ft)
Bl642 engine:
12N.m{1.2kgf.m,
8.7lbt.ft)
WATER
PUMP
BLEEDHOLE
B16A2engine:
BLEEDHOLE
d
orp,
I
@;2
6x1.0mm
12 N.m 11.2kg{.m,
8.7 tbf.ft)
O.RING
Replace.
3. Installthewaterpumpin the reverse
orderof removal.
NOTE:
o KeeptheO-ringin position
wheninstalling.
BLEEDHOLE
10-14
.
Clean the spilled engine coolant.
Fuel and Emrsslons
ldle Control System
.....,...."..,.11-2
SoecialToofs
11-190
............
SystemDoscriplion
Component Locations
Flowcharts
Troubleshooting
. . . . . . .1. .1 - 3
l n d e x. . . . . . . . . . . . . . . . . . . . . ,
......11-192
ldle ControlSystem
Svstem Description
I 1-19i1
Va1ve
....................................
ldle
Air
Control
.........
11-12
................,,..,..
VacuumConnections
11'202
StarterSwitch Signal ....................................
.......11-29
ElectricalConnections...............,.,.,...
11'201
Air ConditioningSignal .................................
S y s t e mC o n n e c t o r .s. . . . . . . , . , . , . . . . . . . . . . . . . .1.1. .-.5. .1. . . . . .
. 11-208
AhernatorFRSignal ....................................
Troubleshooting
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.f. .1.". 2
. .1. .0. . .
S
i
g
n
a
l
B
r
a
k
e
S
w
i
t
c
h
1
1
8
1
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
T r o u b l e s h o o t i nPgr o c e d u r e s
Power Sleering ProssureSwitch Signal ......11-212
EngineControlModule/Powertrain
11-216
ControlModuleTerminal
A/T GearPositionSignal...............................
11-88
....,.,.....
Afiangement
11-214
ClutchSwiich Signal ................................-....
11.97
DiagnosticTroubleCodeChart .................,.,
.............11-220
ldteSpeedSetting.
. 11-103
How to ReadFlowcharts.,..........................
PGM-FlSystem
!
Fuel Supply System
.,...................,.,.,.,11-221
FuelLines
......11-10,1 FuefTube/Ouick-Connect
SystemDescription
11-227
Fittings..........,.,........
TroubleshootingFlowcharts
....'.... 11-230
SystemDescription
EngineControlModule/Powertrain
11-230
.......,.,,...........
FuelPressure
........11-107
Contlol Module
......................11-232
Fueffniectors
ManitoldAbsolutePressureSensor.....'.. ... 11-115
11-231
Fu€fPressureRegulator.....,.......................'...,.
. 11'121
fntakeAir TemperatuieSensor ...... . .,
............................11-235
FuefFifter
Sensol.........,11-128
EngineCoolantTemperatuae
. . . . . . . . . . . . . ' . . . . .1. .1' .-.2. .3 6
F u e lP u m p
11-132
ThrottlePositionSensor ...................,...........
.............11'237
Relay
PGM-FI
Main
PrimaryHeatedOrygen Sensor(Sensor1l ... 11-139
....,...'.'.'
11'211
FuelTank ................
SecondaryHeatedOxygen Sensor
( S e n s o2r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. .1. -. 1
5
3
..............
IntakeAir System
11-157
HeatedOxygenSensorHeater ...................,.
....-.-.....11-243
SystemDescription
......11-164
FuelSupplySystem
.11-211
...........,......."".
Air
Cfeaner
. . . . . . ..,. 1 1 - 1 6 6
R a n d o mM i s l i r e
.....................11-211
Throttle
Cable
11-167
MisfireDetectedin One Cylindsr .................
..'.... . .,.11-211
. , . , . . . . . . . .1. 1
. .-. 1 7 0 ThrottfeBody ........
K n o c kS e n s o r
11-250
,.,.,....-...........
Air
Control
System
Fuel
Iniestion
11'172
Sensor...................................
CKP/TDC/CYP
1t-176
VehicleSpeedSensor...........,......,...,.,...........
Emission Control System
I 1-178
BarometricPressureSensor ...............,.........
.-..........11-252
Description
System
E l e c t r i c aLlo a dD e t e c t o r , . , , . . . . . . . . . . . . . . . . .1. .1. -. .1.7. .9. . .
...............11-252
Taifpip€
Emission
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
.
.
1
.
.
.
1
.
8
3
C K FS e n s o r
11-252
ThreeWay CatafyticConvert€r............,.,,.,.,.,....
I 1-188
ECM/PCMInternalCircuit .............................
11'254
...,.,,,,.,.,.,.,,.
System
Exhaust
Gas
Racirculaiion
I 1-189
A/T Signal{TMA/TMBI..................................
PositiveCrankcas€Ventilation System .... . . .. 11-266
11-267
EvaoorativeEmissionControls..................,,..,.,.
SpecialTools
\-
SpecialTools
R€f. No.
I
Tool Number
Dsscription
Oty
O
A973X_041_ XXXXX
VacuumPump/Gauge,
0 - 30 in.H9
I
@
/n
@
@
@
07JAZ- 0010008
- 0010100
07PAZ
07sAz- 001000A
07406- 0040001
07406- 0040304
Vacuum/Pressure
Gauge,0 - 4 in.Hg
SCSServiceConnector
BackprobeSet
FuelPressureGauge
FuelPressureAdapter,6x 15 mm
I
1
2
1
I
ta
1n
\Y
11-2
I
Pagr Reference
11-251,256,
257,
273,274, 283,284,
286, 288,289, 291,
294,296,297
11-294,295
11-81
11-83
1't-230,231,234
11-230
a
GomponentLocations
lndex
D16Y5engine:
THROTTLEPOSITIONITP)
SENSOR
page11-132
Troubleshooting,
EXHAUSTGAS RECIRCULATION
IEGRIVALVEand EXHAUSTGAS
RECIRCULATION
IEGRIVALVE
LIFTSENSOR
page'l1-254
Troubleshooting,
MANIFOLDABSOLUTE
PRESSURE
IMAPI SENSOR
page1'l-115
Troubleshooting,
(IAC)VALVE
IDLEAIRCONTROL
{M/T)
page11-194
Troubleshooting,
EXHAUSTGAS RECIRCULATION
{EGRICONTROLSOLENOID
VALVE ICW)
page11-254
Troubleshooting.
INTAKEAIR TEMPERATUR€
{IATISENSOR
Troubleshooting,
EMISSION
EVAPORATIVE
IEVAPIPUNGECONTROL
SOLENOIDVALVE
Troubfeshooting,Page11'211, 243
LOAD
ELECTRICAL
DETECTOR
IELD)(USA mod6l)
page11 179
Troubleshooting,
POWERSTEERINGPRESSURE
(PSP)SWITCH(USAI
Troubleshooting,
Page11-212
CRANKSHAFT
POS|TTON/
TOPDEADCENTER/
CYLINDER
POS|T|ON
SENSOR
ICKP/TDC/CYP}
(Builtintothe distributor)
KNoCK SENSoR(Ks)
(cwl
Troubleshooting,
Page11'170
T r o u b l e s h o o t i n g ,P a g e 11 ' 1 7 2
(CKF}SENSOR
FLUCTUATION
Troubleshooting,
Page11-183
VEHICLESPEEDSENSOR
Troubleshooting,
Page11-176
ENGINECOOLANT
TEMPERATURE
IECT)SENSOR
Troubleshooting,
Page11 128
IDT.E
CONTROLIIACIVALVE
{cw)
Troubleshooting,
Page11 198
WAY CATALYTIC
CONVERTER
ITWCI
PRIMARYTIEATED
Troubleshooting,Page 11-252
HO2SI
SENSOR
{PNIMARY
tsENsoR1t {M/Tl
Troubleshooting,
Page'l1-146
PRIMARYHEATEDOXYGEN
SENSOR(PRIMARYHO2SI
1l{cw}
tsENsoR
Troubleshooting,
Page11-139
L
HEATEDOXYGEN
SECONDARY
HO2S)
SENSOR{SECONDARY
{SENSOR2)
page11 153
Troubleshooting,
(cont'd)
11 - 3
Component Locations
Index(cont'd)
THROTTLEPOSITION{TPI
SENSOR
page11-132 MANIFOLOABSOLUTE
Troubleshooting,
PRESSURE
{MAPI SENSOR
INTAKEAIR TEMPERATURE
page11-115
Troubleshooting,
IIATISENSOR
Troubleshooting,
page11,124
IDI.EAIR CONTROLIIACIVALVE
lMtfl
ELECTRICAL
LOAD
Troubleshooting,
page11-194
DETECTOR
IELDI{USAI
EVAPORATIVE
page
EMISSION
Troubleshooting,
11-179
IEVAPIPURGECONTROL
SOLENOIOVALVE
CRANKSHAFT
Troubleshooting,page 11 271. 283
POSTTTON/
TOPDEADCENTER/
POWERSTEERINGPRESSURE
CYLINDER
(PSPISWTTCH|USA)
POStTtON
page11-212
Troubleshooting,
{CKP/TI'C/CYPISENSOR
(Builtinto the distributor)
KNOCKSENSORIKSI
Troubleshooting.
page11-172
page11 170
Troubleshooting,
D16Y8enginc:
CRANKSHAFT
SPEED
FLUCTUANONICKFISENSOR
Troubleshooting,
page11,183
IDI.E
{A/T)
CONTROL{IACIVALVE
page11 198
Troubleshooting,
ENGINE
COOLANT
PRIMARYHEATEDOXYGENSENSOR
TEMPERATURE
{PRIMARYHO2S}(SENSOR1l {'96 - 98 modolsl
{ECTISENSOR
page11-139
page11128 Troubleshooting,
Troubleshooting,
'96 - 98 modols:
'9!t 00 modols:
THREE
WAYCATALYNC
CONVERTER
ITWCI
page11-252
Troubl6shooting,
SECONDARY
HEATEDOXYGEN
SENSOn
(SECONDARY
HO2SI(SENSOR2I
page11-153
Troubleshooting,
11-4
SECONDARY
HEATEDOXYGEN
SENSOB
ISECONDARY
HO2S}ISENSOR2I
page11-155
Troubloshooting,
THREE
WAYCATALYNC
CONVERTER
ITWCI
page11-252
Troubleshooting.
PRIMARYHEATEOOXYGENSENSOR
IPRIMARYHO2SIISENSOR1I
page11-141
Troubleshooting,
D16Y7engine:
MANIFOLDABSOLUTE
(MAPI SENSOR
PRESSURE
Page11-115
Troubleshooting, r1-132 Troubleshooting,
THROTTLEPOSITIONITPI
SENSOR
(VSSI
SENSOR
SPEED
VEHICLE
1
1-176
Troubleshooting,
Page
LOAO
ELECTRICAL
(ELD)IUSA}
DETECTOR
Troubleshooting,
Page11'179
CRANKSHAFT
POSTTTON/
TOPDEADCENTER/
CYLINDER
POSITION
SENSOR
{CKP/TDC/CYPI
(Builtintothe distributorl
't
Troubleshooting,
Page 1-172
INTAKEAIRTEMPERATURE
IIATISENSOR
page11124
Troubleshooting,
PRESSURE
POWERSTEERll\lG
{PSP'SWTTCH
{USA)
Troubleshooting,
Page11 212
IDLEAIR CONTROL(IAC)VALVE
page11-198
Troubleshooting,
l
/i
CRANKSHAFTSPEED
FLUCTUATIONICKFISENSOR
Troubleshooting,
Page11-183
ENGINECOOLANT
TEMPERATURE
(ECTISENSOR
page11 128
Troubleshooting,
EMISSION
EVAPOBATIVE
(EVAPIPURGECONTROL
HEATEDOXYGEN
SECONDARY
HO2S)
SOLENOIDVALVE
SENSOR(SECONDARY
Troubfeshooting,page11 271, 283 (SENSOR2l
Troubleshooting,
Page11-153
PRIMARYHEATEDOXYGEN
SENSOR(PRIMARVHO2S)
{SENSOR1l
page11'139
Troubleshooting,
THNEEWAY CATALYTIC
CONVERTERITWCI
page11-252
Troubleshooting,
(cont'd)
tr
, l . l -r,
|
|
Component Locations
Index(cont'dl
MANIFOLOAESOLUTE
PRESSURE
IMAPI SENSOR
INTAKEAIR TEMPERATURE
page11-119
Troubleshooting.
IOLEAIR CONTROL{IAC)VALVE
SENSOR
{IAT}
Bl6A2 engine:
page11,196
Troubleshooting,
Troubleshooting,
page1'1-125
THROTTLEPOSITIONITPI
ELECTRICAL
LOAD
SENSOR
DETECTOR
IELDI(USA)
page11-134
Troubleshooting,
page11-180
Troubleshooting,
POWERSTEERINGPRESSURE
CRANKSHAfi
(USA)
{PSPISWTTCH
POStTtON/
page11-214
Troubleshooting,
TOP DEADCENTER/
CYLINDER
POStTtON
{CKP/TDC/CYPI
SENSOR
(Bualtintothe distributor)
Troubleshooting,
page11-174
VEHICLESPEEDSENSOR{VSS}
Troubleshooting,
page11-177
ENGINE
TEMPERATURE
IECTISENSOR
Troubleshooting,
pageI 1-128
CRANKSHAFT
SPEED
(CKFISENSOR
FLUCTUATION
Troubleshooting,
page11-t85
THREEWAY CATALYTIC
CONVERTER
ITWC)
Troubleshooting,
page11,252
S€CONOARY
HEATEDOXYGEN
sf rlsoR
sfCoNDARY HO2SI{SENSOR2)
: ? s h o o t r n pg a, g e1 1 1 5 5
1 1- 6
PRIMARYHEATEDOXYGENSENSOR
IPRIMARYHO2S)ISENSOR1I
Troubleshooting,
page11-141
CLUTCHSWITCHlDl6Y5 ongino
M,/TI
page11-218
Troubleshooting,
Sell-diagnosticProcedures.
p a g e1 18 1
'9!, - 0o modol3:
'96 - 98 modsls:
PGM.FIMAIN RELAY
RslayTesting,page11-237
page11-238
Troubleshooting,
PGM.FIMAIN RELAY
RelayTesting,pagel1 237
pago1'! 238
Troubleshooting,
I
CHECKCONNECTOR ENGINCCONTROLMOOUI.T
SERVICE
tzPl
(FCMI/POWERTRATN
Self-diagnostic Procedures,
page11-81
CONTROLMODULEIPCMI
page11-107
Troubleshooting,
CONNECTOR
SERVICE
l2Pl
Self-diagnosticProcedures,
page11-81
ENGINECONTROLMODU1T
(ECM}/POWERTRAIN
CONTROLMODULEIPCMI
page11 111
Troubleshooting,
{cont'd)
11-7
ComponentLocations
Index (cont'dl
'96 D16Y8engine(coupel,
'97 D16Y7engine(coupe:KL model,
sedan:KL (LXl model),
'97 D16Y8engine(coupe:
all models,sedan:KL modell,'98-allmodels:
FUEI-VAPORPIPE FUELGAUGESENDINGUNIT
FUEL FEEDPIPE
Testing,seesection23
FUELFILTER
Replacement,
FUELPUMP
Testing,page11 236
page11 236
Replacement,
FUELFILL
CAP
€VAPOFATIVEEMISSION
(EVAPICONTROLCANISTER
VENTSHUTVALVE
page l1'283
Troubleshooting,
EVAPORATIVE
EMISSION
IEVAPICONTROLCANISTER
page11 283
Troubleshooting,
FUEL
TANK
pageI l-241
Replacement,
EVAPORATIVE
EMISSION
IEVAP)BYPASSSOLENOID
VALVE
page11-283
Troubleshooting,
FUELINJECTORS
page11-232
Replacement,
EVAPORATIVE
EMISSION
(EVAPITWOWAYVALVE
page11294
Testing,
TANK PRESSURE
SENSOR
FUEL
REGULATOR
T r o u b l e s h o o t i n g ,p a g e 1 1 - 2 7 5
FUEL
Testing,page 11-234
R e p l a c e m e n t ,p a g e 1 1 - 2 3 4
FITTINGS
page11-227
Precautions,
page11 227
Disconnection,
page11-228
Connection,
'96 Dt6Y5engine,'96D16Y7engin€,'96
D16Y8engine(sedanl,
'97 D16Y5engine,'97 Dl6Y7 engins (coupe:
l(A, KC models,
sedan:KA, KC, KL (DXl models, hatchback:all models),
'97 Dl6Y8 engine (sedan:KA, KC modelsl:
FUEL
VAPORPIPE
FUEL FEEDPIPE
FUELFILTER
Replacement,
page11-235
EMISSION
EVAPORATIVE
IEVAPICONTROLCANISTER
page11-271
Troubleshootiog,
FUELPUMP
Testing,page11-236
page11-236
Replacement,
FUELTANK
page11 241
Beplacement,
TIVEEMISSION
{EVAP)TWO WAY VALVE
Testing,page11-294
TUBE/OUICK.CONNECT
FITTINGS
FUELPRESSURE
page11-227
Precautions,
REGULATOR
page11'227
Disconnection,
Testing, page 11'234
page11-228
Connection,
FUEL
RETURN
PIPE
p
a
g
e
Beplacement,
11 234
11-8
'99 - 00 models:
EMISSION
EVAPORATIVE
IEVAP}PURGECONTROL
SOLENOIDVALVE
page11'288
Troubleshooting,
FUEL FEEDPIPE
UNIT
FUELGAUGESENDING
Testing,seesection23
VAPOR
ONBOARDREFUELING
R€COVERY
IORVRI
FUELVAPORPIPE
VENT SHUTVALVE
Test,page11 296
FUELFILTER
page11-235
Beplacement,
FUEI-PUMP
page11236
Testing,
page11-236
Replacement,
EMISSION
EVAPORATIVE
{EVAP)CONTROLCANISTER
VENT SHUTVALVE
FUELFILL
CAP
T r o u b l e s h o o t i n g ,P a g e 11 _ 2 8 8
EVAPORATIVE EMISSION
{EVAPICONTROL
page11_288
Troubleshooting,
EMISSION
EVAPORATIVE
{EVAP)BYPASSSOLENOID
VALVE
page11-288
Troubleshooting,
FUEL
PULSATIONDAMPEB
FUELTANK PRESSURE
SENSOB
Troubleshooting,
Page11'274
FUEL
RAIL
EMISSION
EVAPORATIVE
IEVAPITWO WAY VALVE
Testing,page11 295
FUELINJECTORS
page11'232
Replacement,
FUELPRESSURE
REGULATOR
Testing,page11-234
page11 234
Replacement,
FUEL RETURNPIPE
R e p l a c e m e n t ,p a g e 11 - 2 4 1
I
FUELTUBE/OUICK.CONNECT
FITTINGS
page1l-227
Precautions,
page11 227
Disconnection,
page11-228
Connection,
(cont'd)
11 - 9
Component Locations
Index(cont'd)
D16Y5,D16Y8ongine:
AIR CLEANERIACLI
page11-244
Replacement,
THROTTLEBODY(TBI
page11-247
Inspection,
Removal,page11-248
page11 249
Disassembly,
THROTTLECABLE
page 11-244
lnspection/Adjustment.
page 11245
Installation,
RESONATOR
AIR {FIA}CONTROL
VAIVE
{'99 modeli
D16Y86ngin6)
Testing,page11,250
POSITIVECRANKCASE
VENTILATIONIPCV)VALVE
page11-266
Inspection,
D16Y76ngin€:
AIR CLEANERIACLI
page11,244
Replacement,
RESONATOR
11 - 1 0
POSITIVECRANKCASE
VENTILATIONIPCVIVALVE
page11-266
Inspection,
THROTTLECABIT
fnspection/Adjustment.
page11,244
page11-245
Installation,
.iBoov ffet
page11 247
Inspection,
Removal,page11,248
page11-249
Disassembly,
816A2 engine:
THROTTLEBODY{T8)
page11-247
Inspection.
Removal,page1'1-248
page11-249
Disassembly,
AIR CLEANER(ACLI
Replacement,
Page11-244
THROTTLECABLE
lnspection/Adiustment,page 11-244
page11-245
lnstallation,
POSITIVECRANKCASE
VENTILATIONIPCVIVALVE
page11-266
Inspection,
\-
11-11
System Description
VacuumConnections
D16Y5engin6('96- 97 modelsl:
To EVAPORATIVE
EMISSION
(EVAPI
TWO WAY VALVE
MANIFOLD
ABSOLUTE
PRESSURE
IMAPI
SENSOR
EXHAUSTGAS BECIRCULATION
(EGR)VALVEend EXHAUSTGAS
RECIRCULATION
IEGR)VALVE
LIFTSENSOR
\
EXHAUSTGAS RECIRCULATION
(EGR)CONTROLSOLENOID
VALVE
{CVT}
\
.'.-'
\
I
I
\
€VAPORATIVE
EMISSIONIEVAPI
PURGECONTROLSOLENOID
VALVE
)
Qo
Qo
FRONTOF VEHICLE
To CRUISE
CONTROL
DIAPHRAGM
(wathcruisecontrol)
FUELPRESSURE
REGULATOR
O: VacuumhoseNo.
11-12
D16Y5enginel'98 - 00 models):
EVAPORATIVE
EMISSION{EVAPI
CONTROLCANISTER
VENT SHUTVALVE
EMISSION
To EVAPORATIVE
tEVAPITHREEWAY VALVE{98 model)
EMISSION
To EVAPORATIVE
IEVAP'CONTBOLCANISTER
FILTER1'99- 00 modelsl
EMISSION
To EVAPORATIVE
l'99 - 00 modelsl {EVAP)
TWO WAY VALVE
EXHAUSTGAS RECIRCULATION
(EGRIVALVEand EXHAUSTGAS
RECIRCULATION
IEGRIVALVE
LIFTSENSOR
tcwl
..,.-----.-(CWontyl
EVAPORATIVE
EMISSION{EVAP)
PURGECONTROL
CANISTER
EXHAUSTGAS RECIRCULATION
IEGR}CONTROLSOLENOIO
VALVEICVTI
,t'ffi,
ig
MANIFOLD
ABSOLUTE
PRESSURE
{MAPI
SENSOR
EVAPORATIVE
EMISSION{EVAP)
PURGECONTROLSOLENOID
VALVE
Qo
To CRUISE
CONTROL
DIAPHRAGM
(withcruisecontrol)
FRONTOF VEHICLE
REGULATOR
FUELPRESSURE
o: VacuumhoseNo.
L
(cont'd)
11 - 1 3
System Description
VacuumConnections
{cont'd}
Dl6Y8 enginel'96 - 98 models):
EVAPORATIVE
EMISSION(EVAPI
CONTROLCANISTER
VENT SHUTVALVE
{'96coupe,'97coupe:all models,
'97 sedan:KL model. 'g8-modelsl
To EVAPOBATIVE
EMISSION
IEVAPITHREEWAY VALVE
'97 coupe:all models.
{'96 coupe,
'97 sedan:KL model. 'g8-models)
To EVAPORATIVE
EMISSION
{EVAP)
TWOWAYVALVE
EVAPORATIVE
EMISSION{EVAPI
PUBGECONTROL
CANISTER
{'96coupe,'97coupe:all models,
sed6n:KL model)
FUELPRESSURE
REGULATOR
MANIFOLDABSOLUTE
(MAP)SENSOR
PRESSURE
I
EVAPORATIVE
EMISSION
{EVAPIPUBGE
CONTROLCANISIER
'97 sodan:
l'96 sadan,
XA,
KC mod6l3l
EVAPORATIVE
EMISSION{EVAPI
PURGECONTROLSOLENOID
VALVE
FRONTOF VEHICLE
11-14
To CRUISE
CONTROL
DIAPHRAGM
{withcruisecontrol)
Dl6Y8 ongino ('99 - 00 modols):
(EVAP}
EMISSION
€VAPORATIVE
CONTROL
CANISTER
VENTSHUTVALVE
EMISSION
To EVAPORATIVE
{EVAPICONTROLCANISTER
FILTER
EMISSION
To EVAPORATIVE
(EVAPI
TWOWAYVALVE
EVAPORATIVE
EMISSION
IEVAPI
PURGECONTNOL
CANISTER
To CRUISE
CONTROL
DIAPHRAGM
(with cruise control)
FRONTOF VEHICI-E
REGULATOR
{cont'd)
11 - 1 5
System Description
(cont'dl
VacuumConnections
D16Y7engine('96models,'97coupe:KA. Kc models,'97 sedan:KA, Kc, KL lDx) models,'97hatchback:all modelsl:
EVAPORATIVE
EMISSION(EVAPI
PURGECONTROL
FUEL
PRESSURE
REGULATOR
To EVAPORATIVE
EMISSION
{EVAP}
TWO WAY VALVE
MANIFOLDABSOTUTE
(MAP)
PRESSURE
To CRUISE
CONTROL
DIAPHRAGM
lwith cruise
EVAPORATIVE
(EVAPI
EMISSION
PURGECONTROL
CANISTER
11-16
FRONTOF
VEHICLE
model):
Dl6YTengine('97coupe:KL model,'97sedan:KL ILX)model,'98model"gg model"oo
EMISSION
To EVAPORATIVE
{EVAP}THREEWAY VALVE
l'97 coupe:KL model,
'97 sedan:KL (LX) model,
'98 modell
EMISSION
To EVAPORATIVE
EMISSION(EVAP) {EVAP)CONTROLCANISTER
EVAPORATIVE
CONTROLCANISTER
FILTER('99- 0Omodels)
VENT SHUTVALVE
EMISSION{EVAP)
EVAPORATIVE
CONTROLCANISTER
VENT SHUTVALVE
EMISSION
To EVAPORATIVE
IEVAPI
TWO WAY VALVE
PURGEJOINT
EVAPORATIVE
EMISSION{EVAP}
PURGECONTROL
CANISTER
FUELPRESSURE
REGULATOR
_.\,,..,_..-.
{'97coupe: KL model,
'97 sedan:KL (LX) model.
'98 model)
MANIFOLDABSOLUTE
PRESSURE
{MAP)SENSOR
To CRUISE
CONTROL
DIAPHRAGM
lwith cruisecontrol)
EVAPORATIVE
(EVAP}
EMISSION
PURGECONTROLSOLENOID
VALVE
gtt
FRONTOF VEHICLE
(cont'd)
11-17
System Description
VacuumGonnections(cont'd)
B16A2engine:
EVAPORATIVE
EMISSION(EVAPI
CONTROL
CANISTER
VENTSHUTVALVE
To EVAPORATIVE
EMISSION
(EVAPICONTROLCANISTER
FILTER
To EVAPOBATTVE
EM|SS|ON
(EVAPI
TWOWAYVALVE
EVAPORATIVE
EMISSIONIEVAPI
PUBGECONTROLSOLENOID
VALVE
MANIFOI.D
ABSOLUIE
(MAPISENSOR
PRESSURE
EVAPORATIVE
EMISSION{EVAPI
PURGECONTROL
CANISTER
2
To CRUISE
CONTROL
DIAPHRAGM
(withcruisecontrol)
VEHICLE
FUELPRESSURE
REGULATOR
11 - 1 8
Dl6Y5 engine ('96 - 97 modelsl:
:li Vacuum hose No
*: CVTonly
o PRIMARY1'HEATEDOXYGENSENSOR{PRIMARYHO2S,
SENSOR
HEATEDOXYGENSENSOR(SECONDARY
SECONDARY
HO2S.SENSOR2l
,6i MANIFOLDABSOLUTEPRESSURE
{MAP)SENSOR
(ECTISENSOR
@ ENGINECOOLANTTEMPERATURE
IIAT) SENSOR
INTAKEAIR TEMPERATURE
KNOCKSENSOR(KS)
(CKF}SENSOR
SPEEDFLUCTUATTON
CRANKSHAFT
(IAC}
VALVE
AIR
CONTROL
IOLE
@
€) THROTTLEBODY(TBI
@ FUELINJECTOR
FUELPULSATIONDAMPER
FUELFILTER
REGULATOR
@ FUELPRESSURE
(il FUELPUMPIFPI
(i' FUELTANK
o
o
! ' a
{DFUELTANK EVAPORATIVEEMISSTON{EVAP)VALVE
AIR CLEANER
o
(D RESONATOR
IPCVIVALVE
@ POSITIVECRANKCASEVENTIL/ATION
IEGR)CONTROL
@ EXHAUSTGAS RECIRCULATION
SOLENOIDVALVE
(EGRIVALVE
@ EXHAUSTGAS RECIRCULATION
IEGRIVALVELIFT
@ EXHAUSTGAS RECTRCULATION
SENSOR
EMISSIONIEVAPIPURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
EMISSION{EVAP}CONTROLCANISTER
@ EVAPORATIVE
EMISSION{EVAP}TWO WAY VALVE
@ EVAPORATIVE
(TWCI
@ THREEWAY CATALYTICCONVERTER
(cont'd)
11 - 1 9
System Description
VacuumConnections
(cont'd)
D16Y5engine('98modet):
-: VacuumhoseNo,
*: CW only
il) PRIMAFYHEATEDOXYGENSENSORIPRIMARYHO2S.
SENSOR
1)
O SECoNDARYHEATEooxYGEN sENsoR {sEcoNDARY
HO2S.SENSOB2)
iq] MANIFOLDABSOLUTEPRESSURE
(MAPISENSOR
O ENGINECOOLANTTEMPERATURE
IECT)SENSOR
5 INTAKEAIR TEMPERATURE
{IATISENSOR
! KNOCKSENSOR
tKSl
O CRANKSHAFT
SPEEDFLUCTUATIoN{cKF)sENsoF
O IDLEAIR coNTRoL {IAc) vALvE
99 THROTTLEBODYITBI
@ FUELINJECToR
O FUELPULSATIONDAMPER
@ FUELF -TER
@ FUELPRESSURE
REGULAToR
[4 FUELPUMPIFPI
(9 FUELTANK
(D FUELTANK EVAPoRATIVEEMIssIoN
IEVAPIVALVE
O' AIR CLEANER
(D RESoNAToR
11-20
(9 POSITIVECRANKCASE
VENTILATION{PCV}VALVE
?!J EXHAUSTGAS BECIRCULATION
(EGR}CONTROL
SOLENOIO
VALVE
'1 ExHAUSTGAs RECIRCULATIoN
IEGRIVALVE
22 EXHAUSTGAS RECIRCULATION
{EGR}VALVELIFI
SENSOR
€J EvApoRATtvE EMtsstoN {EvAp} puRGEcoNTRoL
SOLENOIDVALVE
q4 PURGEJOINT
@ EVAPoRATIVEEMIssIoN {EVAP)coNTRoL CANISTER
@ EVAPORATIVE
EMISSIONIEVAP}BYPASSSOLENOID
VALVE
?? EVAPORATIVE
EMISSION{EVAP)THREEWAY VALVE
ITIIEVAPORATIVE
EMISSIONIEVAP}CONTROLCANISTER
VENT SHUTVALVE
O FUELTANK PRESSURE
sENsoR
QlI EVAPORATIVE
EMISSION{EVAP}TWOWAY VALVE
8' THREEWAY CATALYTICCONVERTER
{TWCI
D16Y5engine('99- 00 modelsl:
(PBIMARYHO2S,
O) PRIMARYHEATEDOXYGENSENSOR
1)
SENSOR
HEATEOOXYGENSENSOR{SECONDARY
O SECONDARY
HO2S.SENSOR2)
IMAPI SENSOR
6] MANIFOLDABSOLUTEPRESSURE
IECTISENSOR
COOUruT TEMPERATURE
rO CruCIruC
0AT) SENSOR
o rrurlxe ln ETUpERATURE
.d KNOCKSENSOR(KS}
(CKFISENSOR
SP:ED FLUCTUATION
O CN,NruXSXITT
IEGR}CONTROL
@ EXHAUSTGAS RECIRCULATION
SOLENOIDVALVE
(EGR)VAI-VE
6 EXHAUSTGAS RECTRCULATION
rf exxlust cls nectRcuLATloN IEGR)vALvE LIFT
SENSOR
EMISSION(EVAPIPURGECONTNOL
@ EVAPORATIVE
SOLENOIDVALVE
O} PURGEJOINT
O THROTTLEBODY(TB)
@ FUELINJECTOR
E) FUELPULSATIONOAMPER
t? FUELFILTER
REGULATOR
G) FUELPRESSURE
OI FUELPUMP(FP)
Gi FUELTANK
G) AIR CLEANER
fi? RESONATOR
(PCV)VALVE
Gl posmvr cnglrcAsE VENTILATION
VALVE
EMISSION{EVAP)CONIROLCANISTER
6 EVAPORATIVE
FILTER
EMISSION(EVAPICONTROLCANISTER
@ EVAPORATIVE
VENTSHUTVALVE
SENSOR
OA FUELTANK PRESSURE
er,/tlssloN tEvAPl TWO WAY VALVE
6 :vlponlnvg
0Ac)valvE
@ rou an corurnoL
L
cANlsrER
coNTRoL
io :vaponanveeutssloN(EVAP)
soL-eNolD
tEvAPlBYPASS
d rvlponlrtve EmtsstoN
{onvRlVENT
6 oNgoanonerueltNcvAPoRREcovERY
SHUTVALVE
(ORVRIVAPOR
VAPORRECOVERY
€!) ONBOARDREFUELING
VALVE
RECIBCULATION
(TWCI
@ THREEWAY CATALYTICCONVERTER
(cont'd)
11-21
System Description
VacuumConnections
(cont'd)
D16Y8engine ('96 sedan, '97 sedan:KA, KC modelsl:
{M/T}
i
:
@
l
F @ i
HiiFl
(A/T)
I
ENGINE
I
i@
l/A.
(Or)l
\)l#t,/
0) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S.
SENSOR
SECONOARY
HEATEDOXYGENSENSOR{SECONDARY
HO2S,SENSOR2l
-l
MANIFOLDABSOLUTEPRESSUBE
{MAPI SENSOR
@ ENGINECOOLANTTEMPERATURE
{ECTISENSOR
INTAKEAIR TEMPERATUFE
IIATI SENSOR
!o, KNOCKSENSORIKSI
(t CRANKSHAFTSPEEDFLUCTUATION{CKFISENSOR
IDLEAIR CONTROLIIACIVALVE
@ THROTTLEEODY(T8)
@ FUELINJECTOR
@ FUELFILTER
t;
11-2 2
I
coor-rruri
i+i
nfi |
/U[ |
,6
@ FUELPRESSURE
REGULATOR
@ FUELPUMP{FPI
@ FUELTANK
(9 FUELTANK EVAPORATIVEEMISSIONIEVAP}VALVE
@ AIR CLEANER
@ RESONATOR
@ POSITIVECRANKCASEVENTILATION{PCV}VALVE
(D EVAPORATIVEEMISSIONIEVAP)PURGECONTROL
SOLENOIDVALVE
@ EVAPORATIVE
EMISSIONIEVAPICONTROLCANISTER
A) EVAFORATIVEEMISSIONIEVAP}TWO WAY VALVE
@ THREEWAY CATALYTICCONVERTER
(TWC'
D16Y8engine l'96 coupe.'97 coup6: all models.'97 sodan: KL modol.'98 modell:
PRIMARYHEATEOOXYGENSENSORIPRIMARYHO2S,
1)
SENSOR
HEATEDOXYGENSENSORISECONDARY
? SECONDARY
HO2S.SENSOR2l
IMAPI SENSOR
3- MANIFOLDABSOLUTEPRESSURE
IECTISENSOR
ENGINECOOLANTTEMPERATURE
(IATISENSOR
INTAKEAIR TEMPERATURE
6 KNOCKSENSOR{KS)
ICKFISENSOR
SPEEDFLUCTUATION
7. CRANKSHAFT
a IOLEAIR CONTROL{IAC)VALVE
9 THROTTLEBODYITBI
,! FUELINJECTOR
FUELFILTER
REGULATOR
1? FUELPRESSURE
! FUELPUMPIFPI
1 { FUELTANK
EMISSIONIEVAP)VALVE
r 5 FUELTANK EVAPORATIVE
a
@ AIR CLEANER
o RESONATOR
@ POSITIVECRANKCASEVENTILATION(PCV)VALVE
EMISSIONIEVAPIPURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
EMISSION{EVAPICONTROLCANISIER
@ EVAPORATIVE
EMISSIONIEVAPIBYPASSSOLENOIO
@ EVAPORATIVE
VALVE
EMISSION{EVAPITHREEWAY VALVE
@ EVAPORATIVE
EMISSIONIEVAPICONTROLCANISTER
@ EVAPORATIVE
VENT SHUTVALVE
@ FUELTANK PRESSUFESENSOR
EMISSIONIEVAP)TWO WAY VALVE
@ EVAPORATIVE
ITWCI
@ THREEWAY CATALYTICCONVERTER
(cont'd)
11-23
System Description
VacuumConnections
(cont'dl
D16Y8enginel'99 - 00 modetsl:
--j
I
n
-fr
1ry|
IMTTI^
14[l(2i)
l-
'-
*o'*-
-
COOLANT
]L
n
r
l
L
*
ii8'x'",
(]-i PAIMARYHEATEOOXYGENSENSOR{PRIMARYHO2S,
SENSOR1)
..2rSECONOARY
HEATEOOXycEN SENSOBISECONDARY
HO2S,SENSOR2l
i3) MANIFOLDABSOLUTEPBESSURE
{MAPI SENSOR
(ECTIsENsoR
O ENGINEcooLANT TEMPERATURE
(5) INTAKEAIR TEMPERATURE
{IAT}sENsoR
G] KNOCKSENSORIKSI
?r CRANKSHAFT
SPEEoFLUCTUATTON
{CKF)SENSOR
.O IDLEAIR coNTRoL {IAc)vALvE
i-9]THROTTLEBOOY{TB)
(O FUELINJECToR
I]'i FUELFILTER
.O FUELPRESSURE
REGULAToR
[t FUELPUMP{FPl
.D FUELTANK
il' AIR CLEANER
TD RESONATOR
O FUELTNJEC oN AtR tFtA)coNTRoL vAt_vE
.19POSITIVECRANKCASE
VENTILATION{PCVIVALVE
11-24
.19)EVAPORATIVE
EMIssIoN {EVAP)PURGEcoNTBoL
SOLENOIDVALVE
€g PURGEJorNT
tj EVApoRATtvEEMtsstoN {Evap} coNTRoL cANtsTER
C4 EVAPONANVEEMISSION(EVAP)BYPASSSOLENOID
VALVE
?3 EVAPORATIVE
EMISSION{EVAP}CONTROLCANISTER
FILTER
A4 EVAPoBATIVEEMIssIoN (EVAP)coNTRoL CANISTER
VENT SHUTVALVE
C! FUELTANK PRESSURE
sENsoR
EO EVAPOBATIVE
EMISSION(EVAP)TWO WAY VALVE
e? oNBoARD REFUELtiIGvApoR REcovERy {oRvR} VENT
SHUTVALVE
@ oNBoARD REFUELTNG
vapoR REcovERy (oRvR) vapoR
RECIRCULATION
VALVE
iP THREEWAY CATAI.YTIC
CONVEBTER
{TWCI
DI6YTengine('96mode|.,97coupe:KA,Kcmode|s,,97sedan:KA,KC,KL{Dx}modets,'gThatchback:a||models}:
COOLANT
o
l) PRIMARYHEATEDOXYGENSENSOR(PRIMARYHOzS,
1)
SENSOR
HEATEDOXYGENSENSOR{SECONDARY
SECONDARY
HOzS,SENSOR2)
r.-.
IMAP)SENSOR
MANIFOLDAESOI-UTEPRESSURE
IECT)SENSOR
.t) ENGINECOOLANTTEMPERATURE
(IAT}SENSOR
INTAKEAIR TEMPERATURE
(CKF)SENSOR
SPEEDFLUCTUATION
CRANKSHAFT
a:!)IDLEAIR CONTROL(IACIVALVE
BOOY(TB)
-o THROTTLE
FUELINJECTOR
aroFUELFILTER
a1tFUELPRESSUREREGULATOR
o
|-
FUELPUMP IFPI
[3) FUELTANK
EMISSION(EVAPIVALVE
@ FUELTANK EVAPORATIVE
aoAIR CLEANER
(oRESONATOR
IPCVIVALVE
VENTILTATION
a POSITIVECRANKCASE
EMISSION(EVAP}PURGECONTROL
@ EVAPORATIVE
SOLENOIDVALVE
(0 EVAPORATIVE
EMISSION(EVAP)CONTROLCANISTER
EMISSIONIEVAPITWO WAY VALVE
@)EVAPORATIVE
(TWCI
THREEWAY CATALYTICCONVERTER
(cont'd)
11-25
System Description
VacuumConnections(cont'd)
Dl6Y7 angin6 ('97 coup.: KL mod€l, sedan: KL (LX) model,,9g
modet):
i1] PRIMARYHEATEDOXYGENSENSOR(PRIMARYHO2S,
SENSOR1)
E) SECONDARY
HEATEDOXYGENSENSOR{SECONDARY
HO2S,SENSOR2l
ABSOT_UTE
€l MANTFOLD
PRESSUnEtMAp) SENSOR
€r ENGINECOOLANTTEMPERATURE
|ECT)SENSOR
€] INTAKEAIR TEMPERATURE
IIAT}SENSOR
6 CRANKSHAFT
SPEEDFLUCTUATION
ICKFISENSOR
17 IOLEAIR CONTROLIIACIVALVE
@ THRoTTLEBoDY {TBI
O FUELINJEGToR
(9 FUE|-FTLTEF
O FUELPRESSURE
REGULAToR
@ FUELPUMP{FPI
(D FUELTANK
@ FIFL TANK EVAPoRATIVEEMIssIoN {EVAPIVALVE
(, AIR CLEANER
11-26
(tORESONATOR
l? PoSITIVEcRANKcAsE VENTILATIoNIPcv}VALVE
IA EVAPORANVEEMISSIONTEVAPIPURGECONTROL
SOLENOIDVALVE
19 EVAPORATIVE
EMISSIONIEVAPICONTROLCANISTER
E EVAPORATIVE
EMISSION(EVAPIBYPASSSOLENOID
VALVE
€' EVAPoRATIVEEMIssIoN IEVAPITHREEwAY vALvE
Q' EVAPORATIVE
EMISSIONIEVAPICONTROLCANISTER
VENTSHUTVALVE
@ FUELTANK PRESSURE
sENsoR
{?1!EVAPORANVEEMISSIONIEVAPITWO WAY VALVE
?5 THREEWAY CATALYTICCONVERTER
ITWC'
Dl6Y7 engins ('99 - 00 modelsl:
a PRIMARY1)HEATEDOXYGENSENSOR{PRIMARYHO2S,
SENSOR
6t
sENsoRISECoNDARY
iiconoanv neareooxYGEN
HO2S,9ENSOR2)
(MAP)SENSOR
MANIFOLDABSOLUTEPRESSURE
(ECT}SENSOR
TEMPERATURE
COOLANT
@ ENGINE
(IATISENSOR
!., INTAKEAIR TEMPERATURE
ICKFISENSOR
SPEEDFLUCTUATION
CRANKSHAFT
IOLEAIR CONTROL(IAC}VALVE
@ THROTTLEBODY (TBl
ao FUELINJECTOR
@ FUELFILTER
REGULATOR
@ FUELPRESSURE
FUELPUMP (FP)
(} FUELTANK
@ AIR CLEANER
@ RESONATOR
o
VENTILATION(PCV)VALVE
6d POSITIVECRANKCASE
coNTRoL
PURGE
6 rvapoamve eutssloNtEvAP)
SOLENOIDVALVE
COPURGEJOINT
cANlsrER
coNTRoL
6 evlponnnve eutssloN(EvAPl
solrNolD
BYPASS
i evlponnnve eussloN {EVAP}
VALVE
EMISSION(EVAPICONTROLCANISTEN
6) EVAPORATIVE
FILTER
(EVAP)CONTROLCANISTER
EMISSTON
@ EVAPORATIVE
VENT SHUI VALVE
SENSON
A FUELTANK PRESSURE
rwo wAYvALvE
d rvlpoamve emtsstoNtEvAPl
loRvnlvENT
vAPoRREcovERY
6 orueonnonerueLING
SHUTVALVE
{ORVR)VAPOR
€) ongolno neruellNc VAPORRECOVERY
VALVE
RECIRCULATION
(TWC)
€) THREEWAY CATALYTICCONVERTER
(cont'd)
11-27
I
a
System Description
VacuumConnections(cont'd)
816A2engine:
(' PRIMARYHEATEDOXYGENSENSORIPRIMARYHO2S.
SENSOR1l
.?) SECONDARY
HEATEDOXYGENSENSOR{SECONDARY
HO2S,SENSOR2)
13] MANIFOLDABSoLUTEPRESSURE
(MAP)sENsoB
i' ENGINECOOLANTTEMPERATURE
IECT)SENSOR
O INTAKEAIR TEMPERATURE
ITATISENSOR
i6l KNOCKSENSOR{KS}
O oRANKSHAFTSPEEDFLUCTUATIoN{cKF}sENsoR
@ IDLEAIR coNTRoL (IAc} VALVE
€) THRoTTLEBoDy trB|
(D FUELINJECToR
O FUELPULSATIoNDAMPER
[D FUELFILTER
@ FUELPRESSURE
REGULAToR
!I FUELPUMPIFP)
f,' FUELTANK
(iD ArRCLEANER
t' RESONAToR
'.1]iPOSITIVEcRANKcAsE VENTILATIoN{Pcv} VALVE
11-28
@ EvApoRATtvE
EMtsstoNtEvAp)puRGEcoNTRoL
SOLENOID
VALVE
JoINT
@ PURGE
€t EvApoRATtvE
EMtsstoN(EVAptcoNTRoLcaNtsTER
(EVAP)
QAEVAPORATIVE
EMISSION
BYPASS
SOLENOID
VALVE
@ EVApoRATtvE
EMtsstoNlEvAplcoNTRoLcaNtsrER
FILTER
@ EvApoRATtvE
EMtsstoN{EvAptcoNrRoL cANtsrER
VENTSHUTVALVE
@ FUELTANKPRESSURE
sENsoR
(EVAP}
GI EVAPORATIVE
EMISSION
TWOWAYVALVE
@ ONBOARD
REFUETING
VAPORRECOVERY
{ORVR}VENT
SHUTVALVE
@ oNBoAnDREFUELING
vApoRREcovERy(oRvRlvApoR
VALVE
.(c} RECIRCULATION
THREE
WAYCATALYTIC
CONVERTER
{TWCI
ElectricalGonnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/T)
(
To A/C PlEStUnC 6wrctt
clEc{
.2.Arr pt6rt, DraYt.nlh.t
.nsrF
Drar, .ndn
arr .nd Drart
I .a: AfI
=.5 Er..d afr.nd Dla\t 6eh.
r?, cvt (D,t6ys ddn.tDd
Oiew d!lh.
o [rnEnoRUGtlTlt.s Ar
.8:'S6 Dr6Y3 dsin. td|p.), '97 Dl6Y8 {tin.
lG nod.ll, sa Or6Y5 mdn',
{cou9.; .ll Dod.b..r!.t:
o HoRxtr5 AF
'10: MfI lD1aV5.ncir.l
rrt. Exc.orM/I (D15Y5.ntin.l
r12: O16Y5.Ol6Ya.ncln.
o rcr l|o Ar
No, 13l{ Et tU[9 ll5 Al
No. ri Al'ltElATOll gt l€Ntol
t{o. 3l EtAatEn gc at lt.5 al
r: h tL
o.d..{ood
io/t
lt,5 Al
l.v bor
(cont'd)
rt5. i9? Ot0\., ssid l6up.; (L mod.l,..d..:
Kl ttxl mod.ll, 9a Dl6rr.ndn.
11-29
System Description
ElectricalConnections('96- 98 Models,,99- 00 D16Y5enginewith M/Tl
(cont'd)
SENSOF
PRESSURE
SENSOE
EGR
UFT
s E N s o R* 3
c-rrusren
vemsrurvtvrlf;
EGR
solENotovALvE*3
uF
wec soLeton vltve'!2
SENSOR
SPEED
sENsoR'2
COUNTEFSHAFI
s P E E Ds E N s o R * 2
soeeloto vltve l*2
ToI|{TEFLOCK
CONTBOLUNIT
ECM/PCMA(32P)
ECM/PCi/lBEsP)
ECM/PCMD(16P)
TERMINALLOCATIONS
11 - 3 0
*l: t SA model
*2: A/T(DI6W,oi6y8 engine)
*3:CVT(DI6Y5
6ngine)
1.4: A"/Tand Dl6Y7engine
*5; ExceptA/Tand Dl6Y7engine
*6: A/T(O16YO
engin6)
*7:CW(DI6y5 ongine)and D16y8engino
*8;'96 Ol6Y8sngine(coupe),,97 D16y5
ongine(coup€:all modol!,sedan: KL
modoD,'98 Dl6Y5engine,'98 ot6Y8
en9ne
*9:D16Y5engin.
*10: |!UT(D16Y5
engine)
*ll : ExceptiUT(Dl6Y5engine)
*12: D16y5,016yoengino
*13:DI6YO
engine
*14:Dl6Y7engine
*15:'97D16Y7
engine[coupe:KL modet,
ssdan: KL(LX)modetl,'9gDt6y7engine
(
lSEiV|qE CHECK
@NI\IECIOR
[*-
I
l-.i-*.,*,.
r-Bu(
@NI\ECIOR
f-*
ceor
(cont'd)
11-31
System Description
ElectricalConnections('96- 98 Models,,99- 00 Dl6y5 enginewith M/T)
(cont'd)
ptozs'"
pozslttc*rr
Ho2s(sENsoFl)
c125
WHT,'RED'l
s02sHTc
-BLK/WHT
*12
aLKlyeL!
wrlaeo!{-L
wrzneo.=r.:
GFN/BLr-I FcFN,wHrJ
alvwrr'Ll
-ff
ar-x,rvnr,
f--fi"-r".^'--]
I
LraeL*ro
;lcnr-caz
fi
Ho2s (sENsoR2)
crls*'u
\
pozsntc*lu
H O 2 S( S E N S O R '
:soL*3
c142
ecRcortnoL*3
SOLENOID
VALVE
c14o
BLU/ALK
VT€C PRESSURE
12: A/T (Ol6Y7, Dl6Y8
enginel
'3: CvT
lDt6Y5 engane)
ia: A/T and Dl6Y7 enqine
15: Erc.pt A/T.nd Dr6Y7
engine
'6:A/T (O16Y8.ngine)
i7: CVI
{Dl6Y5 Gosin.) .nd D16yo snqine
r8:'96 DI6YB .ngi..
,97
lcoup.),
Dt6yl
ensio. (coups: lll mod6ts, s.d6n. KL
dod6ll,'98 D16y5 6ngine.,9a D16y8
o n g i n e , ' 9 9- 0 0 O t 6 Y 5 ( M / T l o n o i n e
'9: Dl6Y5 ongine
'10: M/T
lO16Y5engine)
'l r: Ex@pt M/T (Dt6y5
engine)
r'12:Ot6Y5, Ol6Y8.ngine
11-32
'15r'97 D16Y7.ngine
{coupe: Kt- model, sedan:
(L (l-Ximod.l), '98 Dl6y7 angins
PSPSWITCHI
c1t7
/YEL Jlr.^r'\-r
atu/wHT =..'-_
wHr---] FaMrr=ll
8r-x,--L-
I
L_id-ll
|
IT GRN/WI{T
CAI\IISTERVENT
tr--+r
-*' I
=
calT
_
66s'
l-BL!(---
_-o_
I
ctor
-
fr:-l
lf.a
I
CLUTCHSWTCH'X
(cont'd)
11 - 3 3
System Description
ElectricalConnestions{'96- gBModels,,99- 00 Dl6yS enginewith M/T)
(cont'dl
s€N90fi
I
I
rDc
rDic M
sEt\tsoi
RET'
I
ct(P P
I
cxP
CXPM
YEUGifl
CIG M
FIF']EE
TTiT
8At{/ aR / !R|{/ AAX/
\
lhx/
ALJ(I
A&
L:]
11-3 4
l'l
12:A/t tD16Yt,Dt0Y8.ncin.t
13: C1/t lDtOYSssin.t
'4 A/T .I(| Di6Y7 .nsi..
r5: Erc.tr A/r ..d Dl6Y7 .nsin.
t6: AIt lDl6Y8 .ngin.l
i7:CvI lO16Y5..!ln.) ..d Dt6Y8.neln.
13: s6 Dt6Y6 ftsi..lco!p.I.
9t Dr6Y8.nqin.
lcolF:.rl mo.Llr..d.n: (L no.t.l),,s Di6Y5.nsin..
'98 DI6YB.ncin.,'99 -0o
O't6Y5(M/Tt.nsin.
r10: M/I {D16Y5.nsin.}
11r: Exc.pt M/T {D16V5.nsin.l
'12: Or6Y5,Dl6Ya.ngin.
.i5:3', O16Vt.ngin. lcoup.: X! mod.l,..d.n:
(L lLXl mod.ll, 93 ol6Yt.nsin.
LCB'
NCSC'
L
(cont'd)
11 - 3 5
System Description
ElectricalConnections('96- 98 Models,'99- 00 Dl6Y5 enginewith M/Tl
(cont'dl
cart c5o2
Cl3i C,ta6
c5t2
t--l
o",.uonr.
l| FSIX'
GA|l/OfiN
|
Orl0
GRN/BIXI.
LT GRflr-
-
T
LT
8r"K/8ru
{
FYEI
g. l
C50il
l
c5t0
r
I
GRN/aaX:
dYEr.
LrGiN'
-
8rK/8ru
-
f"*
f r
- -J
BEo
I
GRN-_'-
8ru'--1
".*,".u---f
-
REo--__-
Etur
YEri
Gur{------Brur-
l
L ArGEAR ?O6frO
Swlrcs
IYTENLOC|(
CO TROT UMI
BLu/REo,-
T'
l
f
B!u/FEo,-----l
FronIAD|AtOh FAx
RElAv EqtswIrEH
ro a/c swrrcH
t_.1
ct3t c&t6
12:A/l (Dr5Y7,Dl6Y8.nglnel
r3: CyI lOl5Y5..sinel
'.: A/T.nd Dr6Y7.nsin.
15:Erc.pt A/T .nd D16Y7.ngin6
'5r A/i {Dl6Ya.ngin€l
17:CVT (D16Y5.noin.) rnd O16Ya.ngine
'8r'96 015Y3.ngin. lcoup.), 9t O16Yasngin.
(coop.r.llnod.l.,..d.n:KLmod.l), 98ol6Y5o.gins,
'94 Di6YA
.ngin., '99 - 0OD15Y5lM/Tl 6ngin.
11 - 3 6
,10: M/T {D16Y5..sin.l
.11: Erc.pt M/l lOr5Y5.nginel
'12: Ol6Y5,DlSYa.ngin.
'15: 97 Dl5Y7.ngin. {coup.:Klmod.l, $d.n:
(l lLXlmod.ll, 9A DIOYT.nsin.
UGIfI
o5A)
&AMRY
60a)
ct31
WH'/ALU
-wHT/gtU
-BLVRED
A//C CIUICH
c354
-
GRN/REO
f"*
u o€R.HOOD
BOX
FUSE/REIAY
*t*'fi
-l
-*r
F*n*Aros^
I lsrc
8ru/wHr-.1
YEUGRN |i il?-\.p--lI
a I ncB
|
f*-__l
I
".-;"{
BtK,$rtf
t
I
lll
III
F I J EPLI I / | P
lt n * l ll l
n
l5-,i
I Na15
l arlnrl Ton
I sPsE*soaoia
l<\-,o
I NczsMErER
I 05$
'*+
F-l
l
I
| |
l Ll
l l
lil
I
|
uN0€n-oAsH
FTJSE/FEIAYBOX
(cont'd)
11-37
System Description
ElectricalConnections('96- 98 Models,'99 - 00 Dl6Y5 enginewith M/Tl
(cont'dl
atu
EVA? EVPASS
F]I " l
Tf
c13r c4a6
R€D/ AED
GRII
o.3a
_ lr- tr---------------
t |
ll
1 |
J tt
{
t
) caQ
Lll
|
I
r
lrl
--
I lJ/c
.t
I
|
I
I
]-t
GRt{n'Y}rP-___-.l
i
rcrr
-
l
l
ol25
Srli$},€
'AAXE SWIICH
'2: A/T {Dl6Y7,016Y8.ngin.)
,3: CW {Dl6Y5.nsin.l
14:A/T rnd DIGYTlnginc
'5: Ex6pt A/T.nd O'l6Y7.ngin€
'6r A/T (Ol6Ygcnsin.)
rtrCvI lol6Y5 .ngin€) .nd Ol6Y8€ngin.
18:'96O16Y8.ngin. lcoup.l, '97 Dl6Y8.nein.
{coop.:.ll mod.l., t d.nr KL mod.t,,'98 Dr6Y5.ngin6,
'98 Dr
6YE.nein., '!Xl- 0OO16Y5{M/T).ngin.
11-38
19: Dl6Y5.ngin6
rl0: M/T {Dl6Y5.ngin!)
il1: Exc.pt M/r
{Dr6Y5 angin€l
'12: Dl6Y5, 016Y8.ngin.
'13: O l6Y8 angin.
'1a: Ol6Y?.ngin.
'15:'97 Dl6Y7..qin.
(coup€: Kl dod.t, sd.n:
Kl (Lx) mod.l), 98 D16Y7 6ngin.
ElectricalConnestions('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
-:
T
)
I
FUEI II{JECIOBS
L ChUISECOXTnOI UNII
lo CO|IPi€33OR CUrrcH BEI Y
lo A/c PRESSUiEalYrc|l
To FAoIAIOR FAI REL Y EcT3wllcll
SENSOF
FIJSES:
(DIN1ERIOR
UGHTO5A)'
@ BACKUPO5A*
@HonN(15A).
(DSATTERY
OOA*
@ rcl (104*
@FrvM(r5A*
(lEA)
@No.I3FUELPLMP
@ No.25MEIERCrsA)
SPSEI{SOR
OJA)
@ ib. 15ALTERNATOR
SIGML (75A)
O ib. 3l STARTER
': h lhc ud.rhood lu..//rcbY box
(cont'd)
11-39
System Description
ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
(cont'd)
0
T:I
1
c26 ECT
EVAPPURGECONTROL
SoLENOtOVAIVE
c25 tAT
EVAPCOI{TROLCANISIER
ECTSENSOR
D
IATSENSOR
ta-t
HO2S
(sENSoFt
)w
EVAPBYPASSSOI.ENOID
VALVE
cl Po2s{tc
"Eso! 87
EGFcoNTRoLsolENorovaLvE'"
c16PHO2S
vlsBr2
VTECSOLEr{O|D
VATVE
H02S
iSENSOR2)
,w
A23 SHO2S
VTECPFESSUFESWITCH
-t
,.1 f
BRAKE SWITCH
sEt{soR
I
c7 sG1
--t
SENSOB
(Bulnl o
F
@E
GAUGE
lfil /V\ |
_r*
l -
I
I
D5VBSOL
*
l-
o4tNDA14
lassEMBL
I
I
N DTI
SPEEOSENSOR
NC DTO
SPEEDSENSOR
tr
L S +B l 7
T'I AT?04
Pr.l
03alP03
LS- a3
UNEARSOLENOID
VALVE
LCA 01
LOCI
LCB 03
SHE D2
P CONTBOISOIENOiDVALVE
B
IOI{IROLSOLENOID
VAIV€ A
SHIFI COTITROL
SOLENOID
VALVEB
To IIIT!FLOCKCONTROLUNIT
POStTtON
t---I
-.._.._.._.._l
11-40
,'-J
L
-'
DRIVEPULLEY
SPEEDSENSOR
GAUGE
ASSEMALY
ORIVENPULLEY
SPEEDSENSOR
SECONOARY
GEABSHAFT
SPEEDSENSOR
SOLENOID
To INTERLOCK CONIBOL UNIT
*l : USAmodel
*2: a/T(D16Y/,D16Y8engine)
,.3: CW(016Y5engine)
*4: A/T and D16Wengine
*5: ExceptA/Tand Dl5Y7engine
*6: Cw(Dl6Y5 engine),Dl5Y8engineand 816A2engine
EcM/PcMB(25P)
EcM/PcMA(32P)
10
16 1 7 1 8 1 9 2012122 23
7
t4
I
I
11
24
ECM/PCMD(I6P)
ECM/PCMC(31P)
I
(cont'd)
TERMINALLOCATIONS
11-41
System Description
ElectricalConnections('99- 00 ModelsexceptD16Y5enginewith M/Tl
(cont'dl
UFTSENSOR
sEnucEcSEcK
CONNEC'OR
L
ABS CONTROL
UNIT
_r"*
-
CONI{ECTOR
"to'
aLul-_--r
".*
I
I
lll*,
11-4 2
BLX
ft *31ou..."
"on"t"to"
\
llo2s (sENsoR
t
SECONOARY
HO2S(SENSOR
2)
I- wrrzneo'f15151
-]
FCA ,a[HT fFELWWHI.FFi/v\^F ETJVWrfT'--I l+
I
I
|
HO2S(gENSOR2)
\-
11-43
System Description
ElectricalGonnections('99- 00 ModelsexceptDl6yS enginewith M/T)
(cont'd)
Fl
TI
"u,
|
LB|.X'--Jf-ll
cad__J
PsPswrcH'
h/wFDl
q30
t-l + l
1""
vss
VTEC
soLEt{oto
VALVE
clia
----J----]
BLTC.YEL
neozvef--l
neo,"yrr.'--{l- ---5
|
EVAP PUBGE
CONTROL
SOLENOIDVALVE
clat
EVAP CONTROL
CANISTEFVENT
SHUI VALVE
l,,"
I
11-4 4
-E--l
qYP
$rsoi
|
I
^
Y
I
I
I
/.JrDc
I
Y SEr$OiI
-
l
I
I
t
Il
I
I
f--Av) o'
I
sEr,rsoi
I
|f-------l
ll
' cM
I
|
_L:_---J
DIgIRIBUTOR
til
|-
EiN/
ELxl
tr:-l
FI
t E l--
TI
|
CKFSENSOR
I
I AFN/
BRN/ ar-xl
ELxt
BFN/
ar-xl
EFN/
aLKl
BRN/
B!K'
J-
I*l
I
;q ,l o l
L P I
(cont'd)
11-45,
System Description
ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
(cont'd)
cl09
racvP*{
-
-l
qt
BLK/eLu
pl
SOLENOID
VALVE
--
MAINSHAFT
SPEEOSENSOR
clla
COUN'IERSHAFTSPEED
SENSOR
c121
t t
I
I
UNEAR
SOL€NOIDVALVE
11-4 6
"f
iFx/'ORN
I
' - LI
YEL
Lll
c!o4
crro
qF /ELKT
lrcnf
RED
GiN
aLuT
At c€AR PO3tllOl{ SWlrCH
wnnrd#"Si"*fi[*
BLU
GR+
CnXr#
BLI,IREO+
I
"
35111'o,u",,
F 'h MDIA'ORFAr{FELAY'
ToA/CSwlICH
(cont'dl
11-47
System Description
ElectricalConnections('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
(cont'dl
DRIVEPULIEYSPEEOSENSOF
SECONDAFY
GEAF
SHAFTSPEEOSENSOR
PNK/BLK
YE!'
SCLSM
PNK/BIU
INHSOL
cnvauC
c131
GFN/Brf
CrKa
I f
L_
cnvsuC
,T
11-48
GEAF POSII|ON SWITCH
;:l
A/CO-UfAl
ELD''
BLtCWlfi -
T
BLK
UNDER-HOOD
BOX
FUSE/RELAY
YEVGRI{
*tT
sLrc\t/trt
1
BLvwHr
1
c501
r.. -{
UNDER-DASH
FUg€/FELAY AOX
(cont'd)
11-49
System Description
ElectricalConnections('gg- 00 ModelsexceptDl6y5 enginewith M/Tl
(cont'd)
Elt^-l
'tF'tF
I
t
L--
L
q23
r_ c446
- l l-- ,.,-,.u
vever-u
|
l
cnrzer-rc-{f
cnnzar-x,
'-
YELI6RN
BLK __1\
CsO5 -r-\
f/
P
I t
\
\'----l
/
I
YEL/GRN
-
YEL/GRN
YEVELU
-
YEVBLU
lr cat'
_
qar/auC
LT GRN2
-
qaN/eud
BLVWHf
-
BLK/WiT
BLIII
-
BLul
I
Ft,EL PUMP
EVAPBYPASS
SOLENOID
VALVE
ft
I lJ/c
T__l I
t.]
I
ti-l
T
I
LwHr
c425__
GRN {-l
_cnnzwm'_{h\_,
I
aBAKEStlflTCB
*l : USAmod6l
*2: A/T(Di6W,Dt6Y8engine)
*3: CW(DI6Y5engino)
*4: A,rTe16 915y7"nn,n"
*5: ExceB AfTand Dl6Y7engine
,16:Cyr(DI6Y5€n9ine),D16y8engineand B,tOA2
engins
*7: Dl5Y8,816A2engine
11 - 5 0
SystemConnectors[FuelPumpl
'95 - 98 models, '99 - 00 Dl6Y5 engine with M/T:
c792*r,.'5
c793|.,.s
c7931...15
c565
E ffi
NOTE:.
.
.
ffi
*1r USA mod€l
'2: A/T {O16Y7,D16Y8 ensine}
13: CVT {O16Y5ensin€l
*4: A/T ind D16Y7 .ngane
*5: ExceFt A/T end D16Y7 engine
'6: A/T lDl6Y8 enginel
*7: CvT (Dl6Y5 enginoland 016Yg engine
'8: ,96 Dl6YB engine {coupe),'97 Dl6Y8 sngine
{coupe: sll models, s€d.nr KL modell,
' 9 8 D l 5 Y 5 . n g i n e , ' 9 8 D 1 6 Y 7e n g i n e ,
'99 - OODl6Y5 (M/Tl engine
r9: D16Y5 ongine
t 1 0 : M / T { D 1 5 Y 5e n s i n e l
r 1 t : E x c e D tM / T ( D 1 6 Y 5e n g i n e )
t l 2 : D 1 6 Y 5 ,D l 6 Y g e n g i n e
*13:Dl6Y8 engine
r14: D16Y7 engine
*15:'97 Dl6Y7 ensine {coupe: KL model, sodan:
KL (LX) modeu,'98 Dt6Y7 engine
them (for example'YEUBLK1
Differentwireswith the samecolor have beengivena numbersuffixto distinguish
and YEVBLK'are not the samel.
O: Relatedto Fueland EmissionsSystem'
- Connectorwith maleterminals(double outline):View f rom terminal side
- Connectorwith femaleterminals(singleoutline):View from wire side
11 - 5 1
System Description
SystemConnectorsIEngineCompartment]
'96 - '98 Dl6Y5,
Dl6Y8 engin€, '99 - O0Dt6y5 engine wirh M/f:
I
:
ir
I
\
11-52
c102
r'Trtt
:lo.
l'lrl
lrl.l
_-l
l6lwtr,eED' -l
E|BFIvBLK
l6lga-tnEcl--l
c108
c107
ffi
ffi
Cl0,r
{C.nadal
r'fr]
l6mrrrnru I
ElilrwA----l
lTltHtBtu__l
c109..
c106
c105
Etr ffi
Bffiffi
c113*1
fr
r'frtr
-l
16lonl
l@LYEUBLK' I
bfgl-rcgtu'---l
c114
ffiffi
c1a2.r
fr
,D GRN/BLK'
(9 LT GRN?
BLU]
3
8
NOTE:.
.
.
Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem
and YEUBLK' arenot the same).
O: Relatedto Fueland EmissionsSyst€m'
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View trom wire side
(for 6xample,YEUBLK1
(cont'd)
11-53
System Description
SystemGonnectors[EngineCompartmentl(cont,d)
t
36 - 98 Dl6Y5, Dl6Y8 engine, ,99 - O0Dt6y5 engine with M/T:
I
C1,&r.3
c139r"
c120
c354r1
c122
G101
11-54
I
II
c112
cl11
c1t7
cl16
c1t5
fr
r'ffi]
f'TBLir-l
lO BLX,YEI
I
l6lEtu^tHr__-l
c120
c118"
c122
c123
i
trl-clrl---]
I
latlIBLU,
BLU5
REO!
YEL'
9 8tu
10 BLK/YEL
5
c128.'
c127*'
fr
ffi
ffi
IFFEc'--__l
ftlwHn-'_l
fOTwHn-_-l
I
-c,1*
:.trn
.EL
[tT,l.l
v
Ii
16lwrrin+o' t
liSlcFN/BLK I
16T8LK^'Er--l
-.,IBaK,r/Hr. I
o
YEUGFN
8L(,
c126*'
lOlREo.
ffi
ffi
ffi
ffi
wHl/8tK
I
c125
c121*'
1618r-uf/EL-_]
-l
161-cfl,avHr
cl45rrc
c141*'
___l:t_
c1a0rt
c13!,.f
E
fr
tdl cnN/YEt--l
l6lgrf,---_-l
IOIREB
l-lrl
I'
I
LTGRNA/VHT
I
f€,]-BLK,rEf-__l
c351
Ft_
t-El-r
3l
l 1 I 2 'l u
l
l-,T,ITd
t_-Ttli I
l.l
16lvvrrr/BtK---.l
BLF--l
l g l c n N / B r KI ,
lETcRNi
ET-YtrrrruBiu-__-l lO YEvBru I
16rlsrK'
ET-
f+plr-,
--
I
-_l
q]54't
r,f,"|
I i IBLK4/VHT
I
lOlsLK
I
IO LGRN/REDI
NOTE:.
.
.
them
Differentwireswith the samecolor havebeengivena numbersuffixto distinguish
and YEUBLICare not the same).
O: Belatedto Fueland EmissionsSystem'
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutlins):View from wire side
(for example,YEUBLK'
{cont'd}
11 - 5 5
System Description
SystemConnectorslEngineCompartmentl{cont,dl
\
36 - 98 D15Y7€ngine:
'l
\,
11 - 5 6
c1o4
'1
c102
c101
ffi
l3l.l
f,ftl
f
6 WHT/BLU
BLI(YEL
YEVGflN
I BLU
BLK'
3 YEVBED
'4. B R N / 8 L K '
c104
lcanadal
r'ftl
c105
ffi
I. WHT/FED. I
| ? lEFN/8LK' I
f3TBr--/BEo-l
BLK,A/VHT
.alY E U B L K i
l 0 BLKYEL
c108
c107
c106
ffi
EE
ffi
c112
ffi
c113*!
r=1
,
'
l
\
\2
li
G R N -.
ftELiJ
-l
I
o
GRNELKI
o
ELUT
3
1
I
givena numbersuffixto distinguishthem {for example.YEUBLKl
NOTE:o Differentwireswith the samecorornavebeen
and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSystem
(cont'd)
with maleterminals(doubleoutline):View from terminalside
a - Connector
side
wire
from
(single
View
outline):
- Connectorwith femaleterminals
11-57
System Description
SystemConnectorsIEngineCompartment](cont,d)
\
'96 - 98 Dl6Y7
.ngin.:
\
I
11 - 5 8
c114
c109
ffi
r'ff;t
Flo-'u
I
l! veugLx' I
ftFwatu;'--l
r'ftr
BLKtEt
ffi
Flrl
I O I G F N '-
fdl'.,c---_l
l?
c123
cl18 {A/T}
cl17
16lBarr--
I
b]-Br.-^^,Hr-_-l
cl24 (A/Tl
c125
fr ffi
l3l.l
lTlzRN,tsril
---l I
l6l-YtL,
-l
lTltHr/R$'
loiiED/vEr--l
bfBaK/vEL- l
f!]BLX,1,,iHT'-l
t
I
l
YEUGNN
8LU5
@ CRN:
YELl
5
cl26 (A/Tl
fr
fol;nrr-_-l
lOlREo.
o
BIK3
BLU
10 8LX]"/E!
9
c121 |AFI
cl28lA/T)
ffi
Fl,l
16lwHr--l
I
lolFED/wHr I
fd-cRN/8tK'_]l
BEF
lOlREp
IC ISLU/YEL
I
c141r16
ffi
I
I
161-Grr.,*1/Hl
lO LTGBN,.VVHT
I
161-BIK/YEL-_--l
Gt54*,
F1Eh
l'l3LlJ
l6ElKl,,/Hr-l
-_l
I6TBLK
R/E D
IO LGRN
I
them
NOTE:o Differentwireswith the samecolorhavebeengivena numbersuffixto distinguish
L
(for example,YEUBLK1
and YEUBLK'are not the same).
O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
11 - 5 9
System Description
SystemGonnectorslDashand Floor]
'96 -
98 modols, 'gtl - 00 Dl6yS engine with M/T:
11-60
I
crlo tA/Tl
6 t 7
v
8 l s l r o' t l
12
!t
ffi
tffii
lEr.r.r,ll
l1 lslx,^/tl'
ll lsl'(^,!Hr
-]l
13 wHT,aLK
FF*
lllrlnEo'
l?IBLX
I
I
I
I
BLX
I
5
BLU
l-r-lw'r/cFNl'l
'
sdurnyAlrm sFr.m
a:2'
c125
w
l--r;-l
l! LcFN,.,vH?|
lalwHrresN I
lrl|
hl- -
L]-]llg!N ,-l
ll lcRY
I
l(JcRN^nH
PI
--.1
l6ltHrGFN
22
csto |ArIl
BLK
YEL
suffix to distinguishthem (Jorexample,YEUBLKT
Differentwires with the same color have been given a number
and YEUBLK'are not the same)
a o: Relatedto Fueland EmissionsSystem'
(cont'd)
side
a - Connectorwith maleterminals(doubleoutline):View from terminal
wire
side
from
- Connectorwith femaleterminals(singleoutline):View
NOTE: o
11-61
System Description
SystemConnectorslDashand Floorl(contd)
'96 - 98 models,'99 00 Dl6Y5 engine with M/T:
c432*13
11-6 2
(
(O16Y5,
Dl6Y8.nlin.3l
lOl6Y?.ngir.l
C134{EC[r,l/FCMal
ct33.r tFcM-B)
c t32 {ECt/r/pcM-a)
6
E
2
12 t 3 l/a 'ts t 6 1 7 1E l 9 20
21
2a 29 30
25
9
l0
tl
24
c{t3
ca3l
cr35lEcM/PCM-D)
ffi
f'Tfl'n
--Tttr-Ei ll
FltEtstK
l.
9
r o l r t
7
12 t 3
@
I-IBLffiHJ-Il]l
ltlcRr'r/wlr -l
l-''lwHtREcp
--l
liELx/wNr'
FfwNr/RED''_l
l
lTltHr/BL(
I
l!
2
12 1 3
a l 5
8
9 t0
1 7 t8 l9
ffi
FIrt
Irli I
tilwHT,"Ed-l
| . lcFMMr
I
11 BLX^VHT'I
B!x.^rHr
I
11
(for example,YEUBLKT
NOTE:e Differentwireswith the samecolor have beengivena numbersuffixto distinguishthem
same).
are not the
and YEUBLK'
O: Relatedto Fueland EmissionsSystem
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
11-63
System Description
SystemConnectorsIEngineCompaftment]
'99 - 00 D16Y5
ICVT),D16Y8engine:
cl14
*1: USA model
'2: A/T {D16Y7,
O16Y8engine)
*3: CVTlD16Y5engine)
*4:A/T and D16Y7engine
*5: ExceptA/T and D16Y7engine
*6: CVT {D16Y5engine).
O16YBengin€and
816A2 engine
*7: D'|6Y8,81642 engine
11-6 4
C142'3
c'r02
c101
r'fil--dl
_"1on
ffi
{Canada)
lrl2 3l
l3 {l
ffiffi
_-l
lSltHr/REo" ll
Fl xrvef
I
F]-wHrr+r/BLU
lElwHr/FED"lttl-R^r/BLrlSfBruritnEp-
c108
c'r04
A
---l
I€ IYEVBLKI
r-E--r
1 1 2 l
\^y
'-l-t_,
l 1 l 23 l
lglE*
C11,t
cl13*,
c109*.
|6IcFN;--l
FIBLr
I
l
|5lBwBuJ-u--l
c137r'
c138'5
c e
NOTE:.
.
.
c112"
ffi
c302
ffi
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1
and YEUBLK' arenot the same)
O: Relatedto Fueland EmissionsSystem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
11 - 6 5
System Description
SystemConneetorsIEngineCompartment](cont'd)
v
'9!l - 00 Dl6Y5
{CvT}, Dl6Y8 onginol
C14,0*3
c139
cl20
c1{{}
c122
11 - 6 6
c112
cl17
t1l2l
l1 2l3l
BLK'
YEVBLK]
BLKI
ELKI
YEUBLKI
YEUELKI
o
o YEVBLK'
0,
ALKI
(9 B L K '
BLKJ
YEVBLKI
c120r3
c118*'
ffil
l5l6l7lEl
a
BLU'
.11
c123
a
l1 2l
m
IoFED //Hr--l
1olcnlriBirc I
o
YEUGFN
J.
c122
v
l 1 l 2 l 3 l 1 l
l1 2l
REDl
l6ELK,wHr
c128r'
C.127.'
l6TE"^r"". 1
I
ItT"Eu
c140
Clitl
A
fr
f f i f f i f f i
Iij wHri FEDi_l
I a IGFN/BLK, I
I9 BLK,ryEL I
l1 2l
ll
lolTlx,wH-r'
c126r'
trtr
F-i
t 0 8LK/YEL
5
rffil
--l
FiiTwHr.
l€ cnN,,srr,I
121+'
lt|sLKrElll
ALKI
o YEL'
c125
|6l;LKr-----l
lOlELK,^/EL
ll I
I tlsLU^/vHl
8 BLK
1
o YEUELKI
ffi;F----
l,IRFD'
I
FlREo,-___l El;*lvr.l
lr lwHr'
l6EnNta,
--.l
l e r l c R N / w H r Ir
I
w
16lBLLliBLa--l
--_l
I6ELK'
l6lir cFlr/wnT
I]l I
ITIBL/./YEL
I
c143*3
c144*3
c145'3
ffi
_,q.
,---t
/-----f
t./t2ts al
lffi
l5lcl7l8l
11 2l
lr t2 3J
c147r3
c145.3
fr
\-/
ldElK ^iHrr_l
I J IWHr/BLK I
|-|cFN,RLr<,--1
I
trlwirmEp,I
l(1-]l68N,
I
l6tFtj--reDtsLu]
FIYEUR.I
c351
c352
1l5l
@
(,
(9 PNVBLU
PNI(BLK
l6FEDl.ryxF_l
l
fdvi Hr.
GRN/YEL3
C35/a'1
Lr/H-1-_r
/it El
toltrl
it] GRN/BLK]
o
f,ftf
l5l0
GRN
2
3 WHT/BLK
o
16l BLK/wHr
I-l I
16lgl(
16lGBNinEol
9
i,
o
6 BLX'EL
1
aL&a€D
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKT
and YEUBLK'are not the same).
o: Relatedto Fueland EmissionsSystem
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
(cont'd)
11-67
System Description
SystemConnectorslEngineCompartmentl(cont'dl
\
'99 - 00 D16Y7engine:
I
I
11 - 6 8
a
c101
c106
c102
c104*,
C1oia
{Canade)
c10s
f'tr]
rftr
r'ffi-a
ffi
c107
ffi
ffi
c113r'
c3o2
a
EE
c10B
ffi
c112
ffi
tu
(for example,YEUBLK'
Differentwires with the same color have been given a number suftix to distinguishthem
and YEUBLK'are not the samel.
a O: Relatedto Fu€land EmissionsSystem.
(cont'd)
a - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wir€ side
NOTE: .
11-69
System Description
SystemConnectors[Engine Compartmentl(cont,d]
'99 - 0OD16Y7
€ngin€:
11-7 0
r'ft]
@
_-l
flofr-N
cl16
c115
c11a
cl10
c109
o
.!l GBN/8TKI
8TK?YEL
o
2 BLICYEL
BLK/YEL
BLfiEL
(t BLK/YEI
ItIYEUBLK, I
IEIBLvBLU' I
o
. . + ,
lOlGBN,
c123
ffi
1
l+'.1'+:l
l-l,l
@fBLK-_-l
GRN/BLK'
cl20
c11EtA/Tl
F1ftr
GRN/BLK
12
!3 GRN/BLX'
BLKJ^/EL
8LK/YEL
clr7
GffN/8TK1
@ GNN/aLK?
I
f6lBr-r,--l
I a BLKTYEL-l I
|ol-Balro/Hl
c121lAtfl
l-lrl
c125
rfrr
Etr
M c n N / B L K ' __-l
I I t lwHriREo'
_-l I
ItrIRED/YEL,-l
f4tEr--
c126lA/Tl
fr
c128(A/Tl
c12t l[lTl
_El-
ffi
I ' l, l
_l
EIwHI-__-lI
l€)lFEp5
EIWHF
l(?lREp,
IOIBLUryEI' -lI
I
161-crNalrHr'
c141
ffi
16TLr cRN^/v-H;l
161-BrxtEL-__l
blBLK Ea
ftl BLK^tHi'l
c351
c352
(xlsarr
Ftr.T
l6ELffiHr-]
-___-l
tr18!(
lglcRN/REp
I
(for example,YEUBLKl
Differentwireswith the samecolor haveb6engivena numbersuffixto distinguishthem
the
same).
not
and YEUBLK' are
a O: Relatedto Fueland EmissionsSystem.
(cont'd)
a - Connectorwith maleterminals(doubleoutlinel:View from terminalside
- Connectorwith femaleterminals(singleoutlin€):View from wire side
NOTE:.
11-71
System Description
SystemConnectors[EngineCompartment](cont'dl
816A2engins:
11-72
F1+..r
l 1 2 3 l
.1' BLKYEL
e
BLKI
6 WHT/BLU
1 YEUGRN
3 YEUREO
8
5 l YEUBLKI
9 BLKryVFT
10 BLK,ryEL
C10,1
(Canadal
c104
c102
c101
l 1 2 l
l-f.l
-l
16lwHrsEo.
cl t3
c107
c108
ffi
ffi
ffi
I2 BLK/YEL
D
ffi
l3 4l
C11il
ffi
c137
a
:d) GBN/BLK'
GRN/8LK'
GRN/BLK'
BLK,YEL
rlj
ELKTYEL
BLI(YEL
I
ftlwHri BLUIl'l
c123
3
ffi
Irlz 3l
--.l
ffl'wHnr€D"
ItrERlxBLa__l
lo."llBurntotl-l
c106
BLK^/EL
2 BLK/YEL
c105
GRN/BLK'
12
rt
GFN/BLK'
!l
c138
c302
A
v
tu
FTBtKiBLtr__l
lZTYEuBLKi l
NOTE:o Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKl
and YEUBLK' arenot the same).
a O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
(cont'd)
- Connectorwith femaleterminals(singleoutline):View from wire side
11-73
System Description
SystemConnectors[EngineGompartmentl(cont'd]
81642 enginoi
11-7 4
v
c112
ffi
c122
cl17
A
,g
r'trTl
16lBLK,-__-l
lO BLX,\,E[
|
l-iln'eo*r,vHr__-l
l[lcRNiBLitl]l
16l Btu/wil-
Cliro
o
_-l
l6l-ciN/YEL'
C1'11
ffi
c'54*1
f r lz l s l
fflErKwH---l
lOlBLr
-lI
f6lGrrunEp
NOTE:.
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1
and YEUBLK' arenot the same).
O: Relatedto Fueland EmissionsSystem,
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
11-75
System Description
a
SystemConnectors[Dashand Floor]
('99 - fil models except D16Y5engine with M/Tl
11-76
L
a
L
a
v1 s
t5
t 2 13
8 l 7 l 6 l et 0r l ! 2 1
14
i! a L (
5
LTATU
1
E
t0 t 1
,/ ./ie /
1Al,/ 20
2
9 t0
a
l 2 13111/
l6 1 7 1 8
!t
t1t
' S€cuitAr.h
Sysi.m
cL5
lwithod cruir. cort?oll
elz5
{with crui*
r'ffitr
;--F-t r t 2 l
w
l-T l .
-
codrol)
1 3 r l
2 3 I
1 0 1 1 12 t3
/lr5l/
7 a 9
18 t9
12
--l
lElwHT"cRN I
I
YEL
c510ta/T)
YEL
2
3LK
YEL
f,ED/BLK
.!
D
t!
(for example,YEUBLKl
Differentwires with the same cotor have been given a number suffix to distinguishthem
and YEUBLK' arenot the same).
a O; Relatedto Fueland EmissionsSystem
(cont'd)
a - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
NOTE: o
t-
11-77
System Description
SystemConnectorslDashand Floor](cont'dl
('99 - 00 mod€ls oxc€pt Dl6Y5 ongine with M/T)
11-78
ct3r
c130
1 l z 3 l t / X 6 1 7 8 9 t o
10
I
l 1 12 13 1,4 t 5 t a 1 1 t 8 t 9
cr35lPcl|.D,€
cr35 lPCM-Dr:
cr34 tEcM/PCM-C)
ca32
l r 2 3 . 1
't/
/ t g
3l-1.
to
'lt
5
1
lll*
Ill
IiGTNiBN
l5l-wxr,nol]l
l:a BLXvHI
at6
2
111'12
It
lrl2l
12 l 3
tn Bs
I
E e t|0
I t It[l
-_-l
I
I
c,|52tEcM/PCM-Al
c1a
lr 2l
f.fil
,bl onrrwlrl.l
ftlBLrwHri- l]-l
Flirx,lvHJ
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLK1
and YEUBLK,are not the samel.
a O: Relatedto Fueland EmissionsSvstem.
- Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from wire side
NOTE;.
\-
11-79
SystemDescriptions
SystemConnectorslFuelPump]
\
('9!,- 00 models 6xcept Dl6Y5 ongino with M/T)
I
c565
c568
E ffi
NOTE: o
c792
c793
fr
Differentwireswith the samecolor havebeengivena numbersuffixto distinguishthem (for example,YEUBLKI
and YEVBLK,are not the same).
a O: Relatedto Fueland EmissionsSystem.
a - Connectorwith maleterminals(doubleoutline):View from terminalside
- Connectorwith femaleterminals(singleoutline):View from
wire side
11 - 8 0
(
Troubleshooting
TroubleshootingProcedures
How To BeginTroubleshooting
problem,usethe appropr'When the MalfunctionIndicatorLamp (MlL)has beenreportedon, or there is a driveability
problem'
the
repair
ate orocedurebelowto diagnoseand
A. Whenthe MIL hascome on:
,1.connectthe HondaPGMTesteror an oBD ll scantool to the 16PData Link connector(DLC)locatednearthe left
kickpanel.
2. Turn the ignitionswitchON (ll)
3. Checkthe DTCand note it. Also checkand note
the freezetramedata
Referto the DiagnosticTroubleCode Chart and
begintroubleshooting.
MALFUNCTION
INDICATOR
LAMP
NOTE:
.SeetheoBD||scantoolorHondaPGMTesteruser,smanua|sforspecificoperatinginstructions..
.Thescantoo|oltestercanreadtheDiagnosticTroub|ecodes(DTc},freezeframedata,currentdata,andoth
ControlModule(PCM)data'
EngineControlModule(ECM)/Powertrain
oFreezeframedataindicatestheengineconditionswhenthefirstma|function,misfireorfue|trimma|functio
was detected.lt can be usefulinformationwhen troubleshooting'
problem,referto the SymptomCharton page 11-84'
B. Whenthe MIL hasnot come on , out thereis a d riveability
c.DTcswi|lbeindicatedbytheb|inkingoftheMa|function|ndicatorLamp(M|L)withthescsserviceconnectorco
nected.
shown (The 2P ServiceCheckConnectoris
Connectthe SCS serviceconnectorto ServiceCheckConnectoras
|ocatedunderthedashonthepassenger,ssideofthevehic|e')TurntheignitionswitchoN{||)'
OBOll SCANTOOLol
HONOAPGM TESTER
scs sERvlcE
Il6PI
DATA LINKCONNECTOR
SERVICECHECK 07PAZ- (x)l0100
CONNECTOR
I2P)
(cont'd)
11-81
Troubleshooting
TroubleshootingProcedures(cont,dl
ll,
EngineControlModule(ECM)/powertrain
ControlModule(pCM)Resetprocedure
NoTE: Resettingthe EcM/PcM will erase any stored DTcs and any
freezedata. lt will also restart all readinesscode
monitors.
Eitherof the followingactionswill resetthe ECM/PCM.
.
Usethe OBDll scantool or HondapGM Testerto clearthe EClM,s/pCM,s
memory.
NorE: see the oBD ll scantool or HondaPGMTesteruser'smanuals
for specificoperatinginstructions.
'
Turn the ignition switch oFF. Removethe BACKuP (7.5A) fuse from
the under-hoodfuse/relaybox for 10 seconds.
NorE: Bemovingthe BACKuP (7 5 A) fuse cancelsthe clockand the
radio presets.Make note of the customer,s
presetsso you can resetthen
lll. FinalProcedure(thisproceduremust be done afterany troubleshoottng)
1. Removethe SCSServiceConnectorif it is connected.
NoTE: If the Scs serviceconnectoris connectedand there are no DTcs
storedin the EcMipcM,the MtL will stay
on when the ignitionswitchis turnedON 0l).
2. Do the ECM/PCMResetprocedure.
3. Turnthe ignitionswitchOFF.
1-82
checksat the ECM/PCMconnectors,removethe right
lf the inspectionfor a particularcode requiresvoltageor resistance
ABS control unit if so equipped.unbolt the EcM/
the
Remove
ECM/PCM.
the
to
expose
kick panel.Pull the carpetback
as describedbelow
PCM bolt. Turn the ignition switch oFF, and connectthe backprobesets and a digital multimeter
pages'
following
listed
on
the
checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)
The illustration
shows '96 - '98 models.
KICK PANEL
How to Use lhe BackprobeSets
to a multimeter.using the wire insulaconnectthe backprobeadaptersto the stackingpatchcords,and connectthe cords
into the connectorfrom the wire side
gently
the
tip
slide
adapter.
tion as a guide for the contouredtrp of the backprobe
wire'
the
end
of
with
terminal
until it comesin contact
BackProbe
SET
BACKPROEE
lTwo
07SAZ- 001000A
DIGITALMULTIMETER
(Commerciallyavail.bleI or
(cont'd)
Ks - AHM - 32 - oo3
11 - 8 3
Troubleshooting
TroubleshootingProcedures(cont,dl
\
CAUTION:
. Punqturingihe insulation on a wirs can causepoor or intermiftent electricar
connections.
I Bring the test€r probe into contacl with the terminatlrom the terminal
side of wire harnesgconncctors in the gngin€
compartment. For temale connectors,iust touch lightly with the tester probe and
do not inse.t the probe.
RUBBERSEAL
TESTERPROBE
TERMINAL
Symptom Chart
Listedbeloware symptomsand probablecausesfor problemsthat Do NoT causethe Malfunction
indicatorLamp(MlL)to
c o m eo n . l f t h e M I Lw a s r e p o r t e do n , g o t o p a g e1 1 _ 8 1 .
Troubleshooteachprobabrecausein the orderristed(from reftto right)untirthe symptom
is eriminated.
The probablecauseand troubleshooting
pagereferencecan be found berow.
*: '99 - 00 models
SYMPTOM
PROBABLECAUSE
Enginewill not start
4 , 2 , 3 ,5 , 2 0 ,1 4 ,1
Hardstarting
2, 4, 11, 16,13,'t9
Coldfast idle too low
?, s^6. 16
Cold fast idle too high
1,8,10.9
ldle speedfluctuates
7 , 8 ,1 0 . 9
Misfireor rough running
Troubleshoot
for misfireon pagesl1-166,167
2,9, 10,12, 11, 16,'t8,20
LOW power
E"g|*
"t"lb
Difficultto refuel*
2,4,11,7,20,8,5,15
't9,
21
Fueloverflowsduring refueling*
1r,,1
OtherProbableCausesfor an enginethat will not start:
- Compression
- Startingsystem
- lntakeair leakage - Overheating
- Enginelockedup - Battery
- Timing belt
11-84
L
I
ProbableCauseList lFor th€ DTCChart, see page 11-971
ProbableGause
Page
1
11 - 1 0 7
2
11-230,231
't't-237
3
Section23
*: '99 - 00 models
System
ControlModule(l'uM)
EngineControlModule(ECM)/Powertrain
PGM-Flmain relay
l^^iti^n
cwetam
't1-124
Fosltlonsensorclrculr'Lr\Fselrsor
CrankshaftPosition/fopDeadCenter/Cylinder
circuit
IntakeAir Temperature(lAT)sensorcircuit
7
11 - 1 9 4
ldle Air Control(lAC)Valve
I
11-220- 223
5
1' 1-172,183
ldle speedadjustment
11-241
ThrottlebodY
'10
11-244
Throftlecable
11
11-115
12
11-132
't1-178
ManifoldAbsolutePressure(MAP)sensor
ThroftlePosition(TP)sensor
13
14
15
16
Barometricpressure(BARO)senso'
switchsignal
Section14.11-218 Mf g"a, po"itionsignal(seepage11-216)or clutch
Brakeswitchsignal
11-210
't1-244
Air Cleaner
lntakeair pipe
18
11-252
19
11-261
fuel
Contaminated
20
21*
Three Way CatalyticConverter(TWC)
emission(EVAP)control
Evaporative
11-296
ORVRvent shut valvs
(cont'd)
11-85
Troubleshooting
TroubleshootingProcedures
(cont,dl
(
ECM/PCMData
By connectingthe OBD ll scantool or the HondapGM Testerto the l6p data link connector(DLC),
variousdata can be
retrievedfrom the EcM/PcM.The itemsIistedin the table belowconformto the sAE recommendedpractice.
The HondaPGMTesteralso readsdata beyondthat recommendedbv SAE.
understandingthis datawil help to find the causesof intermittentfairuresor engineprobrems,
NOTE:
' The "operatingvalues" given below are approximatevaluesand may
be differentdependingon the environmentand
t h e i n d i v i d u avle h i c l e .
. Unlessnotedotherwise,"at idle speed,,meansidlingwith the enginecompletely
warmed up, Ay'Tin position@ or E],
M/T in neutral,and the Ay'Cand all accessories
turnedoff.
Data
Description
Operating Value
Diagnostic
TroubleCode
(DTC)
lf the ECM/PCMdetectsa problem,it will storeit as a
code consistingof one letterand four numbers.
Dependingon the problem,an SAE-defined
code (poxxx)
or a Honda-defined
code (Plxxx)will be outDutto the
rester.
lf no problemis detected,
there is no output.
EngineSpeed
The ECM/PCM
computesenginespeedfrom the signals
sent from the Crankshaft
Positionsensor.
This data is usedfor determiningthe time and amountof
fuel injection,
Nearlythe sameas
tachometerindication.
The ECM/PCM
convertspulsesignalsfrom the Vehicle
SpeedSensor(VSS)into speeddata.
The absolutepressurecausedin the intakemanifoldbv
engineload and speed.
Nearlythe sameas
speedometerindication
YES
With enginestopped:
Nearlythe sameas atmospheflcpressure
At idle speed:
24 - 31 kPa(180- 280
m m H g ,7 . 1- 1 1 . 0i n H g )
YES
VehicleSpeed
Manifold
Absolute
Pressure{MAP)
E n g i n eC o o l a n t The ECTsensorconvertscoolanttemperatureinto volt_
Temperature
age and signalsthe ECM/PCM.
The sensoris a thermistor
(ECT)
whose internalresistance
changeswith coolanttemDera_
ture.The ECM/PCMusesthe voltagesignalsfrom the
ECTsensorto determinethe amountof iniectedfuel.
HeatedOxygen The HeatedOxygen Sensor detectsthe oxygen content
Sensor{HO2S) in the exhaustgasand sendsvoltagesignalsto the
(Primary,
ECI\4/PCM.
Basedon thesesignats,the ECM/pCMcon_
S e n s o r1 )
trols the airlfuelratio.Whenthe oxygencontentis high
(Secondary
(thatis, when the ratiois leanerthan the stoichiometric
Sensor2)
ratio),the voltagesignalis lower.
Whenthe oxygencontentis low (thatis, when the ratio
is richerthan the stoichiometric
ratio),the voltagesignal
is higher.
11 - 8 6
FreezeData
YES
With cold engine:
Sameas ambienttemper,
atureand IAT
With enginewarmed up:
176- 194.F(80- 90.C)
0 . 0- 1 . 2 5V
At idle speed:
about0.1- 0.9V
YES
YES
NO
( S e n s o1r )
Data
HO2S
Feedback
Loop Status
ShortTerm
FuelTrim
LongTerm
FuelTrim
lntakeAir
Temperature
{IAT)
Throttle
Position
lgnition
Timing
Calculated
LoadValue
{CLV)
Descriotion
"open" or "closed"'
Loopstatusis indicatedas
Closed:Basedon the HO2Soutput,the ECM/PCMdeterminesthe airlfuelratioand controlsthe amountof inject-
Operating Value
At idle speed:closed
ed fuel.
Open:lgnoringHO2Soutput,the ECM/PCMrefersto signalsfrom the TP,MAP,and ECTsensorsto controlthe
amountof injectedfuel.
! 20%
The air/fuel ratio correction coefficientfor correctingthe
amountot injectedfuel when H02Sfeedbackis in the
closedloop status When the signalfrom the HO2Sis
weak,shortterm fuel trim gets higher,and the ECM/PCM
the amountof injectedfuel The airlfuelratio
increases
graduallygets richer,causinga higherHO2Soutput
the shortterm fuel trim is lowered,and
Consequently,
the ECMiPCMreducesthe amountof injectedfuel
This cvclekeepsthe airlfuelratiocloseto the stoichiometricratiowhen in closedloop status'
! 20%
Longterm fuel trim is computedfrom shon term fuel
supply
the
fuel
in
occurring
changes
trim and indicates
svstemover a long Period
lf long term fuel trim is higherthan 1.00,the amountof
injecGd fuel must be increased.lf it is lower than 1 00'
the amountof injectedfuel must be reduced'
The IAT sensorconvertsintakeair temperatureinto voltWhen intakeair temperaage and signalsthe ECM/PCM.
of the sensor
ture is low, the internalresistance
increases.
and the voltaqesignalis higher'
F eeza Data
YES
YES
YES
With cold engine:
Sameas ambienttemPer'
atureand ECT
YES
pedalposition,the open'ng
Basedon the accelerator
is indicated
valve
angleof the throttle
lgnitiontiming is the ignitionadvanceangleset by the
gCV/eCV.tn" gCU/PCMmatchesignitiontiming to the
drivingconditions.
At idle speed:
approx.10 %
YES
At idle speed:12'i 2'
(81642engine:16"t 2")
BTDCwith the SCSservice connectorconnected.
NO
CLVis the engineloadcalculatedfrom the MAP data'
At idle speed:
15-35%
At 2.500rpm with no load:
12 - 30%
YES
r o
11-87
Troubleshooting
Engine/P_o,weft
rain ControlModuleTerminal Arrangement
('96- 98 Models,'99- 00 Dl6ySenginewith M/T) ECM/PCMCONNECTOR
A I32PI
1
2
1
I N J 6 INJ3 INJ2 I N J l
1 2 13
ACV
11
5
6
7
I
1 5 1 6 1 7 1 8 1 9 20
PCS FLR acc MIL ALTC tcM
27
2A 25 30
LG1
22
10
PGl
l1
IGPl
PG2
21
IGP2
VSVSLU
ECM/PCMCONNECTOR
A (32P)
Wire side of female terminals
NOTE:Standardbatteryvoltaget s 1 2
Sign.l
1
YEL
BLU
8ED
2
3
88N
5
BLXAVHT
6
FED{
l N J 4 ( N o . 4 F U E LI N J E C I O B )
D ves No 4 ruel injector.
l N J 3 l N o . 3 F U E LT N J E C T O B J
D r i v e sN o . 3 l u e I n t e c l o r .
I N J 2 ( N O ,2 F U E I I N J E C T O N )
Drives No. 2 iuel njector.
l N J l ( N o . 1 F U E LI N J E C T O B )
SO2SIITC(SECONDAFYHEATED
OXYGENSENSOFHEATEFCON
TFOL)
PO2SHTC(PRIMAFYHEATEO
O X Y G E NS E N S O RH E A T E R
CONTROL)
ESOL (EGF CONTRO!
SOIENOIO VALVE)
Dives No. 1 ruelinjector.
Orives secondary heated oxyqen sensor
9
With ignilion switch ON (lll: batery vo lage
W i t h f ! l l y w a r m e d u p e n g i n er u n n i n q : d L t vc o n t r o l e d
Drives prihary healed oxygen sensor
W i t h i g n i t i o ns w i t c hO N l t t ) : b a n e r y v o t t a s e
w l h r d l l y w d r m e d u p c n g n e , L n n r r dq u r y , o r l . o t r e d
D r i v e sE G F c o n l r o l s o l e n od v a t v e .
Wilh EGRoperating during drving wiih fu|y warmed
up engrne:duty controtted
W i l h E G F n o l o p e f a t i n g : OV
W i t h E G F o p e r a t i n gd u . i n g d r i v o g w i l h i u t y w a r m e d
u p e n 9 i n e :d u t y c o n t . o l t e d .
With EGR not ooeralino; o V
E.EGR
8*r/
W i l h e n g i n er u n n i n q :d d l y c o n i r o t e d
GFN/YEL
WS (VTECSOLENOTD
VALVE)
Drives VTECsolenoid va ve
BflN/BLK
L G 1 ( L O G I CG R O U N D )
W i l h e n g n e a t o w e n g i n es p e e d : OV
Wirh engine at h gh enqine speedr banery vohaae
G r o ! n d l o r t h e € C M / P C Mc o n l r o t c r c u i t .
L e s s l h a n1 . 0V a t a t t i m e s
t0
ALK
P G 1I P O W E FG F O U N D )
G r o u n di o r r h e E C M / P C Mp o w e r . t c u f .
11
YEVBLK
IGPTiPOWEFSOUFCE)
Power source forthe Ec[,l/PcM conlro
BLVBLU
IACV(IDLEAIN CONTROLVALVE)
Wilh ignition swirch ON (tt): battery voltage
With gntron switch OFF:0 V
W i l h e n g i n er ! n n n g : d l t y c o n t r o e d
Orives IAC vaive (posilive side).
FEO/YEL
I A C VN l I D L EA I 8 C O N T F O L
VALVE NEGATIVESIOE)
IACV P (IDLEAI8 CQNTROL
VALVE POSITIVESIDE)
PCS (EVAPPURGECONTFOT
SOIENOIOVALVE)
Drives EVAP pu.ge controtsolenoid vatve.
W i l h e n g i o er u n n i n g ,e n g i n €c o o t a n ib e t o w 1 5 4 , F
'68'Cr bancry vohaSe w'ln ens nc runn,.o. eng,rc
GRN/YEL
FL8 (FUELPU[4P FELAY)
O r i v e sf u e l p u m p r e l a y .
0 V {or two secoros ahe' tJ n ng 'onir or \wnch ON ,,,,,
I7
BLI(REO
ACC (A,/CCLUTCHRELAY)
Drives A/C clutch relay.
18
GFN/ONN
W i r h c o m p r e s s oO
r Nr0 V
Wilh compressof OFF:banery votrage
W i t h M I L l L r n e dO N : 0 V
With illl turned OFF: banery volaqe
Wirh fully warmed.up engine ru.ntng: battery votlas€
During drivins wnh smatl eteclricattoad: O V
w i t h i g n l t l o ns w i l c h O N ( t l ) : b 6 n € r yv o h a g e
W i l h e n s i n er u n n i n s :a b o u l t 0 V ( d e p e n d i n go n
o8N
13,.
BLVBLU
Drivesthe IAC valve {negalive side).
MIL (I\,lALFUNCTION
INDICATOF
19',
AITC {AITERNAIOR CONIROL)
20
YEVGRN
NO N T R O L
I C M ( I G N I ' T I OC
MOOU!E)
22
23
BRN/BLK
BLK
L G 2 ( L O G I CG A O U N D )
P G 2i P O W E AG R O U N D )
Ground for the ECM,/PCM
conrrot ci'cu L
G r o ! n d l o r t h e E C M / P C Mp o w e r c i r c u i r .
Lessthan 1.0V at a tt mes
24
YEUBLK
lGP2 (POW€RSOUSCE)
Power sou.ce lor the ECM/PCl, conrrol
VSEFIREFEflENCEVOLTAGE)
Wnh ignilion swilch ON {it):battery vohage
W i l h i g n i l i o ns w i t c hO F F : 0V
ProvrdesreferencevoIaOe to TCM.
FANC {RAOIATORFAN
CONTFOL)
2WBS (EVAPBYPASS
SOLENOIOVALVE]
VSV (EVAPCONTFOTCANISTEF
VENT SHUT VAIVE)
KO N T F O L
S L U ( I N T E F L O CC
UNIT)
r V
W i t h i g n i t i o ns w i t c hO N ( t t ) : a b o u 5
W t h g n i t i o ns w l t c hO F F :O V
Drives radialof fan ielay.
WHT/FED
25*6
21'1
GFN
BL!
LT GRNA/VHT
WHT/NED
'2: A./T(D16Y7,016Y8
engine)
13: CvT (D16Y5enoin€)
',4: A/T and D16y7 engine
*5: ExceptA/T and D16Y7€nsine
'6r A/T (D16Y8ensine)
'7 Cw
1D16Y5
e n g , n e la n d D 1 6 y 8e n s r n e
se.ds ahernator controt signat.
Orives EVAP bypass sotenotd va !e.
W i t h i g n i r i o ns w r r c hO N ( t t ) : b a r e r yv o r a s e
Drives EVAP conlfot canisrer venl shul
w n h i g n i r i o ns w ' t c hO N l r | l b a r e r y v o l a q e
Detects intenock conlrotLn t signal
W h h i g n i t i o ns w i t c hO N ( t t ) a n db r a k ep e d a
depf essed: battery vollage
'"'3:Bi..I?'Jt;".'e'.!ti.?i?l'""."T8"_";btfr
"fl
11 - 8 8
With radialor fan f!nn nqr O V
Wilh radiato.tan stopped: battery
'10i i,4/T(D16V5engine)
r 1 1 E x . e p tM / l ( D 1 6 V 5
enqinel
r 1 2 : 0 1 6 Y 5 ,D 1 6 Y Be n q i n e
r 1 5 : ' 9 7 0 1 6 Y 7e n g i n e
l c o u p e :K L m o d e t ,s e d a n :K L ( L X l m o d e t ) ,
'98D16Y7
engine
B {25P)
PCMCONNECTOR
Wire sideof {emaleterminals
B (25P)',
FCM CONNECTOR
Terminal
Wire
numoer
cotol
1
2
3
4
5
8
1l
12
13
14
RED
BLU/YEL
a
Terminal
name
Description
SOLENOID Groundfor linearsolenoidvalve
LS_(LINEAR
VALVE- SIDE)
-Drii6l
linear solenoidvalve
LS+(LINEARSOLENOID
VALVE+ SIDE)
-Drives
shift controlsolenoidvalveA
SHA{SHIFTCONTROL
VALVEA)
SOLENOID
Driveslock up controlsolenoid
valveB.
Driveslockup controlsolenoid
CONTROL
LC B (LOCK'UP
VALVEB}
SOLENOID
CONTROL
LCA (LOCK.UP
YEL
VALVEA)
SOLENOID
ATPD3(NT GEARPOSI.
PNK
TIONSWITCHi
SHB(SHIFTCONTROL
VALVEB)
GRN^lr'HT SOLENOID
GRN/BLK
CON
SLU (INTERLOCK
WHT/RED TBOLUNIT)
D4 IND(D4INDICATOR
GRN/BLK LIGHT)
WHT
RED
!
NOTE:Standardbatteryvoltageis 12 v'
't1
BLU
22
GRN
23
BLU
24
YEL
25
LT GRN
DetectsPy'Tgear Positionswitch
signal.
DnGs shift conttolsolenoidvalveB
-DlivEilite'lock
control,rnit.
NMSG{MAINSHAFT
GROUND)
SENSOR
SPEED
SPEED
NM {MAINSHAFT
SENSOR)
ATPR{M GEARPOSI
TIONSWITCH)
ATP2{A/T GEARPOSI
TIONSWITCH)
NCSG(COUNTERSHAFT
GROUND)
SENSOR
SPEED
NC (COUNTERSHAFT
SPEEDSENSOR)
ATPD4{M GEAFPOSITIONSWITCH)
ATPNP(A"/TGEARPOSI
TIONSWITCH)
DrivesD4 indicatorlight.
GZiiI'for
Wii-ignnionswitctroN {ll}:pulses
With ignilionswitchuN (lll:pulses
With enginerunningin 2nd,3rdgears:
batteryvoltage
With enginerunningin 1st,4thgears:
about0 V
With lock-upONI batteryvoltage
With lock-upOFF:0v
With lock-uPON: bafteryvoltage
With lock-upOFFi0 V
In [D31position: 0 V
ln ;y other position: battery voltage
With enginerunningin 1st,2nd:battery
vo|taqe
With;ngine runningin 3rd,4th:about0 V
With ignition switch ON (ll) and brake
pedaldepressed:0 V
With Pll indicator lrghtturneo urr: oarterv
voltaoe
W i t h l d i n d i c a t o r l i g h t t u r n e d O F F :0 v
mainshaftspeedsensol
Detectsmainshaftspeedsensor
srgnal.
DetectsM gear Positionswitch
signal
DetectsA/T gear Positionswitch
signal.
Ground for countershaftspeed
sensor.
Detectscountershaftspeedsensor
signal.
DetectsM gearPositionswitch
signal.
Detects A/T gear Position switch
srgnal,
* 1 i U S Am o d e l
*2: A/T (D16Y7,Dl6Ygengine)
*3: CVT(D16Y5engine)
*4: M and Dl6Y7engane
*5: ExceptA.rTand 016Y7engine
*6: A,/T(D16Y8engine)
*7r CVT(D16Y5engine)and D16Y8engine
* 8 : ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) , ' 9 7D 1 6 Y 8e n g i n e ( c o u p e : a l l
m o d e l s ,s e d a n :K L m o d e l ) , ' 9 8D t 6 Y 5e n g i n e , ' 9 8 D 1 6 Y 8
engine,'99 00 Dl6Y51M/Tiengine
Signal
Withenginerunning:
Pulses
0V
InE position:
In any other position:batteryvoltage
I n E p o s i t i o n0:V
In any other position:batteryvoltage
Vvithignition switch ON (ll), and front
wheels rotating: Pulses
ln E position:0V
In any otherposition:5 V
0
I n E o r E p o s i t i o n :V
In any other position:batteryvoltage
*9: D16Y5engine
*10:M/T (D16Y5engine)
*11:ExceptM/T {D16YS
engine}
*12i D16Y5,D16Y8engine
* 13:D16Y8engine
*14:D16Y7engine
*15:'97 Dl6YTengine(coupe:KL model,sedan:KL (LX)model)'
'98D16Y7
engine
(cont,d)
11-89
Troubleshooting
Engine/P_o_wgrtrain
ControlModuleTerminalArrangement
('96- 98 Models'99 - 00 Dt6y5 enginewith M/T) tc'oniOi
ECM/PCMCONNECTOR
C {31PI
1
2
a
CKFPCXPP TDCP
12 13 1 4
7
5
ACS
t5
sTsscs
1 5 17
ALTF
23 21 25
lP+
ECM/PCMCONNECTOR
C (31PI
I
I
10
rMA v8u
TE
vss
29
30
TMA
Wiresideof femaleterminals
NOTE: Standard baftery voltage is 12 V
To.min!l
number
Wira
coloa
1
2
3
BLU/RED
BLU
GRN
YEL
4
5
BLU/FED
6
BLU/ORN
8RN
LT8LU
Torminal
name
CKFP(CKFSENSORP SIDE)
CKPP(CKPSENSOF
PSIDE)
TDCP{TDCSENSOR
PSIDE}
10
WHT/BLU
11
WHT/RED
12
RED
14
BLK
15."
BLU/BLK
DetectsCKFsensor.
DetectsCKPsensor.
DetectsTDC sensor,
CYPP(CYPSENSORP SIDE)
DetectsCYPsensor.
ACS{Tr'CSWITCHSIGNAL)
Detects,ay'Csw;tch signat.
STS(STARTER
SWITCH
SIGNAL)
SCS(SERVICE
CHECK
SIGNAL)
Detects staner swilch signal,
K , L I N E( D L C )
GRY
9+3
Do6criptlon
VBU(VOLTAGE
BACKUP)
S e n d sa n d r e c e i v e ss c a ni o o l s i g n a l ,
D a t 6c o m m u n i c a t i o nw i t h T C M : E C M
control ctat6output
Power source forthe ECM/PCM
control circuit. Power sourc€ lorthe
DTC memory
Wirh ignition switch ON { ): about 5 V
W i t h i g n i t i o ns w i t c h O N ( t t ) : p u t s e s
TDCI\4(TDCSENSORM
SIDE)
CYPM (CKPSENSOB M
SIDE}
Groundfor TDCsensorsignal.
GRN
'17
Groond for CYP sensor signal.
OetsctsVTECpressureswitchsignal.
swtTcH)
ALTF (ALTERNATORFR
SIGNAL)
VSS{VEHICLE
S P E E DS E N SOR}
Detects ahernator FR signal.
BLK
lP+{HO2SPUtr4P
CELL+}
RED
rP-,vs- {Ho2scoMt oN)
ControlsHO2Spumpce .
Reference
voltagesupply.
LTGRN*'
VS+(VSCELLVOLTAGE)
ATPNP(Ar'TGEARPOSI,
TroN swrTcH)
CLSW(CLUTCH
SWITCH}
WHT/RED
18
BLUI/VHT
23+14
24.10
25*ro
29
RED{ro
30
PNK4
TMB
OetectsVSS signal.
DetectsVS cell voltage.
Deteds Ay'Tg6srposhion switch signat.
Detectsclutch switch signal,
Data communication with TCM:
E C M c o n t r o l d a t ai n p u t
'1: USA model
r 2 r A , . T( D 1 6 Y 7 O
, 1 6 Y 8e n s a n e )
* 3 : C V T( O 1 6 Y 5e n g i n e )
*4: Ay'Tand O16Y7engine
'5: Excepl A./T
snd Dl6Y7 engine
16: Ay'T(D16Y8ensine)
{ 7 : C V T( D l 6 Y 5 e o s i n e )a n d
O 1 6 Y 8e n o i n e
"8: 96 Dl6Y8 engine(coupe),'97
D 1 6 y 8 e n g i n e ( c o u p e :a t l
'99 - 00
:ed-9I t!!rnodelr,'98 D16y5ensine,,98D16y8e;sine.
D 1 6 Y 5l M / T ) e n s i n e
11 - 9 0
Battery voltage at all times
Groundfor CKPsensors;gnat.
(P/SOILPRESSURE Detects PSPswitch signal.
PSPSW
16
W i t h e n g i n e r u n n i n g :p u l s e s
With Iy'C switch ONr 0 V
With Ay'Cswitch OFF:batrery vottage
W i t h s t a n e rs w i t c h O N l t l t ) :b a t e r y v o h a g e
With staner switch OFF:0 V
Withthe connectorconnected:
OV
with the connectordisconnected:
about5 v
or batteryvoltage
Groundtor CKFsensorsignal.
swtTcH)
Withenginerunning:
pulses
W i t h e n g i n e r u n n i n g :p u l s e s
W i t h e n g i n er u n n i n g :p u t s e s
Detectsservicecheckconnectorsignal
{thesignalcausing
a OTCindicationl
CKFM{CKFSENSORM
SIDE)
CKPM(CKPSENSOR
M
SIDE)
VTM (VTECPRESSURE
Signal
Wrth engine at low enginespeed:0 V
Wth engineathigh enginespeed:tatteryvoltase
At idle with steering wheel in straight ahead
p o s i t i o n : 0V
At idle with stsering wheet at fult tock battery
voltage
With fullyw6rmed up engine running:0 V- batteryvohage (dependingon electricattoad)
W h h i g n i t j o ns w i t c h O N { t t )a n d f r o n t w h e e t s
rotating: cycles 0 V- 5 V
W i t h i g n i t i o ns w i t c h O N ( l l ) :a b o u r 0 . 5- 5 . 3V
W i t h f u l l y w a r m e d u p e n g i n ee t i d l e :
a b o u t 2 . 6 - 2 . 8V
W i t h i g n i t i o ns w i t c h O N t ) : a b o u r 7 V
InE orE position:
OV
ln any otherposition:batteryvottage
Wilh clutch pedal released: about 5 V
With clutch pedal deDressed: O V
W i t h i g n i t ; o ns w i t c h O N ( l t ) : p u t s e s
1 9 : D 1 6 Y 5e n g i n e
'10: M/T (Dl6Y5engine)
* 1 1 rE x c e p tM / T
1 1 6 Y 5e n g i n e )
* 1 2 : D 1 6 Y 5 ,D 1 6 Y 8e n g i n e
*13:Dl6Y8 enqine
* 1 4 : O 1 6 Y 7e n g i n e
i 1 5 : ' - 9 7O 1 6 Y 7e n g j n e ( c o u p e :
KL modet, sedan: KL (LX) modet),
'98D16Y7
enqine
D I16P)
ECM/PCMCONNECTOR
Wire sideot femaleterminals
ECM/PCMCONNECTORD l16P)
Te.minal
numb€r
Wire
color
NOTE: Standardbattery voltage is 12 V
Terminal
n!me
Dor.ription
POSITIONDetectsTP sensorsignal.
TPS(THROTTLE
RED/BLK SENSOR}
REDA/VHT
3
RED/GRN
YEURED
5
GRNMHT
6*?
RED/BLU
1
8
RED//EL
9*l
WHT/BLK
10
11
12
YEUBLU
DetectsECTsensorsignal
COOLANT
ECT{ENGINE
SENSOR
TEMPERATURE
DetectsMAPsensorsignal.
ABSO'
MAP {MANIFOLD
SENSOR}
LUTEPRESSURE
VOLTAGE) Power sourcelor MAP sensor.
VCCl (SENSOR
BKSW{BRAKESWITCHI
Detectsbrakeswitch signal
KS {KNOCKSENSOR}
PHO2S(PRIMARYHEATEDOXYGENSENSOR,
1)
SENSOR
DetectsKS signal.
DetectsPrimaryheatedoxygen
sensor(sensor1l signal
DetectsLABELresistance
LABEL
DetectsIAT sensorsignal.
(INTAKE
AIR
TEMIAT
SENSOR)
PERATURE
DetectsEGRvalve lift sensorsignal
EGRLiEGRVALVELIFT
SENSOR)
VOLTAGE) Providessensorvoltage,
VCC2(SENSOR
GROUND}
SG2(SENSOR
(SENSOR
GROUND)
SG1
GRN,4/1r'HT
GRN/BLK
(SECONDARY
SHO25G
GRN/BLK*1?HEATED
SEN'
OXYGEN
Sensorground.
Ground for MAP sensor.
Ground for secondaryheatedoxygen sensor(sensor2).
2 GROUND)
SOR,SENSOR
14
WHT/RED
15|3.*15
LT GRN
16*1
SH02S(SECONDARY
HEATED
OXYGENSEN'
Detectssecondaryheatedoxygen
sensor(sensor2) signal.
2)
soR,sENsoR
PTANK{FUELTANK PRES. Detectsfueltank prgssuresensor'
SURESENSOR)
DetectsELDsignal.
EL(ELD)
GRN/RED
*1: USA model
*2r A/T (D16Y7,D16Y8engine)
*3: CVT(D16Y5engane)
*4: A,/Tand Dl6Y7engine
*5: ExceptA/T and D16Y7engine
*6: A"/T(D16Y8engine)
i7: CVT(Dl6Y5engine)and Dl6Y8engine
* 8 : . 9 6 D 1 6 Y 8e n g i n e( c o u p e i , ' 9 7D 1 6 Y 8e n g i n e(coupe:all
'98 D16Y8
m o d e l s ,s e d a n rK L m o d e l ) , ' 9 80 1 6 Y 5e n g i n e ,
'99
(M/T)
engine
00 D16Y5
engine,
Signal
With throttle fully open: about 4.8 V
With throttlefully closedlabout0.5V
With ignitionswitchON{ll):about0.1- 4 8 v
(dependingon enginecoolantlemperature)
With ignitionswitchON(ll):about3 V
At idle:about1.0V
on enginespeed)
{depending
With ignitionswitchON (ll):about5 v
With ignitionswitchOFF:0 V
With brakepedal released:0 v
With brakepedaldepressed:bafteryvoltage
With engineknocking:Pulses
With throttle fullv openedfrom idle with
Iully warmodup engine:above0.6V
With throttle quickly closed:below 0.4 v
With enginer!nning:about0.3- 4.9V
With ignitionswitch ON (ll):about 0 1 4.8V {dependingon intakeair temperature)
At idlewithoutvacuum:about'12 V
mmHg,8in. Hg):about4 3 V
With27 kPa(2OO
With ignitionswitchON(ll):about5 V
With ignitionswitchOFF:0V
Lessthan 1.0V at alltimes
Lessthan 1.0V at alltimes
With throftle fully openedlrom idle with
fully warmedup engine:above0.6V
With throttlequicklyclosed:below0.4V
With fuelfill caDopened:about2.5V
With parkinglightsturnedon at idle:about
2.5- 3.5V
turnedon at
With low beamheadlights
idle:about1.5- 2.5V
*9: D16Y5engine
*10:M/T (D16Y5engine)
*11:ExceptM/T (Dl6Y5engine)
* 12rD16Y5.D16YBengine
*13:D16Y8engine
*14: Dl6W engine
*15:'97 D16Y7engine(coupe:KL model,sedan:KL lLX) model),
'98D16Y7
engine:
(cont'd)
11 - 9 1
Troubleshooting
Engine/P_o,wertrain
ControlModuleTerminalArrangement
('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
ECM/PCMCONNECTOR
A I32PI
ECM/PCMCONNECTOR
A (32P)
Wire sideot temaleterminals
NOTE:Standardbatteryvoltageis l2 V
Sign!l
3
2WSS(EVAP8YPAsSSOLENOID Drives EVAPbypass solenoid vatve,
With gn'tion swnch ON (lll banery votlage
VSV {EVAPCONTNOLCANISTER
VENTSHUTVALVE]
Drives EVAPcontrot can isrer v€nt shut
Wilh ignilion switch ON {tl): b€ttery vottage
8LU/GNN
C8S (CRUISECONTSOLSIG
Oown shift signal inpot lrom c.uise conrrol
When crurss control is used:purses
Drives EVAP purge conrrol sotenoid vatve.
With engine running, enginecootant,betow r54.F (6a,C):
8ED/YEL
PCS{EVAPPURGECONTROL
SOTENOIOVALVE)
BLU
LT GRN/I/VIIT
6
With engine.unning, €ngine coolant, abov€ 154.F
(68'C): duty conlrolled
YEL
8
BLK,IflHT
LT GRN
t0
ootects A/T gear posnion swilch s,gnar.
(SECONDARY
SO2SHTC
HEAT
EDOXYGEN
SENSOS
HEATEF
CONTFOL)
Drives sscondary h€ared oxygen senso.
Wilh isn,rion swirch ON (ll):banery votrase
W i t h l u l l y w a r m 6 dd p € n g i r e r u n n ' n g : d u r yc o n t r o l e d
ATPNP (AT GEAF POSITION
SWITCH)
EH E C KS I G N A L )
S C S( S E R V I CC
oereds A/T 9€ar position switch signat.
I n P a r r o r n e u l r s l : 0V
I n a n y o t h e r p o s i t i o na p p r o x . 5 v
Oetectsssruice check connecror signal
(the signalcausing a OTC indication)
with rh€ t6rminal connected:0 v
With the rerm inaI disconneded: abour 5 V of ban€ry
D 4 I N D( D 4 I N D I C A T O N ]
Drives Oa indicaio. lighr.
FTF (FUELPUI\,4P
SELAY)
W i t h D 4 i n d i c a t o rl i g h t t u r n e dO N : O V
With D4 indicator lightturned OFF:battery vo ttage
Orivos tuel pump relay,
0V for two s€conds lfrer turnrng rgnilior swtcn ON
(ll), then batt€ry voltage
ACC (Al/CCTUTCHSELAY)
Drives A./Cclutch reray.
With compressor ON:O V
Wilh comp.ssor OFF;battery vottage
88N
GNN/BIK
G8N/YET
11
ATPD {AT GEAR POSITION
SWITCH)
BTI(RED
In otherthan @ posilion:Apprcx. 5 V
18
GFN/OFN
MI! (A,IAIFUNCTIONINDICA.
TOF LIGHT)
19
8tu
N E P( E N G I N ES P E E DP U T S E I
Oulputs6ngine speed pulse,
W i l h e n g i n 6 . u n n i n gp
: utses
20
GFN
TnoL)
FANC {SADIATORFAN CON
Orives radiarortan relay.
21
ELUA/EL
W i r h r . d i s t o rt 6 n r u n n i n g : O V
With radiatortan stopped: banery vottage
With ignition switch ON (ll):p!ts€s
22'l
BLU
W i t h M l L t u r n e dO N : 0 V
With l\,llLtornod OFF|batreryvotrsge
K LINE
Sends and r€ceivess.an lool signal.
ATP L {AT GEAS POSITION
OelocisA"/Tgear posirion switch siSnat.
23
SHO25 (SECONOARYHEATED
OXYCEN SENSOR,SENSOF2)
Detectssecondsry hoar€doxygen sensor
24
STS ISTAFTENSWITCHSIG
Debcrs staner switch signat.
PSPSWiPlS PNESSURE
SWITCII SIGNAL)
ACS (AJCSWITCHSIGNALJ
DerecrsPSPswitch signat.
Atidle with steoringwheolin srraightaheadposition:O V
At idl6with steering wheetal fult lock: barery vo ttags
Oer*ts ,ay'C
swirch signat.
Wiih ty'C switch ON;0V
Wilh Ay'Cswitch OFF|aboor 5V
S L U i I N T E R L O CC
KO N T R O I
UNIT)
Drivos interloct control unit.
With ignltion switch ON (ll)and brake pedal
depresed: batlory volrage
PTANK (FUELTANK PFESSUEE
SENSOR)
Oer6ds lu€l tank pr€ssura sonsor signat.
W i l h i g . r r r d s w i r c hO N r t t ra n d f u e t t i c a p o o e n 6 d .
26
GFN
27
BLU/REO
WHT/RED
29
LT GRN
swtTcH)
Er(ELOI
30
GRN/FEO
32
GRN/'WHT
AKSW (BFAKESWITCH)
' 1 : A . / T( D 1 6 Y 7
D,1 6 Ye8n g i n e )
*2: rvt/T
13:CVT(D16Y5
engine)
11-9 2
In othfflhan E position:Apprcx. 5 V
With lhronle f! lly or'6ned from idte with fu y
warmod up engine: above 0.6 v
Wiih th.onl6 quickb, closd:below 0,4 V
Wirh srarterswitch ON (tttJ:batteryvottoge
With sraftsr cwirch OFF:0 V
W i t h p a r k i n gl i g h l s r u r n e do n a r i d t e i a b o u i2 . 5 - 3 . SV
Wirh low beam he€dlights turnqd on ai idts: aboul 1.5
2 . 5V
Detets brak€ swrtch signEt,
With brake pedal r6l€ased:0 V
Whh brake pedaldepres*d: battery voltEse
B (25PI
ECM/PCMCONNECTOR
Wiresideof femaleterminals
FCM CONNECTORB {25P)
NOTE: Standardbattery voltage is 12 V
Sign.l
YELtsLK
BLK
FED
BLU
YEL
6
BLI(BIU
BED
PNKSLK
8.,
9
YEUBLK
whh ignilion swilch ON (ll)ibatteryvoltage
With ignition switch OFF:0 V
IGP1IPOWERSOUflCE)
Powor sou rca for the ECM/PCMconlrolcir
P G l{ P O W EG
BN O U N D )
contrclcncuit'
Ground fo. the ECM,/PCM
Lessthan 1.0 V at slltimes
l N J 2 ( N o 2 F U E LI N J E C I O R )
l N J 3 ( N o . 3 F U E LI N J E C T O B )
Drives No. 2 fu€l inieclor'
Wirh enqine runnin9: dulv conlroll6d
l N J , rl N o . 4 F U E LI N J E C T O F )
IACV P (IDLEAIR CONTROL
VAIVE POSITIVESIDE)
Orives No.3 fuel inieclor'
Drives No. 4 luel injector'
O.iv€s IAC valve {Posirivoside)
Wilh engine running: duty conrrollod
ESOL {EG8 CONTROL
SOLENOIDVALVE)
Drives EGF controlsolonoid valve
With EGRoperaiing during driving wirh follv warmed
up onginsl dutY controlled
W i l h E G Rn o l o p € r . r i n g : 0V
CONTnOL
HlC tstvr(PH-PL
LINEAflSOLENOIDNEGATIVE
st0E)
PFESSURE
LS- (A/TCLUTCH
SOTENOIDVALVE'
CONTROL
sroE)
SOUFCE)
rGP2{POWE8
G rcund for PH-PLcontrol linsar solsnoid
A/Tclutch prsssure conrrol sol€nod valv€
pow6r slpply negative elecrode
With ignilion swirch ON (ll):dutv controll€d
Powor $urce for lhe ECI{,'PCMcontrolc'rcuit
wnh ignirion swirch ON (ll): ban€ry voltag€
with ignirion swnch oFF:0 v
10
BLK
GSOUNDI
PG2IPOWER
11
8RN
I N J l { N o , 1 F U E LI N J E q I O R )
Ground lor ths ECM/PCMcontrolctrcuil
orives No. r ru6l Iniocror.
GRN,.YEL
VALVE)
WS (WECSOLENOID
Orivos WEC solanoid v.lvs.
12"
13
YEUGRN
With onsino at low lpm:0V
with ens,n. ar hish tpm:bsneryl9!9glWith ignition switch ON (ll)r b5n6ry volt€gs
Wilh engino running: Puls6
Drivos the IAC valve lnogativ€ 3idel
With €ngin€ ru nningi dr]tv controlled
15
ORN
LS + (A,/TCIUICH PRESSURE
CONTFOTSOIENOIOVALVE +
SIDE}
HLC LSP (PH-PI CONTROI LIN.
EA8 SOLENOIDPOSITIVESIDE)
A/T clutch pr€so.6 controlsolenoid valve
pow6r slpply posiliv€ oroclrode
Wirh ignition swatchON (lll: dutYcontrorled
SCLSM(STAfiTCLUTCH
N€GATIVE
SOLENOIO
LINEAR
SIDE)
Groundforstartclutchcontrol
BnN/AtK
LGI (LOGICGEOUNO)
VBU IVOLTAGE8AC( UP)
22
BFN/8IK
23
8LI(BLU
LG2 (LOGICGSOUND)
IACV (IOTEAIR CONTROL
Ground for lh€ EcM/PcM controlcircuit'
Powet sourcetorlhe ECM/PCMcontrol circuit
Power sourco tor th6 DTC m€mory'
Ground iorths ECMnCM conrrol circuir'
RED
PNK/BTU
20
ICM {I6NITION CONTROLMOD
ULE}
IACV N (IDLEAIN CONTSOI
VALVE NEGATIVESIOE)
21
25'3
YEL
r1: A/r (D16\t, D16Y8ensins)
SC LSP {STANTCLUTCHLINEAR
Orives PH-PLcontrol line€r solenoid
With qnition switch ON (lll: Pulsing srgnal
line6r
L 6 s er h a n 1 . 0v . i a l l t i m e s
Battaryvoltage aitnEtrmes
tsss thah 1.0 v al all times
Witn ongine funning: dutv conrol!6d
Orives sran clutch control linesr solonoid.
With ignilion swilch ON (ll): Pulsing sign3r
slDE)
PoSlrlvE
sotENorD
'4: Ol6Y5, Dl6Y8, B164? onsina
' 3 : C V T{ O 1 6 Y 5 e n s i n o )
(cont'd)
11 - 9 3
Troubleshooting
Engine/P_owertrain
ControlModuleTerminal Arrangement
('99- 00 ModelsexceptDl6Y5 enginewith M/Tl (cont,d)
ECM/FCMCONNECTOR
C 13lPI
ECM/PCMCONNECTOR
C {31P)
Wire sideof femaleterminals
NOTE;Standard
i s 1 2V .
Sig.al
l
2
BLK4/VHT
WHT/GFN
(PNIMARY
PO2SHTC
HEATEO
OXYGEN
SENSOB
HEATES
CON
TROL)
Drivss primary hoated orygen sensof
With ignition switch ON (lr)rbanery volage
Wrh fJly warned up €ngir. ru..i19: duty.oaro ed
ALTC (ALTESNATOBCONTSOL)
Sends aliernalo. control sig nal,
With fullywa.med upengine ronning; banery vohase
D u r i n gd . i v i n gw i t h s m a l l e l e c t . i c a t i o a dO;V
3
8ED/BLU
K5 (KNOCKSENSOR)
5
WHT/RED
ATTF {AITEFNATOR FR SIGNAL'
Detects slternaror FR si9n.l.
WHT/8LK
E G R L( E G NV A I V E L I F T S E N
SOR)
Dete.ts EGRvalve lrft sensorsignat.
GRN,4r'l/flT
S G l I S E N S OGEB O U N D )
Groond fo. MAP s€nsor.
8lu
CKPP(CKPSENSORP SIOE'
8
9
BLU/BLK
16
FED/GRN
18
'19
GBN/8LK
YEUNED
Ground for CKP sensor.
wlvl (wEcPREssuSE
swtTcll
D€toctsVTEC pfessure switch signat,
W i t h € n g i n ea t l o w e n g i n o s p e e d : 0 V
With engin€ at high engino speed : banery vo ttaae
Oetectsprimary heated oxygen s6nsor lsen-
With lhrottle f!l1y open€d from idtewith tuly,
wa.med !p engin€: Ebove 0.6 V
Wilh thronl€ quickly closed: b€tow 0.4 V
MAP (I\,4ANIFOLD
ASSOLUIE
PFESSUSE
SENSOB}
Dotocrsi,4APsensor signsl.
With ignitioh switch ON (ll):about 3 V
A t i d l e i 6 b o u l1 . 0V ( d e p e n d i n go n e n g i n es p e e d )
Powersourcero
MAPsenso..
W i t h i g n i t i o ns w i l c h O N { l l ) : a b o u t5 V
W i r h i q n i t i o ns w i t c hO F F ] 0V
S G 2( S E N S O R
GSOUND)
VCCl (SENSORVOLTAGEI
GNN
IDCP (TDCSENSOBP SIDEI
8ED
TDCI\,I(TDCSENSORM SIOE)
C K F P( C K FS E N S O RP S I D E )
BTU/NED
25
L e s st h a n 1 . 0V a r a l t t i m e s
With ongine running: pulses
Ground lor TOC aensor.
With engine running: p!lses
VSS {VEHIClESPEEDSENSOR)
BED/YEL
L € s sr h a n 1 . 0v a t a l l t i m e s
SIGNAI)
PHO25 (PRII\,1AFY
HEATED
O X Y G E NS E N S O RS, E N S O R1 )
21
23
W i t h t u l l y w a r m e du p e n g i n er u n n i n g : OV - b a t t e r y
v o r t a g e ( d e p e n d i n g oenr e c t f i c at to a d )
With engine running: pulses
CKPM {CKPSENSORM SIDEI
20
22
with sngine knocking: pulses
W i l h i g n r t | o ns w i c h O N r l l rs n d l r o n t w l - e e 'r o t a t i n g .
cycles 0 V about 5V or baneryvottage
IAT ONTAKE
AIFTEi,4PEBA.
TUEESENSOR)
Detects IAT senso. signat.
With ignition switch ON (ll): about 0.1 4.8 V
ldepending on i.take air ternpe.ature)
Oelects ECT sensor signal.
W i t h i g n i r i o ns w i r c hO N { l l ) : a b o u t 0 . 1- 4 . 8 V
(depending on engine coolant temperature)
26
8ED,ryVHT
ECT (ENGINECOOLANTTEI\,I.
PESATUBESENSOR)
21
NED/BLK
TPS (THROTTLEPOSITIONSEN,
SOF)
DetectsTP sensor signal.
Wilh th.onle fully op€n: about 4.a V
With rhronle f!lly closed: about 0.5 V
2a
YEVBLU
VCC2(SENSORVOLTAGE)
Provides s6nsor voltag€.
W i t h i g n i r i o ns w i r c hO N ( t t ) : a b o u 5t V
With ignilion swiich OFF:0 V
CYPP(CYPSENSORP SIDE)
CYPM (CYPSENSORM SIDE]
G,ound for CYP sonsor.
29
YEL
3o
BLK
J1
WHT/FED
CKFM (CKFSENSOBM SIDE)
* 1 ; 4 " / Tl D 1 6 Y 7D
, 1 6 Y 8e n s i n e l
4 3 :C V I ( 0 1 6 Y 5e n g i n e )
'4: D16Y5,D16Y8,81642 engin€
11-9 4
W i l h € n g r n er u n n i n g :p r u s e s
Ground fo. CKF sonsorsign6i.
O {16P)
ECM/PCMCONNECTOR
D {16P)
ECM/PCMCONNECTOR
(D16Y7,D16Y8enginel
Wire sideol temaleterminals
NOTE: Standard battery voltage is 12 V.
5i!ml
YEL
LCA (LOCK.UPCON]ROL
SOLENOIDVALVEA)
Orivos look-up controlsol€noid wlv€ a.
With lock-up ON: httery vollage
With lock-up OFFi 0 V
SHB {SHIFTCONTFOL
SOLENOIOVALVE B)
Drivos sh ift cont.ol solanoid valv6 B
ln E posnion,in 1stlnd 2ndeoat,n E E pos'
tion:Battsryvoltago
I n E l p o s i r i o ni n. 3 r ds e a ti n p d , E l i n . t h s e a ri n
l_d polition: o v
LC8 (IOCK UP CONTBOL
SOLENOIDVALVE B)
VSSOI (BATTEsYVOLTAGE
FOB SOLENOIDVALVE)
Drivs locl up conttol sol€noid v6lv€ B
when fulllock-up: Banory vollaga
Wnh naf locl-uP: Pulsing si9n6l
wirh ignirion sitch ON (ll): battory voltaoe
Wirh ignnion switch OFF:0 v
ATPR(AT GEARPOSITION
swrTcH)
DetecrsAy'Tg6a. position switch signal.
SHA iSHIFI CONTROL
SOLENOIDVALVEA)
Oriv€6sh ift conirol sol€noid valve A.
ATPO3(AT GEAR POSITION
SWITCH)
Oot6ctsAy'TS6.r poeirioo switch siSnal
ATPD4 {AT GEAE POSITION
Oorocts A/I gs8r position switch signal.
GRN,M/HT
3''
GRN/BLK
5',
BLK/YEL
Powe. sourc€ ol solGnoidvalve
8LU/YEL
PNK
L
9''
13''
YEL
sig.als
BIU
NC (COUNTERSHAFTSPEED
SENSOB)
DetocB counr€.shaftsp66d $osr
REO
NM (MAINSHAFTSPEEDSEN.
O€l€cts mainshalt sp€€d 3.nsor 3ign.ls
soR)
NMSG {MAINSHAFTSPEEO
SENSORGFOUNO)
Groundfo, mainshaft sp@d sensor.
ATPNP {AT GEAF POSITION
oetscts A/T 96ar pGitaon swhch signal
ATPz{ATGEAEPOSITION
swrTcHl
SPEED
NCSG{COUNTEBSHAFT
S E N S OG
ER O U N D )
Dor€cis!y'T gos. posilion swilch signal.
!T GFN
BLU
16''
swrTcH)
GAN
swrrcH)
In any olh€r position: APProx. 10 V
in 2nd€nd3rdsearin lpd, &l
lntr,tr position,
posirion:Batt€ryvollsgo
;n 1d soarin E, E position,in.ih se6rin E
In Enyoth.r position: APPror, t0 v
In any oth6t position:APProx 5 V
D€p€nding on v6hicls 8pe€d;Pul.ins signal
Wh6n v€hicls i5 ltoPPsd:0 v
Wi$ engino rLrnninglPUls6s
In par* or n6ulral:0 V
In sny olhd po3ition: APProx l0V
In any oth6r Position:APProx, 10 V
Ground lor countershaii sp€3d s6nsor.
.1 A/J (Dl6Y7, Dr6Y8 engine)
rlo
(cont'd)
11 - 9 5
Troubleshooting
Engine/P_oweft
rain ControlModuleTerminaI Arrangement
('99- 00 ModelsexceptDl6YSenginewith M/Tl (cont,dl
ECM/PCMConnectol D (16P1
ECM/PCMCONNECTON
D (r6P)
Wire side of female terminats
ECM/PCMCONNECTORD {16P)(Dl6YS engine: CVTI
NOTE:Standardbatteryvoltageis 12 V
f€rminal
Wire color
numDea
Terminalname
Description
VEL(SECONDARY
gearshaftspeed
GEAR Secondary
SHAFTSPEED
SENSOR) sensor,
1+3
WHT/RED
2*3
GRN/BLK SOLENOIDCONTROL)
3+3
SHLSM(SHIFT
CONTROLGroundfor shiftcontrollinear
SOLENOID
GRN/YEL LINEAR
solenoid.
NEGATIVE
SIDE)
INHSOL{INHIBITOR
5*3
6*3
10*.
11*3
12*3
13*3
14*3
16*r
Inhibitorsolenoidcontrol.
(SHIFT
SHLSP
CONTROL Drivesshift control linear
BLU^/vHT LINEAR
solenoidpower.
SOLENOID
POSITIVE
SIDE}
VBSOLlBATTERY
Power sourceof solenoidvalve.
BLK,/YE
L
VOLTAGE
FOR
SOLENOID
VALVE)
(AT
ATPR
GEAR
DetectsA,/Tgearpositionswitch
WHT
POSITION
SWITCH)
srgnal.
VELSG(SECONDARY Groundfor secondary
gearshaft
BLKA/VHI GEARSHAFTSPEED
speedsensor.
SENSOR
GROUND)
(DRIVEN
NDN
Detects
PULLEY
drivenpulleyspeed
WHT
SPEED
sensorsrgnal.
SENSOR)
(DRIVEPULLEY
Detects
drivepulleyspeed
RED/BLU NDR
SPEED
sensorsrgnal.
SENSOR)
NDRSG(DRIVE
PULLEY Ground for drive pulley speed
GRN
SPEED
sensor.
SENSOR
GROUND)
ATPS(ATGEAR
DetectsAy'Tgear positionswitch
LT GRN/RED
POSITION
srgnal.
SWITCH)
DIND1DINDICATOR
LIGHT)
NDNSG(DRIVEN
RED^/VHT PULLEY
SPEED
S E N S OG
RR O U N D )
GRN/BLK
*3: CVT (Dl6Y5 engine)
11 - 9 6
DrivesD indicator.
Ground for driven pulley speed
sensor.
Signal
Dependingon vehiclespeed:pulses
When vehicle is stopped:0 V
With inhibitor solenoidON: baftery
voltage
With inhibitorsolenoidOFF:0 V
With ignition switch ON (tl):pulses
With ignition switch ON (ll):banery
voltage
With ignition switch OFF:0 V
InRposition:0V
In anyotherposition:
Approx.10V
In otherthanParkor neutral:pulses
In otherthanParkor neutraltpulses
I n S p o s i t i o n :V0
In anyotherpositioniApprox,10V
With D indicator
turnedON:5 V
WithD indicator
turnedOFF:OV
DiagnosticTroubleCode(DTCIChart
DTC
{MlL indication*l
Delection liem
ManifoldAbsolute
PressureCircuit
Problem
Range/Performance
P0107
(3)
P0108
(3)
. Vacuum connection
. MAP sensor
Page
11 1 1 5
ManifoldAbsolute
PressureCircuit
Low Input
Openor short in MAP sensorcircuit
MAP sensor
ECMiPCM
TCM*1
11
ManifoldAbsolute
PressureCircuit
H i g hI n p u t
Openin MAP sensorcircuit
MAP sensor
ECtvt/PCM
't 1 121
't1'l
. IATsensor
1 .5( 1 0 )
P 0 . 1 1 1 * 1* 4
lntakeAir Temperature
Circuit
Problem
Range/Performance
PO112
{10}
IntakeAir
TemperatureCircuit
Low Input
Short in IATsensorcircuit
IAT sensor
ECMiPCM
P0113
(10)
lntakeAir
TemperatureCircuit
H i g hI n p u t
Open in IATsensorcircuit
IAT sensor
ECM/PCM
P0116
(86)
E n g i n eC o o l a n t
TemperatureCircuit
Problem
Range/Performance
PO't't7
{6)
EngineCoolant
TemperatureCircuit
Low Input
Short in ECTsensorcircuit
ECTsensor
ECM/PCM
11-129
P0118
(6)
E n g i n eC o o l a n t
TemperatureCircuit
H i g hl n p u t
ThrottlePosition
Circuit
Low Input
Openin ECTsensorcircuit
ECTsensor
ECM/PCM
11-130
Openor short in TP sensorcircuit
TP sensor
ECM/PCM
TCM*1
11-132
?0122
t1l
P0123
(7)
P0131*'
(1)
P0132*'
('r)
PrimaryHeatedOxygenSensor
CircuitHighVoltage
( S e n s o1r )
P0133*'
(61)
PrimaryHeatedOxygenSensor
Slow Response
( S e n s o1r )
P0135*? (41)
! ta
ProbableCause
ThrottlePosition
Circuit
H i g hI n p u t
PrimaryHeatedOxygenSensor
CircuitLow Voltage
( S e n s o1r )
PrimaryHeatedOxygen
SensorHeater
CircuitMalfunction
(Sensor1)
11-124
. ECTsensor
. Coolingsystem
Openin TP sensorcircuit
TP sensor
ECM/PClvl
Short in PrimaryHO2S(Sensorl) circuit
PrimaryHO2S{Sensor1)
Fuelsupplysystem
ECM/PCM
Open in PrimaryHO2S{Sensor1} circuit
PrimaryHO2S(Sensor1)
ECM/PCM
. PrimaryHO2S(Sensorl)
. Exhaustsystem
. Openor short in PrimaryHO2S
(Sensor1) heatercircuit
. ECM
11-125
't1-126
11-124
11-136
11 - 1 3 9
11-143
11-145
11-151
*: The DTCSin parenthesis
will be indicatedby the blinkingof the MalfunctionIndicatorLamp(MlL)when the SCSservice
connectoris connected
a1: Dl6Y5 engine(CVT)
*2: ExceptD16Y5engine(M/T)
* 1 4 : ' 9 7m o d e l
* 1 5 : ' 9 6m o d e l
* 1 6 :' 9 8m o d e l
(cont'd)
11-97
Troubleshooting
,Jla
DiagnosticTroubleCode(DTCIChat (cont'dl
DTC
lMlL indicationl
P0137
(63)
P0r38
{63)
P0'139
(63)
P0141
(65)
Datectionhsm
Secondary
HeatedOxygenSensor
CircuitLowVoltage
(Sensor
2)
Secondary
HeatedOxygenSensor
CircuitHighVoltage
(Sensor
2)
Secondary
HeatedOrygenSensor
SlowResponse
(Sensor
2)
Secondary
HeatedOxygenSensor
Heater
CircuitMalfunction
(Sensor
2)
SystemToo Lean
(45)
P0171
SystemToo Rich
(45)
P0172
}l?
P0300*16'
and
some of
Random Misfire
Po3o1
P0302
P0303
P0304
/r'' \
l72l
l73l
\74l
P0301
P0302
P0303
P0304
/rt\
172l
l73l
\74l
P0325*3
(23)
P0335
(4)
P0336
(4)
P040' r*r
(80)
P0420
(67)
- Cylinder1
- Cylinder2
- Cylinder3
- Cylinder4
Misfire Detected
KnockSensor(KS)Circuit
Malfunction
CrankshaftPosition
SensorCircuit
Malfunction
Crankshaft
Position
Sensor
Range/Performance
ExhaustGas
Recirculation
InsufficientFlow Detected
CatalystSystem
Efficiency
Below
Threshold
*3: D16Y5engine (CVT),D16Y8engine and B1642 engine
*4: D'16Y5engine
*16: '98 model
+17:'99 - 00 models
11 - 9 8
Probablo Cause
Shortin Secondary
HO2SlSensor2) circuit
Secondary
H02S{Sensor
2)
ECM/PCI\4
Openin Secondary
HO2S(Sensor
2) circuit
Secondary
HO2S(Sensor
2)
EC[I/PCM
Secondary
H02SlSensor2)
Page
11 - 1 5 3
11-154
1l-156
. Openor shortin Secondary
HO2S(Sensor
2) heatercircuit
. ECM/PCM
Fuel supply system
PrimaryHO2S(Sensor1)
MAP sensor
Contaminatedfuel
Valve clearance
Exhaustleakage
Fuelsupplysystem
PrimaryHO2S(sensorl)
MAPsensor
Contaminated
fuel
Valveclearance
lgnitionsystem
Fuelsupplysystem
MAPsensor
EGRsystem
IACvalve
Contaminated
fuel
Lackof fuel
FuelInjector
FuelInjectorcircuit
lgnitionsystem
Lowcompression
Valveclearance
Openor shortin KnockSensor(KS)circuit
KnockSensor{KS)
ECM/FCtvl
Crankshaft
PositionSensor
Crankshaft
PositionSensorcircuit
ECM/PCM
. CrankshaftPositionSensor
. Timing belt skippedteeth
11-157
11,164
11-164
r1-r66
11 167
11-170
11-172
11-172
' EGRvalve
. E G Rl i n e
. Th.eeWay Catalyticconverter
. Secondary
HO2S
11 253
,'o
DTC
{MlL indication}
L
(92)
P0451'11
(91)
P0452{6
(9r)
FuelTankPressure
SonsorCircuit
Range/Parformance
SensorCircuit
FuelTankPressure
LowInput
P0453*6
{91)
SensorCircuit
FuelTankPressure
HighInput
P0500*1,
(17)
VehicleSpeed
SensorCircuit
Malfunction
P0501*'3
l17l
VehicleSpeed
SensorCircuit
Range/Performance
P0505
(14)
P0700*r3
andsomeof
P0715
P0720
P0730
P0740
P0753
P0758
(70)*
P0700*1
and
P0725
(70)*
P1107
Pressure
Barometric
( 1 3 ) Circuit
Range/Performance
Problem
Barometric
( 1 3 ) Pressure
Circuit
Low Input
Barometric
( 1 3 ) Pressure
Circuit
H i g hI n p u t
ldle ControlSystem
lvlalfunction
Automatic
Transaxle
EVAPPurgeControlSolenoidVaive
Openor shortin EVAPPurgeControl
SolenoidValvecircuit
EVAPControlCanister
Vacuumlines
ECM/PCM
. FuelTankPressure
Sensor
' ECM/PCM
Sensorcircuat
Shortin FuelTankPressure
Sensor
FuelTankPres$ure
ECM/PCM
Sensorcircuit
ODenin FuelTankPressure
FuelTankPressureSensor
ECM/PCM
V€hicleSpeedSensor
VehicleSpeedSensorcircuit
ECM
V€hicleSp€edSensor
VehicleSpeedSensorcircuit
PCM
. IAC valve
. Throttle Body
P 1 1 2 1 * ' . * 1 6*. ' ?
\71
P1122'14.*16.*n
17l
P1129*1r.*16.*"(5)
Page
11-271
1 12 7 4
11-275
11-219
11-176
r 1-176
11-192
Section 14
Transaxle
Automatic
15)
! l
Evaporative
Emission
Control
SystemInsufficient
PurgeFlow
P0441*5
P1108
ProbableC.use
Detoction lt€m
Section14
. ECM/PCM
(Barosensor)
. ECM/?CM(Baros€nsor)
. ECM/PCM
lBarosensor)
11 - 1 7 8
11-178
11 - 1 7 8
ThrottlePositionLower Than
Expected
ThrottlePositionHigherThan
Expected
. I r sensor
11-138
. TP sensor
11-'138
ManifoldAbsolutePressure
LowerThanExpected
ManifoldAbsolutePressure
HigherThanExpected
. MAPsensor
11 ' 1 2 3
. MAPsensor
't1-123
*:The E indicatorlight and the MaltunctionIndicatorLamp (MlL) may come on simultaneously.
*1: D16Y5engine (CVT)
"5: '96 D16Y5engine,D16Y7engine,D16Y8engine (sedan).'97D16Y5engine,Dl6Y7 engine (coupe:KA, KC models,sedan:KA.
KC, KL (DX) models,hatchback:all models),D16Ygengjne (sedan:KA, KC models)
*6: '96 D16Y8engine (coupe),'97Dl6Y7 engine (coupe:KL model, sedan:KL (LX) model),'97 D'16Y8engine (coupe:all models,
sedan:KL model),'98-allmodels,'99-allmodels,'00-allmodels
*12: ExceptA,,/T(D16Y7,D16Y8enginei
*13: A"/T(D16Y7,D16Y8engine)
* 1 4 : ' 9 7m o d e l
(cont'd)
* 1 6 : ' 9 8m o d e l
'99
" 17:
- 00 models
11 - 9 9
Troubleshooting
DiagnosticTroubleCode(DTGIChart(cont'dl
DTC
(MlL indicationl
Detection lt6m
PrimaryHeatedOxygenSensor
(Sensor1) Circuit
Malfunction
PrimaryHeatedOxygenSensor
(Sensor'1)Circuit
SlowResponse
Probablc Cause
Page
Openor shortin PrimarvHO2S(Sensor1
PrimaryH02S(Sensor1)
11-146
P1162+1
(48)
P]163'
(61)
Pl164*r
(61)
P1165*?
(61)
P1166'
(41i
P1167*'
(41)
P1168*'
(48)
. PrimaryHO2S(Sensor1)
PrimaryHeatedOxygenSensor
(Sensor1) CircuitRange/
Performance
Problem
PrimaryHeatedOxygenSensor
Openor shortin PrimaryHO2S(Sensor1)
(Sensor'1)HeaterSystemElectrical
heatercircuit
Problem
PrimaryHO2S(Sensor1)
ECM/PCM
PrimaryHeatedOxygenSensor
Openin PrimaryHO2S(Sensor1)VS+circuit
PrimaryHO2S(Sensor1) Heater
lSensor1) HeaterSystem
Malfunction
PrimarvHO2S{Sensor1)
. Shortin PrimaryHO2S(Sensor1) LABEL
PrimaryHeatedOxygenSensor
(Sensor1) LABELLowInput
circuit
Pl169*?
(48)
PrimaryHeatedOxygenSensor
(Sensor1)IABELHighInput
PrimaryHeatedOxygenSensor
(Sensorl) CjrcuitRange/
Performance Problem
WEC System Malfunction
P1259*3
(221
P1297*s
(20)
ElectricalLoad
DetectorCircuit
Low Input
Pr298+'
l20l
Electrical
Load
Detector
Circuit
H i g hI n p u t
BandomMisfire
ano
someof
P0301
l71l
P0302
l72l
P0303
l73l
P0304
l74l
*7: D16YS
engine(M/T)
*8: D16Y5,
D'16Y8
engine
*9: USAmodel
* 1 4 r ' 9 7m o d e l
*15r'96 model
11 - 1 0 0
. PrimaryHO2S(Sensor1)
11-145
. PrimaryHO2S(Sensor1)
11-150
. Openin PrimaryHO2S(Sensor1)IABEL
circuit
. Shortin groundcircuit
WEC SolenoidValve
Openor shortin WECSolenoid
Valvecircuit
VTECPressureSwitch
Openor short in VTECPressureSwitch
circuit
ECM,FCM
ElectricalLoadDetector
ElectricalLoadDetectorcircuit
ECM/PCM
ElectricalLoadDetector
ElectricalLoadDetectorcircuit
ECM/PCM
lgnitionsystem
Fuelsupplysystem
MAPsensor
EGRsystem
IACvalve
Contaminated
fuel
Lackol fuel
11-150
11 - ' 1 6 1
11-163
11-151
11.152
Section6
11-179
11 - 1 8 1
11-166
DTC
(MlLindicationl
P1336
(54i
P1337
(54)
P13s9
(8)
P1361
(8)
P1362
(8)
P1381
{9)
P1382
(9)
CrankshaftSpeed
FluctuationSensor
IntermittentInterruption
. CKFsensor
CrankshaftSpeed
Fluctuation
Sensor
N oS i g n a l
CrankshaftPosition/Top
DeadCenterSensor
Disconnected
Top DeadCenter
SensorIntermittent
Interruptron
Top DeadCenter
SensorNo Signal
CKFsensor
CKFsensorcircuit
ECM,PCM
' CKP/TDC
sensorcircuit
CylinderPositionSensor
IntermittentInterruption
CylinderPositionSensor
No Signal
Control
Evaporative
Emission
SystemLeakDetected
{FuelTank
Area)
P1456*5
(90)
L
Evaporative
EmissionControl
SystemLeakDetected(EVAP
Area)
ControlCanister
P1457*6
(90)
Probable Cause
Detection ltem
Page
11183
11-'183
11-187
. tuL sensor
11-172
TDCsensor
TDCsensorcircuit
ECIV/PCM
. CYPsensor
11-172
11-172
CYPsensor
CYPsensorcircuit
ECM/PCM
11-112
Fuelfillcap
Vacuum connection
Fu€ltank
Fueltank pressuresensor
EVAPbypasssolenoidvalve
EVAPtwo way valve
EVAPcontrol canistervent shut valve
EVAPcontrol canister
EVAPpurge control solenoidvalve
11-283
Vacuum connection
EVAPcontrol canister
Fueltank pressuresensor
EVAPbypasssolenoidvalve
EVAP two way valve
EVAPcontrol canistervent shut valve
Fuel Tank
EVAPpurge control solenoidvalve
11-283
*6: '96 D16Y8engine(coupe),'97
Dl6Y7engine(coupe:KL model,sedan:KL (LXlmodel),'97D16Y8engine(coupe:all models,
models.
models,'99-all
models,'00-all
sedan:KL model),'98-all
I ta
(cont'd)
1 1 - 10 1
Troubleshooting
DiagnosticTroubleCode(DTCIGhart(cont'd)
DTC
lMlL indicationl
Detegtion hom
EGRValve
Lift Insufficient
Detected
EGRvalve(withlift sensor)
EGRvalvelift sensorcircuit
EGRcontrolsolenoidvalve(A,/I)
EGRcontrolsolenoidvalvecircuit
E G Rl i n e
EGRvalvecircuit(M/T)
ECM
EGRValve
Lift Sensor
High Voltage
EGRvalve (with lift sensor)
EGRvalve lift sensorcircuit
ECM
IACvalve
IACvalvecircuit
ECM
Openor shortin IACvalvecircuit
IACvalve
ECM/PCM
P1491*!
\12J
P1498*.
112)
Pl508*10
(14)
ldleAir ControlValve
CircuitFailure
{14)
ldleAir ControlValve
CircuitFailure
P1607
1-)
Probablo Csuss
EngineControl
Module/Powertrain
Control lvlodule
lnternal
CircuitFailureA
't1-256
11-265
'11-194
1l-198
. ECM/PCM
TMA,/TMB
SignalLineFailure
ODenor sho.t in TMA,/TMB
circuit
P1655*1 (30)
Automatic
Transaxle
P1705
P1706
P1753
P1758
P1768
P1785
P1790
P1791
(70)*
P1793
P1870
P1873
P1879
P1885
P1886
P1888
P1890
P1891
*: The E indicatorlightandthe Malfunction
Indicator
Lamp{MlL)maycomeon simultaneously.
*4: D16Y5engine(M/T)
+10:ExceptA/TandDl6Y7engine
*11:A,/TandD16Y7engine
*18:D16Y5engine(CW)(except'99- 00 models)
11-102
Page
11-188
11-189
Section14
How to ReadFlowcharts
A flowchartis designedto be usedfrom startto final repair.lt's likea map showingyou the shortestdistance.But beware:
"map" anywherebut a "stop" symbol,you can easilyget lost.
lf you go off the
tSrARTl
flowchart.
the conditionsor situationto starta troubleshooting
Describes
FanoNl
Asksyou to do something;performa test,set up a conditionetc.
(boldtype)
@
tsroPI
{boldtype)
direction.
Asksyou aboutthe resultof an action,then sendsyou in the appropriatetroubleshooting
The end of a seriesof actionsand decisions.describesa final repairactionand sometimesdirectsyou to
an earlierpart of the flowchartto confirmyour repair,
NOTE:
. The term "lntermittentFailure"is used in thesecharts,lt simply meansa systemmay have had a failure.but it checks
out OK at this time. lf the MalfunctionIndicatorLamp(MlL)on the dash does not come on, checkfor poor connections
or loosewires at all connectorsrelatedto the circuitthat you aretroubleshooting(seeillustrationbelow)'
ControlModule
. Most of the troubleshootingflowchartshave you resetthe EngineControlModuls (ECM)/Powertrain
(pCM)and try to duplicatethe DiagnosticTroubleCode(DTC).lf the problemis intermittentand you can't duplicatethe
code,do not continuethoughthe flowchart.To do so will only resultin confusionand, possibly,a needlesslyreplaced
ECM/PCM.
. ,,Open"and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidentalconnectionof a wire to ground or to anotherwire. In simple electronics,this usuallymeanssomethingwon't
this can sometim€smean somethingworks,but not the way it's
work at all. In complexelectronics(likeECM's/PCM'sl.
to.
suDDosed
toosE
11 - 1 0 3
PGM-FISystem
SystemDescription
INPUTS
ENGINE
C O N T R OM
L O D U L E( E C M Y
POWERTRAIN
CONTROL
MODULE(PCM)
OUTPUTS
CKP/TDC/CYP
Sensor
MAPSensor
IATSensor
TP Sensor
EGRValveLiftSensor*'
PrimaryH02S
SecondaryHO2S
VSS
BAROSensor
ELD*'
KS€
StarterSignal
ALT FRSignal
Air Conditioning
Signal
A/T GearPositionSignal
BatteryVoltage{lGN.1}
ErakeSwitchSignal
PSPSwitchSignal
FuelTankPressure
Sensor*i
VTECPressure
Switch*5
ClutchSwitchSignal*6
Countershaft
SpeedSensornB
MainshaftSpeedSensorrs
F ; i l r rj " - - - - - f i - t r i - ' r . ; l
Fb"t."'i"d" c;;il
- \
----t
/
F,h"'c;;tr*".io";-l
@."r.l"sc;;ll
B""k-pF"""till
EaM/PcM
r\
-:/
FuelIniectors
PGM-FlMain Belay{FuelPump)
MIL
IACValve
!y'CCompressor
ClutchRelay
RadiatorFanRelay*,
CondenserFanRelay
ALT*'
lcM
EVAPPurgeControlSolenoid
PrimaryHO2SHeater
SecondaryH02SHeater
EGRControlSolenoidValve*r
EGRvalve*6
EVAPBypassSolenoidValve*'
EVAPControlCanisterVentShut
VTECSolenoidValve*5
DLC
Lock-upControlSolenoidValve*a
ShiftControlSolenoidValve*3
LinearSolenoidValve*3
*1: Dl6Y5engine
*2: USAmodel
*3: CW (D16Y5
ensine),D16Y8engineand 81642ensine
*4: '96 D16Y8enginelcoupe),'97Dl6Y7engine(coupe:KL model,sedan:KL (LX)model),'97D16Y8engine{coupe:all models,sedan:KL
model),'98-all
models,'99'allmodels,'00-all
models
+5:D16Y5,D16Y8,816A2
engine
*6: M/T (D16Y5enginei
*7: CVT1D'l6Y5
engine)
+8:A/T (D16Y7,
D16Y8engine)
*9: '96 D16Y5engine,'96D16Y7engine,'96Dl6Y8 engine(sedan),'97D16Y5engine,'97Dl6Y7 engine(coupe:KA, KC models,sedan:
KA, KC,KL (LX)models,hatchback:
all models),'97D16Y8engine(sedan:KA,KC modelsi
PGM-FI Sy3lem
The PGM-Fl system on this model is a sequential multipon fuel injection system.
Fuel iniector Timing and Duration
The ECM/PCM contains memories for the basic discharge durations at various engine speeds and manifold air flow rates.
The basic discharge duration, after being read out from the memory. is further modified by signals sent from various sensors to obtain the final discharge duration.
ldle Air Control
ldle Air Control Valve llAC Valve)
When the engine is cold. the A,/Ccompressor is on, the transmission is in gear, the brake pedal is depressed,the P/S load
is high, or the alternator is charging, the ECM/PCMcontrols current to the IAC Valve to maintain the correct idle speed.
lgnition Timing Control
. The ECM/PCM contains memories for basic ignition timing at various engine speeds and manifold air flow rates.
lgnition timing is also adjusted for engine coolant temperature.
. Aknockcontrol system was adopted which sets the ideal ignition timing for the octane rating ofthegasoline used.*3
Othgr Control Funqtions
1. Starting Control
When the engine is started, the ECM/PCM provides a rich mixture by increasing fuel injector duration.
2. Fuel Pump Control
. When the ignition switch is initially turned on, the ECM/PCM supplies ground to the PGM-Fl main relay that supplies current to the fuel pump for two seconds to pressurizethe fuel system.
. When the engine is running, the ECI\4PCM supplies ground to the PGM-FI majn relay that supplies current to the fuel
oumo.
. When the engine is not running and the ignition is on, the ECM/PCM cuts ground to the PGM-FI main relay which
cuts current to the fuel pump.
11-104
FuelCut-offControl
. Duringdeceleration
with the throttlevalveclosed,currentto the fuel injectorsis cut off to improvefuel economyat
speedsover the followingrpm:
. D 1 6 Y 5e n g i n e( M / T ) : 8 5 r0p m
. D]6Y5engine(CVT),D'16Y8
engine(USAM/T):920 rpm
. Dl6Y8 engine(USAA,/I),D16Y7engine(USAA,/T);910rpm
. D16Y8engine(CanadaM/T),D16Y7engine(canada):990 rpm
' D16Y8engine(CanadaM/T):1,000rpm
. 8 1 6 A 2e n g i n e9: 7 0r p m
. Fuelcut-offactionalso takesplacewhen enginespeedexceeds6,900rpm (D16Y5,D16Y7engine;D'16Y8engine:
7,000rpm. 816A2engine:8.100rpm), regardlessof the positionof the throttlevalve,to protectthe enginefrom
'99 Dl6Y7 engine(A,/T)and '99 D16Y8engine(A./T),
the PCMcutsthe fuel at enginespeedsover
over-rewing.With
5,000rpm when the vehicleis not moving.
IVC CompressorClutchRelay
When the ECM/PCMreceivesa demandfor coolingfrom the air conditioningsystem,it delaysthe compressorfrom
and enrichesthe mixtureto assuresmoothtransitionto the A,/Cmode
beingenergized,
Emission(EVAP)PurgeControlSolenoidValve*'
5 . Evaporative
When the enginecoolanttemperatureis above 154'F(68'C).the ECM/PCMcontrolsthe EVAPpurgecontrolsolenoid
valvewhich controlsvacuumto the EVAPpurgecontrolcanister.
Emission(EVAP)PurgeControlSolenoidValve*a
Evaporative
When the enginecoolanttemperatureabove 154"F(68"C),intakeair temperatureabove32"F(0'C)and vehiclespeed
above 0 mile (0 km/h)or [Ay'Ccompressorclutch on and intakeair temperatureabove 160"F(41'C)],the ECM/PCM
controlsthe EVAPpurgecontrolsolenoidvalvewhich controlsvacuumto the EVAPpurgecontrolcanister.
(EGR)ControlSolenoidValve*?
6. ExhaustGasRecirculation
When EGRis requiredfor controlof oxidesof nitrogen(NOx)emissions.the ECMcontrolsthe EGRcontrolsolenoid
valvewhich suppliesregulatedvacuumto the EGRvalve
1 . AlternatorControl
with the electricalload and driving mode,
The systemcontrolsthe voltagegeneratedat the alternatorin accordance
fuel
economy.
improve
the
engine
load
to
which reducesthe
3.
.1.
ECM/PCMFail-safe/Back-upFunctions
1. FailsafeFunction
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMignoresthat signal and assumesa pre-programmedvaluefor that sensorthat allowsthe engineto continueto run.
Function
2. Back-uD
When an abnormalityoccursin the ECM/PCMitself,the fuel injectorsare controlledby a back-upcircuitindependent
of the systemin orderto permitminimaldriving.
3. Self diagnosisFunctionlMalfunctionIndicatorLamp(MlL)l
When an abnormalityoccursin a signalfrom a sensor,the ECM/PCMsuppliesgroundfor the lvllLand storesthe DTC
in erasablememory.When the ignition is initiallyturned on, the ECM/PCMsuppliesground for the MIL for two secondsto checkthe MIL bulb condition.
4. Two Trip DetectionMethod
idle control
To preventfalse indications,the Two Trip DetectionMethodis usedfor the HO2S,fuel metering-related.
functions.When an abnormalityoccurs,
system,ECTsensor,EGRsystemand EVAPcontrol systemself-diagnostic
the ECM/PCMstoresit in its memory.When the same abnormalityrecursafterthe ignitionswitch is turned OFFand
this functionis
ON 0l) again,the ECM/PCMinformsthe driver by lightingthe MlL. However,to easetroubleshooting,
an
abnormality
jump
immediately
when
will
then
blink
you
The
MIL
check
connector.
the
service
cancelledwhen
occurs,
5. Two (or Three)DrivingCycleDetectionMethod
A "DrivingCycle"consistsot startingthe engine.beginningclosedloop operation,and stoppingthe engine.lf misfiring that increasesemissionsis detectedduringtwo consecutivedrivingcycles,or TWCdeteriorationis detecteddurthis function
ing three consecutivedrivingcycles,the ECM/PCMturns the MIL on. However,to easetroubleshooting,
is cancelledwhen you jump the servicecheckconnector.The MIL will then blink immediatelywhen an abnormality
occurs.
(cont'd)
1 1 - 10 5
PGM-FISystem
SystemDescription(cont'dl
Lean Burn Control {D16Y5engine: CvT)
TOC/CKP/CYP
SENSOR
MAP SENSOR
CKF SENSOR
Comparison
oI currentair
fuel ratio to target ratio
ECM
The lean burn control system is basedon the characteristic
increasein crankshaftangularacceleration
which occursin
when the air-fuelratiogets leaner.
The CKFsensor,which is mountedon the crankshaft,monitorssnginespeed,lf crankshaftangularacceleration
falls below
a certainlevel(targetair-fuelratiolevel),the amountof injectedfuel is reouceo.
lf crankshaftangularacceleration
exceedsthis level.the amountof fuel is increased.
This system improvesfuel economyand driveabilityby controllingthe amount of injectedfuel in the lean burn range
immediatelvbeforecombustionstartsto deteriorate.
1 1 - 10 6
I
EngineControlModule/PowertrainControlModule(ECM/PCM)
t'96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl
The Malfunc{ion Indicator Lamp
{MlLl never comes on (evenlor
two secondsl atter ignition is
turned on.
7.5A) in the
checkfor a loosefuse No. 25 {METER
NOTE:lf this svmptomis intermittent,
terminalA18,or an intermit
underdash{use/relaybox, a poor connectionat ECM/PCM
(A18)and the gaugeassemblv.
wire betweenthe ECM/PCM
tent ooenin the GRN/ORN
Turnthe ignitionswitchON (ll).
ls the low oil pressurelighton?
-
Repair short or open in the
wile botwoen No. 25 {M€TERI
17,5Altus€ and gau99 assem'
bty.
ReplacoNo.25 IMETERI(7,5
A)tuse.
Try to start the engine.
A I32PI
ECM/PCMCONNECTOR
PGl {BLKI
Doesthe enginestan?
Checklor an open in the wiles
{PGlinosl:
1. Turnthe ignitionswitchON (ll).
2 . l d e a s u r ev o l t a g e b e t w e e n
b o d y g r o u n da n d E C M / P C M
connectorterminalsA10 and
A23 individually.
L
Check tor an open in the wire ot
bulb (MlL line):
1. Turnthe ignitionswitchOFF.
2 . C o n n e c t h e E C M / P C Mc o n nector terminal A'18to body
groundwith a jumperwire.
3. Turnthe ignitionswitchON (ll).
Wire sideot femaleterminals
Repair open in the wire(s)
b e t w e e n E C M / P C Ma n d G 1 0 1
(localod at the thetmostat hous_
ingl that had morethan 1.0V.
ls thorelessthan 1.0V?
Substituto . known-good ECM/
PCM and recheck.It symptom/
indication go6s away, roPlace
the origin.l ECM/PCM.
ls the MIL on?
-
Substitute a known-good ECM/
PCM and .echeck.lf symptom/
indication goes away, replaco
the origin.l ECM/PCM.
! 1 ,
Repair open in th€ wires
betwoen ECM/PCMlAl8l and
gaug6 a$embly.
Replacethe MIL bulb,
A (32P}
ECM/PCMCONNECTOR
8
6
2
12 l 3
t 5 t 6 1 t I t 19 20
25
MrL
22
l0
11
23
2a
xt 30
27
I luanpenwrnr
IGRN/ORN) I
Wire sideof femaleterminals
(cont'd)
11-107
PGM-FISystem
EngineControlModule/PowertrainControlModule(ECM/PCMI
('96- 98 Models,'99- 00 Dl6Y5enginewith M/Tl (cont'd)
The Maltunction Indicator Lamp
(MlLl stays on o. comes on eftar
two s€conds,
Check the Oiagnoslic Trouble
Code{DTC}I
1. Connecta scantool or Honda
PGMTester.
2. Turnthe ignitionswitchON (ll).
3. Read the DTC with the scan
tool or HondaPGMTester.
Are any DTC{s)indicated?
NOTE:
. Whenthereis oo Diagnostic
TroubleCode(DTC)stored,the MtL wi stay on if the SCS
servace
connectoris connected
andthe ignitionswitchis on,
. lf this symptomis intermittent,
checklor:
- A looseFl E/M115A) fuse in the underhoodluse/relaybox
- A looseNo. 13 FUELPUMPfuse(15A) in the underdashfuse/relay
box
- An intermittentshon in the wire betweenthe ECM/PCM(C7)and the servicecnecK
connector
- A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M( A 1 8 )a n d t h e g a u g e
assembly
- An intermittentshon in the wire betweenthe ECM/PCM{D4)and the MAp sensor
An intermittentshort in the wire betweenthe ECM/PCM(D10),the Tp sensor,the
EGRvalve l:ft sensor (D16Y5engine)and/or the Fuel tank pressuresensor (,96
Dl6Y8 engine(coupe),'97 016Y7engine(coupe:KL model,sedan:KL (LX)modeli,
'97 016Y8
engine{coupe:all models,sedan:KL modeti,'98,allmodels}
- PGM-FImain
relay
. Seethe OBD ll scantool or HondaPGMTesteruser'smanualslor speciticoperating
instructions.
Go to troubleshooting p.oc€dur€s
(se€pago 11{11.
Checkthe DTCby MIL indication:
1. Turnthe ignitionswitchOFF.
2. Connectthe SCSservicecon,
n e c t o rt o t h e s e r v i c ec h e c k
connector.
3. Turnthe ignitionswitchON (lli.
Doesthe MIL indicateany DTC?
Repair opon ol short in wire
botwoen the ECM/PCM (C8)
and Data Link Connector.
Go to troublelhooting procedure ls6epage11-811.
ECM/PCMCONNECTOR
C 13lPI
scs tBRNI
Try to startthe engine.
Doesthe engine start?
Wire side of female terminals
Check for a short in the wire
(SCSlin€l:
1 . D i s c o n n e ctth e S C S s e r v i c e
connector.
2. Stop the engineand turn the
ignitionswitchON {lli.
3. Measurevoltagebetweenthe
ECM/PCMconnectorterminal
C7 and body ground.
ls thereapprox.5 V?
(To page11,109)
11-108
(To page11 109)
Ropair short to body Iround in
the wire betweon ECM/PCMlCTl
and sorvicecheckconnector.
l F r o mp a g e1 1 1 0 8 )
Checkfor a short in the wire {MlL
linell
1. Turnthe ignitionswitchOFF.
2. Disconnectthe Eclvl/PCMconnectorA (32P).
3. Turnthe ignitionswitchON {ll).
ls the MIL ON?
Ropair short to body gtound in
the wir. between the ECM/PCM
lA18)and MlL.
Substitute a known-good ECM/
PCM and recheck.lt 3ymptom/
indicaiion goes away, rePlace
ihe original ECM/PCM.
( F r o mp a g e1 1 1 0 8 )
InspectFl E/M (10 A) fuse in the
undeFhoodIuse/relaybox.
-
-
Repair short in the wirg
b€tweon Fl E/M (15 A) luse
and PGM-FImain rolay.
ReplaceFl E/M (15 Alfuse.
InspectNo. 13 FUELPUMP(15A)
fuse/relaY
fuse in the under-dash
-
-
Repait lhort in the wire
botween No. 13 FUEL PUMP
115Al fuse and PGM-FImain
reray.
RoplaceNo. 13 FUELPUMP
115Al tu3o.
Checkfor a short in a 3€nsor:
1. Turnthe ignitionswitchON (lli.
2. Disconneclthe 3P connector
from eachsensorone at time:
. TP sensor
. EGRvalvelift sensor(D16Y5
engrne)
. F u e l t a n k p r e s s u r es e n s o r
( ' 9 6 D 1 6 Y 8e n g i n e( c o u p e ) ,
' 9 7 D 1 6 Y 7e n g i n e ( c o u P e :
K L m o d e l , s e d a n :K L ( L X )
m o d e l ) , ' 9 7D 1 6 Y 8e n g i n e
l c o u p e :a l l m o d e l s ,s e d a n :
KL model,'98-allmodels)
!
{To page11 110)
(cont'd)
11 - 1 0 9
PGM-FISystem
EngineControlModule/Powertrain
ControlModule(ECM/pCMl
('96- 98 Models,'99 - 00 D16Y5enginewith M/Tl (cont,dl
( F r o mp a g e 1 1 - 1 0 9 )
ECM/PCMCONNECTOR
D {16P}
Doesthe N4lLgo OFF?
Replacethe sensor that caused
the light to go out.
Check fo. a short in the wi.os
(VCClines):
':. Turnthe ignition
switchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorD (16P).
3. Checkfor continuitybetween
b o d y g r o u n da n d E C M / P C M
c o n n e c t o tre r m i n a l sD 4 a n d
D10individually.
Ropair short to body ground
in the wire betweon ECM/
PCM{O4)and MAP s6n3or.
Repair short to body ground
in the wire between ECM/
PCMlD10l,the TP sensor,the
EGRvalve lift sensor{D16Y5
engine) and/or the Fuel tank
pressuresensor {'96 Dl6Yg
enginelcoupe),'97 D16Y7
e n g i n e ( c o u p e :K L m o d e l ,
s e d a n : K L ( L X l m o d e l ) ,' 9 7
D16Y8 engine (coupe:all
models,sedan:KL model. €8allmodelsl.
ls therecontinuity?
Checktor rn open in the wires
(lGPlines):
1. Disconnectthe fuel injectors
and IACvalveconnectors,
2. Turnthe ignitionswitchON (ll).
3 . M e a su r e v o l t a g e b e t w e e n
b o d y g r o u n da n d E C M / P C M
c o n n e c t otre r m i n a l sA 1 1 a n d
424 indivjdually.
ls therebatteryvohage?
ls therelessthan 1.0V?
Substitute 6 known-good ECM/
PCM and r€check.lf symptom/
indication 9o€s away, replace
the original ECM/PCM.
11-110
Wire sideof femaleterminals
ECM/PCMCONNECTOR
A (32P}
IGP 1
{YEL/BLKI
2
I
l 5 t 6 I t t 8 t 9 20
12 1 3
25
27
11
23
-
-
Repair open in the wirels)
between ECM/PCM (A11,
A24land PGM-Flmain relay.
Check for poor connections
or loose wiras at the PGM-FI
main relay,
Test the PGM-FImdin relav
lseepag611-237).
v) (l
Wire sideof femaleterminals
LG1
{8RN/
BLK)
I
2
5
8
'12 t t 1 1 t 5 l 6 1 7 t 8 t 9 20
2A 23 30
LG2
{8RN/
8LK}
Repair open in the wirolgl
b€twe€n ECM/PCM {A9, A22} and
G101that had more than 1.0V.
21
2a 29 3 0
IGP2
(YEL/BLKI
Checkfor an open in the wires
(LGline3):
1. Reconnectall sensorconnec
tors.
2. Reconnect
the ECM/PCM
connectorD (16P).
3. Turnthe ignitionswitchON (ll).
4. Measurevoltage between
b o d y g r o u n da n d E C M / P C M
c o n n e c t o tr e r m i n a l sA g a n d
A22individually.
VCCl {YEL/RED}
to
l1
23
2a
ControlModule(ECM/PCM)
EngineControlModule/Powertrain
('95- 00 ModelsexceptDl6Y5 enginewith M/T)
The Mrlfunction Indicator LamP
{MlL) never comes on {even tor
two seconds) after ignition is
turnedON lll).
Turnthe ignitionswitchON lll).
NOTE:
. Whenthere is no Diagnostic
TroubleCodelDTC)stored,the MIL will staYon if the SCS
seruiceconnectoris connectedandthe ignitionswitchis on.
. lf this symptomis intermittent,
checkfor:
box
- A looseNo. 25 (METER)
{7.5A) fusein the underdashfuse/relay
box
- A looseFl E/M(15Alluse in the undeFhoodfuse/relay
box
fuse/relay
- A looseNo. 13 FUELPUMPfuse(15A) in the under-dash
(A18)and the gaugeassem'
- An intermittentshon in the wire betweenthe ECM/PCM
an intermittentshort in the wire betweenthe ECM/PCM(C19)and the MAP sensor
An intermittentshort in the wire betweenthe ECM/PCM{C28),the TP sensor,the
EGRvalvelift sensor(D16Y5engine)and/orthe Fueltank pressuresensor('96D16Y8
engine (coupe),'97D16Y7engine lcoupe: KL model, sodan:KL (LX) model)"g7
Dt6Y8 engine(coupe:all mod;ls, sedanlKL model),'98-allmodels,'99-al'models'
'00-allmodels.
- PGM'FImain relay
. See the oBD ll scantool or HondaPGM Testeruser'smanualsfor specificoperating
instructrons,
-
ls the low oil pressurelighton?
-
Repair shott or open in tho
wire bstwoon No. 25 IMETER)
l?.5A)tuse and gaugatsom_
blv.
ReolaceNo. 25 (METERI(7.5
Alluse.
A I32PI
CONNECTOR
ECM,/PCM
Try to start the engine.
Doesthe enginestart?
Checkfor an opon in the wire or
bulb (MlL line):
1. Turn the ignitionswitchOFF.
2 . C o n n e c t h e E C M / P C Mc o n '
nectorterminal A18 to body
groundwith a iumperwire.
3. Turnthe ignitionswitchON (ll)
Wiresideof {emaleterminals
-
-
Turn the ignitionswitchOFF.
InspectFl E/M(15A)fuse in the
underhood Iuse/relaybox.
Repair open in tho wire3
betwoon ECM/PCM (A18) and
gaugo .*tembly.
Rool.ce the MIL bulb.
Substitute a known-good ECM/
PCM and rochoc&. lf sYmptom/
indication goes sw6y, repl.ce
tho original ECM/PCM.
Rop.ir short in the wirc
betwo€n Fl E/M (15 A) luso
and PGM-Flmrin rGl.y.
Reol.ce Fl E/M (15 A)tusa.
lnspectNo. 13 FUELPUMP{15A}
luse in the under-dashfuse/relay
-
.f,
-
Reoair short in the wiro
between No. 13 FUEL PUMP
115Al luse sod PGM-FImain
relay.
ReolaceNo. 13 FUEL PUMP
115A) tuse.
(cont'd)
(Topage11 112)
11-111
PGM-FISystem
EngineControlModule/Powertrain
ControlModule(ECM/PCM)
('99- 00 ModelexceptDl6Y5 (M/Tl engine)(cont'd)
( F r o mp a g e ' 1 1 - 1 1 1 )
Checkloi an open in the wires
(lGPlinesl:
1. Disconnect
thelueliniectorand
IACvalveconnectors.
2. Turnthe ignitionswitchON (ll).
3 , M e a s ur e v o l t a g e b e t w e e n
b o d y g r o u n da n d E C M / P C M
c o n n e c t o tr e r m i n a l s8 1 a n d
Bg individually.
Wiresideof femaleterminals
-
ls there batteryvoltage?
-
R e p a i ro p e n i n t h e w i r o ( 3 )
between ECM/PCMlBl, B9l
and PGM-Flmain relay.
Check tor poor connections
or loose wires al the PGM-FI
main relav.
Test tho PGM-FImain rehy
(3.e page 11-237).
ECM/PCMCONNECTOR
B {25P)
Checktor an open in the wires
(PG,LG lines):
1 . R e c o n n e ctth e f u e l i n i e c t o r
and IACvalveconnectors.
2. Measurevoltage between
body ground and ECM/PCM
connectorterminals82, 810,
820 and 822 individually.
ls therelessthan1.0V?
Check for a short in the wires
{VCCI,VCC2lin6s}:
Measurevoltage between body
ground and ECM/PCMconnector
terminals
C19andC28individually.
ls thereapprox.5V?
Repair open in the wirels)
b e t w e e n E C M / P C Ma n d G 1 0 1
llocated ai the l6ft side of tho
intaks m.nifoldl thrt h.d more
than 1.0V.
Checktoa a 3hort in s 3ensor:
While measuring voltage
betweenbody ground and ECM/
P C [ / tc o n n e c t o rt e r m i n a l sC 1 9
and C28 individually,disconnect
the 3P connectorof each sensor
one at time:
. MAPsensor
. TP sensor
. EGRvalve
. Fueltankpressuresensor
ls thereapprox.5 V?
Substiiute a known-good ECM/
PCM and racheck. ll symptom/
indicetion goes eway, replace
th6 original ECM/PCM.
11-112
Replace tho sansor that had
.pprox. 5 V.
LG1(BRN/BLKI
Wiresideof femaleterminals
ECM/PCMCONNECTOR
C (31P)
vcc2
f e m a l e t e r m i n a l s IYEL/BLUI
vccl
{YEL/RED)
Reoairshort in lhe wire betwe.en
M A P 3 a n s o r ,T P s e n s o r , E G R
valve, Fuel tank pres3ure3ensor
and ECM/PCM{Cl9, C28).
The Malfunction Indicator LamP
lMlL) staYson or comes on after
NOTE:
"in-"n tf'"r" is no DiagnosticTrouble Code (DTCistored,the MIL will stav on ;{ the scs
andthe ignitionswitchis ON (ll)
is connected
serviceconnector
checkfor:
. lf this symptomis intermittent,
(A10)and the servicecheck
- An intermittentshortin the wire betweenthe ECM/PCM
-
C h e c kt h e D i a g n o s t i cT r o u b l e
Code(DTC):
1. Connecta scantool or Honcla
PGMTester.
2. Turnthe ignitionswitchON (ll)
3. Read the DTC with the scan
tool or HondaPGMTester.
indicated?
Are any DTC(S)
'l
connector
( A 1 8 1a n d t h e g a u g e
A n i n t e r m i t t e nst h o r t i n t h e w i r e b e t w e e nt h e E C M / P C M
. s"" it'" Oab ll scantool or HondaPGMTesteruser'smanualsfor specificoperating
instructions.
Go to troubloshooting Proc€dures
(seepage 1141).
check the DTCby MIL indic.tion:
1. Turnthe ignitionswitchOFF
2. Connectthe SCSservicecon_
n e c t o rt o t h e s e r v i c ec h e c k
3. Turnthe ignitionswitchON (ll)
Doesthe MIL indicateanYDTC?
Repair open or 3hort in wiro
between ihe ECM/PCM(A21)
and Data Link Connector.
Go to troubleshooting Ploce_
du.es (seepage 11-811.
Try to start the engine
Substitute . known-good ECM/
PCM and recheck lt sYmptom/
indication goes awaY, rePlaca
th. original ECM,/PCM.
A I32P)
ECM/PCMCONNECTOR
C h e c kf o r a s h o r t i n t h e w i . e
(Scs line):
1. Turn the ignitionswitch OFF
and turn the ignition switch
o N1 ) .
2 - M e a su r e v o l t a g e b e t w e e n
body groundand the ECM/
PCMconnectorterminalA10
ls there batteryvoltage?
Wire side of female terminals
Reoair short to body ground in
the wiro bstwaen ECM/PCM (A101
and service ch€ck connoctot.
(cont'd)
(Topage11-'114)
1 1 - 11 3
PGM-FISystem
EngineGontrolModule/PowertrainControlModule(ECM/PCMI
('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'dl
{ F r o mp a g e 1 1 1l 3 )
Checkfor a short in the wi.e lMlL
linelr
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMcon
nectorA (32P).
3. Turnthe ignitionswitchON (ll).
l s t h e M I LO N ?
Substituto a known-good ECM/
PCM and r€check.lf symptom/
indication goes away, roplace
the o.iginal ECM/PCM.
11-114
Repairshorl to body ground in
the wire between the ECM/PCM
{A18}andMlL.
ManifoldAbsolutePressure(MAP)Sensor('96Models)
problem (vacuumleak) in the
The scan tool indicatesDiagnosticTrouble Code (DTC)P0106:A mechanical
ManifoldAbsolutePressure(MAP)Sensorsystem'
TheMAPsensorconvertsmanifoIdabsoIutepressureintoeiectricaIsigna|sandinpUtstheEcM/PcM'
OUTPUT
VOLTAGE
(v13.5
3.0
2.5
2.0
1.5
1.0
0.5
0
-
The MIL has been reported on
OTCP0106is storod.
Or from PtobableCauseLisl.
300
lin. Hgl GAUGE
READING
(mm Hgl
Problomverificetion:
1. Do the ECM/PCMResetProcedure.
2. Start the engineand keep
enginespeedat 1,000rpm for
one minutewith the transmis'
sion in @ or I Position{Mff
in neutral).
ls DTCP0106indicated?
Checkthe MAP sensoroutPut:
1. Turnthe ignitionswitchOFF
2. Turnthe ignitionswitchON (ll).
3. Checkthe MAP with the scan
tool.
C h e c kt o r v a c u u m l e a k a g eo r
blockagebetweenthe MAP sen'
sor and throftlebody
ls thereleakageor blockage?
Chockthe MAP s€nsol output:
1. Stopthe engane.
2. Turnthe ignitionswitchON (ll).
3. Checkthe MAP with the scan
tool.
l l ,
( T op a g e1 1 - 1 1 6 )
(Topage11 116)
{cont'd)
1 1 - 11 5
PGM-FISystem
ManifoldAbsolutePressure(MAP)Sensor('96Modelsl(cont'dl
( F r o mp a g e1 1 - 1 1 5 i
Chockto. poor response:
1 . S t a r t t h e e n g i n e .H o l d t h e
engineat 3,000rpm with M in
E or E position, M/T in neu
tral untiltheradiator
tan comes
on, then turn the ignition
switchOFF.
2. Startthe engine.
3. Checkthe MAP with the scan
tool.
{ F r o mp a g e1 1 - 1 1 5 )
Checklor poor response:
1 . S t a r t t h e e n g i n e .H o l d t h e
engineat 3,000rpm with M in
E or E position,M/T in neutral until the radiatorfan comes
on, then turn the ignition
switchOFF.
2. Startthe engine.
3. Checkthe MAP with the scan
tool.
ls a N4APot 40.0kPa {300mmHg,
12.0in.Hg)or lessindicated
within
one secondafter staning the
engine?
The MAP sensor is OK st this time.
ls a MAP of 40.0kPa(300mmHg,
12.0in.Hg)or lessindicated
within
one secondafterstartingthe
engine?
Substitute a known-good ECM/
PCM and rechock. lt symptom/
indication go6s .way. .6plrce
th€ original ECM/PCM.
11-116
ManifoldAbsolutePressure{MAP}Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/T)
(high vacuum) problem in the
The scan tool indicatesDiagnosticTrouble Code (DTC)PO107:A low voltage
ManifoldAbsolutePressure(MAP)sensor.
Tho MIL has been roport€d on.
DTCP0107is storod.
Problamverification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe MAP with the scan
lool.
ls approx.101kPa(760mmHg,
30 in.Hg)indicated?
lntormittont failuro, sYatgmia OK
al thb timo. Chocklor Pool con_
noqtiona or looso wirca at C111
{MAP !6nsor) ond ECM/PCM.
(C111)
MAP SENSOR3P CONNECTOR
Chockfor an opon in wiJe (VCCI
lino):
1. Turn the ignitionswitchOFF.
2. Disconnectthe MAP sensor
vccr
(YEL/BEDI
3. Turn the ignitionswitchON (ll).
4. Measurevoltagebetweenthe
MAP sensorconnectorNo l
terminaland No 2 terminal
I
Wiresideof femaleterminals
ls thereapprox.5 V?
Ropair open in tho wit b€twocn
ECM/PCM(Dill tnd MAP !enso].
Checkfor .n open or ahort in the
MAP 3€naor:
C h e c kt h e M A P w i t h t h e s c a n
tool.
ls approx.2 kPa(15mmHg,
0.6in.Hg)or lessindicated?
(D16Y5engine (with
YES
cw))
T
Chsckto. a short in the TCM:
1. Turn the ignitionswitchOFF.
the 22Pconnector
2. Disconnect
from the TCM.
3 . T u r n t h e i g n i t i o ns w i t c hO N
0r).
4. checkthe MAP with the scan
tool.
( T op a g e1 1 - 1 1 8 )
(cont'd)
11-117
PGM-FISystem
ManifoldAbsolutePressure(MAp)Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/Tl (cont,d)
( F r o mp a g e1 1 - 1 1 7 )
ls approx.2 kPa('15mmHg,0.6
in.Hg)or lessindicated?
MAP SENSOR3P CONNECTOR
IC1l1I
Check for a short in ihe wire
{MAPline)l
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / p C M
connectorD (16P).
3. Checkfor continuitybetween
the MAPsensorconnectorNo.3
terminalandbodyground.
MAP
(RED/GRNI
Wiresideof femate;rminats
R6pairlhort in tha wire b€twaen
ECM/PCM {D3l .nd MAP !6ru0r.
Substitute a known-good ECM/
PCM..nd recheck. normal MAP
is indiceted, .eplsce lhe original
ECM/PCM,
11-118
|'
ManifoldAbsolutePressure(MAP)Sensor
(;gg- OOModelsexceptDl6Y5 enginewith M/T)
A low input (high vacuuml problem in the
The scan tool indicatesDiagnostrcTrouble Code (DTC)PO1O7:
ManifoldAbsolutePressure(MAP)sensor'
signalsand inputsthe ECM/PCM'
The MAp sensorconvertsmanifoldabsolutepressureinto electrical
OUTPUT
VOLTAGE
lvl3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
lq,
.-l
-
2oo 3q, (x,
5q)
6q) 700
(in.Hgl GAUGE
REAOING
(mmHgl
The MIL h'3 been reported on
OTCP0107b stor€d.
Problemverilication:
1. Turnthe ignitionswitchON {ll)
2. check the N4APwith the scan
tool.
ls approx. 101kPa(760mmHg,
30 in.Hg)indicated?
lntermittent failuro,3Ystomis OK
at this time. Ch€ckfor Poor con'
nection3 or loose wiros at C111
IMAP sonsorl and ECM/PCM.
IC114)
MAP SENSOR3P CONNECTOR
Ch.ck for an opcn in wit. {vCC1
linel:
1. Turnthe ignitionswitchOFF
2 . D i s c o n n e ctth e M A P s e n s o r
connector.
3. Turn the ignitionswitchON (ll).
4. Measurevoltagebetweenthe
MAP sensorconnectorNo. 1
terminaland No 2 terminal
vccl
tYEL/RED)
Wire sido of fomalg tormin6ls
ls thereapprox.5 V?
Repairopsn in the wirg botween
ECM/PCM(C19)rnd MAP seGor.
(To page 11-120)
{cont'd)
1 1 - 11 9
PGM-FISystem
ManifoldAbsolutePressure(MApl Sensor
('99- 00 ModelsexceptDl6yS enginewith M/T) (cont,dl
( F r o mp a g e1 1 1 1 9 )
Checkfor an open or shon in the
MAP s€nsor:
C h e c kt h e M A P w i t h t h e s c a n
tool.
ls approx.2 kPa(15mmHg,
0.6in.Hg)or lessindicated?
MAPSENSOn
3PCONNECTOB
tcllilt
Check tor a sho.t in lhe wire
{MAPline):
1. Turnthe ignitionswitchOFF.
2 . D i s c o nn e c t t h e E C N 4 / p C N 4
connectorC (31P).
3. Checkfor continuitybetween
the MAPsensorconnectorNo.3
terminalandbodyground.
MAP
(RED/GRNI
Wire side of female terminals
Repairshort in the wire between
ECM/PCM{Cl7} and MAp s€nsor.
Substitute a known-good ECM/
PCM and rech6ck.lf no.mal MAp
is indicated, replace the o.iginal
ECM/rcM.
11-120
!
ManifoldAbsolutePressure(MAPISensori;idlga lil;dels,'99- 00 Dl6Y5ensinewith M/T)
voltage (low vacuum) problem in the
The scan tool indicatesDiagnostrcTrouble code (DTC)Po108:A high
ManifoldAbsolutePressure(MAP)sensor.
The MIL has beenreportedon
OTCm108 is stolod.
Problemvetitication:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rPm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
let it idle.
2. Checkthe MAP with the scan
tool.
ls 101kPa(760mmHg,300 in.Hg)
or higherindicated?
lntormittent lailure, sFtom k OK
.t thb time. Chocklor Poor con'
nections or loorg wires at Cll'l
|MAP sensorl snd ECM/PCM.
ICl11}
MAP SENSOR3P CONNECTOR
Check tor an open in the MAP
36nSOt:
l l
1. Turnthe ignitionswitchOFF
2 . D i s c o n n e ctth e M A P s e n s o r
3P connector.
3. Installa jumperwire betlveen
the MAP sensor3P connector
No 3and No 2.
terminals
4. Turnthe ignitionswitchON (ll).
5. Checkthe MAP with the scan
tool.
MAP
IRED/GRNI
JUMPERWIRE
Wire sideol femaleterminals
ls 101kPa(760mmHg,30 0 in.Hg)
or higherindicated?
vccl
IYEL/RED)
Checkfor an open in wire (SG1
line):
1. Removethe iumperwire.
2. Measurevoltagebetweenthe
MAP sensor3P connectorte.
minalsNo. 1 and No 2
ls thereapprox.5 V?
Rapai. open in the wito batwoen
ECM/PCM(D12).nd MAP !en.or.
D (16PI
ECM/PCMCONNECTOR
JUMPERWIRE
Check for an oPon in the wiie
(MAPlinel:
1. Turnthe ignitionswitchOFF.
con2 . C o n n e c tt h e E C M / P C M
nectorterminalsD3 and D12
with a iumPerwire.
3. Turnthe ignitionswitchON (ll).
4. Checkthe MAP with the scan
tool.
MAP
(RED/GRN)
sG1
(GRN/WHT)
Wire sideof femaleterminals
ls 101kPa(760mmHg,30 0 in.Hg)
or higherindicated?
lr,
Repairopon in the wiles bstlt oon
ECM/PCM(D3l and MAP 3oGor.
(cont'd)
Substituto a known'good ECM/
PCM and rochock.ll normal MAP
is indicated, replace tho original
ECM/PCM.
11-121
PGM-FISystem
ManifoldAbsolutePressure(MAPISensor
('99- 00 ModelsexceptD16YSenginewith M/T) (contd)
The scan tool indicatesDiagnosticTrouble Code (DTC)P0108:A high voltage flow vacuum)problem
in the
ManifoldAbsolutePfessure(MAp)sensor,
Tho MIL has boon rcDortodon.
DTC ml 08 b stolod.
Problemverification:
'1.Start
the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
let it idle.
2. Checkthe MAP with the scan
toot,
ls 101kPa(760mmHg.30
in.Hg)or higherindicated?
Intormittent f.ilu.e, rystom is OX
at thi! time. Chocktor poor conn6ction3 or looso wirea at C111
(MAP 3en.or) and tho ECM/
PC-M.
Check for an open in the MAP
aon5('r:
1. Turnthe ignalionswitchOFF.
2 . D i s c o n n e ctth e M A P s e n s o r
3P connector.
3. Install a jumper wire betwesn
the MAP sensor3P conn6ctor
terminals
No.3 and No.2.
4. Turnthe ignitionswitchON {ll).
5. Checkthe MAP with the scan
tool.
(C111I
MAP SENSOR3P CONNECTOR
MAP
IRED/GRNI
JUMPERWIRE
Wiresideof femaleterminals
ls 101kPa(760mmHg,30
in.Hg)or higherindicated?
vccl
IYEL/RED)
Check fo. an opcn in wiro (SGl
line):
1. Removothe jumperwire.
2. Measurevoltage between the
MAP sonsor3P connectorter
m i n a l sN o . 1 a n d N o . 2 .
ls there approx. 5 V?
Roprir opon in tha wiJo bctwoen
thc ECM/FCM(C7l rnd the MAp
sonln t.
Chsck for an open in tho wi.e
{MAPlino}:
1. Turnthe ignitionswitchOFF.
2. Install a jumper wire on the
ECM/PCMconnectorsbetween
C7andC17.
3. Turnthe ignitionswitchON (ll).
4. Checkthe MAP with the scan
tool,
ls 101kPa(760mmHg,30
in.Hg)or higherindicated?
Substituto a known-good ECM/
PCM and rechcck,It normal MAP
is indiceted. r.place tho original
ECM/PCM.
11-1 2 2
-
ECM/PCMCONNECTOR
C (31PI
Repairop€n in the wir6a bstwoon
tho ECM/FCM(C171and rh6 MAp
scnltoa.
JUMPERWIRE
Wiresideof femaleterminals
ManifoldAbsolutePressure(MAP)Sensor(cont'dl
(MAP)lower than
The scan tool indicatesDiagnosticTroublecode (DTc) P1128:ManifoldAbsolutePressure
exoected.
-
Tho MIL has been t€Portedon.
DTCP1128is stored.
Problemverification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe MAP with the scan
tool.
ls 54.1kPa(406mm Hg, 16.0
in. Hg)or higherindicated?
lntermitteni failu.e, sYstomi! OK
at thb time.
higherthan
The scantool indicatesDiagnosticTroublecode (DTC)P1129:ManifoldAbsolutePressure{MAP)
exoected,
L
-
The MIL has beenroportedon.
DTCP1129is slorod
Problemv6rilicaiion:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
2. Checkthe MAP with the scan
tool.
ls 43.3kPa(325mm Hg, 128
in. Hg)or lessindicated?
Int6rmittent failuto, sy3tem i3 OK
at thi3 time.
11-123
PGM-FISystem
IntakeAir Temperature(lAT)Sensor('96- 97 Models)
The scan tool indicatesDiagnosticTroublecode (DTC)P0111:A range/performance
problemin the lntakeAar
Temperature(lAT)Sensorcircuit.
The IAT sensor is a temperaturedependantresistor(thermistor).
The resistanceof the thermistordecreasesas the intake
air temperatureincreasesas shown below.
-
The MIL hss beon reportedon.
DTCP0111is stored.
Or from ProbableC.use List.
RES|STAI{CE
{tol
Problemverification:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the IAT sensor2P
connector,
3. Removethe IATsensor.
4. Reconnectthe IAT sensor2p
. 32 .. ro. tr. 2r, zaa r..l
-20 o 20 /|o ao ao 100 rrotlcl
5. Leavethe IAT sensorexposed
to ambaent
temperature,
6. Turn the ignitionswitch oN fll).
7. Checkthe IAT with the scan
tool.
INTAIG AIR TEMPEMTURE
Rsplscgthe IAT sensor.
Checktho IAT sensoroutput:
1. Warm the IAT sensorwith a
hair dryer2. Checkthe IAT with the scan
tool.
Didthe IATrise2"F(1.C)or more
from the ambienttemperature?
Replscethe IAT sensor.
11-124
Int€rmittont failu.e, system is OK
at this time.
I
IntakeAir Temperature(lATl Sensor
The scantool indicatesDiagnosticTroubleCode{DTC)P0112:A low voltage(hightemperature)problemin the
lntakeAir Temperature(lAT)sensorcircuit.
The MIL has beenTeportedon.
DTCP0112is stored.
RESISTANCE
IKOI
Problemverification:
1. TurntheignitionswitchON 1ll)
2. Checkthe IAT with the scan
tool. a2 .. toa rra rrl l:rt t.al
20 0 20 ro ao ao too t2ot.cl
AIRTEMPEFATURE
INTAXIE
ls 302'F(150"C)or hagher(or
H Limit in Hondamode ot
PGMTester)or 0 V indicated?
ls the correctambrenttemper
atureindicatedi' ?
Roolac€tho IAT 3ensor.
*2: lf the engineis warm, it will be
higherthan ambienttemPerature.
.-l
lntermittent failure, svstom is OK
6t this tim€. Checkfor Poor Gonnections or loos€ wires st C112
{lAT.en3orl and ECM/PCM.
Checktor a shon in the IAT sensor:
1. Disconnectthe IAT sensorcon
nector.
2. Checkthe IAT with the scan
tool.
l s 3 0 2 " F( 1 5 0 ' C ) ohr i g h e (r o r
H'Limitin Hondamodeof
PGMTester)or 0 V indicated?
{C112)
IAT SENSOR2P CONNECTOR
-+-r
Ch6ckfor s short in the wira (lAT
lin€):
1. Turn the ignitionswitchOFF
2. Disconnectthe ECM/PCMconnectorD (16P)(C(31P))*'.
3. Checkfor continuitybetween
the IATsensor2PconnectorlerminalNo.2 andbodyground.
I-_T' l ' l
I
IAT
{RED/YEL)
=
Wire sideof femalet e r m r n a r s
Reoairshort in the wire bstween
ECM/PCMtD8 (c25)'1) and IAT
rf,
Substitute a known-good ECM/
PCM and recheck. It normel IAT
is indicated, replace the original
ECM/PCM.
* l: '99 - 0Omodels except Dl6Y5 engine with M/T-
11-125
PGM-FISystem
IntakeAir Temperature(lAT)Sensor
('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode(DTC)POl13:A high voltageflow temperature)problem
in the
IntakeAir Temperature(lAT)sensorcircuit,
The MIL has beenreportedon.
DTCP0113b sto.6d.
Problemveritication:
1. Turnthe ignitionswitchON (ll).
2. Checkthe IAT with the scan
tool.
ls -4'F 1-20"C)or less(or L Limit
in Hondamodeof PGNITester)or
5 V indicated?
Intermittent tailuJe,systom is OK
at this time, Check to. poor connections or loose wir.s at C112
{lAT senso.l .nd ECM/PCM,
Checkfor an open in the IAT sensol:
1. Disconnect
the IAT sensor2p
connector,
2. Connectthe IAT sensor2P conn e c t o rt e r m i n a l sN o , 1 a n d
No.2 with a jumperwjre.
3. Checkthe intakeair tempera,
ture with the scantool.
ls -4"F ( 20'C)or less(or L-Limit
in Hondamodeof PGMTester)or
5 V indicated?
taT sENsoR2PCONNECTOn
(Cl12l
I ' j r l
'---.]__+
SG2
(GRN/BLKII
I
tAT
IRED/YEL}
JUMPER
WIRE
Repbcethe IAT sensor.
Wire sideof femaleterminals
ECM/PCMCONNECTOR
D (16PI
Check tor an open in th6 wires
{lAT.SGzline!):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsD8 and D11 with a
3. Turn the ignitionswitchON (ll).
4. Checkthe IAT with the scan
tool.
IAT IRED/YEL)
sG2
(GRN/BLK)
JUMPERWIRE
ls -4"F ( 20'C)or less(or L-Limit
io Hondamode ol PGMTester)or
5 V indicated?
Substitute a known-good ECM/
PCM end recheck. lf normal IAT
is indic.ted, replace the original
ECM/PCM.
11-1 2 6
R€p6ir opan in the wiro! hween
EC-M/PCMlD8. 011l and IAT sen-
Wiresideof femaleterminals
L
IntakeAir Temperature(lAT)Sensor
('99- 00 ModeisexceptD16Y5enginewith M/Tl
(low temperature)problemin the
The scantool indicatesDiagnosticTroublecode (DTC)P0113:A high voltage
IntakeAir Temperature(lAT)sensorcircuit.
The MIL has be€nrePortedon.
DTCP0113i3 stored.
Probl€mvetification:
1. Turnthe ignitionswitchON (ll).
2. Checkthe IAT with the scan
tool.
ls -4"F (-20"C)or less(or L-Limit
in Hondamodeof PGMTester)or
5 V indicated?
I
Intormittont
.t thi! tim..
nactions or
tlAT ..n!or)
f.iluro, tyrtom i. OK
Chocl for Poor con'
looso wit6 !t C112
rnd ECM/PCftl,
r-+-r
Checktor an open in tho IAT son'
304:
the IAT sensor2P
1. Disconnect
connector,
2. Connectthe IATsensor2Pcon_
n e c t o rt e r m i n a l sN o . 1 a n d
No.2 with a jumPerwire.
3. Checkthe intakeair temperature with the scantool.
I t l , llAr
L1__f
sG2
IGRN/BLK} I
I
(RED/YELI
JUMPER
WIRE
Wire sideof femaleterminals
ls -4"F {-20"C)or less(or L-Limit
in Hondamodeof PGMTester)or
5 V indicated?
C (31PI
ECM/PCMCONNECTOR
Check lor an open in iho wirg3
{lAT,SG2 linesl;
1. Turnthe ignitionswitchOFF
2. ConnectECM/PCMconnector
terminalsC18and C25with a
iumperwire.
3. Turnthe ignitionswitchON (ll)
4. check the IAT with the scan
tool.
ls -4"F (-20"C)or less(or L-Limit
in HondamodeoI PGMTesterlor
5V indicated?
IAT SENSOR2P CONNECTOBIC112'
JUMPERWIRE
Wiresideof lemaleterminals
Roprir opan in tho wilaa brlwocn
ECM/PCM (C18, C25l .nd IAT
!on30r.
substituts a known'good ECM/
PCM and recheck. ll normal IAT
is indicated, replace the otiginal
ECM/PCM.
11-127
PGM-FISystem
EngineCoolantTemperature(ECTISensor
The scan tool indicatesDiagnosticTrouble code (DTC)P0116;A range/performance
problem in the Engrne
CoolantTemperature(ECT)Sensorcircuit.
The ECTSensoris a temperaturedependantresistor(thermistor).
The resistance
of the thermistordecreases
as the engine
coolanttemperatureincreases
as shown oetow.
RESISTANCE
(ko)
THERMISTOR
- a 3 2 6 8r 0 al a 0 l ? 62 t 22 4 8 1 ' r r
-20 o 20 ao o D r@ Il, r'c)
ENGINE COOLANT IEMPERATURE
NOTE:lf DTCP0117and/orP01'18
are storedat the sametime as DTCP0116,troubleshootthose DTCSfirst. then recheck
for DTCP0116.
PossibleCause
. ECTsensordeterioration
. Malfunctionin the thermostatand coolingsystem
TroubleshootingFlowchart
-
The MIL has bognreportedon.
DTCP0116is stored.
Problemverification:
1. Start the engine.Hotd the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
2. With the scantool, checkthe
is 176 200'F{80- 93'C)or
0.0-0.TVindicated?
Check the thermostat and the
cooling system. ll they als OK,
raplacethe ECTsensor.
11-1 2 8
Intermiftent lailure. system is OK
ai thi. time. Ch.ck the thc.mostat 6nd thc cooling system.
|.
fD;r.tt
|jg
The scantool indicatesDiagnosticTroubleCode(DTC)P0117:A low voltage(hightemperature)problemin the
EngineCoolantTemperature(ECTIsensorcircuit.
The MIL has been,eported on.
DTCml 17 is storod.
Problomvorification:
1. Turn the ignitionswitchON (ll).
2. Checkthe ECTwith the scan
tool.
or higher{or
ls 302"F(150"C)
H-Limitin Hondamodeof
PGMTester)or 0 V indicated?
Intermittont failulo, sy3tom it OK
at thk tim., Chockfor Poor oonn.ctions or loo!. wiraa at C122
IECT3en orl and ECM/FCM.
ChecktoJ a short in the ECTs.n5('t:
the ECTsensor2P
1. Disconnect
connector.
2. Checkthe ECTwith the scan
rool.
' f
ls 302"F(150"C)
or higher{or
H-Limitin Hond6modeof
PGMTesterl or 0 V indicated?
(C122I
ECTSENSOR2P CONNECTOR
Check for a 3hort in tho wiro
IECTlinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorD (16P)(C{31P))*.
3. Checkfor continuity between
the ECTsensor2PconneclorterminalNo,1 andbodyground.
Wiresideof femaleterminals
B.gair short in the wiro bltween
ECM/PCM(D2 (C261'l.nd ECT
Substitute . lnown-good ECM/
PCM .nd rocheck.It normrl ECT
is indic.ted, replaco the original
ECM/PCM,
*:'99 -Oo modelsexceptD16Y5enginewithM/T
.1,
(cont'd)
11-129
PGM-FISystem
EngineCoolantTemperature(ECT)Sensor
('96- 98 Models,'99- 00 D16YSenganewith M/T) (cont'd)
The sc€ntool indicatesDiagnosticTroubleCode(DTC)P0118;A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
-
Tho MIL ha3bcen r€oortedon.
OTCm118 b stored.
Problomvorificttion:
1. Turnthe ignitionswitchON (ll).
2. Checkthe ECTwith the scan
tool.
ls -4"F (-20'C) or less(or L-Limit
in Hondamode ol PGMTester)or
5 V indicated?
Intcrmitt.nt failui.. rydom is OK
at thir timc. Chackfor Door connaction! or loor! wiaar at C122
IECT..n.orl .nd ECM/rcM,
ECt SENSOR2P CONNECTOR
{C1221
Chscklor sn open in thc ECT3ansoa:
1 . D i s c o n n e ct h e E C Ts e n s o r
2P connector.
z . L o n n e c rr n e E L t s e n s o rz F
connectorterminalsNo. 1 and
No.2 with a jumperwire.
3. Checkthe ECTwith the scan
tool.
ECT
IRED/WHTI
JUMPERWIRE
sG2
(GRN/BLK)
Wire side of female terminals
ls -4'F (-20'C) or loss(or L-Limit
in Hondamode ol PGMTesterlor
5 V indicated?
ECM/PCMCONNECTOR
D Il6PI
JUMPERWIRE
sG2tGRN/81r0
Chack for an opon in the wire.
{ECT,SG2lin..l:
1. Turnthe ignitionswitchOFF.
2. Connect ECM/PCMconnector
terminals D2 and D11 with a
jump€rwire.
3. Turn the ignitionswitchON (ll).
4. Checkthe ECTwith the scan
tool.
ls -4'F 1-20'Clorless(o. L-Limit
in Hondamode ol PGMTester)or
5 V indicated?
Sub3titut. s known-good ECM/
FCM and r.chcck, It normel ECT
i! indicatod, roplaco tho origin.l
ECM/PCM.
11 - 1 3 0
Wire side of Iemale terminals
Repriroprn in tha wirar bstwoon
CCM/PCM
IDZ Dl1) .nd EGTrcnaor.
PGM-FISystem
t
EngineCoolantTemperature(ECT)Sensor
('99- 00 ModelsexceptDl6Y5 enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode(DTC)P0118:A high voltage(low temperature)problemin the
EngineCoolantTemperature(ECT)sensorcircuit.
The MIL has been reportedon,
oTC P0118is stored.
Problemverilication:
1. Turnthe ignitionswitchON (ll).
2. Checkthe ECTwith the scan
tool.
ls -4'F (-20"C)or lesslor L-Limit
in Hondamodeo{ PGMTester)or
5 V indicated?
I
lntormittent failuro, systom is OK
at thb timo. Checklor poor con'
nections or 10036wiraa at C122
{ECTssnsorl and ECM/rcM.
{C122)
ECTSENSOR2P CONNECTOR
ECT
(RED/Wr{T)
Checkfor an open in the Efi sen'
sori
the ECTsensor2P
1. Disconnect
connector,
2 . C o n n e c tt h e E C Ts e n s o r2 P
connectorterminalsNo, 1 and
No.2 with a jumperwire.
3. Checkthe ECTwith the scan
tool.
JUMPERIVIRE
sG2
{GRN/BLK)
wire side of female terminals
ls -4"F 1-20"C)or less(or L-Limit
in Honda mode of PGMTester)or
5 V indicated?
C 131PI
ECM/PCMCONNECTOB
Check for sn open in the wires
IECT.SG2 linesl:
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC18and C26with a
jumperwire.
3. Turn the ignitionswitchON (ll).
4. Checkthe ECTwith lhe scan
tooi.
ls -4'F {-20"C)or less(or L-Limit
Tester)or
in Hondamodeof PGN4
5 V indicated?
JUMPERWIRE
Wiresideof femaleterminals
Rspair opon in th6 wiros bstwoon
ECM/PCM (Cl8, C26l and ECT
3ensot.
Substitute 6 known-good ECM/
PCM and recheck.l{ no.mal EcT
is indicatod, .eplace the original
ECM/PCM.
11-131
PGM-FISystem
ThrottlePositionITP)Sensor('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode (DTC)P0122:A low voltageproblemin the ThrottlePosition
(TP)sensorcircuit.
The TP Sensor is a potentiometer. lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle
positionsensorvariesthe voltagesignalto the ECM/PCM.
-
OUTPUTVOLTAGEIVI
Tho MIL h63 boon roportod on.
DTCm122 i. storcd.
1
2
1
0
Probl6mvoritic€tion:
1. Turn the ignitionswitchON (ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls there approx..49V when
the throttle is fully closedand
approx.4.5V when the throttle
is lully op6ned?
Int..mittent tailura, rFiem ir OK
at thit tima. Chocktor Door connections or loorc wires !t C110
ITPlonrorl .nd ECM/FCM.
OPENING
FULL
THROTTLE
TP SENSOR3P CONNECTOR
ICllOI
s{i2
(GRN/BLKI
Ch6ck lor rn opon in the wire
(VCC2linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectths TP sensor3P
connector.
3. Turnthe ignitionswitchON lll).
4, Measure voltage between
the TP sensor3P conn€ctorterminalsNo.l and No.3.
THROTTLE
vocz
(YEL/BLUI
Wire sideot femal6terminals
ECM/PCMCONNECTOR
D IT6PI
ls thereapprox.5 V?
Checkfor rn opcn in wire IVCC2
line):
Measurevoltage betweenECM/
PCMconneclorterminalsD10and
011.
Chockfor rn open or 3hort in TP
lon30t:
1. Turnthe ignitionswitchOFF.
2. At the s€nsor side, measure
resistancebetweenthe TP sensor terminals No. 1 and No. 2
with the throttle fully closed.
{ T op a g el 1 - 1 3 3 )
ls thereapprox.5V?
SG2 IGRN/ALKI
Wire sideof femaleterminals
Roplir op€n in thg wiro batwcsn
ECM/PCM{DlO) rnd TP ren3or.
Substitut6 r known-good ECM/
PCM and rach6ck. lf pro$ribod
vohrge i! now avrilablc, replac€
tho o.iginel €CM/FCM.
Terminalsideof maleterminals
11-1 3 2
t
{Frompagel1'132}
ls thereapprox.0.5- 0.9k0?
'P SENSOR3P CONNECTOR
Checkfor an opsn or 3hort in tho
TP sensor:
Measureresislancebetweenthe
T P s e n s o rt e r m i n a l N o . 2 a n d
No. 3 with the throttlefully closod.
ls thereapprox.3.6- 5.4k0?
Terminalsideof maleterminals
Chock lor an open in the ECM/
PCMITPSlin6l:
1. Reconnectthe TP sensor 3P
connector.
2. Turn the ignitionswitchON {ll}.
3. Measurevoltage between
ECM/PCMconnectorterminals
D l a n dD 1 1 .
ls there approx.0.5Vwhen the
throttleis fully closedand
approx.4.5Vwhen the throttle
is fully opened?
D {16PI
ECi'/PCM CONNECTOR
t-
sG2IGRN/BLK)
TPSIRED/
Btx)
hm
Substitut. r known-good ECM/
PCM and r.ch.ck. lf pt6crib.d
vohrga i. now !Y!il.blo, lcpl.co
tho odginal ECM/PCM.
6
I
tl
t5
t
to
tl
12
ta
Wire side ol lemale terminals
lDl6Y5 engine
f
Checktor . short in tha TCM:
1. Turn the ignitionswitchOFF.
2. Disconnectthe 22P connector
from the TCM.
3. Turn the ignitionswitchON (ll).
/t. MeasurevoltagebetweenECM
c o n n e c t o rt e r m i n a l sD 1 a n d
D11.
TPSIR€O/
BLKI
SG2IGRN/BLKI
V whenthe
ls thereapprox.0.5
throftleis tully closedand
approx.4.5V whon the throttle
is fully opened?
Ropairrhort in the wir€ bdtwcon
ECM/PCM(D11,TCM and TP i.n.
30r,
11 - 1 3 3
PGM-FISystem
Throttle Position(TPlSensor('99- 00 ModelsexceptD16Y5enginewith M/T)
scantool indicatesDiaqnosttcTroubleCode (DTC)P0122:A low voltageproblem in the Throttleposition
lTO12Z
_TI
{ | r, sensoacrrcurl.
The TP Sensor is a potantiometer.lt is connectedto the throttle valve shaft. As the throttle position changes,the throttle
position sensor varies the voltage signal to the ECM/PCM.
-
ERUSH
HOI.DEN
Th. MIL har boon.6portcd on.
DTCP0122b siored.
OUTPUTVOLTAGE(VI
BRUSH
BESIS?OF
Problemverification:
1. Start the engine,Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n .
then turn the ignition switch
OFF,
2. Turnthe ignitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
5
4
3
TERi'I AL
2
1
INNER
BUS}IING
THROTTLE
OPE II{G
o
FULL
THROTTLE
TP SENSOR3P CONNECTOR
{Cl1OI
ls there approx..49V when
the throttle is fully clos€dand
approx,4.5 V when the throttle
is fullyopened?
l||t rmittont failura, lyrtom b OK
at thi! tima. Chocktor poor connactionr o. looao wires rt C110
{TP3.n!or} rnd ECM/PCM.
vcc2
sG2
IGRN/8LKI
Checkfor an opan or 3hort in tho
wi.c (VCC2linc):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connector,
3. Turn the ignitionswitchON (ll).
4. Measure voltago between
the TP sensor3P connectorter
minalsNo. 1 andNo.3.
(YEUBLUI
Wiresideof temaleterminals
ECM/PCMOONNECTOR
C 131P)
ls theroapprox.5 V?
Chccl tor .n opln in wiro IVCC2
lin€l:
Mgasurevoltago betweenECM/
PCMconnectorterminalsC18and
Ch.Gkfor rn opan or 3hort in TP
36nlot:
1. Turnthe ignitionswitchOFF.
2, At the sensor side, moasure
r e s i s t a n c eb e t w e e n t h e T P
sensor3P connectorterminals
No. 1 and No. 2 with th€ throt,
tle fullyclosed.
(Topage11-135)
ls thereapprox.5 V?
Wire sideol femaleterminrls
R.prir opcn in the wiro bctw.en
ECM/PCM(C281and TP 3€nror.
Subrtituto r known-good ECM/
PCM .nd rochcck. lf pro.c.ibed
voltaga i! now available,roplaco
tho origin.l ECM/PCM.
Terminal side of male terminals
11-134
L
L
(Frompage11-134)
TP SENSOR3P CONNECTOR
lsrhereapprox.0.5- 0.9ko?
Chockfor an open or 3hort in the
TP 3en30r:
Measure resistancebetween the
TP sensor3P connectorterminals
No. 2 and No. 3 with the throttle
tully closed.
Terminalsideol maleterminals
ls thereapprox.4.5k0?
Check for .n opon in th€ ECM/
PCM(TPSlino):
1. Reconnectthe TP sensor connector.
2. Turn the ignitionswitch ON {ll).
3. Measurevoltago between Cl8
terminaland C27terminalon
the ECM/PCMconneclor.
I
ls there approx.0.5V when the
throttleis fully closedand
approx.4.5V when the throttle
is fully open€d?
C (31PI
ECM/PCMOONNCCTOR
Sub.lltut. . known-good ECM/
PcM lnd r.chock. ll pr6cribod
vohago b now lvallabla, aeplrca
tho originrl ECM/PCM,
Wire sideoI femaleterminals
Ropairahort in th. wiro b€{ween
ECM/FCMlC18l .nd TP ..n.o].
.1,
11-135
PGM-FISystem
ThrottlePosition(TP)Sensor(€6 - 98 Models,39 - 00 D16Y5enginewith M/T)
The scantool indicatesDiagnosticTroubleCode (DTC)P0123:A high voltageproblemin the ThrottlePosition
(TP)sensorcircuit.
The MIL has been reportodon.
DTCP0123is sto.ed.
Problomveritication:
1. Turnthe ignitionswitchON {ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls thereapprox.10%whenthe
throttleis fully closedand
approx.90o/o
when the throttle
is lully opened?
Intermittont tailuro, system is OK
at thb timo, Checkfor ooor connociion3 or loos6 wiros at C110
ffP s€nsor)and ECM/PCM.
Chgckto. an opan in the TP sonsot:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
connector.
3. Turn the ignitionswitch ON (ll).
4. At the harnessside,measure
voltagebetweentho TP sensor
3P connecterterminalsNo, 1
a n dN o . 3 .
TP SENSOR3P CONNECTOR
IC1lOI
sG2
IGRN/BLKI
vcc2
{YEL/BLUI
Wire sideof femaleterminals
ls thereapprox.5V?
ECM/PCMCONNECTOR
D (16P)
Ch.ck tor .n open in the wira
(SG2linel:
Measurevoltage betweenECM/
PCMconnector
terminalsD10and
D11.
SG2 (GRN/BLKI
ls thereapprox.5 V?
Repairop6n in the wire betwoen
ECM/PCM(D11)rnd TP s6nsor.
Wire sideof femaleterminals
Substitute a known-good ECM/
PCM snd rech.ck. lf pra3cribed
voltago is now available,replsce
tho original ECM/PCM,
11 - 1 3 6
ThrottlePosition(TP)Sensor('99- 00 ModelsexceptD16Y5enginewith M/Tl
I
The scantool indicatesDiagnosticTroubleCode{DTC)P0123:A high voltageproblemin the ThroftlePosition
{TP)sensorcircuit.
The MIL has been reportedon
DTCP0123is slored.
Problemverification:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n
then turn the ignition swatch
OFF,
2. Turnthe;gnitionswitchON (ll).
3 . C h e c kt h e t h r o t t l e P o s i t i o n
with the scantool.
ls thereapprox.10%whenthe
throttleis fullyclosedand
approx.90%when the throttle
is fullyopened?
'l'
lntormittenl tailure, 3ystom is OK
at this time. Check tor Poor con'
neqtions or loo3€ wires at C'110
(TPsensorltnd ECM/PCM.
Ch€ckfor an open in the TP s6nsoJ:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe TP sensor3P
TP SENSOR3P CONNECTOR
{C11OI
sG2
{GRN/BLKI
voc2
{YEUBLU}
Wiresideof femaleterm;nals
3. Turnthe ignitionswitchON (ll).
4. At the wire harnessside, measure voltagebetweenthe TP
sensor3P connectorterminals
N o .1 a n dN o . 3 .
ls there approx. 5 V?
C (31PI
ECM/PCMCONNECTOR
Check tor an open in the wire
(SG2lino):
Measurevoltage betweenECM/
PCMconnectorC (31Piterminals
C18and C28.
ls thereapprox.5 V?
Repairopen in the wite betwe€n
ECM/PCM(Cl81and TP son.or.
Wiresideof femal€terminals
Substitute a known-good ECM/
PCM and recheck. lf Pr$cribed
voltage is now aveilabl6. replace
the original ECM/PCM.
(cont'd)
11-137
PGM-FISystem
ThrottlePosition(TP)Sensor(cont'd)
I Pl 121 | The scan tool indicatesDiagnosticTroubleCode(DTC)Pl 121:ThrottlePosition(TP)lowerthan expected.
-
The MIL hss been.eportedon.
DIC P1121i. stored.
Problemvedficatiod:
1. Turnthe ignitionswitchON (ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls TP *% or higherindicated
when the throftle is tully
openod?
Intermittent tailure, ryttem i! OK
rtthistimo.
* : 1 1 . 8{ D 1 6 Y e5 n g i n e i
12.9{016Y7engine)
12.2(D16Y8engine)
13.7(816A2engine)
TroubleCode(DTC)P1122:ThrottlePosition(TP)higherthanexpected.
I P1122 I The scantool indicatesDiagnostic
-
The MIL ha3 be6n repoJted on.
DTCPl122 i. llorod.
P.oblomv6dfication:
1. Turnthe ignitionswitchON (ll).
2 . C h e c kt h e t h r o t t l e p o s i t i o n
with the scantool.
ls TP'70 or l€ssindicatedwhen
the throttleis fullyclosed?
*: 16.5{Dl6Y5,Dl6Y8engine}
16.9(D16Y7engine)
16.5(81642engine)
11 - 1 3 8
Intormitt6ot frilu.o, aFtom b OK
at thb timo.
t
PrimaryHeatedOxygenSensor{PrimaryHO2SI(Sensor1)
('96- 98 ModelsexceptDl6Y5 enginewith M/Tl
In operation,
The HeatedOxygenSensor(HO2S)detectsthe oxygencontentin the exhaustgas and signalsthe ECM/PCM.
the ECM/PCMreceivesthe sjgnalsfrom the sensorand variesthe durationduring which fuel is injected To stabilizethe
sensor,soutput,the sensorhasan internalheater.The PrimaryHO2S(Sensor1) is installedin the exhaustmanifold.
HO2S:
SENSOR
VOLTAGE{VI
ztRcoNlA
- LEAN
R|cH-AIRFUEL
RANO
The scan tool indicatesDiagnosticTrouble Code (DTC)P0131;A low voltage problem in the Primary Heated
OxygenSensor(H02S)(Sensor1) circuit.
The MIL has be€nteportedon.
DTCP0131is siorcd.
Problomverificalion:
1. Do the ECM/PCMResetPro'
cedure.
2. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson,
3. Test-drivewith the A/T in E
position(M/Tin 4th gear)
4. Check the Primary HO2S
(Sensor1) output voltagewith
the scantool duringacceleration usingwide openthrottle.
lntcrmift€nt failura, 3Y3temis OK
at this tims. Checkfor Poor connections or loo3e wi.o3 at C123
(Primlry HO2S, 3sn3or 1) and
ECM/PCM,
(Topage1I-140)
{cont'd)
11 - 1 3 9
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2S)(sensor1l
('96- 98 ModelsexceptDl6Y5 enginewith M/T) (cont'dl
( F r o mp a g e1 1 - 1 3 9 )
Checkfor a shon in the HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1) 4Pconnector.
3. Startthe engineand let it idle.
4. Check the Primary HO2S
(Sensor1)outputvoltagewith
the scantool,
Doesit stayat 0.1V or less?
PRIMARYHO2Slsonsor 1l ,tP CONNECTOR
lC123l
Check for a short in lhe wire
(PHO2Slinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorD ('l6P).
3. Checkfor continuitybetween
the PrimaryHO2Slsensor 1)
4 P c o n n e c t o tre r m i n a lN o . 1
and body ground.
Wire sideof femaleterminals
Repairshort in lhe wire b6tw6en
ECM/rcM (D7)and PrimaryllO2S
{Sensor1}.
Substitute a known-good ECM/
PCM and recheck.ll symptom/
indicationgoes awry, replacothe
original ECM/PCM.
11-1 4 0
Fjq?S)(Sensor1l
PrimaryHeatedOxygenSensor(Primary('99- 0b Modelsexiept D16Y5enginewith M/T)
T h e H e a t e d o x y g e n s e n s o r s ( H o 2 S ) d e t e c t t h e o x y g e n c o n t e n t i n t h e e x h a u s t g a s a n d s i ginjected.
n a | s t h eTo
E cstabilize
M / P c Mthe
'|noperati
variesthe durationduring which fuel is
the EcM/pcM receivesthe signarsfrom the sensorand
sensor,soutput,thesensornasaninternaIheater.ThePrimaryHo2S(sensorl)isinsta|ledinexhaustmanifo
81642engine:exhaustPiPeA)
SENSOR
TERMINALS
VOLTAG€(VI
HEATER
HEATER
TERMINALS
The scan tool indicatesDiagnosticTrouble Code
OxygenSensor(HO2S)(Sensor1) circuit
-
RICH+ AIR- - LEAN
FUEL
RATIO
(DTC)P0131:A low voltage problem in the Primary Heated
The MIL has been t€Ported on.
DTC P013'l is stored.
Problemveritication:
1. Do the ECM/PCMResetPro2. Start the engine.Hold the
engine at 3,000rpm wrth no
load (in Parkor neutral)until
the radiatorfan comeson
3. Check the PrimarY HO2S
lSensor 1) output voltagewath
the scantool during accelera
tion usingwide openthrottle
Doesthe voltage stay at 0 5 v
or less?
lntermittont f.ilure, 3ystem i3 OK
at thi3 time. Check tor Poor con'
nections or loose wires el C123
{Primary HO2S, Sensor 1) and
ECM/PCM.
C h e c k t h e f u e l p r e s s L l r e( s e e P a g e
11,109).
(cont'd)
(To page 11 142)
11-141
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1)
('99- 00 ModelsexceptDl6Y5 enginewith M/T) (cont'd)
( F r o mp a g e 1 1 1 4 1 )
Chockfo. a shori in the HO2S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1i 4Pconnector.
3. Stanthe engineand let it idle.
4. Check the Primary HO2S
(Sensor1) outputvoltagewith
the scantool.
Doesit stayat 0.5V or less?
Roplacothe HO2S(Sensor1).
PRIMARYHO2S{S€oror 1} 4P CONNECTOR
lc123l
Check tor a short in the wire
{PHO2Slinel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EcltI/PcM connectorC {31P).
3. Checkfor continuitybetween
the PrimaryHO2Slsensor 1)
4P connectorterminal No. 1
and body ground.
PHO2S
f----l
,wHl_l:-f;-l
0ffi
_L
Wire side of femaleterminals
ReDairshorl in the wi.e between
E C M / P C M( C l 6 1 a n d P r i m a r y
HO2S(Sercor 11.
Substitute a known-good ECM/
PCM and recheck. lf symptom/
indication goes away, replace the
original ECM/PCM.
1 1- 1 4 2
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1)
('96- 9b ModelsexceptDl6Y5 enginewith M/Tl
The scantool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the PrimaryHeated
OxygenSensor(PrimaryH02S)(Sensor'l)circuit.
Probl€mverification:
1. Do the ECM/PCMResetProcedure.
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson
3. Test-drivewith the A/T in E
position(M/Tin 4th gear)
4. Check the PrimarY HO2S
(Sensor1) oLltPut
voltagewith
the scantool duringdecelera'
tion using completelyclosed
throttle.
Doesthe voltagestay at 1.0V
or more?
Int.rmittont fiilur., system it OK
at thb timo. Chockfor Poot connections or loo3a wir63 at Cl23
lPrimarY HO2S,SensoJ 1l .nd
ECM/PCM.
HO2S(Sonso.'ll 4PCONNECToR
PRIMARY
tc123t
PHO29
IWHT}
Checkfor an open in the Primary
HO2S:
1. Turnthe ignitionswitchOFF.
the PrimaryHO2S
2. Disconnect
(Sensor1) 4P connector'
3 . C o n n e c tt h e P r i m a r YH O 2 5
lSensor l) 4P connectortermin a l sN o . 1 a n d N o . 2 w i t h a
sG2
IGRN/
BLKI
Wire sideot femaleterminals
4. Turnthe ignitionswitchON (ll).
5. Check the PrimarY H02S
(Sensor1i outPutvoltagewith
the scantool.
lsthere1.0V or more?
Check for an open in the wiro
{PHO2Sline):
1. Turnthe ignitionswitchOFF.
2. ConnectEcM/PcMconnector
t e r m i n a l sD 7 a n d D 1 1w i t h a
jumperwrre,
3. Turn the ignitionswitchON lll)
4. Check the PrimarY HO2S
(Sensor1) output voltagewith
the scantool,
ls there1.0V or more?
D I16PI
ECM/PCMCONNECTOR
JUMPERWIRE
SG2 IGRN/BLKI
PHO2S(WHT}
Replir open in tho wirc b€twccn
ECM/PCM lo?) and Prim!.Y
HO2Slsonsor 1).
Wiresideof tem6leterminals
Substitute a known-good ECM/
PCM and recheck. lf 3ymptom/
indicetion goos awey, roplace
the oliginal ECM/PCM.
11-143
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(Sensor1)
('99- 00 ModelsexceptD16Y5enginewith M/T)
The scan tool indicatesDiagnosticTroubleCode (DTC)P0132:A high voltageproblemin the primary Heated
OxygenSensor(PrimaryHO2S){SensorI ) circuit.
The MIL has beenreportedon.
OTCP0132
is stored.
Problemvorificalion:
1. Do the ECM/PCMResetPro
cedure,
S t a r tt h e e n g i n e .H o l d t h e
enganeat 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson.
C h e c kt h e P r i m a r y H O 2 5
{Sensorlioutput voltagewith
the scantool duringdecelerataonusing completelyclosed
throttle.
Intermittent tailure, systom k OK
at this time. Chocktor poor connections or looso wir* at Cl23
(Primaly HO2S,Sonsor 1) and
ECM/PCM.
Checklor an open in the Primary
H02S:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
lSensor1)connector.
3 . C o n n e c tt h e P r i m a r yH 0 2 S
(Sensor1)4P connector
termi
n a l sN o . 1 a n d N o . 2 w i t h a
PRIMARYHO2Sls€n3or 1' 4P
CONNECTOR
(c123t
PHO2S
IWHTI
sG2
(GRN/
BLK)
Wiresideof temaleterminals
4. Turnthe ignitionswitchON (ll).
5. Check the Primary H02S
{Sensorl) output voltagewith
the scantool.
ls there1.5V or more?
Check lor an open in th€ wire
(PHO25lin€l:
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsC16and C18with a
jumperwire.
3. Turnthe ignitionswitchON {lli.
4. Check the Primary HO2S
(Sensor1i output voltagewith
the scantool,
ls there1.5V or more?
Subsiitute a known-good ECM/
PCM and r.check. lf symptom/
indication goos away, replece
the original ECM/PCM.
11- 1 4 4
ECM/PCMCONNECTOR
C 131PI
Roptir op.n in tho wire betweon
E C M / P C Ml C l 6 l a n d P r i m . r y
HO2Slsensor 11.
SG2 IGRN/8LK}
Waresideof femaleterminals
PrimaryHeatedOxygenSensor(PrimaryHO2S)(Sensor1l
Heated
tool indicatesDiagnosticTroubleCode(DTC)P0133:A slow responseproblemin the Primary
scan
tFol3alThe
OxygenSensor{PrimaryH02S)(Sensor1) circuit.
Heated
The scantool indicatesDiagnosticTroublecode (DTC)Pl163:A slow responseproblemin the Primary
I P 1 1 6 3 OxygenSensor(PrimaryHO2S)(Sensor1)circuit
Description
2), the deteriorationof the
By controllingthe airlfuelratiowith a PrimaryHo2S {Sensor1) and a secondaryHO2S{Sensor
period
the Ho2s exceedsa cerof
primaryHO2S(Sensor1) can be evaluatedby its feedbackperiod.when the feedback
judged
deteriorated
as
tain valueduringstabledrivingconditions,the sensorwill be
and DTCP0133or P1163*will be stored'
when deteriorationhasbeendetectedduringtwo consecutivetrips.the MIL comeson
P0133,troubleshootthose DTCSfirst' then
NOTE:tf DTCP0131,P0132and/orP0135are storedat the sametime as DTC
the sametime as DTCP1163,troubleshootthose
troubleshootDTCP0133.lf DTCPl 162,P1168and/orP1169are storedat
DTCSfirst,then recheckfor DTCPl163.
PossibleCause
'l)
o PrimaryHO2S(Sensor Deterioration
(Sensor
1)Deterioration
o PrimaryHO2SHeater
. Exhaustsystemleakage
Troublsshooting Flowchart
-
The MIL has been reportedon
DTC P0133and/or Pl163* is
stored,
ProblemVerilication:
1. Do the ECM/PCMResetPro
cedure2. Connectthe scantool
3 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson
4. Connectthe SCSserviceconnector.
5 . T e s t - d r i v eu n d e r I o l l o w i n g
conditions.
- 55 mph (88 km/h) steady
speed
- A/f in D position {M/T in
5th gear)
codecomes
Untilreadiness
lntermittent failure, 3Y3tem i3 OK
at thi3 time. Ch.ck lol Poor conncctions or loosc wiros at C123
{C145)!lPrimaryHO2S,Sensor1l
and ECM/PCM.
Replaceth6 Prim.ry HO2S (Sen'
sor 11.
*: P'l163(D16Y5enginewith M/T)
11-145
PGM-FISystem
Itil-"w HeatedOxygenSensor(primaryHO2S)(sensor1l
(Dl6Y5
enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)p1162:A malfunctionin the primary
HeatedOxygen
Sensor(PrimaryHO2S)(Sensor1) circutt.
Doscription
ThePrimaryHeatedorygen sensor(Primary
Ho2s){sensor1) operates
overa wideairlfuelrange.The primaryHo2S
(Sensor
1)is installed
in theexhaust
manifold.
SEI{SOR
ELEMENT
SENSOR
TERMINALS
NOTE:lf DTCPl162 is storedat the sametime as DTCPl167,troubteshootDTCp1162first,then recheck
for DTCp1167.
-
lh6 MIL hes b6on reDortedon.
DTCPl162 ir 3tored.
Problomv6rificationi
1. Do the ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttlvo minutes.
ls DTCP1162indicatod?
Test drive tor severalmiles with
the transmission
in 3rd gear.Hold
the enginespeedat 1,500rpm.
ls DTCP1162indicated?
Chock for an open in the wire
(lP+lins):
1. Turnthe ignitionswitchOFF.
2. DisconnectECM connectorC
{31P)from the ECM.
3. Disconnectthe 8P connector
from the PrimaryHO2S{Sens o r1 ) .
4. Checkfor continuity between
the PrimaryHO2S(Sensor1)
8P connectorterminal No. 7
and ECM connectorterminal
c23.
Intermittent tailuro,systom is OK
at this timo. Checktor poor connections or loose wires at C145
(Plimr.y HO2S, Senso. t) and
ECM,
ECMCONNECTOR
C (31PI
PRIMARYHO2S
(SENSOR
1)8P
CONNECTOR
{Clir5)
femaleterminals
of female
terminals
Repairopen in the wire betwaon
ECM (C231end Prim.ry HO2S
lsen3orl).
Inspectlor poor terminal to terminal contact at the Primary HO2S
lsensor 'l I connoctorand ECM.
It terminal contect is OK, roplace
lh6 Primrry HO2S{Sensor1}.
(To page 11-147)
11-146
ECMCONNECTORS
l F r o mp a g e ' 1 1 - 1 4 6 )
Checkthe ECMinput vottage{lP-/
VS- lino):
1. Turnthe ignitionswitchOFF.
2 Turnthe ignitionswitchON (ll)
3. Measurevoltage between
ECMconnectorterminalsC24
D {15P)
c (31Pl
sG2
(GRN/BLKI
tP-/vs-tREol
femaletermrnals
ls theremorethan 0.5V?
6
'17
16
1 1 12 1 3 l a 1 5 t 6
Ch.ck the ECM:
1. Turnthe ignitionswitchOFF
2. DisconndctECM connectorC
{31P){romthe ECM.
3. Checklor continuity between
b o d y g r o u n da n d E C M c o n
nectorterminalC24
23 2a 25
9 10
22
29 30
27 2a
O\ rP-/vs:Z taeot
-
Checkto. r short in the wi.e {lP-/
VS- lin6l:
1. Disconnectthe 8P connector
from the PrimaryHO2Slsens o r1 ) .
2. Checktor continuity between
body ground and ECMconnector terminalC24
8
3 a
2
I
,l
Repair open in the wire
betw€en ECM {C2{l and Prima.y HO2S{S€nsor1l.
Substitute a known-good ECM
and recheck.It symptom/indi
cation goes away. replacethe
odginalECM.
5 5
3 a
1 1 1 2 13 1 a 1 5 1 6 1 7 t 8
21 2A
23 21 25
2
9 10
I
22
E 30
0) {REDr
Ropairshort in the wire bstween
the Primary HO2Slsensor 1) and
ECM (C24).
Check the ECM output voltage
{VS+linel:
voltage between ECM
N4easure
C25and D11.
connectorterminals
ls theremote than 0.5V?
Checkfor a short in the wire (VS+
line):
1. Turnthe ignitionswitchOFF.
2. DisconnectECM connectorC
{31P)Irom the ECM.
3. Check{or continuitybetween
b o d y g r o u n d a n d E C Mc o n
nectorterminalC25.
1
5
't6
'15
17 18
l 1 12 13 ta
27 2A
23 21 E
2
3
a
8
9
10
22
29 30
[]) vs*
I rwsrt
(cont'd)
( T o p a g e 1 1 -1 4 8 )
(To page 11 148)
11-147
PGM-FISystem
PrimaryHeatedOxygenSensor(PrimaryHO2SI(sensorl)
(Dl6Y5enginewith M/T) (cont'd)
( F r o mp a g e 1 l - 1 4 7 )
( F r o mp a g e1 1 1 4 7 )
Substitute a known-good ECM
and rechock. tf symptom/indicrtion goes away, replacethe originalECM.
Checkfor a short in the wire llP+
lin6):
1. Disconnectthe 8P connector
Irom the PrimaryHO2S(Sens o r1 ) .
2. Checktor continuitybetween
body ground and ECMconnector terminalC25.
|
2 3 r a
tl 12
a
1
to
9
t 5 16 1 1 1 a
p ffi;r,w''.""i0"or.
I
lemate lerml
Repairshort in the wiro botween
the Primarv HO2S{Sensor1} and
ECM {C25}.
Replaceth€ Primary HOzS {Sensor 11.
a
7
It
ls theremorethan 5.0V?
t 6 '11
1 2 t3
check the EcM:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 8P connector
from the PrimaryHO2S(Sensor 1).
3. Turnthe ignitionswitchON (ll).
4. MeasurevoltagebetweenECN4
connector
C25andD11.
9 t0
ta
VS+
{WHT}
sG2
{GRN/BLK}
3
5
,
2
9 ,10 1l
12
l 3 'ta t 5
15
ls theremorethan 5.0V?
Check the ECM input voltage llP-/
vS-linel:
1 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (transmission
in neutral)
untiltheradiator
fan comeson,
then letit idle.
2. MeasurevoltagebetweenECM
connectorterminalsC24 and
Dt1.
Subslitute a known-good ECM
and rgcheck. It symptom/indication goes away, repl.ce the original ECM.
ls there2.6 2.8V?
Checkth6 ECM output voltage
(VS+linel:
Measurevoltage between ECM
connectorterminalsC25and D11.
1
2 i 3
't2 'tt
11-1 4 8
13
9 t0
22
sG2
(GRN/8I-K}
6 l t
(Topage 11 149)
rl
VS+
{WHT)
2
(Topage11-149)
a
5
t5 t t
3
9
15
ll
( F r o mp a g e 1 1 1 4 8 )
( F r o mp a g e1 1 ' 1 4 8 )
Roplac€th€ Primary HOzS (Sen'
sor 11.
ls therelessthan2.8V?
Substitute a known-good ECM
and recheck. lf symptom/indica'
tion goes awav, replaceth€ odgi'
nalECM.
Check the ECM oulput voltage
(lP+linel:
Measurevoltage between ECM
terminalsC23and D11
connector
ls theremorethan 0.4V?
sG2
(GRN/BLKI
Substitute a known-good ECM
and recheck f symptom/indication goes awaY,replacethe origi_
nal ECM.
Wire sideof
femaletermanals
8
6
2 3 a
1
22
a 30
21 25
Checkthe ECM:
1. Turnthe ignitionswitchOFF.
2. DisconnectECM connectorC
(31Plfrom
t h eE C M .
3. Checkfor continuitybetween
b o d y g r o u n d a n d E C Mc o n nectorterminalC23
I
Check fot an oPen in tha wire
llP+ linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 8P connoctor
from the PrimaryHO2S(Sensor'l).
3. Checkfor continuitybetween
the PrimarYHO2S(Sensor1)
8P connectorterminal No. 7
and ECM connectortermrnal
c23.
lP+
6) tBrK)
C {31P}
ECMCONNECTOR
PRIMARYHO2S
(SENSOR
1l8P
coNNECTORlC1a5l
lP+
(BLK)
Wire sideof
femaletermrnals
Substitute a known_goodECM
and r6check. lf symPlom/indica'
tion goos away, replacethe odginalECM.
2
3
a
6
7
1 1 1 2 1 3 1 l 1 5 16 1 1 1 8
23 2a 25
Repairshort in lhe wire belween
'l)
the Primary HO2S(Sensor dnd
ECM{C23).
Replacethe Primary HO2S (Sen'
s o r1 ) .
of female
terminals
Repairopen in the wire belween
E C M { C 2 3 1a n d P r i m a r y H O 2 S
{Sensor11.
NO
Checkfor a short in the wire llP+
line):
1. Disconnectthe 8P connector
from the PrimaryHO2S{Sen'
s o r1 ) ,
2. Checkfor continuitybetween
b o d y g r o u n da n d E C M c o n nectorterminalC23.
9 10
1 1 12 1 3 1 4 1 5 1 6 1 7 1 8
I
I
,4
10
22
A
30
A\ lP+
Ij/ IBLK)
(cont'd)
11-149
PGM-FISystem
HeatedOxygenSensor(primaryHO2SI(sensor1l
l:in1.".fy
(D16Y5
enginewith M/D (cont'd)
The scan toor indicatesDiagnosti"
code (DTC)pl164: A range/performance
probremin the primary
-Tl:y|*
HeatedOxygenSensor(primaryHO2S)
(Sensor1)circuit.
The MIL has beonreponed on.
DTCP1164is stored.
ProblemVerilication:
1. Do the ECMBesetProcedure.
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (transmission
in neutral)
untiltheradiatorfan
comeson.
3. Connectthe SCSserviceconnector.
4. Test-drivein 4th gear. Starting
at 1,600rpm, accelerate
using
wide openthrottlefor at least5
seconds.Thendeceleratetor at
least 5 secondswith the throt
tle completelyclosed.
ls DTCPl164indicatedT
Intgrmittent failure, syrtem b OK
at this time. Checktor Door connoctions or loose wires at C1a5
(Primary HO2S. Senso.
and
ECM.
The scan tool indicatesDiagnosticTrouble Code (DTC)p1165:A range/performance
problem the pnmarv
HeatedOxygenSensor(primaryHO2S)(sensor1) circuit.
-
The MIL has been reoortedon.
DTCP1165is stored.
ProblemVo.ification:
1. Do the ECMResetProcedlre.
2 . S t a r t t h e e n g i n e .H o t d t h e
engine at 3,000rpm with no
load (transmission
in neutral)
u n t i l t h e r a d i a t o rf a n c o m e s
3. Connectthe SCSservicecon,
nector.
4 . T e s t - d r i v eu n d e r f o l l o w i n g
conditions.
- 55 mph steadyspeed
Transmission
in 5th gear
Until readinesscode comes
ls DTCP1165indicated?
Replace the P.imary HO2S (S6nsor 11.
11 - 1 5 0
Intermittent l.iluro, system b OK
at lhis time. Ch€cktor poor connoctions or loose wir6 at Ci45
(Prioary HO2S, Sen3or 1l .nd
ECM.
t
(DTC)P1168;A low voltageproblem in the PrimaryHeated
The scan tool indicatesDiagnosticTroubleCode
OxygenSensor(PrimarvHo2S)(Sensor1) LABELcircuit'
-
The MIL has b6€nreponed on'
DTCP1168is storcd
Problemvedfication:
1. Do the ECMResetProcedure
2. Startthe engine.
3. Wait at leasttwo minutes
ls DTCP1168indicated?
lntalmittent failure' aYstomb OK
at thi3 time. Chocklor Poor connection3 or loo3o wiro3 at C145
(Primary HO2S,S.n.or 1l and
ECM.
D {16PI
ECMCONNECTOR
LABEL{WHTI
Chockth. ECM:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECM connec'
torD 116P).
3. Check for continuity between
ECM connectorterminal D7
and body ground
wire side of female terminals
Sub3titut. e known-good ECM
6nd r.chock. lf rymptom/indication gocr away, r.Placs the origi_
nal ECM.
LABEL(WHTI
Check for t shott in lhg wire3
ILABELline):
the PrimaryHO2S
1. Disconnect
(Sensor1) 8P connector'
2. Check for continuitv between
ECM connectorterminal D7
and body ground
Reoair short in the wir63 botlvoon
lhe Primary HO2S{Sensor1} end
ECM(O71.
(cont'd)
PGM-FISystem
IiT-"-w Heated9{ygglSensor(primaryHO2SI(Sensor1)
(Dl6Y5
enginewith M/Tl lconr'd)
scan tool indicatesDiagnosticTroublecode (DTc) P1169:A high volrageprobtemin
the pnmary Heated
-1T1163 Ih"
UxygenSensor{primaryHO2S)(Sensor.l) LABELcircuit.
-
The MIL hrs been reported on.
DTCPl169 i3 stored.
Problemverification:
L Do the ECMResetProcedure.
2. Startthe engine.
3. Wait at leasttwo minutes.
PSTMARY
HO2S(SENSOR
(145)
1l8p CONNECTOR
ls DTCP1169indicated?
LABELIWHTI
Intormittent f.ilure, sv*em b OK
at this time. Checkfor poor conn.ctions or loose wires at C145
(Prim.ry HO2S, Sensor 1l and
ECM.
Ch€ck Ior an op6n in th€ wire
(LABELline):
1. Turnthe ignitionswitchOFF.
2. Disconnect
the PrimaryHO2S
(Sensor1) 8P connector.
3. Turn the ignitionswitchON (ll).
4. Measurevoltage between
Primary HO2Slsensor 1) 8P
connectorNo, 4 terminaland
body ground.
ECMCONNECTOR
O {16P}
1
2
3
6
8
9 10 1 t
Ropairopon in the wires betweon
lhe P.imary HO2S{Sensor't} and
ECMtD7l.
Check lor an open in the wire
{SG2linel:
1. Turnthe ignitionswilchOFF.
2. DisconnectECM connectorD
(16P)tromthe ECM.
3. Check for continuity betlveen
ECM connectorterminal D1l
and PrimaryHO2S(Sensor1)
8P connectorterminalNo.3.
ls therecontinuity?
Roplacethe Primary HO2S (Sensor 1).
11-152
5
12
sG2
16
t3 1 4 15
ls there approx. 5 V?
a
(GRN/BLK)
sideof
female
e terminals
tll
I
I
;G2
-- rl I IGRN/BLKI
2 3 4
6
8
R€pairopen in th6 wire between
the Primary HO2Slsensor 1) and
ECM(011).
(Sensor2l
SecondaryHeatedOxygenSensor{secondaryHO2S)
problemin the SecondaryHeated
The scantool indicatesDiagnosticTroubleCode(DTC)P0137:A low voltage
OxygenSensor(SecondaryHO2S)(Sensor2) circuit'
-
Tho MIL has beenreportedon
DTCP0137is stored.
Problemverification:
1. Do the ECM/PCMResetPro
cedure.
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm wlth no
load (in Parkor neutral)until
the radiatorfan comeson
3. With the scantool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputvoltageat 3,000rPm
Doesthe voltage staYat 0.3 V
or less?
lntermittent frilure, sYdem is OK
at this tim6. Checkfor Poor con'
nections or loolo wir.3 at C131t
(locatodundor right.ido of desh)'
C432. {located under middle of
dashl, cl25 lc782lr {Secondary
HO2S)tsensor 2l .nd ECM/PCM.
Ch6cktot a sho.t in the S€condery
HO23:
'1. Turnthe ignitionswitchOFF.
2 , D i s c o n n e c tt h e S e c o n d a r Y
HO2SlSensor2)4Pconnector.
3. Startthe engine.
4 . C h e c kt h e S e c o n d a r YH O 2 S
lsensor 2) outputwith the scan
tool,
SECONDARYHO2S ls.n.ot 2)
(C125,C782')
,rPCONNECTOR
C h e c kt o r a s h o r t i n t h e w i r e
{SHO2Slinel:
1. Turnthe ignitionswitchOFF.
2 . D i s c o nn e c t t h o E c M / P C M
connectorD {16P){A (32P))*'
3. Checkfor continuitybetween
the SecondarYH02S (Sensor
terminalNo 1
2) 4P connector
and body ground.
Wire side oI temale terminals
R€pairshort in tho wire bstwoen
E C M / P C M l D 1 4 ( A 2 3 1 * ' |a n d
SecondarvHOzS(Sensor2).
Substitute a known-good ECM/
PCM and recheck lf 3ymptom/
indicalion go€s awaY, tePltco
the oiigin.l ECM/PCM.
(cont'd)
*'t: D16Y8engine
*2:'99 - O0m;dels except D16Y5enginewith M//T
11 - 1 5 3
PGM-FISystem
Heated
OxygenSensor(Secondary
HO2S){sensor2l
9ggoqOfry
'99
('96 98 Models; - 00 D16YS
enginewith M/Tl
I
The scantool indicatesDiagnosticTroubleCode(DTC)PO'138:
A high voltag€problemin the SecondaryHeated
OxygenSensor(Secondary
HO2SI(sensor2) circuit.
-
Ths MIL ha3 bcen r6port.d on.
DTCm138 i. 3tored.
Problemvorilication:
1. Do the ECM/PCMResetProcedure.
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3.000rpm with no
load (in Parkor neutral)until
the radiatorfancomeson.
3. With the scan tool, ch€ckthe
S e c o n d a r yH O 2 S{ S e n s o r2 )
outputvoltageat3,000rpm.
Into.mittant failurc, sy3tem b OK
rt thi3 tims. Ch6cktor poor conn6clionr or loo3€ wiroa at C13'l*
(locat d und6r right lido of dr'h),
C/€2r (loc.tod und€r middle ol
d.rhl, C125 {C782lr (Socond.ry
HO2SS6n3or2) .nd ECM/PCM.
SECONDARY
HO2Sls.nsor 2l
4P CONNECTOR
C125tc782t*
JUMPERWIRE
sHo2s
IWHT/RED}
Chcd( for rn open in the Socond!ry
f|o2s:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e c tt h e S e c o n d a r y
HO2S(Sensor2) 4P connector.
3. Connectthe SecondaryHO2S
(Sensor2) 4P connectorterminalsNo. 1 and No.2 with a
JUmperwire.
4. Tu.n the ignitionswitch ON (ll).
5 . C h o c kt h e S e c o n d a r yH O 2 S
(Sensor2) output vollage with
the scantool.
sHo2sG
(RED/YEL)
(GRN/WHT)*
(GRN/BLK)*'
Wiresideof femaleterminals
a
ECM/FCMCONN€CTORD Il6PI
ls there0.6V or more?
sH()2sG
{YEL/RED)
{GRN/BLK}'
JUMPERWINE
Check tor an open in the wiro
(SHO2Slin6l:
1. Turnth6 ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsD14 and D13with a
jumperwire.
3. Turn the ignitionswitch ON {ll}.
4 . C h e c kt h e S e c o n d a r yH O 2 S
( S e n s o r2 ) o l t p u t v o l t a g e
with the scantool.
ls thore0.6V or more?
Subslituto a known-good ECM/
PCM .nd rccheck. lt symptom/
indication goe! rway, replace
the original ECM/PCM.
'i D16Ygengine
*1i Dl6Y5 engine
11-1 5 4
Wire sideof femaleterminals
Rapairop.n in the wiio botw.on
ECM/PCMlD13 and/or Dlal and
S.cond.ry HO2Sls€nsor 21.
a
(Sensor2l
SecondaryHeatedOxygenSensor(SecondarytlO2S)
('99- 00 lilodelsexceptDtGYSenginewith M/T)
problemin the secondaryHeated
The scantool indicatesDiagnosticTroublecode (DTC)P0138:A high voltage
(Sensor
2)
circuit.
(Secondary
H02S)
OxygenSensor
-
The MIL has beon reportod on.
DTCm138 is.tored.
Ploblem vorification:
ResetPro1. Do the ECM/PCN4
cedure.
2. Start the engine Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiator{ancomeson
3 . C h e c kt h e S e c o n d a r YH 0 2 S
(Sensor2) output voltage at
3,000rpm with the scantool
Does the voltage stay at 0 6 V
or more?
lntormittont failuio, sYstom b OK
st thir timo. Checkfor Poor con_
nections ot loo39 wiJo3 af Cl3lr
(locatedunder right ride ot desh),
C432' (locatod undot middle of
dashl, Cl25 {C782lr (Secondaiy
HO2SSon3or2l and ECM/PCM.
Ct€d( tor an opan in the Secondary
HO2S{S€nsot2}
SECONDARY
Cl25 lc782l'
4P CONNECTOR
l|o2s:
1. Turn the ignitionswitchOFF
2 . D i s c o n n e c tt h e S e c o n d a r Y
HO2S(Sensor2) 4Pconnector.
3. Connectthe SecondaryHO2S
(Sensor2) 4P conneclorter_
minalsNo. 1 and No.2 with a
iumperwire.
4. Turnthe ignitionswitchON (ll)
5. Check the SecondarYHO2S
lSensor2) outptltvoltagewith
the scantool,
JUMPERWIRE
sH02s
(WHT/RED)
sG2
{GRN/BLKI
Wire sideof femaletermanals
lsthere0.6V or more?
ECM/PCMCONNECTORS
A (32P1
Check lor an open in the wiro
(SHO2Sline):
1. Turnthe ignitionswitchOFF.
2. ConnectECM/PCMconnector
terminalsA23 and C18with a
jumperwrre,
3. Turn the ignitionswitch ON (ll).
4 . C h e c kt h e S e c o n d a r YH O 2 S
{ S e n s o r2 ) o u t P u tv o l t a g e
with the scantool.
ls there0.6V or more?
gs92g 111yp17p5py
| .lutuPeawtne
Repairopon in tho wire betwecn
ECM/PCM (A23) and SocondarY
HO2S{Sansor2).
Wire sideot femaletermlnals
I
r
Substitut€ a known'good ECM/
PCM and recheck. It symptom/
indication goes awey, JePlaco
the otiginel ECM/PCM
*i 016Y8 engine
11 - 1 5 5
PGM-FISystem
SecondaryHeatedOxygenSensor(SecondaryHO2S){sensor2l
The scantool indic€tesDiagnostic
TroubleCode{DTC)P0139:A slow responseprobtemin the SecondaryHeated
-[FO13a]l UxygenSensor(HOzS)(Sensor
2) circuit.
-
The MIL has beenreportedon.
DTCP0139is stored.
Problemverification:
1. Do the ECM/PCMResetPro2. Start the engine.Hold the
engine at 3,000rpm with no
load {in Parkor neutral)until
the radiatorfan comeson.
3. With the scantool, checkthe
S e c o n d a r yH O 2 S( S e n s o r2 )
outputat 3,000rpm.
Doesthe voltagestaywithin
0.3- 0.6V for two minutes?
*: D16Y8
engine
11 - 1 5 6
Intermiftent failure, system i! OK
at this tims. Check for pool connections or loos6 wiles at C131.
{locatedundor ght lide of dash),
C432' (locrted under middle ot
d.shl Cl25 (C782lr (Socondary
HO2S)(Sonsor2) and ECM/FCM.
HeatedOxygenSensor(HO2SIHeater
('96- 98 Mbdels,'99- 00 Dl6Y5enginewith M/Tl
probl€m in the Primary Heated
The scan tool indicatesDiagnostrcTrouble code (DTC)P0135:An electrical
tFo135l
OxygenSensor(PrimaryHOiS) (Sensor1) Heatersystem(ExceptD16Y5enginewith M/T)'
Heatedoxygen sensor
The;can tool indicatesDiagnosticTrouble code (DTC)P0141:A problem in the secondary
iPol4tl(secondarvHO2S)(Sensor2) Heatercircuit.
-
The MIL h.s boenJeponedon.
DTC P0135,and/or Polal .re
stoled.
Problemverificationl
1. Do the ECM/PCMResetProceduae,
2. Startthe engine
Checkfor an open or 3hort in tho
HO25:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe HO2S(Primary
or Secondary*)(Sensor1 or
Sensor2) 4Pconnector'
3 . A t t h e H o 2 s s i d e ,m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .
lniermittent tailura, sYttam i! OK
at thi3 time, Chsck for Poor con'
neciion3 or loose wilG3 at
C131** (locat.d undo. right sido
ot dashl, C{32** (loc.ted under
middle ol dashl, C123 (PrimarY
HO2S.Sansor 1) C125 lc782l*r
{Socondery H02S, Sonsor 2l'
and EcM/PcM.
PRIMARYHO2S(Son.or 1l aP CONNECTOR
SECoNDARYHO2Stsensor 2l ilP CONNECTORT
Terminalsideof maleterminals
ls there10- 40 0?
C h e c kf o r c o n t i n u i t y b e t w e e n
b o d y g r o u n d a n d t h e H O 2 S4 P
c o n n e c t o rt e r m i n a l sN o . 3 a n d
N o . 4i n d i v i d u a l l y
ICl23I
PRIMARYHOzS (SENSOR1) 4P CONNECTOR
{C125I*
HO2SISENSOR2) 4P CONNECTOR
SECONDARY
PO2SHIC,SO2SHTC
IBLK/WHT)
Wire sideof femaleterminals
Chockfor an oPen ot short in tho
wire |PO2SHTC,SO2SHTC*linol:
1. Turnthe ignitionswitchON (ll).
2. Measurevoltage between the
HO2S4P connectorterminals
N o . 3a n dN o . 4 .
HO2SISENSOR2)
SECONDARY
,tP CONNECTOR
1C782)'*
so2sHTC
{BLK/WHT)
Wire sideoI femaleterminals
I
( T op a g e1 1 ' 1 5 8 )
*: p0141
(To page11-158)
**: D'16Y8
engane
(cont'd)
11-157
PGM-FISystem
a
HeatedOxygenSensor(HO2S)Heater
('96- 98 Models,'99- 00 D16Y5enginewith M/T) (cont'dl
( F r o mp a g e1 1 - 1 5 7 )
Checktor an op6n or 3hoft in the
wire {lGl lin6):
M e a s u r ev o l t a g e b e t w e e nt h e
HO2S4Pconnector
terminals
No.3
(D16Y8engine:No. 4) and body
ground.
PRIMARY
HO2S{SENSOR
1I 4PCONNECTOR
{c1231
SECONDARY
HO2S{SENSOR
2}4P
coNNECTOR
1C125)r
r-l --'1
l l i 2 l
f;T;t
-
Check for an open in the wire
SO2SHTC'linel:
IPO2SHTC,
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P connector.
3. Disconnectthe ECM/PCMconnectorA (32P).
4. Turnthe ignitionswitchON (ll).
5. Measurevoltage between the
ECM,/PCM
connectorterminals
46 and410 {A5andA10)*.
ls there0.1V or less?
tcl
|BLK/ &)
YELI Y
Repair open or shon in the
wire between Primary HO2S
lson.or 1), {No. 15 ALTERNATOR SP SENSORI(7.5 Al fuse
and SecondaryHO2S,Sonsol
Wiresideof fomalelerminals
2t,.
Replacethe No. 15 ALTERNATOR SP SENSOR17.5A) tuse.
SECONDARYHO2S
ISENSOR2) 4P CONNECTOR
{c78ilf
IBLK/WHT)
Ropail opan in the wire b€twoen
ECM/PCMlA6, A5l* and HO2S
{Primary,Secondary+1.
a
Wire sideof lemaleterminals
ECM/PCMCONNECTOR
A I32P)
Substitute a known-good ECM/
PCM and recheck. ll symptom/
indication goes awry, repbce
tho origin.l ECM/PCM.
pozsxtc E/
^
so2sHrcI IBI-K/WHTI
,-----{v}tBLK/WH0.J
|
(Frompage11-157)
3
12 r3
. = , |
I
uI JsTgTro
t 5 t 6 I t ta r9 20
25
27
2A 2i 3o
z2l 23
PG1
IBLK}
ll
21
Wire sid€ ot temale terminals
Check tor a short in the wire
SO2SHTC*line):
{PO2SHTC.
'1. Turn
the ignitionswitchOFF.
2. Disconnectthe ECM/PCMconnectorA (32P1.
3. Checkfor continuitybetween
the ECM/PCMconnectorterminal46 (A5)*and bodyground.
SO2HTC(BLK/WHTI* PO2SHTC{BLK/WHTI
Repairshort in thg wire betwe€n
ECM/PCMlA6, A5*l .nd HO2S
(P.im.ry, Socondary*).
Substitute a known-good ECM/
PCM and recheck. It symptom/
indicetion goes away, rophce
the original ECM/PCM.
*: P0141
*+: Dl6Y8engine
11-158
I
HeatedOxygenSensor(HO2S)Heater
i'ss - oo Mb-delsexceptD16Y5enginewith M/Tl
problem in the Primary Heated
The scan toot indicatesDiagnosticTrouble Code (DTC)P0135:An electrical
Fo13slOxygen
Sensor(PrimaryttOiS) (Sensor1) Heatersystem{ExceptD15Y5enginewith M/T)'
-scan
The
TroubleCode(DTC)P0141;A problemin the SecondaryHeatedOigen Sensor
tool indicatesDiagnostic
Fol11l(SecondarvHO2S){Sensor2) Heatercircuit
-
The MIL has been reponed on.
DTC P0135.and/or P0141are
storod.
Problemvorification:
1. Do the ECM/PCMResetProcedute.
2. Stanthe englne.
Chockfoi an open or short in the
HO25:
1. Turnthe ignitionswitchOFF
2. Disconnectthe HO2S(Primary
or Secondary*)lSensor 1 or
Sensor2) 4Pconnector'
3 . A t t h e H 0 2 S s i d e ,m e a s u r e
resistancebetween the HO2S
4P connectorterminalsNo. 3
a n dN o . 4 .
lntermiftent failuro, sYstomb OK
at thit limo. Ch6ck lor Poor oon'
nectiont or looso wita! at
C131'* {loc.tod und.t right ido
ol drshl, C432'* (located undel
middlo of dashl, C123 (PrimarY
HOzS,Sensor 1) C125 (Ct82lr'
(socondary HO2S, Sensor 2)t
.nd ECM/PCM.
PRIMAFYHO2Sls.n.or ll rrPCONNECTOR
HO2S(Srn.ol214PCONNECTOR'
SECOITIDARY
Terminalsideof maleterminals
ls there10- 40 n?
C h e c kf o r c o n t i n u i t y b e t w e e n
b o d y g r o u n d a n d t h e H O 2 S4 P
c o n n e c t o rt e r m i n a l sN o . 3 a n d
No.4 individuallY.
PRIMARYHO2S{SENSOR1} ilP @NI{ECTOR lc123l
sEcoNDARY HO2SISENSOR2) aP @NNECTOR(C125)'
3l-, l-tl-t
so2sHrc
Fo2sHrc.
ver.t l '^-1
.'l {BLK/wHrl
11 !'l-l
--=|u----{v)'---..-'I
Wire side of {emaleterminals
Checkfor an opon or short in lho
SO2SHTC+line):
wire (PO2SHTC,
'1. Turnthe ignitionswitchON (ll).
2. Measurevoltage between the
H02S 4P connectortermlnals
N o . 3a n dN o . 4 .
Ho2S (SENSOR2,
SECO'TIDARY
{C7&llt'
4P CONNESTOR
so2sHTc
(BLKnflHTl
IBLK/WHT)
Wire sideoI femaleterminals
{To page11-160}
r: p0141
{To page 11-160}
* * : D 1 6 Y ge n g i n e
(cont'd)
11 - 1 5 9
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater
('99- 00 ModelsexceptD16Y5enginewith M/T) (cont'dl
PRIMARYHO2SISENSOR1I 4P CONNECTOB
( F r o mp a g e1 1 - 1 5 9 )
{c123)
SECONDANY
HO2SISENSOR
2} 4P
(C125)*
coNNECTOR
Checkfor an open in the wires
{lGl* line}i
Measurevoltagebetweenthe pri
mary HO2S4P connectorterminal
No. 3 (D16Y8engine:No. 4) and
body ground.
-r--r ,
lr zl
-
ls there batteryvoltage?
Check,or an open in the wires
(PO2SHTC,
SO2SHTC'linel:
1. Turnthe ignitionswitchOFF.
2. Reconnectthe HO2S4P connector,
3. Disconnectthe ECN4/PCM
con
nectorC (31Pi(ECM/PCM
connectorA (32P))i.
4. Turnthe ignitionswitchON (lli.
5. Measurevoltagebetweenthe
ECM/PCM
connectorterminals
82 andCl 182andAB)*.
ls there0.1V or less?
lc'l
Repeir open or shon in the
wire between Primary HO2S
lsensor 1), {No. 15 ALTERNATOR SP SENSOR)(7.5 A) fus€
and SecondaryHO2S,Sensor
-f1 3 4 l
L--r-J-r
relxr p1
YELI
Y
Wiresideof temaleterminals
2t,.
ReDlacethe No. 15 ALTERNATORSP SENSOR{7.5 A tuse.
SECONDARY
HO2S
(SENSOR214P CONNECTOR
{c782}rr
IG1 IBLK/WHT)
Wiresideof femaletelminals
Reprir open in the wirc betwo€n
ECM/PCM(Cl, A8i) and HO2S
(Primary,Secondary+).
ECM/PCMCONNECTORS
NO
Substitute a known-good ECM/
PCM and recheck.lf symptom/
indication goes away, replace
the origin.l ECM/PCM.
(Frompage11 l59i
Check tor a short in the wires
SO2SHTC*linel:
IPO2SHTC,
1. Turnthe ignitionswitchOFF.
2. Disconnect
the ECM/PCM
connectorC (31Pi(ECM/PCM
con
nectorA (32P)i*.
3. Checktor continuitybetween
the ECM/PCMconnectortermi
nalC1{A8)*and bodyground.
Wiresideof femaleterminals
ECM/FCMCONNECTORS
Repai. short in the wire b€tween
ECM/PCMlcl, A8.l and HO2S
(Pdmery,Secondary*1.
Substitute a known-good ECM/
PCM end recheck.lf symptom/
indication goes away, replace
the o.iginal ECM/PCM.
*: P0141
**: Dl6Y8engine
1 1 - 16 0
Wire side of female terminals
HeatedOxygenSensor(HO2SIHeater(Dl6Y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P1166:An electricalproblem in the Primary Heated
OxygenSensor(PrimaryH02S)Heatersystem.
-
The MIL has been lePorted
-
DTCPl166 b stored.
Problemverilication:
1. Do the ECMResetProcedure.
2. Startthe engine.
ls DTCP'l166indicated?
Intermitlent failura, sYstemb OK
at this time (te3t drive maY be
ngcessary).Check for poor connections or loose wires between
C145 (PrimaryHO2S,Sen3or1l
end ECM.
Checkthe Primary HO2S(Sensot
1l resistence:
1. Turnthe ignitionswitchOFF
the PrimaryHO2S
2. Disconnect
(Sensor1) 8P connector.
3 . A t t h e P r i m a r yH O 2 S( S e n
s o r 1 ) , m e a s u r er e s i s t a n c e
betweenNo. 1 and No. 2 ter_
ls there2 13 O?
PRIMABYHO2SISENSOR1I 8P CONNECTOR
Terminalsideof
maleterminals
Replacelhe Primery HO2S (Sensor 11.
Checkfor a shorted PrimarY
HO2Slsensor 1):
C h e c kf o r c o n t i n u i t y b e t w e e n
bodygroundand eachterminal.
ls there conlrnuily?
Checkfor a shorted PrimarY
HO2S{S€nsor1l:
Checkfor continuity betweenter'
s o.3,
m i n a lN o . 1 a n d t e r m i n a l N
4, 6, 7 and 8 individually.
I
(cont'd)
(Topage11'162)
11-161
PGM-FISystem
HeatedOxygenSensor(HO2S)Heater(Dl6Y5enginewith M/Tl (cont'd)
\.
PRIMARYHO2S(SENSOR1} 8P CONNECTOR
{Cl45I
( F r o mp a g e1 1 - 1 6 1 )
I
PO2SHTC
{BtK/WHT)
Ch6ckthe PO2SHTCcircuit:
1. Start engineand keepengine
rpm at idle.
2. At the engine wire harness,
m e a s u r ev o l t a g e b e t w e e n
PrimaryHO2S(Sensor1) 8P
connectorterminalNo. 1 ter
minaland bodyground.
ls theremorethan5 V?
Check for an open in the wire
(PGlinell
MeasurcvoltagebetweenPrimary
HO2S(Sensor1) 8P connectorterminalsNo. l and No.2.
Repairopon in the wi.o bEtwoon
the HO2S.nd G101 (locatedat
th.rmonat housingl.
ls theremorethan 5 V?
C h e c kl o r a s h o r t i n t h e w i r e
line):
{PO2SHTC
1. Turnthe ignitionswitchOFF.
2. DisconnectECMconnectorA
(32P)tromthe ECM.
3. Checkfor continuitybetween
E C Mc o n n e c t o rt e r m i n a l4 6
and body ground.
Substitule a known-good ECM
.nd .echeck. lt 3ymptom/indication 906! rwry, roplacethe original ECM,
PO2SHTC
IALK/WHTI
!
o
a
ECMCONNECTOR
A {32P}
6
1 2 t3
l 5 t6 1 ' t 8 t 9
25
2'
9l ro
It
221 23
2a
I
a
2a E ito
,1 | ---
femaleterminals
Ropair3hort in tho wire betwoen
the ECM {46} and the Prim.ry
HO2Slson3or 11.
Check for an open in the wire
(PO2SHTC
linel:
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM connectorterminal46 and
the PrimaryHO2S(Sensor1)8P
connectorterminalNo. 1.
Repairopsn in the wir6 botween
ECM {A6} .nd the Primary HO2S
lsonror 1).
Substituto a known-9ood ECM
and rech6ck. lf symptom/indication goes away, replace the original ECM.
11-1 6 2
\
a
The scan tool indicatesDiagnosticTrouble Code (DTC)Pl167: A system malfunctionin the Primary Heated
Orygen Sensor{PrimaryHO2S)(Sensor1) Heatercircuit
-
The MIL has be€nreportedon.
DTCPl167 i3 3tored.
ProblemVeritication:
1. Do the ECMResetProcedure.
2 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000mm with no
in neutral)
load (transmission
until the radiatorfan comes
on.
indicated?
ls DTC1167
Intormittont failure, system i3 OK
at thia time. Chock for Poor con_
noction3 or looso wilgt ai Cl45
(Primary HO2S, Son3or 1l and
ECM.
Check lor sn open in the wire
(VS+linel:
1. Turnthe ignitionswitchOFF
the PrimaryHO2S
2. Disconnect
{Sensor1)8P connector.
3. Turnthe ignitionswitchON (ll).
the
4. Measurevoltage betwe€n
'1)
Primary HO2S(Sensor 8P
connectorterminalNo 6 and
body ground.
ls theremorethan 5 V?
PRIMABYHO2SISENSOR1} 8P CONNECTOR
tc145l
C (31P)
ECMCONNECTOR
,l
Ch.ck the ECM:
M e a s u r ev o l t a g e b e t w e e nt h e
ECM connectorterminsl C25 and
body ground.
2
3
a 21 25
VS+
{WHTI
ls theremorethan 5 V?
Replacothe Primary HO2S (Sonsor 11.
4
8
5
9 10
1 1 12 1 3 t 4 1 5 1 6 1 7 1 8
a 30
Wire sideof female
terminals
Repairopon in the wite ECM(C25)
and P m.ry HO2S(S€n3or11.
Substitute ! known-good ECM
and r6check.lf symptom/indication gos6 away, r.place tho origi'
nd ECM,
11 - 1 6 3
PGM-FISystem
FuelSupplySystem
D017-il
Th""""ntool indicatesDiagnosticTroubteCode{DTC)p0171;Thefuetsystemistoo lean.
1P0172 | fne scantool indicatesDlagnosticTroubleCode(DTC)P0172:Thefuelsystemistoo rich.
Description
By monitoringthe LongTerm FuelTrim, long term malfunctionsin the fuel systemwill be detected.
lf a malfunctionhas beendetectedduringtwo consecutive
trips,the MIL will come on and DTCP0171and/orP0172will be
stored.
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as DTCP0171andlot P0172,ltouhleshootthose DTCS
first.then recheckfor DTCP0l7l andlotP0172.
P 0 1 0 6 - 8P,1 1 2 8 **35. ,P 1 1 2 9 **35 M A PS e n s o r
P0135;PrimaryHO2SHeater
P0137.P0138:SecondaryHO2S
P0'141:
SecondaryHO2SHeater
P0401:EGRFlow Insufficient*1
P0441:EVAPSystemInsufficientPurgeFlow*6
P1259:VTECSystem*,
P1491:EGR
ValveLift Insufficient*r
P1498:EGRValveLift SensorHjghVoltage*r
*r: D16Y5engines
*' : Dl6Y5, D16Y8,81642engine
*3:'97 models
* a : ' 9 6m o d e l s
f 5:'98 - 00 models
*6:'96 D16Y5engine,'96D16Y7engine,'96D16Y8engine(sedan),'97D16y5engine,,97D16y7
engine(coupe:KA,KC mo+
els,sedanKA.KC,KL (DX)models.hatchback;
all models),'97D16Y8engine(sedan:KA,KCmodels)
PossibleCause
DTCP0'171
loo lean
DTCP0172
too rach
11-164
FuelPumpinsufficientf lovpressure
FuelFeedLineclogged,leaking
FuelPressureRegulatorstuckopen
FuelFilterclogged
FuelInjectorclogged,air inclusion
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
MAP Sensorrange/performance*.
EGRSystemmalfunction(too much flow)*1
ValveClearance
Exhaustleak
FuelPressureRegulatorclogged,stuckclosed
FuelReturnPipeclogged
FuelInjectorleaking
Gasolinedoesn'tmeet Owner'sManualspec.
PrimaryHO2S(Sensor1) deteriorated
MAP Sensorrange/performance*a
EGRSysteminsufficientflow*1
EVAPPurgeControlSolenoidValveleaking,stuckopened
ValveClearance
t
TroubleshootingFlowchart
-
The MIL ha3 b€onrePorledon.
DTC P0171a^dlot P0172arc
stored,
is the fuel pressureOK?
ls the fuel pressuretoo high
ortoo low?
Checkthe Primary HO2S:
1 . S t a r tt h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
Ioad (in Parkor neutral)until
the radiatorIan comeson
2 . C h e c kt h e P r i m a r y H O 2 S
( S e n s o r1 ) o u t p u t w i t h t h e
scantool,
Checkthe fuel pt€ssureregulator
and fusl re{urn pipe.
Check the tu6l pump. fuel leed
pipe, fu€l fiher, and Iuel Pressure
regulator.
Doesit stayat lessthan 0.3V
or morethan 0.6V?
'l
NO
Check lor a sticking or leaking
EVAPpurge control solenoid
vacuWitha vacuumPumP,aPPIY
u m t o t h e E V A Pp u r g e c o n t r o l
s o l e n o i dv a l v e f r o m t h e i n t a k e
manifoldside.
Does it hold vacuum?
a-,-:- Checkthe MAP sensoroutputr
1. Turnthe ignitionswitchON (ll)
2. Checkthe MAPwith the scan
tool.
YES
Check th6 response of the MAP
sensoa:
1. Startthe engine.
2. Checkthe MAP with the scan
tool.
l s a M A P o f 4 0 . 0 k P a 1 3 0 0m m H g ,
1 2 . 0i n H g ) o r l e s s i n d i c a t e dw i t h i n
one second after starting the
engine?
-
Checkth€ valve cloarance.
Checkthe EGRrystem lD16Y5
enginel.
lf they are OK, r€placethe tuel
iniocto]3.
11 - 1 6 5
PGM-FISystem
RandomMisfire
lFoiool*uo,[FTiool*' *' and
P0304
The scan tool indicatesDiagnosticTrouble Code (DTC)
P 0 3 0 0 * 5o r P 1 3 0 0 * 3* 1 a n d s o m e o f P 0 3 0 1- P 0 3 0 4 :
Randommisfire.
Description
Misfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft.
lf misfiringstrongenoughto damagethe catalystis detected.the MIL will blinkduringthe time of its occurrence,
and DTC
P0300*5
or P1300*3'*'and some of DTCsP0301through P0304will be stored.Then,after misfirehas ceased,the MIL will
come on.
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cycles,the MIL will come on, and DTC
*a and some of DTCSP0301through P0304will be stored.
P0300*5
or P1300*3
NOTE:lf some of the DTCSlistedbeloware storedat the sametime as a misfireDTC.troubleshootthose DTCSfirst,then
recheckfor the misfireDTC.
*5,Pl129*3*5;MAP sensor
P0106*4.
P0107.P0108,P1128*3
P 0 1 3 1P. 0 1 3 2H: O 2 S
P0171,P0112iFuelmetering
P0401,P 1491,P1498:EGRsvstem*1
P0505:ldle ControlSystem
P1253:VTECSystem*,
P 1 3 6 1P, 1 3 6 2T: D Cs e n s o r
P1381,Pl382:CYPsensor
P1508:IACvalve
PossibleCause
. Fuelpump insufficientfuel pressure,amountof flow
. Fuelline clogging,blockage,leakage
. Fuelfilter clogging
. Fuelpressureregulatorstuckopen
. EGRsystemmalfunction*1
. Distributormalfunction
. lgnitioncoil wire open.leakage
. lgnitioncontrolmodulemalfunction
. MAP sensorrange/performance,
poor response*r
. Valvescarbondeposit
. Compressionlow
. IACvalvemalfunctionr.
. VTECsystemmalfunction*,
. Fueldoes not meetOwner'sManualspec.,lackoffuel
. HO2S
. HO2Scircuit
*l: D16Y5engine
*2: D16Y5,D16Y8,Bt6A2 engine
*3: '97 models
*4;'96 models
*5: '98 - 00 models
Troubleshooting
By test-driving,determinethe conditionsduring which misfireoccurs,Dependingon these conditions,test in the order
describedin the table below.
Possible cause
- --^ ---
\
\
\
rage
Only low rpm and
load
EGR*1
system
o
Crankshaft
Fuel
Distributorand
position(CKP)
pressure lgnitionwires
sensor
tcM
section6
11-230,
231
section 23
@
@
Only accelerating
@
Only high rpm and
toao
o
Not specific
o
section 23
Clearance
tAc
MAP
Valve sensor
section 6
1 1 - 1 9 4 11
o
o
o
@
@
o
@
@
NOTE:lf misfiredoesn'trecur,some possiblecausesare fuel that doesn'tmeet owne/s manual
spec,lackof fuel,carbondepositson sparkplug,etc.
1 1 - 16 6
o
I
MisfireDetectedin OneCylinder
P0301 | The scantool indicatesDiagnosticTroubleCode(DTC)P0301:Cylinder1 misfiredetected.
[F03O2l 16"""untool indicatesDiagnosticTroublecode (DTc)P0302:Cylinder2misfiredetected.
[FO3Ofl 16" ".un toot indicatesDiagnosticTroubte Code (DTC)P0303;Cylinder3 misfire detected.
4 misfiredetected.
Cylinder
I P0304I ths..rr toolindicates
Diagnostic
TroubleCode(DTC)PO3O4:
D€scription
lMisfiredetectionis accomplishedby monitoringthe crankshaftspeedwith the crankshaftspeedfluctuation(CKF)sensor
which is attachedto the crankshaft,
and DTC
lf misfiringstrongenoughto damagethe catalystis detected,the MIL will blinkduringthe time of its occurrence,
MIL
will
come
on.
the
or P0304will be stored.Then,afterthe misfirehasceased,
P0302,PO3O3
PO3O1,
lf misfiringthat increasesemissionsis detectedduring two consecutivedriving cyclss,the MIL will come on, and DTC
P0301,P0302,P0303or P0304will be stored.
NOTE:lf some of the DTCSlistedbelow are storedat the sametime as a misfireDTC,troubleshootthose DTCSfirst,then
recheckfor the misfireDTC.
I
P1129*3'*5:
MAP sensor
P0107,P0108.P1128*3'*5,
PO106*1,
P 0 1 3 1P, 0 1 3 2H: O 2 S
P0171,P0172iFuelsuppiy system
P0335,P0336:CKFsensor
P0401.P1491,P1498:EGRsystem
P0441:EVAPsystemInsufficientpurgeflow*6
Pl359.P1361.Pl362:TDCsensor
P1381.Pl382:CYPsensor
*o:'96 models
*6:'96 D16Y5engine,'96D16Y/engine,'96D16Y8engine{sedan),'97D16Y5engine,'97D16\4,engine(coupe:KA,
models),'97D16Y8engine(sedan:KA,KCmodels)
KCmodels,sedanKA.KC,KL (DX)models,hatchback:all
PossibleCause
. Fuelinjectorclogging,fuel leakage,air leakage
. Fuelinjectorcircuitopen or shorted
. Sparkplug carbondeposits,fouling,malfunction
. lgnitionwires open.leaking
. Distributormalfunction
. ComDression
low
. Valveclearanceout of spec
. VTECsystemmalfunction(D16Y5,D16Y8.81642engine)
. HO2S
. HO2Scircuit
r'a
(cont'd)
11-167
PGM-FISystem
Misfirein DetectedOneGylinder(cont'dl
Troubleshooting Flowchart
-
The MIL has beenreoortedon.
DTC P0301.P0302.P0303,or
P030ilis indicated.
Checkthe fuel iniecto. lunction:
Stan the engine,and listenfor a
clickingsoundat the fuel injector
in the problemcylinder.
Checkfor an openor short in the
harnessbetweenECM/PCMand
the fuel iniector.
Repairopen or short in the wir€.
Replacethe fuel iniector.
Sub3titute a known-good
E C M / P C Ma n d r e c h e c k .I t
symptom/indication goes
away, replacethe original ECM/
PCM.
Problemverification:
1. After checkingand recording
the freezedata,do the ECM/
PCMResetProcedure.
the sparkplug from
2. Exchange
the problemcylinderwith one
from anothercylinder,
3. Connectthe SCSservicecon'
nector,
4. Test-drivethe vehicleseveral
timesin the rangeofthe free2e
data.
( T op a g e1 1 - 1 6 9 )
1 1 - 16 8
NOTE:
. lf there is no treezedata of misfiring,
just clearthe DTC.
. It there is no freezedata of misfiring,
t e s t d r i v e su n d e rv a r i o u sc o n d i t i o n s
I
( F r o mp a g e 1 1 ' 1 6 8 )
ls DTCP0301,P0302,P0303,
or P0304indicated?
Intermittent misfire due to spark
plug fouling, etc. (firing is OK ar
this time).
Doesthe misfireoccurin the
othercylinder?
Replacethe faulty spark plug.
Check for fuel iniector malluncl|on:
1. Exchange the fLrelinjector
from the problem cylinder
with one from another cylin
der.
2 . L e t t h e e n g i n e i d l e f o r t r r v om i n utes.
3. Test-drive the vehicle several
times in the range ot the freeze
data.
l
l
NOTE:lf there is no freezedata of mis_
firing, test drives under variouscondi
tions are necessary.
ls DTCP0301,P0302,P0303,
or P0304indicated?
lntermitt€nt mistire due to bad
contact in the fuel iniector connector (firing is OK at this time).
Doesthe mistireoccurin the
othercylinder?
Replacethe taulty fuel injector.
Checklhe following items:
. Cylinderleak-down
. Compression
. Crankshattspeod tluctuation
{CKF)sensoi
t
1 1 - 16 9
PGM-FISystem
KnockSensor(KSl('96- 98 D16Y5enginewith CW and'96- 98 D16Y8
engine)
Forr-l
tool indicates
Diagnostic
TroubleCode(DTC)P0325:
A malfunction
in the circuitof the Knocksensor
I,3,.""""
The MIL has bgenroportsdon.
DTCPO:t25is stored.
Problomveiilication:
1. Do the ECM/PCM
ResetProceoure,
2. Start the engine.Hold the
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rt a n c o m e s o n ,
then let it idle.
3 . H o l d t h e e n g i n e a t 3 , 0 0 04,000 rpm tor at least 60 seconds.
ls DTCP0325indicated?
DIAPHRAGM
Intermittenl fsilu16,3y3l6m b OK
at thi3 timg lteat drivo mav ba
noc63saryl.
Chock tor poor conneclioni or
loose wire3 b€twccn C137{knock
len3or (KS)land ECM/PCM.
Checkfor a short in tho wire {KS
linel:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe knock sensor
2Pconnector,
3 . D i s c o nn e c t t h e E C M / P C M
connectorO (16P).
4. Check for continuity between
E C M / P C Mc o n n e c t o rt e r m i nalsD6 and body ground.
ECM/PCMCONNECTOR
D {16PI
Wire sideof femaleterminals
Reo.ir 3hort in the wire between
ECM/PCM{DG).nd knock 3.n-
(Cl371
KS 2P CONNECTOR
KS
Chock for an open in the wire
(KSlinel:
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM/PCM
connectortorminalD6
and knock sensor 2P connector
terminalNo. l.
ls therecontinuity?
(RED/BLUI
1
I
Ropairopen in the wire bgtweon
ECM/PCMlD6l and knock sen-
\
,_- ,--tl
e s l le oI temal€
tertn i n irls
3('t.
Substitutea known-goodknock
sensorand recheck.
Rsplaceth. o.igin.l knock s€nsor.
Substitute a known-good ECM/
PCM end recheck. lf 3ymptom/
indication goes rway, replace
rhe original ECM/PCM.
11-170
KS
IRED/
BLU)
1
1
2
1
8
9 't0 1 t
13 l4 t5
t6
12
'99- 00D16Y8
engineand
enginewith cw,
Knocksensor(Ks)r99- 00D16Y5
816A2engine
The scantool indicatesDiagnosticTroubleCode(DTC)P0325:A malfunctionin the circuitof the KnockSensor
{KS}.
The MIL has beenreportedon.
DTCm325 is stored
OIAPHRAGM
Problemverification:
1. Do the ECM/PCMResetPro
cedure,
2 . S t a r tt h e e n g i n e H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
3 . H o l d t h e e n g i n e a t 3 . 0 0 04,000 rpm for at least 60 sec'
onds.
ls DTCP0325indicated?
lntermittent failure, system is OK
at thi3 time lt€3t drive maY b€
nocessaryl.
Chsck tor poor connectionsor
loose wiros at C137 {knock sen'
sor {KSll and ECM/PCM.
C (31P)
ECM/PCMCONNECTOR
Ch€ckfor a short in tho wire (KS
linel:
1. Turnthe ignitionswitchOFF.
2, Disconnectthe knock sensor
1Pconnector.
3. Checkfor continuitybetween
E C M / P C Mc o n n e c t o rt e r m i _
nalsC3 and body ground.
Wire side of female terminals
ls therecontinuity?
Repri. short in the wiro bqtwecn
ECM/PCMlc3l and knock 3ensor.
(C1371
KS 2P CONNECTOR
KS
Check for an open in lhe wire
{KS linc):
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM/PCMconnectorterminalC3
and knock sensorconnectorterminalNo. 1.
Replir open in the wire bdtweon
ECM/PCM{Ctl and knock sensor'
ECM/PCMCONNECTOR
S u b s t i t L r t ea k n o w n ' g o o d k n o c k
sensor and recheck,
Wire side of female terminals
Replacetho otiginal knock sensor.
t
substitute a known-good ECM/
PCM and recheck. ll symptom/
indication goes awaY, rePl6co
tha o.iginal ECM/PCM.
11-171
PGM-FISystem
CrankshaftPosition/TopDeadGenter/Gylinder
Position(CKP/TDC/CYP)
Sensor
('96- 98 Models,'!n - 00 D16Y5enginewith M/Tl
scantool indicatesDiagnosticTroubleCode(DTC)P0335:A malfunctionin the Crankshaftposition(CKp)
tFos3slThe
sensorcircuit.
tFffi6l
The scantool indicatesDiagnosticTroubleCode(DTC)P0336:A range/performance
problemin the Crankshaft
Position(CKP)sensorcircuit.
The scantool indicatesDiagnosticTroubleCode
tPr361I (TDC)
sensorcircuit.
fPfi62l
(DTC)P1361:Intermittentinterruotionin the Too DeadCenter
The scan tool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter(TDC}sensor
circuit.
The scantool indicatesDiagnosticTroubleCode
fFr38il{CYP)
sensorcircuit.
(DTC)P1381:Intermittentinterruptionin the CvlinderPosition
The scantool indicatesDiagnosticTroubleCode {DTC)Pl382: No signal in the CylinderPosition(CYP}sensor
tF13s2-l
circuit.
Description
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The Cyp Sensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
Sensoris built into the distriburor.
NOTE:lf DTCP1359is storedatthesametime as DTCP0335.P0336,P1361,Pl362,P1381and/orP1382,troubteshoorDTC
P1359first,then recheckfor those DTCS. Ot6y56ngine:
Dt6y7,ot6y8enqin6s:
-
The MIL hrs beenreportedon.
D T C P 0 3 3 5 ,P 0 3 3 6 ,P 1 3 6 1 ,
P1362,P1381and/or Pl382 6re
stored,
Problemverification:
1. Do the ECM/PCM
ResetProcedure.
2. Stanthe engine.
ls DTCP0335,P0336,P1361,P1362,
P1381and/orP'l382indicated?
TDC
CKP
SENSORSENSOR
SENSOR ROTOR
BOTOR
ROTOR
Intermittent hilu.e, system b OK
at this time. Checktor poor conn€ctions or 10036wiros at C120
{distributor}and ECM/PCM.
SENSOR
ROTOR
SENSOR SENSOR
ROTOR ROTOR
DISTRIBUTOR
1OP
coNNECTORtC120t
TDC P
Check for an open in the CKP/
TDC/CYPsensor:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the distributor10P
CYPM {BLK}
3. Measureresistancebetween
the terminalsof the indicated
sensor(*seetable).
SENSOR DTC
ls there350- 700 0?
Replacethe distributor ignition
housing (soesection23).
CKP
TDC
CYP
11-172
SENSOR ECMfCM
IERMINATTERMINAT COLOR
P033s
2
c2
m336
6
c12
BLU
P1361
3
P1362
7
cl3
RED
YEL
8
c4
c14
P!381
P't382
GRN
8LK
(Frompage | 1-172)
DISTRIBUTOR
10PCoNNECTOR{C1201
Check fo. a sho.t in the CKP/
TDC/CYPsensor:
C h e c kf o r c o n t i n u i t yt o b o d Y
ground on both terminalsof the
i n d i c a t e ds e n s or i n d i v i d u a l l y
1*seetable).
ls therecontinuity?
TDCP (GRNI
Replacothe di3tributorignition
hoGing lsee section23).
Checkfor an open in the wires
line3):
ICKP/TOC/CYP
the distributor10P
1. Reconnect
connecaor.
the EcM/PCMcon2. Disconnect
nectorC {31P}.
resistancebetween
3. N4easure
the terminalsof the indicated
consensoron the ECIM/PCM
nector{*seetabie}.
ls there 350 - 700 o?
Terminalsideof
maleterminals
Repairopen in the indicated sensor wires lrsee tablel.
C 131P)
ECM/PCMCONNECTORS
CI(P P TDC P
CYP P
(YEL)
Chock lor. short in the wires
lines):
ICKP/TDC/CYP
C h e c kf o r c o n t i n u i t y b e t w e e n
conbody ground and ECM/PCM
nectorterminalsC2, C3 and/or C4
individually.
M
ls therecontinuity?
Substitute e known-good ECM/
PCM, and iecheck. ll sYmptom/
indication goes awev, r€Place the
original ECM/PCM.
Repai.short in the indic.ted sen_
sor wire3 ('soe tablol,
M
CKPM
(WHT) (REDI
CKP P
(BLU}
IBLKI
Wiresideof
femaleterminals
TDC P CYPP
(GRN) IYELI
t
11-173
PGM-FISystem
CrankshaftPosition/TopDeadCenter/CylinderPosition(CKP/TDC/CYPI
Sensor
f99 00 ModelsexceptD16Y5enginewith M/T)
The scantool indicatesDiagnosticTroubleCode
l-Fos3sl
sensorcircuit.
The scantool indicatesDiagnosticTroubleCode
tFos36l
Position(CKP)sensorcircuit.
(DTC)P0335:A malfunctionin the CrankshaftPosition(CKP)
(DTC)P0336:A range/performance
problemin the Crankshaft
The scantool indicatesDiagnosticTroubleCode
l {TDC)
tF1361
sensorcircuit.
(DTC)P1361:Intermittentinterruptionin the Top DeadCenter
(TDC)sensor
The scantool indicatesDiagnosticTroubleCode {DTC)P1362:No signalin the Top DeadCenter
Fr362-1
circuit.
The
indicatesDiagnosticTroubleCode(DTC)P1381:Intermittentinterruptionin the CylinderPosition
scantool
tF13sil(CYP)
sensorcircuit.
lTiaSt
:
The scantool indicatesDiagnosticTroubleCode (DTC)P1382;No signal in the CylinderPosition(CYP)sensor
circuil.
DoscriDtion
The CKPSensordeterminestiming for fuel injectionand ignitionof eachcylinderand also detectsenginespeed.The TDC
Sensordeterminesignitiontiming at start-up(cranking)and when crankangle is abnormal.The CYPSensordetectsthe
positionof No. 1 cylinderfor sequentialfuel injectionto eachcylinder.The CKP/TDC/CYP
Sensoris built into the distributor.
NOTE;lf DTCP1359is storedat the sametime as DTCP0335,P0336,P1361.P1362,P1381and/orP1382,troubleshootDTC
engino:
P1359first,then recheckfor thoseDTCS. D16Y5
-
The MIL has beenreportodon.
DTC P0335, P0336. P1361,
P1362,P1381rnd/or P1382.re
stored.
Problemverific{tion:
1. Do the ECM/PCMResetProcedure.
2. Startthe engine.
ls DTCP0335,P0336,P1361,P1362,
P1381and/orPl382 indicated?
TDG
CKP
SENSORSENSOB
SENSORROTOR BOTON
ROTOR
Intormittcnt failure, systom b OK
at thb time. Check to. poor connections or loose wires at C120
(dktributorl and ECM/PCM.
Check tor an open in the CKP/
TDC/CYP3enior:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the distributor10P
connector,
3. Measureresistancebetween
the terminalsof the indicated
sensor(*seetable).
ls there 350 700 0?
TDC
CKP
CYP
SENSOB
SENSOB s€Nson
ROTOR
ROTOR BOTOR
D16Y7,
D16Y8ongine:
S E N S O R DTC
CKP
TDC
Replrce the distributor ignition
hou3ing (!ee section 231.
CYP
P0335
2
c8
P0336
6
c9
P1361
3
c20
GRN
P1362
7
c21
BED
YEL
I
c29
c30
P1381
P1342
(To page11-175)
1- 1 7 4
S E N S O R ECM/PCM
T E B M I N A I TERI\,4INAI C O L O R
8LU
BLK
Dl6Y5.816A2engine:
DISTRIEUTOR
l0PcoNNECTOR
{C120)
(Frompage11-174)
C h o c kf o r . 3 h o r t i n l h o C K P /
Tlrc s6n3o.:
C h e c k{ o r c o n t i n u i t y t o b o d y
ground on both tsrminalsof the
indicatedsensorindividuallY.
Terminalsideol
maleterminals
016Y7,Dt6Y8 engine:
Chsck for an open in the wile3
ICKP/TIrcline6l:
1. R€connectthe CKP/TDCsonsor 4P connector.
2. Disconnectthe ECM/PCMconnectorC 131P).
3. Measureresistancebetween
the terminalsol the indicated
sensoron the ECM/PCMconnector1*seetablel.
ls there 350- 700 o?
DISTRIBUTOR
(Cl201
8P CONNECTOR
Terminalsideol
maleterminals
Ropsiropon in tho indiclted sonior wiro3 l*!sa tabla).
C (31P)
ECM/PCMCONNECTOR
CKPM
IWHT}
Chack for a .ho in th6 wiros
{CKP/TDClino3l:
C h e c kf o r c o n t i n u i t y b e t w e e n
body ground and ECM/PCMconnectorterminalsC8, C20 and/or
C29individually.
lDC M
(REDI
Rcpairrhort in th. indicat.d 36n_
lor wirar {'3ac trblol.
Substituto . known-good ECM/
PCM lnd rechock. lf 3ymptom/
indicatlon go6s aw.y, ropllc.
tho origin.l ECM/PCM.
Wiresideof femsleterminals
ECM/PCMCONNECTOR
c l31P)
CKPP
wire sideof femaleterminals
t
11-175
PGM-FISystem
VehicleSpeedSensor(VSSI('96- 98 Models,'99- 00 D16Y5enginewith M/Tl
@
The scan tool indicatesDiagnosticTrouble Code (DTC)P0500:A malfunctionproblem in the VehicleSpeed
Sensor(VSS)circuitIexceptA!/T(D16Y7,D16Y8engine)1.
The scan tool indicatesDiagnosticTrouble Code (DTC)P0501:A range/performance
problem in the Vehicle
SpeedSensor (VSS)circuit [A,rT{D16Y7,D16Y8engine)].
The MIL has been reDortedon.
DTCP0500or P0501is stored.
ECM/PCMCONNECTORS
A {32P}
Problemverification:
1- Testdrivethe vehicle.
2. Checkthe vehiclespeedwith
the scantool.
ls the correctspeedindicated?
2
LG.t
{BRN/BLK}
3
9
12
1 6 1 1 t 8 t 9 20
l0
lt
23
21
2A 29 30
Intermittent tailure, system is OK
at this time. Checktor Door connectionsor loose wires at C117
{VSSlandECM/PCM.
Checkfor an open in the ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2. Elockthe rearwheelsand set
the parkingbrake.
3. Jackup the frontof the vehicle
and supportit with safety
stands.
4. Turnthe ignitionswitchON (ll).
5. Blockthe righttrontwheeland
s l o w l y r o t a t et h e l e f t f r o n t
c {31P}
3
I
12
tl
8 1 9 1o
ialr5 i6l
1 0 ./
VSS IBLU/WHT}
Wiresideot temaleterminals
6, Measurevoltagebetweenthe
E C M / P C Mc o n n e c t o rt e r m i nalsC18and A9.
Doesthe voltagepulse0 V
a n d5 V ?
Subslitute a known-good ECM/
PCM and recheck.lf symptom/
indic.tion goes away, replacethe
orisinal ECM/PCM.
LGI
(BRN/8LK}
Check tor a short in ihe ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E C M / P C M
connectorC (31P).
3. Turnthe ignitionswitchON {ll).
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowlyrotatethe leftfront
I
3
2
5
a
6
l 5 t 6 1 t l 8 t 9 20
12 l 3
27
9
l0
22
11
2a
20 29 30
5. Measurevoltagebetweenthe
ECM/PCM
connectorterminals
C18andA9.
Does the voltage pulse 0 V
and s V?
-
Repair short in the wire
betwGenECM/PCM{C18}end
vss, TcM.
-
-
Repair open in the wire
between ECM/PCM {Cl8} and
vss.
lf wire is OK, test the VSS
lsee section 23).
11-176
Substitute a known-good ECM/
PCM and recheck. lI symptom/
indication goes away. replace
the original ECM/PCM.
1
2
t 2 l 13l . l
2 3 1r . l s l
9 10
7
I l ,/
t. , ) ,rl
1,/
L
VSS {BLU/WHT}
VehicleSpeedSensor(VSS)('99- 00 ModelsexceptDl6Y5 enginewith M/T)
Thescantoo|indicatesDiagnosticTroub|ecode(DTc)Po5o0:Ama|functionproblemintheVehic|es
fFosoo-l
Sensor(VSS)circuitlexceptA//T(D16Y/,D16Y8engine)l'
Thescantoo|indicatesDiagnost|cTroub|eCode(DTC)Po5o1:Arange/performanceprob|eminthe
lFosoilSDeedSensor{VSS)circuittA,/T(D16Y7,D16Y8engine)1.
The MIL has beenreportedon
OTCP0500or P0501is stored.
Problemveritication:
the vehicle.
1. Test-drive
2. Checkthe vehiclespeedwith
the scantool
ls the correctsPeedindicated?
I
ECM/PCMCONNECTORS
B {25P)
lntermitt6nt failure, sYstemis OK
at thb time. Checktor Poor connections or loose wir6 at C117
{vss} .nd ECM/PCM
Check for an open in the ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2. Blockthe rearwheelsand set
the parkingbrake
3. Jack uP the front ofthe vehicle
and supportit with safety
stands.
4. Turnthe ignitionswitchON (ll).
5. Blockthe right front wheel and
s l o w l y r o t a t et h e l e f t f r o n t
6, Measurevoltagebetweenthe
E C M / P C Mc o n n e c t o rt e r m i _
nalsC23and 820.
D o e s t h e v o l t a g e P u l s e0 V
and 5 V or batteryvoltage?
Wire sideol lemaleterminals
Substituto a known'good ECM/
PcM and rech€ck. ll sYmptom/
indic€tiongoes awaY,lsplace the
originalECM/PCM.
ECM/PCMCONNECTORS
Check for a short in the ECM/
PCM:
1. Turnthe ignitionswitchOFF.
2 . D i s c on n e c t t h e E c M / P c M
connectorC (31P).
3. Turnthe ignitionswitchON (ll)
4 . B l o c kt h e r i g h t f r o n t w h e e l
and slowlyrotatethe leftfront
B E5PI
5. Measurevoltagebetweenthe
terminals
connector
ECM/PCM
C23and 820.
D o e s t h e v o l t a g e P u l s e0 V
and 5 V or battery voltage?
-
t
-
Reoair short in the wire
between ECM/PCM{C23}and
vss. TcM.
Substiiute . known-good ECM/
PCM and r6check. lf symptom/
indication goes awaY, rePlace
the origin.l ECM/PCM.
Wire sideoI femaleterminals
Repai. open in the wire
between ECM/PCM{C231and
vss.
lf wire is OK, tesr the VSS
{seesestion23).
11-177
PGM-FISystem
BarometricPressure(BAROISensor
The scantool indicatesDiagnosticTroublecode (DTC)Pi106:A range/performance
problemin the Baromerrrc
Pressure(BARO)Sensorcircuit.
The MIL ha3 beenr€Dortsdon.
DTCPl106 is stored.
Problemverification:
1 . D o t h e E C M / P C Mr e s e tp r o cedure,
2 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load (in Parkor neutral)until
the radiatorfan comeson, then
let it idle.
3. Connectthe SCS servicecon
nector.
4. Test drive with the A/T in E
position,M/T in 4th gear.
5 . A c c e l e r a t ef o r f i v e s e c o n d s
usingwide openthrottle.
ls DTCP1106indicated?
Intormittont tailure, system is OK
at this time.
Substitut€ e known-good ECM/
PCM and recheck.ll symptom/
indicationgoes .way, .oplscethe
o.iginal ECM/PCM.
fF1lot
The scantool indicatesDiagnosticTroublecode (DTc)P1107:A low voltageprobtemin
the Barosensorcircurr.
The scan tool indicatesDiagnosticTroubrecode {DTC)p1108:A
tPlloal circuit.
The MIL has been.oported on.
DTCP'l107o. Pl108 is stored.
P.oblemveritication:
1. Do the ECM/PClvl
Resetpro
cedure,
2. Turnthe ignitionswitchON (ll).
ls DTCP1107or Pl108indicated?
Substitute a known-good ECM/
PCM and rechock. It symptom/
indication goes away, .6place
the original ECM/PCM.
11-178
Intormittent frilure, syitem i3 OK
at this time.
high vortageprobrem in the Baro sensor
with M/T}
ElectricalLoadDetector(ELDI{'96- 98 Models,'tn 00 D16Y5engine
(DTC)P1297:A low voltage problem in the ElectricalLoad
The scan tool indicatesDiagnosticTrouble code
Detector(ELD)circuit.
Problemverification:
'!. Do the ECM/PCMResetProcedure.
2. Start the engine
3. Turn on headlights
ls DTCP1297indicated?
lntermittent tailure,sYstemis OK
at this time. Checkfor Poor connection3 or loose wires at C131
tlocatedunder righl side of da3h).
C354(ELDIandECM/PCM.
(c35'rl
ELD3PCONNECTOR
l--
Ch.ck lor short in the ELD:
Measurevoltage betweenbody
groundand the ELD3Pconnector
t e r m i n aNl o . 3 .
--f
,
l l l 2 l 3 l
..
ao (GRN/REDI
Y
ls thereapprox.45 V?
O I16PI
ECM/PCMCONNECTOR
Checkfor a short in tho wile (EL
linel:
1. Turnthe ignitionswitchOFF'
con
the ECM/PCM
2. Disconnect
nectorD (16P)
3. Checkfor continuitybetween
b o d y g r o u n da n d E C M / P C M
connectorterminalD16
R6pairshort in the wire between
ELD.
ECM/PCM(D161and
Wire sideof femaleterminals
Substitute a known-good ECM/
PCM and recheck lf symplom/
indication goes awaY, rePlace
the original ECM/PCM
r a
11-179
PGM-FlSystem
ElestricalLoadDetector|ELD)t'glf- 00 ModelsexceptD16y5enginewith M/Tl
The scan tool indicatesDiagnosticTrouble Code (DTC)P'1297;
A low voltage probtem in the ElectricalLoad
Detector(ELD)circuit.
Problemverilication:
1. Do the ECM/PCMResetProcedure.
2. Start the engine.
3. Turn on headlights.
Inlermittont failur6. systom i3 OK
at this time, Chocktor ooor connestions or loose wires at C131
(locrted undor ight side ot d.shl,
C354(ELDIand ECM/PCM.
Checkfor short in th6 ELD:
Measurevoltage between body
groundand the ELD3P connector
t e r m i n aNl o . 3 .
ELD3PCONNECTOR
tC354)
EL
{GRN/REOI
ls thereapprox.4.5V?
ECM/PCMCONNECTOB
A I32PI
Check to. a short in the wne (EL
linel:
'L Turn
the ignitionswitchOFF.
2. Disconnect
the ECM/PCM
connectorA (32P).
3. Checktor continuity betlveen
b o d y g r o u n da n d E C M / P C M
connectorterminalA30.
ls therecontinuity?
Sub3titute a known-good ECM/
PCM and rech€ck. It symptom/
indication goes away. replace
the o.iginal ECM/PCM.
11 - 1 8 0
Repairshort in the wile between
ECM/PCMlA30) and ELD.
Wire side of lemale terminals
- 00 D16Y5enginewith M/T)
ElestricalLoadDetector(ELD)f96 98 Models''99
ThescantoolindicatesDiagnosticTroubleCode(DTC)P1298:AhighvoltageproblemintheElectrical
Detector(ELD)circuit
Problomvcrificttion:
ResetPro1. Do the EcM/PClVl
cedure,
2. Startthe engine.
3. Turnon headlights.
ls DTCP1298indicated)
Ch.ck lor tn oPan in tho wir'
(lGl linol:
1 . T u r n t h e i g n i t i o na n d h e a d '
liohtsOFF
2. D]""onn""t the ELD 3P con_
nector3. Turnthe ignitionswitchON {ll)'
4. Measurevoltagebetweenbody
groundandthe ELD3Pconnec
'1.
tor terminalNo.
lntarmitt..rt l.ilur., ryttcm b OK
.t thia tim. Ch.ck lor Poo' connections or looaa wir.3 at C131
lbcd.d und.r right ide ol dalhl'
Gl5a {EU)} .nd ECM/PCIYI
{G's'I
ELD3PCONNECTOR
Wire side ol femaleterminals
R.oair ogan in tha wira Mw"n
ru".rs ltTEnrlton SPSelSOn
t?.5 A, fu!. in th. undcr-dr3h
tu3e/r.l!Y box .nd ELD.
Chcck lor tn oP.h in thc wire
{GND lincl:
1. Turn the ignition switch and
h e a d l i g h t sO F F .
2. Disconnect the ELD 3P con_
nector'
3. Check for continuity between
body ground and the ELD 3P
c o n n e c t o .t e r m i n a l N o 2
EL IGFN/REDI
Raprir opcn in the wira bstwt€n
ELD conncctor lnd G/O2.
Ch.ck lor !n oplo in tha wirc IEL
lin.l:
Check for continuity between the
ELD 3P connectorterminal No 3
and ECM/PCM connector termi
nal D'16.
Rapaii opcn in the wira b€tw"n
ECM/FCM (I)161.nd th. ELD'
wire side of lemale termrnals
Ch.d( fo. r m.llunction in thc ELD:
1 . R e c o n n e c tt h e E L D 3 P c o n '
2. Start th€ engine and allow it
to idle.
3. Wh ile measuring voltage
beNveen ECM/PCM connector
terminals D16 and A9, turn
t h e h e a d l i g h t so n { l o w ) .
t'a
Wire side of Iemale terminals
Doesthe voltage droP?
Sub3titut. . known_good ECM/
PCM .nd rcch.ct. lt sYmptom/
indication goas away/ iapllc'
thc origin.l ECM/PCM
11 - 1 8 1
PGM-FISystem
ElestricalLoadDetector(ELDI('99- 00 ModelsexceptD16y5enginewith
M/Tl
The scan tool indicatesDiagnosticTroublecode (DTCIPl298: A high
vottageproblem in the EtectricalLoad
Detector(ELD)circuit.
Problemve.itication:
1. Do the ECN4/PCM
Resetpro
cedure.
2. Startthe engine.
3- Turn on headiights.
ls DTCP1298indicated?
Inte.mittent teilu.e, svstem is OK
at this lime. Chockfor Door connections or loose wires at Ci31
{located under Jight side ot
daihl, C354(ELD)and ECM/PCM.
ELD3P CONNECTOR
(65/0
Check for an open in the wire
{lG1line}:
1 . T u r n t h e i g n i t i o na n d h e a d lightsOFF.
2 . D i s c o n n e ctth e E L D 3 P c o n
Wiresideof fernaleterminals
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenbody
groundand the ELD3P connectorterminalNo.
1.
ls there battery voltage?
Repairopon in tho wiro batwe€n
No. 15 ALTERNATOR
Sp SENSOR
{7.5 A} fuse in th6 undor-dash
Iuse/releybox and ELD.
Check for an open in the wiro
{GNDlinel:
1. Turn the ignition switch and
headlights
OFF.
2 . D i s c o n n e ctth e E L D 3 P c o n
nector.
3. Checkfor continuitybetween
body ground and the ELD3P
connectorterminalNo.2,
ls therecontinuity?
Repsir op€n in the wire between
ELD connector and ECM/PCM.
Substitute a known-good ECM/
PCM and recheck.lf symptom/
indication goes away. replace
lh6 original ECM/PCM.
11-182
TI
r l 2 l 3 l
I crvo
(o) (BrKr
Y
Wire sideof lemaleterminals
Repairopen in the wire bstwoen
ELDconnsctor and Gia02.
Check ,or an open in the wire IEL
linel:
1. Disconnect
the ECM/PCM
connectorA (32P).
2. Checkfor continuitybetween
the ELD3P connectorterminal
No. 3 and ECM/PCMconnector terminalA30.
ELD3P CONNECTOR
(CA54I
EL {GRN/REOI
ECM/PCMCONNECTORS
A (32P1
Chockfo. a malfunctionin the ELD:
'1. Reconnect
the ELD connector
and ECM/PCMconnector
A (32P).
2. Stan the engineand allow it
to idle.
3 . W h i l e m e a s u r i n gv o l t a g e
between ECM/PCMconnector
terminals A30 and B2O,turn
the headlighrs
on ow).
Wiresideof lemale
EI-IGRN/RED)
terminals
ECM/PCMCONNECTORS
A {32P)
Doesthe vokagedrop?
Wire side of f€male terminals
\
Fluctuation(GKFISensor
CrankshaftSpeed
'99 - 00 D16Y5enginewith .M/Tl
firC- 48 Models,
fPrk6l
Speed
(DTC)P1336;Intermiftentinterruptionin the Crankshaft
The scantool indicatesDiagnosticTroubleCode
Fluctuation(CKF)sensorcircuit.
ThescantooIindicatesDiagnosticTroub|ecode{DTC)P1337:NosignaIinthecrankshaftspeedF|uctuatio
lFr3g7-lsensorcircuit.
D6scription
T h e d i a g n o s t i c s y s t e m h a s a p u | s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i judges
c k - u p s e n s8n
o r oengine
n t h e emisfire
n g i n e boccurred
l o c k . T hife E c M / P
that
sensorsignal,and
monitorsthe crankshaftspeedftuctuationbasedon the cKF
limit'
the fluctuationgoes beyonda predetermined
-
I
The MtL hds been reported on.
DTC P1336and/or P1337a.e
stored.
P.oblem v€rific.tion:
1. Do the ECM/PCMResetProcedure.
2. Stanthe engine
lntormittont lailur6, tY3tom b OK
at thit tima. Chock tor Poor con'
nactions or loota wito! at C102
IC-KFson$rl .nd ECt /PCM, and
mrka suro CKFtonaor mounting
boh ittigM.
Chockfor .n open in tho CKFaen30t:
1. Turnthe ignitionswitchOFF
2. Disconnectthe CKFsensor 3P
connector,
3 . M e a s u r e t h e r e s i s t an c e
between the CKF sensor 3P
connectorterminalsNo. 1 and
No.3.
CKF SENSOR 3P CONNECTOR
L:l
.)l
l.' Ir-T--T---.]
l- 1 l 2 l 3 l l
L
''---r
C K F MI
I CKFP
twrfit 1,.^\ | lsLul
\.7
ls there1.6- 3.2kO?
Terminalsideof maleterminals
Ch€cktor a short in the CKFson'
30ti
C h e c k{ o r c o n t i n u i t Yb e t w e e n
body groundand the CKFsensor
3P connectortermin6lsNo. 1 and
N o . 3i n d i v i d u a l l Y .
I
CKF M
IWHT}
CKF P
IBLUI
(cont'd)
(To page 11 184)
11 - 1 8 3
PGM-FISystem
CrankshaftSpeedFluctuation(GKFISensor
('96- 98 Models,'99- 00 D16V5enginewith M/Tl (cont,d)
\
(Frompage11 183)
Checklor an open in the wires
ICKFlines):
1. Reconnect
the CKFsensor3p
2. Dlsconnect
the ECM/PCM
connectorC (31P).
3, Measureresistancebetween
E C M / P C Mc o n n e c t o rt e r m i
n a l sC l a n dC l 1 .
ECM/PCMCONN€CTOR
C (31P}
CKFP
(8LU/REO)
6rl-i
ls there1.6 3.2kO?
Repairopen in the wire between
ECM/PCM{C1,C11}and the CKF
Repairshort in the wiro bstwoen
ECM/PCM{Cl) and the CKFson-
11-184
tl
21
CKFM
(WHT/REO)
C h e c kf o r a s h o r t i n t h e w i r e
{CKFline}:
C h e c kf o r c o n t i n u i t y b e t w e e n
body ground and ECM/PCMcon,
nectorterminalC1.
Substitute a known-good ECM/
PCM,and recheck.lf symptom/
indicationgoes awry, replacethe
original ECM/PCM.
rF
a
6
7
8
9 10
1 2 13 1 1 1 5 t 6 1 7 1 8
CKFP
(BLU/RED)
27 2A
29 30
Wire side of female
termtnats
a
t
CrankshaftSpeedFluctuation(CKF)Sensor ('99- 00 MocielsexceptD16Y5enginewith M/T)
DiagnosticTroublecode (DTC)P1336:Intermittentinterruptionin the crankshaftspeed
scantool indicates
Ftu6l The
Fluctuation(CKF)sensorcircuit
Fluctuation(CKF)
The scantool indicatesDiagnosticTrouble Code (DTC)P1337:No signal in the CrankshaftSpeed
tF13g7lsensorcircuat,
Description
T h e d i a g n o s t i c s y s t e m h a s a p u l s e r r o t o r o n t h e c r a n k s h a f t a n d a p u | s e p i c k - u p s e n s o r o n t h e e n g i n e b | o c k . T hife E c M / P
judgesthat an enginemisfireoccurred
monitorsthe crankshaftspeedfluctuationbasedon the cKF sensorsignal.and
limit'
the fluctuationgoesbeyonda predetermined
-
I
The MIL has b€onreportadon.
DTC P1336and/or P1337are
stored.
Problemverification:
1. Do the ECM/PCMResetProce'
dure.
2. Startthe engine
lntermittcnt failuro, sydcm is OK
ai this time. Checklot Poor con_
noctions or loo3e wiros at C102
ICKFs€nsor) and ECM/FCM,and
make suro CKF sansor mounting
bolt b tight.
Checktor an open in the CKFsen_
1. Turnthe ignitionswitchOFF
the CKFsensor3P
2. Disconnect
3. Measure the resistance
b e t w e e nt h e C K Fs e n s o r3 P
connectorterminalsNo. 1 and
No.3.
ls there1.6 3.2kO?
Check for a short in ihe CKF sen_
sot:
Check for continuity between
body ground and the CKF sensor
3P connector terminals No 1 and
No.3 individuallY.
t
CKFSENSOR3P CONNECTOR
r--r t
|-.r-r'--]l
l l ll 2 l 3 l l
.l---'.-T_
C K F MI
t w H T l --\9|/Ai
I CKFP
i lBlul
Terminal side oI male terminals
CKF M
(WHT)
CKFP
(BLU)
(cont'd)
(To page 11-186)
11 - 1 8 5
PGM-FISystem
CrankshaftSpeedFluctuation(GKFISensor
('99- 00 ModelsexceptD16YSenginewith M/Tl (cont,d)
\
I
(Frornpagel1-185)
Check Ior an opsn in the wires
(CKFlines):
1. Reconnect
the CKFsensor3p
connector.
2. Disconnectthe ECM/PCMconnectorC {31P}.
3. Measureresistancebetw€en
E C M / P C Mc o n n e c t o rt e r m i nalsC22and C31.
l s t h e r e1 . 6 - 3 . 2k 0 ?
ECM/PCMCONNECTOR
C 13lPI
Repair opqn in th. wire bo{ween
ECM/PCM(CZ, Ctll and th. CKF
lon30r.
Wire sideof female
terminals
Check tor a short in the wire
ICKFline):
C h e c kf o r c o n t i n ! i t y b e t w e e n
body groundand ECM/PCMconnectorterminalC22.
Roplir thort in tho wirg b.iwoon
ECM/FC'ftllc22l and tho CKF3€n-
I
Substituto a known-good ECM/
PCM, and r.ch.ck. It symptom/
indication90o. aw!y, 6pbco the
originalECM/PCM.
11 - 1 8 6
a
Sensor
Position(CKP/TDC/CYPI
DeadCenter/Cylinder
Position/Top
Crankshaft
Thescantoo|indicatesDiagnosticTroub|ecode(DTc)P1359:Aprob|eminthecrankshaftPosjtion/TopDe
sensorcircuit'
Position(CKP/TDC/CYP)
Center/Cvlinder
-
The MIL has been reportedon
DTCP1359is stored
Problemveritication:
1. Do the ECMResetProcedure
2 . S t a nt h e e n g i n el f t h e e n g i n e
won't start,crank it for at least
10seconds-
ls DTCP1359indicated?
lntermittent failure, sYstem is OK
Check for poor connecllon3or
loose wires at C120 {distributor}
and ECM,/PCM.
C h e c kf o r p o o r c o n n e c t i o n so r
loose wires betweenthe distribu
tor and the ECM/PCM
l , a
Substitute a known'good ECM/
PCM, and rccheck. lt 3ymPtom/
indication goes awtY, rePlace
the original ECM/PCM.
rta
11-1A 7
PGM-FISystem
ECM/PCMlnternalCircuit
[Fi6oil
-
th" """n tool indicates
Diagnostic
Troublecode(DTc)p1607:
An EcM/pcMlnternal
circuitprobtem.
The MIL has beenreportedon.
DTCP1607is stored.
Problernverification:
1. Do the ECN4/PCM
Resetprocedure.
2. Turnthe ignitionswitchON t).
3. Wait 10 seconds.
ls DTCP1607indicated?
Substitule a known-good ECM/
PCM and recheck.lf symptom/
indicationgoes away, .epl.ce the
origin.l ECM/PCM.
11-188
J
I
A/T Signal(TMA/TMBI('96- 98 Dl6Y5enginewith GW)
signallinefailure
Code(DTC)P1681:TIVA,/TMB
[F16551lTh" ""un toot indicatesDiagnosticTrouble
C 131P}
ECMCONNECTOR
TMA IGRYI
Problemverification:
1. Dothe ECMResetProcedure.
2. Drive the vehicleIor several
milesat varyingspeeds
ls DTCP1655indicated?
Check lor an oPen in the wire
(TMAline):
1. Turnthe ignitionswitchOFF
2. DisconnectECM connectorC
(31P)from
t h eE C M
3. Turnthe ignitionswitchON (ll).
4 - M e a s u r e v o l t a ge b e t w e e n
E C M c o n n e c t o rt e r m i n a lC g
and bodyground.
l
l
ls therebatteryvohage?
lnt.rmittent failure, system is OK
at ihis time. Checktor Poor connections or loos€ wires at C131
llocated under right side of dash),
C438ITCM)and ECM.
C h e c kf o r a s h o r t i n t h e w i r e
ITMA line,:
Measurevoltage between TCM
22PconnectorterminalNo 7 and
body ground.
ls there batteryvoltage?
Check for an open in the wire
{TMBline}:
1. Turnthe ignitionswitchOFF
2. ReconnectECM connectorc
(31P).
the 22Pconnector
3. Disconnect
from TCM.
4. Turnthe ignitionswitchON (ll).
5. Measurevoltage between
TCM 22P connectortermlnal
No.6 and body ground.
ls there batteryvoltage?
fcu22P
CONNECTOR
Ropairshod in the wire bstwe€n
the EcM (C!l)and the TcM.
Repairopen in the wire between
th€ EcM {Ca)and the TcM.
Check for a 3ho.t in the wire
{TMB lin6,:
Measurevoltage between ECM
connectorterminalC30and body
ground,
6 7
2 3 1
'12
1
5
1
6
1
7 18
1t
13 1 4
8
29 30
23 2a 25
Substitute a known'good ECM
and recheck. It symPtom/indica'
tion goes away, teplace the original ECM.
Wire side oI temale
terminals
ls there bafteryvoltage?
t l ,
9 10
TMB*
{PNK}
Reoairshort in the wile b6tween
the ECM{C30}and the TCM.
f,epair open in the wire between
the EcM (C30) and the TcM.
11 - 1 8 9
ldle Control System
SystemDescription
The idle speedot the engineis controlledby the ldle Air Control(lAC)Valve.
The valve changesthe amount of air bypassinginto the intakemanifoldin responseto electriccurrentcontrolledbv the
ECM/PCM.
Whenthe IACValveis activated,the valveopenslo maintainthe properidle speed.
D16Y5,D16Y8,Br6A2engine(M/T):
VARIOUS
sEI{SORS
(ROTARYI
tac vat-vE
Dl6Ys {CVTl,D16Y8enginelA/T):
EI{GINE
cooLAI{T
INTAKEMANIFOTD
;iy--, - ---
: INTAKE
AIR
11-250
\
J
Fuol Iniection Air {FlA)Contlol Valve T$ting
1.
Startthe engine.
2.
Removethe vacuum hose from the fitting on the
intakeair duct, and connecta vacuumgaugeto the
nose.
NOTE:Enginecoolanttemperaturemust be below
149"F(65"C).
VACUUMPUMP/GAUGE,
0-30 in.Hg.
A973X- 041-XXXXX
Raiseand lower the engine speed,and make sure
the vacuum gauge readingchangesas the engine
speed changes.
lf vacuum reading does not change check these
rtems:
. The vacuum lines of FIA systemfor misrouting,
leakage,breakageand clogging.
. The FIA controt valve for cracksor damage
. The cooling system (seesection 10).
rpm with no load (in Park
Hold the engineat 3,OOO
or neutral)until the radiatorfan comes on, th€n let
it idle and recheck.
lf vacuumreadingchangeschecktheseitems:
a The FIAcontrolvalvefor cracksor damage.
. The coolingsystem(seesection10).
11-251
EmissionGontrolSystem
SystemDescription
ThreeWay CatalyticConverter
The emissioncontrol system includesa Three Way Catalytic Convener(TWC),ExhaustGas Recirculation
(EGR)
system,. PositiveCrankcaseVentilation(pCV)system and
EvaporativeEmission(EVAP)Controlsystem.The emission control system is designedto meet federaland state
emissionstandards.
*: D16Y5engine
Doscription
The Three Way CatalyticConverter (TWC) is used to
conven hydrocarbons(HC),carbonmonoxide(CO),and
oxides of nitrogen(NOx) in the exhaustgas to carbon
dioxide(COr),dinitrogen(N,)and watervapor.
(TWCI
D15Y5,D16\r, engine:
ENGINESIDE
t
TailpipeEmission
Inspestion
Do not smoke during ihis procedure.Keep
@@
any open flame away from your work area.
1.
Startthe engine.Hold the engineat 3,000rpm with
n o l o a d ( i n P a r ko r n e u t r a l )u n t i l t h e r a d i a t o rf a n
comeson. then let it idle.
2.
Connecta tachometer.
Checkand, if necessary,adjustthe idle speed (see
page 11-220- 223).
Warm up and calibratethe COmeteraccordingto the
metermanufacturer's
instructions.
Checkidle CO with the headlights,heater blower,
rearwindow defogger,coolingfan,and air conditioner off.
) u l l t h e p a r k i n gb r a k el e v e r u p .
N O T E : ( C a n a d aP
Startthe engine,then checkthat the headlightsare
off.
'99 -
00 D16Y8,81642 engine:
CO mete.shouldindicate0.1%maximum.
NOTE:'98 Dl6Y5 engine- lf the idle speedincresses to 8101 50 rpm, this meansthe EVApsystemis
purgingthe canister.To stop the purgingtemporarily. raisethe enginespeedabove 1,000rpm with the
pedal,then slowly releasethe pedal.
accelerator
FORWARD
11-252
e
-
\
(DTc)p0420:catatystsysremefficiencybelowthreshold.
lTo420l Th" """n toot indicatesDiagnosticTroubtecode
Description
outputduringstabledriving
This systemevaluatesthe catalyst'scapacityby meansof the Ho2s {Primaryand secondary)
on and DTCP0420will
MIL
comes
the
cycles.
driving
two
consecutive
during
been
detected
has
conditions.ll deterioration
be stored.
those DTCSfirst. then
NOTE:lf some of the DTCStistedbelow are storedat the same time as DTCP0420,troubleshoot
recheckfor DTCP0420
P0137,P0138:SecondaryHO2S(Sensor2)
H02S {Sensor2) Heater
Po14'1:Secondary
Possibl€Cause
. TWCDeterioration
. Exhaustsystemleakage
Troubleshooting Flowchart
The MIL has beenreportedon.
DTC P0420 is stored
I
Problemverilication:
ResetProce
1. Do the ECM/PCM
dure.
2 . S t a r tt h e e n g i n e H o l d t h e
engine at 3,000rpm wath no
load {in Parkor neutral)until
the radiatorfan comeson.
3. Connectthe SCSservicecon
4. Testdrive 40 - 55 mph for
a p p r o x ,t w o m i n u t e s T h e n
deceleratefor at least 3 sec_
o n d s w i t h t h e t h r o t t l ec o m '
pletely closed-Then reduce
the vehiclespeedto 35 mph,
a n d t r y t o h o l d i t u n t i lt h e
codecomeson
readiness
l s D T C P 0 4 2 0i n d i c a t e d ?
Checkthe TWC {seesection 9l
lf necessary,replacethe TwC
Intermittent Iailure, system is OK
at this time.
EmissionControl System
(EGR)System(D16ySengine)
ExhaustGasRecirculation
Doscription
The EGRsystemis designedto reduceoxidesof nitrogenemissions(NOx)by recirculating
exhaustgas throughthe EGR
valveand the intakemanifoldinto the combustionchambers.lt is composedof the EGRvalve.EGRvacuumconrrotvatve.
EGRcontrolsolenoidvalve.ECMand varioussensors.
The EcM containsmemoriesfor ideal EGRvalve lifts for varyingoperatingconditions,The EGRvalve lift sensordetects
the amountof EGRvalvelift and sendsthe informationto the ECM.The ECMthen comparesit with the ideatEGRvalvelift
which is determinedby signalssent from the other sensors.lf there is any differencebetweenthe two. the EcM cuts currentto the EGRcontrolsolenoidvalveto reducevacuumappliedto the EGRvalve.
EGRCONTROL
CVT:
SOLENoID
vALvE
EGNVALVELIFTSENSOR
BLK
I
I
11-254
4
The scantool indicatesDlagnosticTroublecod€ {DTc}Po4ol:lnsufficientflow in the ExhaustGas Recirculation
(EGR)svstem.
Doscription
the changesin MAP before
Deterioration(clogging,leakage,etc.)in the EGRline or EGRvalve is detectedby meansof
and afterthe operationof the EGRvalve.
DTC P0401will be
lf deteriorationhas been detectedduring two cons€cutivedriving cycles,the MIL will come on and
stored.
Po$ible Causeg
. Clogging.leakagein the EGRline
. FaultyEGRvalve
TroubleshootingFlowchart
-
\
Tho MIL ht! bacn rgportodon.
DTCm40l is 3torod.
Problomvorification:
1. Do the ECM/PCMResetProcedure.
2. Connectthe SCS serviceconnector,
underthe following
3. Tost-drive
conditions.
- Without any electricalload
- Deceleratelrom 55 mPh
(88km/h)lor at least5 seconos
lntormiftam f!ilu.a, ayltam ia OK
.t thb time,
-
Clo.n tho inttkc mlnifold EGR
port wittr carbursto. clotner.
Cl.an the pa$lgo insido tho
EGR valvo with crrburator
cloanol or aoglacatha vllvo.
EmissionControl System
ExhaustGasRecirculation(EGR)System(D16Y5enginewith GWI (cont'dl
lTl49il
-
T_hescantool indicatesDiagnosticTroubleCode(OTC)P1491:A malfunctionin the ExhaustGas Recirculation
l E g h )s v s t e m .
CvT lM/T seepage 1l-2611:
The MIL has been reoortedon.
DTCP1491is stoled.
Problemverification:
1. Do the ECM/PCM
ResetProcedure.
2. Connectthe SCSservicecon'
3 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
load {in Parkor neutral)until
the radiatorfan comeson,
4. Drivethe vehicleon the road
for approx.10 minutes.Try to
keepthe enginespeedin the
1,700- 2,500rpm range.
l s D T CPl 4 9 l i n d i c a t e d ?
Intermittonl failure, system is OK
at this time. Checkfor Door connections or loose wires at, C144
{EGRvelve}and ECM/PCM.
Check fo. vacuum to ihe EGR
1. Disconnectthe No. 16 hose from
t h e E G Rv a l v e .
2. Connect a vacuum pump/
gauge to the hose.
3. Start the engine and let it idle.
EGRVALVE
LIFTSENSOR
#16 HOSE
ls thereany vacuum?
Check tor a malfunction in the
EGR control solenoid valve:
'1.
D i s c o n n e c tt h e E G R c o n t r o l
solenoid valve 2P connector,
2 . B e c h e c kt h e N o . 1 6 h o s e f o r
(To page11 257)
PUMP/GAUGE,0-30 in.Hs
A973X-041-XXXXX
ls there any vacuum?
Substitute a known-good ECM/
PCM and recheck. It symptom/
indicalion goes away, replace
the original ECM/PCM.
11-256
Check vacuum hose routing o,
the entire EGR svstem. lf hose
routing is OK, replac€the EGR
control solenoidvalv6.
EGR
VALVE
J
\
EGRVALVE
LIFTSENSOR
(Frompage11-256)
#16HOSE
Check fo. a mallunction in the
EGFvalv€:
1. ldove the vacuumpump/gauge
to the EGRvalve.
2. With the engineat idle,apply
26.7kPa(200mmHg,8.0in.Hg)
ofvacuumto the EGRvalve.
- 30 in.Hs
PUMP/GAUGE,0
4973X-041-XXXXX
Doesthe enginestallor run
roughand doesthe EGRvalve
holdvacuum?
EGRVALVELIFTSENSOR
3P CONNECTOR
lC14.l)
I
vccz
zF\
Check for an open in the wire
IVCC2linel:
1. Turnthe ignitionswitchOFF.
the EGRvalve lift
2. Disconnect
sensor3Pconnector.
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenthe
EGRvalve lift sensor3P con'
n e c t o rt e r m i n a l sN o . 3 a n d
No.2.
Ill
-r_
. ] IYEL/BLU)
2l3l---l
7
|
v-,, I
SG2IGRN/BLK)
I ^
I{Vts
I
D {16P)
ECMCONNECTOR
ls lhere approx.5 V?
vcc2
IYEL/BLU}
sG2
(GRN/BLKI
Wire sideol temaleterminals
C (31P}'
PCMCONNECTORS
Check for an oDen in the wire
{VCC2line}:
M e a s u r ev o l t a g e b e t w e e nt h e
E C M / P C Mc o n n e c t o rt e r m i n a l s
D10and Dl1 (C18and C28)*.
Wire side of female terminals
YES
l s t h e r ea p p r o x . 5V ?
(To page 1l-258)
Sub3titute t known-good ECM/
PCM end recheck. lt 3ymptom/
indication goos eway, replace
th6 original ECM/PCM.
Rep.ir open in the wire between
r h e E G Rv a l v e s n d E C M / P C M
{Dl0 {C28)*).
(cont'd)
*: '99 - 00 models
1 1-257
EmissionGontrolSystem
(EGRISystem(Dl6Y5enginewith CW) (cont'dl
ExhaustGasRecirculation
{Frompage11-257}
Chocklor an opcn or short in th.
EGRv.lve lift .€nsor
'1. Turnthe ignitionswitchOFF.
2. At the sensorsid€, measur€
resistancebetween the EGR
valve lift sensor 3P connector
terminalsNo. 1 and No.2.
EGRVALVELIFTSENSOR
3P CONNECTOR
{Cl251
EGRL
(WHT/BLKI
ls there continuity or resis'
tanceot 100k0 or higher?
sG2
{GRN/BLK}
Terminalsideol maleterminal
Chocktor sn op€n or lhort in the
EGRvalve lift lonror:
Measureresistancgbetweenthe
EGRvalve lift s€nsor3P connector terminalsNo. 1 and No.3.
EGRL
IWHT/BLKI
ls there100k0 or higher?
ECIT'I
CONNECTOR
D II6PI
Ch.ck tor an ooon or rhon in thc
wiro IEGRLlinc):
1. Beconnecttho EGRv6lve lift
sensor3P connector.
2. Turn tho ignitionswitchON (ll).
3. Measurevoltage between the
ECM/PCMconnectorterminals
D9and Dl1 (C6and C18l*.
EGRL
{WHT/BLKI
sG2
{GRN/BLK}
Wir€ side of f€maleterminals
PCMCONNECTORS
C (31PI*
ls thereapprox.1.2V?
Wire sideof femaleterminals
{Topage11-259)
11-258
(To page11-259)
./
I
(Frompage11-258)
ECMCONNECTOR
O {I5PI
Check for a 3hort in the wire
{EGRLlinel:
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM/PCMconnectorterminalDg
Repairop€n in the wire between
th6 EGRvalve and the ECM/PCM
(D9 tc6trt.
Wire sideof lemaleterminals
PCMCONNECTORS
C (31P)*
ReDairshort in the wirc batweon
the EGRvalve and ECM/PCM{Og
(c5t*).
Wire sideof temaleterminals
(From page 11-258)
I
EGRCONTROLSOLENOIDVALVE
2P CONNECTOR
Checkths vacuum routing:
' 1 . R e c o nn e c t t h e v a c u u m
p u m p / g a u g et o t h e N o . 1 6
hose.
2. Startthe engineand let it idle.
3. At the EGR control solenoid
valve side, connect the battery positiveterminal to the
E G Rc o n t r o l s o l e n o i dv a l v e
connectotterminalNo. 1.
4 . W h i l e w a t c h i n gt h e v a c u u m
g a u g e ,c o n n e c tt h e b a t t e r y
negativeterminalto the EGR
controlsolenoidvalve2P connectorterminalNo.2,
Terminal side oI
malelerminals
ls thereapprox.26.7kPa
1200mmHg,8.0in.Hg)of
vacuumwithin 'l second?
Chockthe vlcuum hos6s:
1. Turnthe ignitionswitchOFF.
2. Inspectthe No. 16 and No. 10
hosesfor leaks,restrictionsor
mtsrouUng.
t
(cont'd)
11,260)
11-259
EmissionControlSystem
ExhaustGasRecirculation(EGR)System(Dl6Y5enginewith CW) (cont'dl
(Frompage11-259)
Chocklor an open in the wire (E
SOL linsl:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 2P connector
Irom the EGRcontrolsolenoid
3. Disconnectthe ECN4/PCM
connectorA (32P)(B (25P))*from
the EcM/PCM.
4. Checktor continuitybetween
ECM/PCl,connectorterminal
47 (86)* and the EGRcontrol
solenoid valve 2P connector
t e r m i n aNl o . 2 .
EGRCONTROLSOLENOID
VALVE2P CONNECTOR
{C142}
Wire side
ESOL
of lemale
IRED)
terminals
ECM
CONNECTOR
a t32Pl
-
ESOL
IRED)
-_-]
EGRCONTROLSOLENOID
VALVE2P CONNECTOR
ICl'2}
Wireside
of female
i
terminals
ECM
CONNECTOR
B l25P)
I
l
ESOL
(REDI
Wireside
of female
rermtnats
ls therecontinuity?
Repair opon in th. wir. bstwocn
tha EGR control 3ol€noid valvo
and tho ECM/PCM(A7 186l'1.
Check for . rhort in the wire
(ESOLlinel:
Checkfor continuity between the
EGRcontrolsolenoidvalve2P connectorterminal No. 2 and body
ground,
R.p.ir ahort in tha wi.c b.twecn
the EGR control iolonoid vllye
and th. ECM/FCM{A7 (46}rl.
Check for an opon in the wiro
IGNDlinel:
Checkfor continuity between the
EGRcontrolsolenoid
vaive2Pconnectorterminal No. I and body
ground,
Rcpai. op€n in the wir6 b6'twoen
the EGR control rol.noid valve
and G101.
Sub3titule a known-good ECM/
PCM and rechock. lf symptom/
indication goes away, replac€
the original ECM/PCM.
*: '99- 00 models
11-260
Wireside
of female
terminals
t J
\
J
System(D16Y5enginewith M/T)
ExhaustGasRecirculation
M/T:
-
Th6 MIL ha3b€onreponed on.
DTCPl,{tl is 3tored.
Prcblem verification:
1. Do the ECMResetProcedure.
2. Connectthe SCSservicecon_
nector.
3 . S t a r t t h e e n g i n e .H o l d t h e
engine at 3,000rpm with no
in neutral)
load (transmission
fan comeson.
untiltheradiator
4. Drivethe vehicleon the road
for approx. 10 minutes.Try to
keep the enginespeedin the
1,700- 2,500rpm range.
ls DTCP1491indicated?
I
(C14'rl
EGRVALVE6PCONNECTOB
lnlermittont tailure, svalem is OK
at thi3 tim6. Checkfoi Poor con'
nections or looso wiro3 at Cl/K
IEGRvalvsl and ECM.
1
a
G10l
IBLK}
Check tor a malfunction in the
EGRvalv6:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EGRvalve 6P
connector.
3. Stantheengineandletit idle
4. Measurevoltage between the
termi'
EGRvalve6P connector
n a l sN o . 4 a n dN o . 6 .
Wi16sideof maleterminals
sG2
ls there batteryvoltage?
PNK
IE.EGRI
Checkthe EGRvalve:
1. Turnthe ignitionswitchOFF
2. Turnthe ignitionswitchON lll).
3. Measurevoltage between the
EGRvalve 6P connectortermi
n a l sN o . 2a n dN o . 3 .
Substitute a known-good ECM
and recheck. It symptom/indica_
tion goes away, replaceth€ original ECM.
ls thereapprox.5V?
(To page11-262)
{GRN/
BLK}
vcc2
{YEL/
BLU)
EmissionControl System
ExhaustGasRecirculation
System(D16Y5enginewith M/T) (cont'dl
\ v
( F r o mp a g e1 1 - 2 6 1 )
ECMCONNECTOR
D {16P)
Check tor open in the wire (SG2
linel:
M e a s u r ev o l t a g e b e t w e e nt h e
E C Mc o n n e c t otre r m i n a l sD 1 0
a n dD 1 1 .
vcc2
(YEL/BLU)
ls thereapprox.5 V?
Repsir open in lhe wire beiween
E C Ml O l l l a n d E G Rv a l v e .
sG2
IGRN/BLK)
Wire sideof femaleterm;nals
EGRVALVE6P CONNECTOR
Checkthe EGRvalve:
1. Turnthe ignitionswitchOFF.
2 , A t t h e s e n s o rs i d e ,m e a s u r e
resistancebetweenthe EGR
valve 6P connectorterminals
No. 1 andNo.2.
EGRL
(WHT/
BLK}
SG2 (GRN/BLK)
Termanal
sideof maleterminals
l s t h e r e c o n t i n u i t yo r r e s i s tanceof 100k0 or higher?
Checkthe EGRvalve:
Measureresistancebetweenthe
E G Rv a l v e 6 P c o n n e c t o tr e r m i
n a l sN o . 1 a n d N o . 3 .
ls there100k0 or higher?
(To pase 11 263)
1 -262
EGRL
{WHT/
BLK}
vcc2
{YEL/BLU}
'l'
T
lFrompage11-262)
ECMCONNECTOR
D I16P'
Chock for rn opon in the wire
{EGRL linel:
the EGRvalvecon
1. Reconnect
nector.
2. Tu.nthe ignitionswitchON (ll).
3. Measurevoltage betweon the
PCM connectorterminalsDg
a n dD l 1 .
WiresideoI femaleterminals
ls thereapprox.1.2V?
Checktor th€ wirc (EGRL line):
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM connectorterminal Dg and
body ground.
Roprir op6n in the wirs botwean
the EGRvalvo.nd th. ECMlD9).
t
Rooair ahort in tho wiro baftr,otn
tho EGRv.lv..nd the ECM lDgl.
EGRVALVE6P CONNECTOR
Ch€ckthe EGRvalve:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EGRvalve 6P
connector.
3. Connectthe battery positive
terminal to EGRvalve 6P connectorterminalNo. 6.
4. Stan the engineand let it id'e,
then connectthe batterynega_
tive terminalto EGRvalve 6P
connectorterminal No, 4,
wire sid6 of lemale te.minals
(cont'd)
EmissionGontrolSystem
ExhaustGasRecirculation
System(Dl6Y5enginewith M/Tl (cont'dl
lFrompage11 263)
Checklor an op€n in the wire (EEGRline):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ECMconnector,
A (32P)trom
the ECM.
3. Checklor continuitybetween
E C Mc o n n e c t o rt e r m i n a lA 7
and the EGRvalve6P connectorterminalNo.6.
J
EGRVALVE
6P CONNECTOR
{C144}
CONNECTOR
A l32P)
Wire side
of female
termtnals
Repairopen in the wiro botween
the EGRvalv6.nd th€ ECM{A71.
Check tor a short in the wire {EEGRlin6l:
C h e c kf o r c o n t i n u i t y b e t w e e n
ECM connectorterminalA7 and
body ground.
J
ls therecontinuity?
Reoairshorl in tho wiro belwe€n
the EGn vake rnd the ECMlA7l.
Check fo. an open in tho wiro
IGNDline):
Checkfor continuity between the
EGRvalve6P connectorterminal
N o . 4 a n db o d yg r o u n d .
2
R6pai. open in th€ wir. between
th6 EGF control solenoid v6lve
and G101.
Substitute 8 known-good ECM
and recheck. It symptom/indication goes away, roplacethe originalECM.
-264
a
I
G101
Q) raur
\
J
System(D16Y5enginel
ExhaustGasRecirculation
The scan tool indicatesDiagnosticTrouble Code {DTC)P1498:A high voltage problem in the ExhaustGas
(EGRlvalvelift sensorcircuit.
Recirculation
-
The MIL has beenreportodon.
DTCP1498is storod.
Probl€mverification:
ResetProce
1. Do the ECM/PCM
dure.
2. Stanthe engine.
ls DTCP1498indicated?
C h e c kf o r a n o p e n i n t h o E G R
valv6 lift sen3or:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe EGRvalve lift
sensor3P (M/T:6Plconnector.
3. Turnthe ignitionswitchON (ll).
4. Measurevoltagebetweenthe
EGRvalve litt sensor 3P lM/T:
6P)connectorterminalsNo. 3
a n dN o . 2 .
I
Intermittent tailure,sy3lem is OK
at lhis time. Check tor poor con'
nections or loose wire3 at C144
|EGRvalveland ECM/PCM.
(C1441
EGRVALVELlFf SENSOR3P {M/T: 6Pl CONNECTOR
cvT:
vcc2
{YEL/BLUI
SG2 IGRN/BLK)
M/T:
ls thereapprox.5V?
Check lor op€n in th€ wire (SG2
line):
Measurevoltage betweenECM/
terminals010 and
PCMconnector
D1l (C18and C28)*.
ls thereapprox.5 V?
Substitute . known-good ECM/
PCM and recheck.ll symptom/
indicrtion goes away, replaco
the original ECM/rcM.
sG2
{GRN/
BLKI
Wir€ side ol lemale terminals
Repairopen in tho wiro betwoen
ECM/PCMlDl1 (Cl8)r) and EGR
valvo lift sensor.
D (16P)
ECMCONNECTOR
vcc2
(YEL/BLUI
sG2
(GRN/BLK)
*:'99 - 00 D16Y5enginewith CVT
Wir€ sideof femaleterminals
C 131P)'
PCMCONNECTORS
Wire sideoI femaleterminals
11-265
EmissionControl System
VentilationIPCVISystem
PositiveCrankcase
tJ
Descripiion
lrcpection
T h e P o s i t i v eC r a n k c a s eV e n t i l a t i o n( P C V )s y s t e m i s
designedto preventblow-by gas from escapingto the
atmosphere.The PCVvalve contains a spring-loaded
plunger.When the enginestarts,the plungerin the PCV
valve is lifted in proportionto intakemanifoldvacuum
and the blow-by gas is drawn directly into the intake
manifold.
1.
2.
Checkthe PCVhosesand connectionsfor leaksand
clogging.
At idle,makesurethere is a clickingsoundfrom the
PCVvalve when the hose betweenthe PCVvalve
and the intakemanifoldis lightly pinchedwith your
fingersor pliers,
D16Y5,D16Y8ongins:
D15Y5,D16Y8,816A2 ongins:
BREATHER
HOSE
BREATHER
HOSE
PCVVALVE
Gentlypinchhere.
Dl6'|116ngin6:
Bl6A2 engins:
-: aLOW-BYVAPOR
-: FnESHAIF
VALVE
PCV
lf there is no clickingsound, checkthe PCVvalve
grommetfor cracksand damage.If the grommet is
OK, replacethe PCVvalveand recheck.
11-266
\
1
EvaporativeEmission(EVAPIControls
Description
The evaporativeemissioncontrolsare designedto minimizethe amount of fuel vapor escapingto the atmosphere.The
systemconsistsof the foliowingcomponents:
EvaporativeEmission (EVAP)Control Canisto]
An EVAPcontrolcanisteris usedfor the temporarystorageof fuel vapor until the fuel vapor can be purgedfrom the
EVAPcontrolcanisterinto the engineand burned.
A.
B. Vapor PurgeControl System
EVAPcontrolcanisterpurgingis accomplishedby drawingfreshair throughthe EVAPcontrolcanisterand into a port
on the intakemanifold.The purgingvacuumis controlledby the EVAPpurgecontrolsolenoidvalve.
VALVEDUTYCONSOLENOID
EVAPPURGECONTROL
ENGINE
AFTER
STARTING
TROLLED
I ' 9 6D 1 6 Y 5e n g i n e , ' 9 6D l 6 Y 7e n g i n e , ' 9 6D 1 6 Y 8
7 1 6 Y 5e n g i n e , ' 9 7D 1 6 Y 7
e n g i n e( s e d a n ) , ' 9 D
r A , K C m o d e l s ,s e d a n :K A , K c '
e n g i n e( c o u p e K
'97
K L i D X ) m o d e l s ,h a t c h b a c ka: l l m o d e l s ) ,
D 16Y8engine(sedan:KA, KC models)l
ABOVE154'F(68'C)
ENGINECOOLANTTEMPERATURE
I
I ' 9 6 D 1 6 Y 8e n g i n e ( c o u p e ) , ' 9 7D 1 6 Y 7e n g i n e
( c o u p e :K L m o d e l ,s e d a n :K L ( L X ) m o d e l ) " 9 7
D16Y8engine(coupe:all models,sedan:KL model)
'98-allmodels,'99-allmodels,'00-allmodelsl
ABOVE154'F{68"C)
ENGINECOOLANTTEMPERATURE
ABOVE32'F (O'C)
INTAKEAIRTEMPERATURE
and
SPEEDABOVEO MILE(OKM/h}
VEHICLE
or
CLUTCHON
l'lc COMPRESSOR
and
ABOVE160"F(41'C)
INTAKEAIRTEMPERATURE
c.
FuelTank Vapor Control System
Whenfuel vapor pressurein the fuel tank is higherthan the set valueof the EVAPtwo way valve,the valveopensand
regulatesthe flow of fuel vaporto the EVAPcontrolcanister.
D. Onboard RefuelingVapor Recovery(ORVRISystem {'99 - 00 models}
Duringrefueling.the oRVR {onboard RefuelingVapor Recovery)vent shut valve openswith the pressurein the fuel
tank.and feedsthe fuel vaporto the EVAPcontrolcanister.
t
(cont'd)
11-267
EmissionControlSystem
EvaporativeEmissionIEVAPIControls(cont'd)
'96 D16Y8ongins (coupol.'97 D16Y8€ngino (coups:all mod€ls,sedan:KL model),'98 D16Y5engine (all mod6lsl,'98
Dl5YB engine {all modols):
BLK/
YEL
{
<
EVAPPURG€
CONTROL
SOLENOIDVALVE
FUEL
TANK
From
No. 15
ALTERNATOR
SP SENSOR
(7.5A)
YEL/
BLU
PRESSURE
SENSOR
.
V€NT SHUT
EVAP
BYPASS
SOLENOID
VALVE
LT GRN
GRN/
BLK
L
L
__
EVAP
TWO WAY
VALVE
BLU
VARIOUS
SENSORS
L TG R N /
WHT
RED/
YEL
INTAKE
MANIFOI.I'
'97 D16Y7engin. (coupa:KL model, sedan: KL {LX) model},38 Dl6\r/ engine:
From
YEL/
BLU
17.5A)
LT G]
GRN/
BLK
FUEL
TANK
PRESSURE
SENSOR
BLU
LT GRN/
WHT
EVAP
BYPASS
RED/
YEL
BLK
VALVE
EVAPCONTROL
CANISTER
EVAP
TWO WA
VALVE
FUEL FILL
CAP
FUELTANK
11-268
No. 15
?:y- --.-'
x
(-.-sK
(9r'
-sPRtNGWASHER
9 . lnstallthemainshaftin the clutchhousing.
1 0 . Placethe transmissionhousingover the mainshaft
and onto the clutchhousing.
' Il . Tightenthe clutch and transmissionhousingswith
several8 mm bolts.
N O T E : l t i s n o t n e c e s s a r yt o u s e s e a l i n g a g e n t
betweenthe housings.
8 x 1.25mm
27 N.m (2.8 kgf.m. 20 lbf'ft)
12. Tap the mainshaftwith a plastichammer.
(cont'd)
13-89
MainshaftThrustClearance
Adjustment(cont'd)
13. Checkthe thrust clearancein the mannerdescribed
oetow.
CAUTION: Measuremenl should be made at room
tempetature.
a. Slidethe mainshaftbaseover the mainshaft.
MAINSHAFT
c. Seatthe mainshaftfully by tappingits end with a
plastichammer.
d. Threadthe mainshaftholder bolt in untjl it just
contactsthe wide surfaceof the mainshaftbase.
e. Zeroa dial gaugeon the end ofthe mainshaft.
f. Turn the mainshaftholder bolt clockwise;stoo
t u r n i n g w h e n t h e d i a l g a u g e h a s r e a c h e di t s
m a x t m u mm o v e m e n t T
. h e r e a d i n go n t h e d i a l
gaugersthe amountof mainshaftend
Dlav.
CAUTION: Turning tho mainshaft holder bolt
more than 60 degreesafter the needle of the dial
g€uge stops moving may damage the transmis_
ston.
DIALGAUGE
MAINSHAFTEASE
07GAJ- PG20.130
b. Attach the mainshaftholderto the mainshaftas
follows:
NOTE:
. Back-outthe mainshaftholderbolt and loosen
the two hex bolts.
. Fit the holder over the mainshaftso its lip is
towardsthe transmission.
. AIignthe mainshafh
t o l d e r . sI i p a r o u n dt h e
groove at the insideof the mainshaftsplines,
then tightenthe hex bolts.
MAINSHAFT
HOLOER
BOLT
g. lf the reading is within the standard,the clearance is correct.
lf the readingis not within the standard.recheck
the shim thickness.
Standard:0.11- O.18mm {0.004- 0.007in}
[--F-e
l6fffi
|
ff
\-/
l\nrx
I/ Borrs
MAINSHAFT
HOLDER
07GAJ- PG20110
MAINSHAFTBASE
07GAJ- PG20130
13-90
07cAJ_ PG20110
Transmission
ReassemblY
1.
Installthe new oil seal
2.
Setthe changePiece.
3.
Installthe shift rod
4.
Installthe steelball'the spring,and the set screw'
5.
Installthe spring washer and changepiece attaching bolt.
6.
Installthe shift rod boots.
8x1.0mm
31 N.m 13.1kg-m,
22lb-ltl
CHANGE
PIECE
SPRING
,
@
/L.256fim
/
t't o'ti"l
B()(
I
{zw"y-6@
@:4
OIL SEAL
Replace.
SPRING
WASHER
q
Setthe springwasherand the washer'
and the shift
1 0 . lnstallthe mainshaft,the countershaft,
fork assemblies.
N O T E :A l i g n t h e f i n g e r o f t h e i n t e r l o c kw i t h t h e
groove in the shift fork shaft.
7.
Installthe oil chamberPlate'
6 x '1.0mm
12 N.m (1.2kg-m,9lb-ft|
SHIFTFORKS
13-91
Transmission
(cont'd)
Reassembly
11. Installthe
c h a n g eh o l d e ra s s e m b l y .
(
13. Measurethe distance@ after mounting the shift
pieceshaft.lf it's incorrect.checkthe installation.
6x1.0mm
15 N.m {1.5kgf.m,
CHANGE
HOLDER
ASSEMBLY
Distance@: 11.9- 12.3mm {0./t7- 0.48inl
12 N.m {1.2kgf.m,9lbtftl
1 2 . Installthe shift pieceand the interlock.then install
the shift pieceshaft.
14. Installthe .everseidler gear and the reverseidler
gearshaft.
REVERSE
IDLERGEAR
REVERSE
IDLE
13-92
15. Installthe reversechangeholder.
1 7 . Installthe oil gutterplate.
1 8 . Bendthe hook of the oil gutterplate,then installthe
16 mm sealingbolt.
6x1.0mm
'15N.m
11.5kgim, 11 lblftl
NOTE: Apply liquid gasket {P/N 08718 0001 or
08718- 0003)to the threads.
BOLT
16mm SEALING
29 N.mt3.0kgl'm,22 lbt'ft}
tl
Instsllthe oil guide plateand the 72 mm thrustshim
into the transmissionhousing.
1 9 . Apply liquid gasketto the surfaceof the transmission housingas shown'
NOTE:
. U s e l i q u i d g a s k e t ( P / N 0 8 7 ' 1 8- 0 0 0 1 o r
08718- 00031.
. Removethe dirty oilfrom the sealingsurface'
. lf 5 minut€s have passedafter applying liquid
gasket,reapplyit and assemblethe housings'
. Allow it to cure at least 20 minutes after assemblv bsforefitlingthe transmissionwith oil'
---
Liqui.lgask€t
(cont'd)
13-93
Transmission
(cont'dl
Reassembly
Installthe dowel pins.
2 1 . I n s t a l lt h e t r a n s m i s s i o nh o u s i n gb y a l i g n i n gt h e
groove in the housingwith the finger on the stop
fl ng.
(
23. Checkthat the snap ring is securelyseated in the
grooveof the countershaftbearing.
Dimension6) as instalt6d:4.6- 8.3 mm
(0.181- 0.327inl
GROOVE
24. Installthe clutch line bracket,transmissionhanger
Lowerthe transmissionhousingwith the snap ring
p l i e r s ,a n d s e t t h e s n a p r i n g i n t h e g r o o v eo f t h e
countershaftbearing.
TRANSMISSION
HOUSING
A and back-uplight switch ctamp,then tighten the
transmission
h o u s i n ga t t a c h i n gb o l t s i n t h e n u m _
beredsequenceshown below.
ATTACHING
BOLTS
8 x 1.25mm
27 N m 12.8kgtm, 20tbt.trl
lar---'o
"W
TRANSMISSION
HANGERA
o
BACK.UPLIGHT
SWITCHCLAMP
13-94
l n s t a l l t h e s t e e l b a l l s ,t h e s p r i n g s ,a n d t h e s e t
screws.
25. Installthe 32 mm sealingbolt
N O T E :A p p l y l i q u i d g a s k e t( P / N 0 8 7 1 8- 0 0 0 1o r
08718- 0003)to the threads.
Installthe back-uplight switchand the transmission
hangerB.
32 mm SEALINGBOLT
25 N.m {2.5 kgl'm,
BACK.UPLIGHTSWITCH
25 N.m 12.5kgt m, 18 lblttl
EALL
\
\
\
8 x 1.25mm
21 N.m (2.4 kgf m,
1 7lbf.ftt
TRANSMISSION
HANGERB
I
I
I
I
\
SETSCREW
'12x 1.0mm
22 N.m (2.2kgf'm,
16 tbt.trl
26. Tightenthe reverseidler gearshaft bolt'
REVERSEIDLERG€AR
SHAFTBOLT
10 x 1.25mm
5a N.rn t5.5 kgl m, {0 lbtftl
13-95
Oil Seals
Replacement
{
Trrn3mirdon Housing:
Clutch Housing:
1.
1.
Removethe oil sealfrom the transmissionhousing.
Removethe oil sealfrom the clutchhousing.
OIL SEAL
Replace.
Install the oil seal into the transmissionhousing
usingthe sp€cialtools as shown,
Installthe oil seal into the clutchhousingusing the
specialtoolsas shown.
HANDLE
07149 - d)l(xxto
HANDTI
0t?a9- 001o(xto
OILSEAL
Replace.
HOUSING
13-96
OIL SEAL
Replace.
GearshiftMechanism
Overhaul
NOTE:
reDlaceany worn or damagedParts.
. Inspectrubberpartsfor wear and damagewhen disassembling;
joint
as shown'
. Installthe springpin and the clip on the change
. Turn the shift rod boot so the hole is facingdown as shown'
. Makesurethe shift rod boot is installedon the shift rod'
I x 1.25mm
22 N.m 12.2kgf.m, 16 lbf.ft)
ffi-:t't:il1ii51i?"'*,
TU
/g3i'51!Exii
V
ExrENsroN
EXTENSfON
ilr'eol.T
MOUNT
\
@2'
\
h
V\
END
EXTENSION
BUSHING
-_.--_-_---
--1'>=2v/,,/ -:liT.i'ff"
BALL SEAT
EXTENSIONEND
WASI{ERB
EXTENSIONROD
.o,-.o*&--ffi{---*,
g
N:
MOUNTING
LEvER
sHrFr
V-oiliiSi[a
.*rr"r,o"-tf
I
BRAcxEr
/
8 x 1.2smm
"u, /
,rar-aoa*,"o
Replace.
6x1.0mm
9.8N.m ('1.0kgt'm,
7 tbr.ftt
xoloen
€9-l--enr
I
u
:-,rro""a,
ii-ri- ri.zrsr.-,
16 tbf.ft)
8x22mm
SPRINGPIN
Replace.
SHIFTI"EVER
--::=t
I
t
-.Q
,,,.
E ,",t.ruaa
9.a-"t't
SHIFTROD
8 x 1.25mm
22 N.m 12.2kgf'm, 16lblftl
,
SHIFTRODBOOT
SPRINGPIN
@
ZW
€lt#
@
CLIP
/
-,\
HOLE
13-97
AutomaticTransmission
"'..'.."...'..'14-1
AutomaticTransmission'....
VariableTransmission
Continuously
14-193
(Cy1l ..........
t ro
AutomaticTransmission
L
Valve Body
14'2
.....'."".'-.-.'
SpecialTools .........
14-139
........'....
Repair....................
14-3
.,....................-......
Description
power Flow
Valve
14"6
......,.................
1,1-1i10
Assembly
14-13
ElestronicControlSystem ..... ................'..'.'..
ATF
Pump
1'l-19
.....'......"
HvdraulicControl
. . . . . . . . . . . ' . . . . . . .1.4. .- 1 4 1
Inspection
.'.'.".'....11-21
HydraulicF|ow......
Body
Main
Valvs
t/t'33
'............
...
Lock-upSystem
y/lnspoction/R.sssembly .'.'.'.'..-.-. 11-112
Disass€mbf
ElectricalSystem
BodY
Valve
Secondsry
14'39
Locations....,.............'......'.............'.,.
Component
Disa$embfy/lnspoction/Rsassembly......'.'.'.'.11-111
PCMCircuit Diagram
'96 - 98 Models) .........'..1/t-40
RegulatorValve Body
lA/T Control Syst€m:
Disa$embly/lnspoction/Rea3sembly..........'...14-1{5
PCMTarminal Volt8ge/MeasuringCondhions
{'96 - 98 Modebl
Servo Body
A/T Control System ............
.".'........ 14-146
Disassombly/lnsp€ction/Reassembly
PCMCircuit Disgram
Lock-upValv6 Body
(A/T Conlrol System: '99 - 00 Modsls) '..........'14-44
Dis$s.mbf y/ln3poction/Rea$embly .'..-.-..'.'.' 11-117
PCMTerminal Voltage/MeasuringConditions
Mainsh!ft
('99 - 00 Models)
til-46
Dkassembly/lnep€ctionReassembly..'...'........14'148
A/T Control System ...
l it-149
rl-48
.............'..........'.
I
Inspoction
....
Proceduros
Troubleshooting
Countsrshaft
Symptom-to-ComPonentChari
'96 - 98 Models'..-.-..."'.'..11-52
Disa$embly/lnspeqtion/Rea3sembly.......'...'..1a-l51
SFiem Efectricaf
11-152
-'99
1+54
.........".
Dba$ombly/Re$s.mblY
...
00 Modols
EloqtricalSystem
14-153
......................
('96
Inspestion
Models)
98
EleclricatTroubl$hooting
14-56
Clutch
Ona-way
Flowcharts
Troubleshooting
Disassembh/lrupoction/Rca$embly .. "'........l4-155
ElectricalTroubleshooting('9!t- 00 Models)
1+81'
Clutch
Troublsshooting Flowchart3
lllustlttcd Ind.x {A48A,B4RATransmlssion)..' 14-156
Lock-upControl Solenoid vslvo A/B AssemblY
14-105
tustr.tod Index (MrnA Transmi$ionl ............til-158
14-160
1+105
RePlacoment
11-162
Rea$emblY
Shift Cont.ol SolenoidValve A/B A3sembly
14-106 Difforrr ial
Test.....,......
........t4-156
14-106
llhdraied Index
Replacement
. 14-167
ln3poction
B.ckhrh
AsssmblY
LinearSolenoid
..-..........11-167
14-107
BoaringRoplacemont
Test.....,.,..........
lil-168
.....14-108
Diftrrsniial CarriorRepl8cemeni .'.-.............'...'
Replacoment......
t4-t 59
Romoval
Oil
Sall
Mainshaft/CountorshaftSpo€dSonsors
1'l'169
Clearance'......'.....'...
ln3tallstion/Sidc
lit'108
Oil
Soal
......'."'...........
Replacemsnt
Torqua Convertcr Housing Boarings
HydraulicSystem
Mlin3haft Besring/Oil Scal Roplac.ment ."..'.. lil-172
Symptom-to-ComponeniChart
r+109
Counio6hatt Betring R.plscem.nt ..'.............14-173
HydraulicSydem
t
4
1
1
3
Housing Boarings
Tranlmission
RoadTe3t
Bearings
Msinsh.ft
/CounteEhaft
Stall Speed
11-171
B!pltcomgnt
1+116
Test
Gear
Rcvo.3s
ldlor
Fluid Level
11-175
lnrtallation
11-117
Checkin9.........."..'.'.....
ParkStop
14-itB
Changing
In3pection/Adiustmsnt...'......'.'............'...."""'14-175
1+119
Testing
Pressure
Transmbgion
Transmission
lil-176
Reassombly
Transmission
. l4-182
............'.'............'..
Plsie
Torquo
Convertet/Drivr
11-122
Rgmoval ..
Transmission
lllustrated Indax
1'l-183
.'..........'.'.'.....
Inrtallation
11.726
Cover'. ....
Transmission/End
.... lil-187
..
Flushing
Cooler
11-128
Hou3ing,.............'.'......'....""..-.-..
Transmission
Torque Conve.ter Housing/ValvoBody ...........14-130 Shift Cabls
RemovaUlnttallation
End Cover
1,1-190
Adiustmont
11-132
lit-191
Lever
.,........
Shift
TransmisgionHousing
Panel
Shift
lndicator
1
4
l
3
i
l
.
.
.
.
.
.
'
.
.
.
.
.
R e m o v a .l . . ' . ' . . . . . .
. . ' . . . . . . . . . . . . . .1. .4. .- 1 9 2
Adiu3tmant
Tolque Convgrter Housing/valvs Body
Hoses
ATF
Coolor
14-136
.............
Rsmoval .........,......
l'l-192
..,............,.,.......
Connection
Valve CaDs
t 4'138
.......'.................
Description
SpecialTools
l.- a
Ref. No.
Tool Number
o
07GAB- PF50101
07GAE- PG40200
or
- PG4O2OA
OTGAE
07HAC- PK4010A
0 7 J A D- P H 8 0 1 0 1
07JAD- PH80200
07LAE- PX40100
07PM - 0010100
07sM - 0010004
OTMAJ- PY4O1
1A
07MAJ- PY40120
07406- 0020400
07406- 0070300
07736- A010004
07746- 0010500
07746- 0010600
07746- 0030100
07749- 0010000
0 7 9 4 7- 6 1 1 5 0 1
,6'\
€)
@)
@@
@
o
@
@
@
@..
@
@
@
@
@
MainshaftHolder
ClutchSpringCompressorBoltAssembly
HousingPuller
Driver Attachment
Pilot,26 x 30 mm
ClutchSpringCompresso.Attachmenr
SCSServiceConnector
BackprobeSet
IVT Oil PressureHose,2210mm
Ay'TOil PressureHose,Adapter
Ay'TOil PressureGauge Set dpanel
A,/TLow PressureGaugeWpanel
AdjustableBearingPulter,25 - 40 mm
Aftachment,62 x 68 mm
Aftachment,72 x 75 mm
Driver40 mm l.D.
Driver
Driver Attachment,68 mm
*07HAE- P150101
can be usedas a substitute.
**Must be usedwith commercially-available _
3/8,, 16slidehammer.
ry
=k
E-E
g
@
I
1
1
1
I
1
,l
'l
1
I
1
1
14-135
14-171
14-' t7'l
14-160,163
14-49
1 4 - 5 01, 1 3
r4-119
1 4 -11 9
14-119
'14-1
19
14-172,173
14-172,'t73,114
14-172,174
14-153,
167.169,170
1+171, 172, 173,17
14-'t7'l
@
lal
o
1 4 - 1 3 31, 8 0
14-160,163
o
€)
e
4
w
o
@
14-2
----a\
/
\<-t-'\26
@
@
@
@
@
@
@
L
a
Description
controlledunit which provides
The automatictransmissionis a 3-elementtorque converterand a dual-shaftelectronically
4 soeedsforward and 1 reverse.
Torque Convertel, Geats,and Clutches
The torqueconverterconsistsof a pump,turbineand stator,assembledin a singleunit.They are connectedto the engine
crankshaftso they turn togetheras a unit as the engineturns.Aroundthe outsideof the torque converteris a ring gear
which mesheswith the starterpinionwhen the engineis being started.The entiretorqueconverterassemblyseryesas a
flywheelwhile transmiuingpowerto the transmissionmainshaft.
The mainshaftis in Iine with the engine
The transmissionhas two parallelshafts:the mainshaftand the countershaft.
The mainshaftincludesthe 1st,2nd and 4th clutches,gearstor 2nd, 4th, reverseand lst (3rd gear is integral
crankshaft.
with the mainshaft,while the reversegear is integralwith the 4th gear).The countershaftincludesthe 3rd clutch,and
gearsfor 3rd,2nd,4th, reverse.1stand park.The gearson the mainshaftare in constantmeshwith those on the countershaft.When certaincombinationsof gearsin transmissionare engagedby clutches.power is transmittedfrom the mainto provideE, ld, E, and E positions.
shaftto the countershaft
ElectronicControl
The electroniccontrol svstem consistsof the PowertrainControl Module {PCM),sensors,a linear solenoid and four
controlledfor comtonabledrivingunderall conditions.The PCMis
solenojdvalves.Shiftingand lock-upare electronically
panel
side
lower
on the passenger's
the
front
under
locatedbelowthe dashboard,
HydraulicControl
The valvebodiesincludethe main vatvebody,the secondaryvalvebody,the regulatorvalvebody,the servobody and the
lock-upvalvebody throughthe respectiveseparatorplates,Theyare boltedon the torqueconverterhousang
The main valve body containsthe manualvalve,the 1-2shift valve.the 2nd orificecontrolvalve,the CPB{ClutchPressure
Back-up)valve,the modulatorvalve.the servo controlvalve,the reliefvalve,and ATF pump gears The secondaryvalve
(Clutch
body containsthe 2-3 shiftvalve.the 3-4shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalveand the CPC
pressureControl)valve.The regulatorvalve body containsthe pressureregulatorvalve,the torqueconvertercheckvalve,
the coolerreliefvalve,and the lock-upcontrolvalve.The servobody containsthe servovalvewhich is integratedwith the
The lock-upvalve body containsthe lock-upshift valve and the lock-uptiming
reverseshift fork, and the accumulators.
valve.The linearsolenoidand the shift controlsolenoidvalveAy'Bare boltedon the outsideof the transmissionhousing,
and the lock-upcontrolsolenoidvalveAy'Bis boltedon the outsideof the torque converterhousing.Fluidfrom regulator
passesthroughthe manualvalveto the variouscontrolvalves.The clutchesreceivefluid from their respectiveteed pipes
or internalhydrauliccircuit.
Shift Control Mechanism
Inputfrom varioussensorslocatedthroughoutthe car determineswhich shiftcontrolsolenoidvalvethe PCMwill activate
a line
Activatinga shift controlsolenoidvalvechangesmodulatorpressure,causinga shift valveto move.This pressurizes
and
B
are
convalves
A
gear,
solenoid
control
The
shift
and
its
corresponding
that
clutch
clutches,
engaging
of
the
to one
trolledby the PCM.
Lock-upMechanism
fluid is drainedfrom the backof the torqueconverter
position,in 3rd and 4th.and in E positionin 3rd, pressurized
In ,Dt1
through a fluid passage,causingthe lock-uppistonto be held againstthe torque convertercover.As this takesplace,the
Togetherwith hydrauliccontrol,the PCMoptimizesthe timing of
mainshaftrotatesat the same as the enginecrankshaft.
the lock-upmechanism.The lock-upvalvescontrolthe rangeof lock-upaccordingto lock-upcontrolsolenoidvalvesA and
B, and linearsolenoid.When lock-upcontrolsolenoidvalvesA and B activate,the modulatorpressurechangesThe lockup controlsolenoidvalvesA and B and the linearsolenoidare controlledby the PCM.
(cont'd)
14-3
Description
(cont'dl
Gear Selection
The shift leverhassix positions:E PARK.E REVERSE,
N NEUTRAL,E 1stthrough 4th gear ranges,E 1stthrough3rd
gear ranges,@ 2nd gear.
Position
De3cription
E PARK
Frontwheelslocked;parkpawl engagedwith pa* on countershaft.
All clutchesreleased.
E REVERSE
Reverse;reverseselectorengagedwith countershaftreversegear and 4th clutchlocked.
N NEUTRAL
All clutchesreleased.
E DRIVE
{1stthrough4th)
Generaldriving;startsoff in 1st,shiftsautomatically
to 2nd,3rd,then 4th,dependingon vehicle
speedand throttleposition.Downshiftthrough3rd,2nd and 1ston deceleration
to stop.The lock-up
mechanismcomesinto operationin @ positionin 3rd and 4th gear.
Ei DRtvE
('lstthrough3rd)
Usefor rapidacceleration
at highwayspeedsand generaldriving;up-hilland down,hilldfiving;stans
otf in 1st,shiftsautomaticallyto 2nd, then 3rd, dependingon vehiclespeedand throttle position.
Downshiftsthrough 2nd to lst on decelerationto stop.The lock-upmechanismcomes into operation
in 3rd gear,
B SECOND
Usefor enginebrakingor bettertractionstartingoff on looseor slipperysurfaces;staysin 2nd
gear,does not shift up and down.
Startingis possibleonly in E and E positionsthroughthe useof a slide-type,neutral-safety
switch.
Automatic Transaxle(A/f, Gear Position Indicator
The Ay'Tgear positionindicatorin the instrumentpanelshowswhich gear has beenselectedwithout havingto look down
at the console.
Clutch€s
The four-speedautomatictransmissionuseshydraulically-actuated
clutchesto engageor disengagethe transmission
gears.
When hydraulicpressureis introducedinto the clutchdrum, the clutchpiston moves.This pressesthe frictiondiscsand
steel platestogether,lockingthem so they don't slip. Poweris then transmittedthroughthe engagedclutch packto its
hub-mountedgear.Likewise,
when the hydraulicpressureis bledfrom the clutchpack,the pistonreleases
the frictiondiscs
and the steelplates,and they are free to slide past each other.This allowsthe gear to spin independentlyon its shaft,
transmittingno power.
lst Clutch
The 1stclutchengages/disengages
1stgear,and is locatedat the end of the mainshaft,just behindthe right sroecover.
The 1stclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the mainshaft.
2nd Clulch
The 2nd clutchengagegdisengages
2nd gear,and is locatedat the middle of the mainshaft.The 2nd clutchis joined
back-to-back
to the 4th clutch.The 2nd clutchis suppliedhydraulicpressurethroughthe mainshaftby a circutrconnected to the internalhvdrauliccircuit,
3rd Clutch
The 3rd clutchengages/disengages
3rd gear,and is locatedat the end of the countershaft.
The 3rd clutchis suoolied
hydraulicpressureby its ATFfeed pipewithin the countershaft.
ilth Clutch
The 4th clutchengages/disengages
4th gear,as well as reversegear,and is locatedat the middleof the mainshaft.The
4th clutchis joined back-to-back
to the 2nd clutch.The 4th clutch is suppliedhydraulicpressureby its ATF feed pipe
within the mainshaft.
14-4
\-a
One-way Clulch
The one-wayclutchis positionedbetweenthe countershaft1stgearand the parkgea.,with the parkgear splinedto the countershatt,The 1st gear providesthe outer racesurface,and the parkgear providesthe inner racesurface.The one-wayclutch
locksup when power is transmittedfrom the mainshaft1st gear to thetountershaft 1st gear.The lst clutchand gears
remainengagedin the 1st,2nd.3rd,and 4th gear rangesin the p!1,p! or L?lposition.
are appliedin the E, E or @ position.
when the 2nd,3rd, or 4th clutches/gears
However,the one-wayclutchdisengages
"speedrange"of the
gears
overrides
the locking
on the countershaft
This is becausethe increasedrotationalspeedof the
the one-wayclutchfree-wheelswith the 1stclutchstill engaged.
one-wayclutch.Thereafter,
zNO CLUTCH
,lTH CLUTCH
1STCLUTCH
MAINSHAFT
COUNTERSHAFT
ONE.WAYCLUTCH
PANKGEAR
3ROCLUTCH
OUTSIDEOF ONE.WAY
CLUTCH
The sprags engage/
disengage
outside
and insideoI the
INSIDEOF ONE.WAY
CLUTCH
Splaned
with counter
shaft
LOCKINGCONDITION
OVER-RIDING
LOCKINGSPEEDCONDITION
14-5
Description
PowerFlow
\ART
POSMON\
E
E
E
1ST
2ND
D]
3RD
4TH
tr
2ND
3RD
E
TOROUE
CONVERTER
o
o
o
o
o
o
o
o
o
o
o
1STGEAR 2ND GEAR 3RDGEAR
2ND
3RD
CLUTCH
CLUTCH
CLUTCH
4TH
CLUTCH
REVERSE
GEAR
o
o
o*,
o*,
o
o
o*1
o
o*1
o
O*r
o+r
o
o
o*1
o*1
o
O: Operates,
x: Doesn'toperate.
*1: Althoughthe 1stclutchengages,drivingpower is not transmittedas the one-wayclutchslips.
*2: The one-wayclutchengageswhen accelerating,
and slipswhen decelerating.
14-6
PARK
GEAR
o
lXl Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmiftedto the countershaft.
E Position
Hydraulicpressureis not appliedto the clutches.Poweris not transmittedto the countershaft.
The countershaftis lockedby the parkpawl interlockingthe parkgear.
TOROUECONVERTER
rST CLUTCH
COUNTERSHAFT
FINALDRIVE
3RD CLUTCH
14-7
Description
PowerFlow (cont'dl
L
lst Gesr(E or @ position)
In lE or E position,
theoptimumgearis automatically
selected
from 1st,2nd,3rd
and4thgears,according
to conditions
suchasthe balance
between
throttleopening(engineload)andvehiclespeed.
pressure
1. Hydraulic
is appliedto the 1stclutch,whichrotatestogetherwiththe mainshaft,
causingthe mainshaft
1st
gear to rotate.
Poweris transmittedto the countershaft1stgear,which drivesthe countershaft
via the one-wayclutch.
Poweris transmittedto the final drive gear,which drivesthe final drivengear.
TOROUE
CONVERTER
MAINSHAFT1ST GEAR
lST CLUTCH
MAINSHAFT
AY CLUTCH
FINALDRIVEGEAR
PARKGEAR
COUNTERSHAFT
1ST GEAR
14-8
2nd Gear {8, E or E position)
E Positionis providedto drive only 2nd gear.
1.
Hydraulicpressureis appliedto the 2nd clutchon the mainshaft,and power is transmiftedvia the 2nd clutchto the
mainshaft2nd gear.
2,
Powet transmitted to the mainshaft 2nd gear is conveyed via tho countorshaft 2nd gear, which drivos the countershaft.
3.
Poweris transminedto the final drivBgear,which drivesthe final drivenge8r.
NOTE: Hydraulic pressureis also applied to the 1st clutch, but since the rotation speed of ths 2nd gear excaadsthat
'lst gear is cut off at the one-way clutch.
of lst gear, power from
TOROUECONVERTER
2ND CLUTCH
MAII'ISHAFT
2I{D GEAR
COUNTEBSHAFT
(cont'd)
14-9
Description
PowerFlow (cont'dl
3rd Gear (bl or bd positionl
1.
Hydraulicpressureis appliedto the 3rd clutch.Powerfrom the mainshaft3rd gear is transmittedto the countershaft
3rd gear.
2.
Poweris transmittedto the final drive gear,which drivesthe tinal drivengear.
NOTE:Hydraulicpressureis also appliedto the 1stclutch,but sincethe rotationspeedof 3rd gear exceedsthat of 1st
gear,powerfrom lst gear is cut off at the one-wayclutch.
TOROUECONVERTER
MAINSHAFT3RD GEAR
MAINSHAFT
COUNTERSHAFT
3RD GEAB
3RD CLUTCH
DRIVENGEAR
14-10
4th cear lE position)
1.
mainshaft4th
Hydraulicpressureis appliedto the 4th clutch,which rotatestogetherwith the mainshaft,causingthe
gearto rotate.
2.
Poweris transmittedto the countershaft4th gear'which drivesthe countershaft'
3.
Poweris transmittedto the final drive gear,which drivesthe final drivengear'
gear exceedsthat of 1st
NOTE:Hvdraulicpressureis alsoappliedto the lst clutch,but sincethe rotationspeedof 4th
gear,powerfrom 1stgear is cut off at the one-wayclutch
TOROUE
MAINSHAFT4TH GEAR
COUNTERSHAFT
FINALORIVENGEAR
14-11
Description
PowerFlow (cont'd)
El Po3ition
1,
Hydraulicpressureis switchedby the manualvalve to the servo valve,which moves the reverseshift fork to the
reverse position. The reverseshift fork engageswith the reverseselector,reverseselector hub, and the countershaft
reversegear.
Hydraulicpressureis also appliedto the 4th clutch.Power is transmitt€dfrom the mainshaftreversegear via the
reverseidler gear to the countershaftreversegear.
The rotation direction of the countershaftreversegear is changedvia the reverseidler gear,
Poweris transmittedto the final drive gear,which drivesthe final drivengear.
TOROUE
MAINSHAFT
COU TERSHAFT
REVERSE
IDLER
REVERSE
SELECTOR
HUB
REVERSE
SETICTOR
FINALON|VENGEAR
14-12
REVERSE
SHIFT
FORK
ElectronicControlSYstem
four solenoid
controtsystemconsrstsof a Powertraincontrol Module(PcM),sensors,a Iinearsolenoidand
The electronac
is located
PCM
The
conditions
all
under
driving
for
comfortable
controlled
electronically
valves,shifting and lock-upare
side
belowthe dashboard,underthe front lower panelon the passenger's
PGM-FI
Control Sy3tem
A/T Control SYstom
Shift Control
Lock-uDControl
14-13
Description
ElectronicControlSystem(cont'd)
Shift Control
The PCM instantaneously
determineswhich gear should be selectedby varioussignalssent from sensors,and actuates
the shift controlsolenoidvalvesA and B to controlshifting.Also.a GradeLogicControlSystemhas beenadoptedto control shiftingin E positionwhile the vehicleis ascendingor descendinga slope,or reducingspeed.
Poshion
8,tr
E
tr
Gear
Shift Control Solenoid
Vslve A
Shift Control Solenoid
Valve B
1st
OFF
ON
2nd
ON
ON
3rd
ON
OFF
4th
OFF
OFF
2nd
ON
ON
Reverse
EON
*See page 14-31for reverseinhibitorcontroldescription.
OFF
Lock-upControl
From sensor input signals,the PCM determineswhether to turn the lock-upON or OFF,and activateslock-upcontrol
solenoidvalveA and/orB accordingly.The combinationof drivingsignalsto lock-upcontrolsolenoidvalvesA and B and
the linearsolenoidpressureis shown in the table below.
Lock-upControl
Solenoid Valvo A
Lock-upControl
SolenoidValve B
Linoar Solonoid
Prggguro
Lock-upOFF
OFF
OFF
High
Lock-up,Half
ON
Duty operation
OFF* ON
Low
Lock-up,Full
ON
ON
High
ON
Duty operation
OFF- ON
Lock-upConditions
LOCK-Up
duringdeceleration
14-14
a
GRADELOGICCONTROLSYSTEM
How it works:
The pCM comparesactualdrivingconditionswith drivingconditionsmemorizedin the PCM,basedon the input from the
vehiclespeedsensor,the throttlepositionsensor,the barometoricpressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile a vehicleis ascendingor descendinga
slope,or reducingspeed.
SIGNALSOETECTED
Judgemenl ot Conirolling Arca
O.iving Resi3lence
. Ascendingmod€
lFuzzyloqicl
. GradualAscendingmode
' Ste€p Ascendingmode
. Oescendingmode
. Gr.du.l Descendingmode
. Steep D6cending mode
14-15
Description
ElectronicControlSystem{cont'dl
L
AscendingControl
When the PCMdeterminesthat the vehicleis climbinga hill in E position,the systemoxtendsthe sngagementareaof
2nd gear and 3rd gear to prevent ths transmissionfrom fr€quently shifting between 2nd and 3rd gears, and between 3rd
and 4th gears,so the vehiclecan run smooth and have more power when needed.Thereare two ascendingmodeswith
different3rd geardrivingareasaccordingto the magnitudeof a gradientstoredin the pCM.
NOTE:
. The PCMmemorycontainsshift schedulesbetween2nd and 3rd gears,and between3rd and 4th gearsthat enablethe
PCM'sfuzzylogicto automatically
selectthe most suitablegearaccordingto the magnitudeof a gradient
. Fuzzylogic is a form of artificialintelligencethat lets computersrespondto changingconditionsmuch like a human
mind would,
DsscondingControl
When the PCM determinesthat the vehicleis going down a hilt in E position,the shift-upspeedfrom 3rd to 4th gear
when th€ throftle is closed becomesfaster than the set speed for flat road driving to widen the 3rd gear driving area.
This, in combinationwith engine brakingfrom the decelerationlock-up,achievessmooth driving when the vehicle is
descending.
Thereare two descendingmodeswith differentdownshift(4 - 3) schedulesaccordingto the magnitudeof a
gradientstoredin the PCM.When the vehicleis in 4th gear,and you are deceleratingon a gradualhill, or when you are
applying the brakeson a steep hill, the transmissionwill downshift to 3rd gear. When you accel6rate,the transmissionwill
then return to 4th gear.
ASCENDINGMODE
DESCENDING
MODE
F
4TH SHIFTING
CHARACTERISIICS
CONTROLAREA
3pe€d
ff.1"11", vehicr.
GRADUAL
ASCENOING
CONTROL
AREA
ff;Tlr.,
vohicre
speed
Docel6rationControl
Whenthe vehiclegoes arounda corner.and needsto first decelerateand then accelerate.
the rcM setsthe datafor deceleration
control to reducethe number of times the transmissionshifts.When the vehicle is deceleratingfrom speedsabove 26 mph
(41km/h),the rcM shiftsthe transmissionfrom 4th to 2nd earlierthan normalto copewith upcomingacceleration.
14-16
.
Circuit Diagram and Terminal Locations-'96
- 98 Modols
IGNITIONSWiTCH
tc1
IOCI(- UPCONTBOL
SOTENOID
VALVEA
IGPl
IGP2
vcc2
TPS
LOCK-UPCONTSOT
soLtNoto valvE I
sG2
SIIIFTCONTFOL
sHrFrc0mioL
B
SOLENOIDVATVE
UI{EARSOLENOIO
14-17
Description
ElectronicControlSystem(cont'dl
L I
CircuitDiagramand TerminalLocations-'99 - O0Models
GNTONSWICH
rcj
,,--b.
PG2
LOCK.UPCONIFOL
SOLEI\Q
D VALVEA
IGP2
v3u
vcc2
sc2
LOCKUPCON'IROL
SOLENODVALVEB
SHFI CONTROL
SHIFTCONTFOL
SOLENOIDVALVEE
L NEAFSOLEIOIO
6NII ONSWICH
14-1 8
HydraulicControl
controlledsolenoids'
and electronically
The hydrauliccontrolsystemis controlledby the ATF pump,valves,accumulators,
TheATFpUmpisdrivenbysp||nesontheendofthetorqueconverterWhichisattachedtotheengine.F|uidfrom
pumpf|owsthroughtheregu|atorva|vetomajntainspecifiedpressurethroughthemainva|vebodytothemanuaIva|
directingpressuretoeachofthec|utches.Theva|vebodyinc|udesthemainvaivebody,theregu|atorvalveb
|ock-upva|vebody,thesecondaryVa|vebody,theservobody,theIinearso|enoid,theshiftcontro|so|enoid
valveAy'Bassemblyand the linassembly,and the lock up controlsolenoidvalveA/B assembly.The shift controlsolenoid
valve A,/Bassemblyis
solenoid
control
lock-up
The
housing.
transmission
ear solenoidare boltedon the outsideof the
housing
converter
boltedon the outsideof the torque
SHIFTCONTROL
SOLENOIOVALVEA/8
ASSEMBLY
LINEARSOLENOID
SERVOBOOY
VALVE
REGULATOR
VALVEBODY
VALVEBOOY
CONTROL
SOLENOIDVALVEA/B
ASSEMBLY
ATF PUMPGEARS
(cont'd)
14-19
Description
HydraulicControl(cont'dl
Msin Valve Body
The main valvebody housesthe manualvalve,the 1-2shift valve,
the 2nd orificecontrolvalve,the cpB valve,the modulator valve'the servocontrolvalve,and the reliefvalve.The primary
functionsof the main valve body are to swatchfluid
pressureon and off and to controlthe hydraulicpressuregoing
to the hydrauliccontrolsvstem.
2ND ORIFICECONTROT
VALVE
1-2 SHIFT VALVE
RELIEFVALVE
VALVE
CONTROL
VALVE
SocondaryValve Body
The secondaryvalvebody is locatedon the main valvebody.The
secondaryvalvebody housesthe 2-3shift vatve,the 3-4
shift valve,the 3-4 orificecontrolvalve,the 4th exhaustvalve,and the
CpCvalve.
3-4 SHTFTV
2.3 SHIFTVALVE
4TH EXHAUSTVALV€
CPCVAL
VALVE
14-20
\
RegulatorValve BodY
valve body consistsof the regulatorvalve'the
The regulatorvalve body is locatedon the main valve body.The regulator
checkvalve,the coolerreliefvalve,and the lock-upcontrolvaive'
torque-converter
VALVE
REGULATOR
VALVE
REGULATOR
BODY
CONVERIER
CHECKVALVE
COOLERRELIEFVALV€
CONTROLVALVE
Lock-upValve BodY
valveis locatedon the regulatorvalvebodv
The lock-upvalvebody with the lock-upshift valveand the lock-uptiming
LOCK,UPSHIFTVALVE
LOCK-UPNMING VALVE
icont d
1+21
Description
HydraulicControl(cont'dl
RegulatorValve
The regulatorvalve maintainsa constanthydraulicpressurefrom the ATF pump to the hydrauliccontrol
system,white
alsofurnishingfluid to the lubricatingsystemand torqueconverter.The fluid from the ATF pump flows through
B and 8,.
The regulatorvalve hasa valveorifice.The fluid enteringfrom B flows throughthe orificeto the A cavity.This pressure
of
the A cavitypushesthe regulatorvalveto the right side,and this movementof the regulatorvalve uncovers
the fluid port
to the torqueconverterand the reliefvalve.The fluid flows out to the torqueconverter,and the relief
valveand regulator
valvemovesto the left side.Accordingto the levelof the hydraulicpressurethrough B, the positionof the regutator
vatve
changesand the amountof the fluid from B' through D and c also changes.This operationis continued.
maantaining
the
line pressure,
NOTE:When used."|eft" or "right" indicatesdirectionon the illustrationbetow.
ENGINENOTRUNNING
ENGINERUNNING
To TOROUECONVERTER Lubrication
STATORSHAFTARM
Stator RoactionHydraulicProssur6Control
Hydraulicpressureincreasesaccordingto torque,are performedby the regulatorvalve using the stator
torque reaction.
The stator shaft is splined with the stator in the torque converter,and its arm end contactsthe regulator
sprangcap. when
the vehicleis accelerating
or climbing(TorqueConvert€rRange),the statortorque reactionacts on the statorshaft,and
the statorarm pushesthe regulatorspringcap in the directionof the arrow in proponionto the reaction.Jne stator
reaction spring compresses,
and th€ reoulatorvalve movesto increasethe line pressurewhich is regulatedby the regulator
valve. The line pressurereachesits maximum when the stator torque reaction reachesits maximum.
TOROUE
CONVERTER
REGULATOR
VALVE
SPRINGCAP
STATOR
14-22
ATORSHAFTARM
\
Servo Body
valvewhich is integratedwith
The servo body is locatedon the secondaryvalve body.The servo body containsthe servo
the
accumulators
the reverseshiftfork,and
2NO ACCUMULA
SERVOBODY
1STACCUMULATOR
3RDACCUMULATOR
SERVOVALVE/SHIFT
FORKSHAFT
NoTE: The illustrationshowsthe'96 -
'98 models;the '99 - 00 modelsare similar'
14-23
Description
HydraulicFlow
GeneralChart ol Hydraulic Pressure
peguratorvarve-_lATFPump-
lra
Linepressure-f-
Moduratorpressure-Clutch pressure
Linearsorenoid
|
pressure
-Torque Converter
t-Lubrication Pressure
Distribution of HydraulicPressur€
. RegulatorValve -]TorqueConverterpressure
Lubricationpressure
F_
iTo regulateLinepressure
.
Manualvalve _
To selectLine pressure_
clutch pressure
'
ModulatorValve
i/odulator pressure_
Shift ControlSolenoidValves
Lock_up
ControlSolenoidValves
LinearSolenoid
___f_
F_
L_
.
.
.
1-2Shift Valve2-3 ShiftValve 3-4 ShiftValve
l
1-
Ctutchpressure
PORTNO. DESCRIPTION
OF PRESSURE
P ORTNO. DESCRIPTION
OF PRESSURE
P ORTNO. DESCRIPTION
OF PRESSURE
1
LINE
6B
LINE
MODULATE
(SHIFTCONTROL
SOLENOID
VALVEB)
41
4THCLUTCH
MODULATE
(LOCK-UP
CONTROL
SOLENOID
VALVEA)
56
LINEARSOLENOID
LINE
6D
MODULATE
(LOCK-UP
CONTROL
SOLENOID
VALVEB)
90
TOROUECONVEBTER
LINE
6D'
MODULATE
(LOCK-UP
CONTROL
SOLENOID
VALVEB)
91
TOROUECONVERTER
LINE
7
LINE
92
TOROUECONVERTER
LINE
8
LINE/CPC
93
ATF COOLER
3"
LINE
4
LINE
9
'10
LINE
20
LINE
20A
2
5
6A
14-24
LINE
94
TOROUECONVERTER
1STCLUTCH
95
LUBRICATION
2ND CLUTCH
YO
2NDACCUMULATOR
97
TOROUECONVERTER
TOROUECONVERTER
LINE
99
SUCTION
X
DRAIN
MODULATE
30
3RDCLUTCH
MODULATE
(SHIFT
CONTROL
SOLENOID
VALVEA)
40
4THCLUTCH
\
@ Position
(ATF)is drawn from (99)and disAs the engineturns,the ATF pump also startsto operate,Automatictransmissionfluid
(1).
pressure
The line pressure(1) is regulated
line
pump
the
becomes
chargedinto (1).Then,ATF flowing from the ATF
(94)
converter through the lock-up
(92)
torque
of
the
pressure
enters
inlet
by the regulator valve. The torque conv€rter
pressurefrom rising'
prevents
converter
the
torque
valve
(901.
ch€ck
converter
torque
The
shift valve and dischargesinto
Underthis condition,the hydraulicpressureis not appliedto the clutches'
"1eft"or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
14-25
Description
HydraulicFlow (cont'd)
L?jPosition
The line pressure(1) flows to the manualvalve and the modulatorvalve.The line pressure(1)
changesthe trnepressure
(4) and (25)at the manualvalve.and changesto the modulatorpressure
at the modulatorvalve.But the moouratorpressure (6) does not flow to each shift valve becauseshift control solenoidvalvesA and B
are turned oN by the pcM. The
line pressure(4) passesthroughthe cPB valveand the cPc valve.and changesto the line pressure(s),
th;n flows to the
1-2shift valve.The line pressure{S)from the l-2 shift valvechangesto the 2nd clutchpressure(20)
at the 2-3 shift valve.
The 2nd clutch pressure(20) is appliedto the 2nd clutch.and the 2nd clutch is engaged.The
line pressure(4) passes
throughthe 1-2shift valve and the orifice,and changesthe lst clutchpressure,The 1stclutchpressure(10)
atsoflows to
the 1stclutch.However,no power is transmittedbecauseof the one_wayclutch.
NOTE:When used,"Ieft" or "right" indicatesdirectionon the hvdrauliccircuit.
14-26
E! or l8! Position
1.
lst Gear
The flow of fluid throughthe torqueconvertercircuitis same as in E position,The line pressuretlows to the manual
valveand the modulatorvalve.The line pressurechangesto the modulatorpr€ssure(6)at the modulatorvalveand to
the line pressure(4)at the manualvalve.The modulatorpressure(61flows to the lsft end of the 1-2shift valveand the
3-4 shiftvalvebecauseshift controlsolenoidvalveA is turnedOFFand B is turnedON by the PCM.The 1-2shiftvalve
is moved to the right side.The line pressure(4) changesto the lst clutchpressure(10)at the 1-2shift valve and the
oritice.The lst clutchpressure(10)is appliedto the 1st clutchand tho 1st accumulator;consquently,the vehiclewill
move as the enginepower is transmitted.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
(cont'd)
14-27
Description
HydraulicFlow (cont'd)
2nd G.!r
As tha speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalve
A is turnedoN by meansof the
PCM The modulatorpressure{64} in the left end of the 1-2 shift valve is r€leased
by turning shift controtsotenoid
valve A oN The 1-2 shift valve is moved to the left side and uncoversthe port
to allow line pressure{5) to the z-3
shift valve. The line pressure(5) changesto the 2nd ctutch pfessure
l2O)at the 2-3 shift valve. The 2nd clutch pressure
(20)is appliedto the 2nd clutch,and the 2nd clutchis engaged.
Fluid flows by way of:
- Line Pressure(4) + cPB varve - Line pressure(s) * 'r-2
shift varve - Line pressure(5) * 2-3 shift varve
- 2nd ClutchPressure(20)+ 2nd Clutch
The hydraulic pressurealso flows to the 1st clutch. However,no power is transmittod
NOTE:When used,"|eft" or ,,right,,indicatesdirectionon the hydrauliccircuit.
14-28
becauseof the one-way ctutch.
I
3.
3rd Gear
As the soeedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveB is turned OFFby meansol the
pCM. Shift controlsolenoidvalve A remainsON. The modulatorpressure(6) flows to the right end of the 1-2 shift
valve and the left end oJ the 2-3 shift valve. The 2-3 shift valve is moved to the right side by the modulator pressure
(68).The 2-3 shift valvecoversthe port to stop line pressure(5)to the 2nd clutchand uncoversto the 3-4 shift valve
(30)at the 3-4
as the 2-3 shift valve is movedto the right side.The line pressure(5) becomesthe 3rd clutchpressure
is
engaged'
(30)
3rd
clutch
pressure
and
the
to
the
3rd
clutch,
is applied
shiftvalve.The 3rd clutch
Fluid flows by way of:
- Line Dressure(4)* CPBValve- LinePressure(5)* 1-2ShiftValve- LinePressure(5)* 2-3ShiftValve
- Line Pressure(5)* 3-4 ShiftValve- 3rd ClutchPressure(30)- 3rd Clutch
The hvdraulicpressurealso flows to the 1st clutch.However,no power is transmittedbecauseof the one-wayclutch
as in 2nd gear.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
NOTE:When used,
14-29
Description
HydraulicFlow lcont'dl
4th Goar {E Position}
As the speedof the vehiclereachesthe prescribedvalue,shift controlsolenoidvalveA is turned OFFbymeans
ofthe
PCM Shift control solenoidvalve B remainsoFF. The modulatorpressure(6) flows to the left
end of the t-2 shift
valve and the left end of the 3-4 shift valve.The modulatorpressure(64) in the left end of the 1-2shift
valve equals
the modulatorpressure{68) in the right end of the 1-2shift valve,the 1-2 shift valve remainsat left
side by the tension of the valvespring.
The 3-4 shift valveis movedto the right side by the modulatorpressure(64).The 3_4shift valve
coversthe port to the
3rd clutchand uncoversthe port to the 4th clutchas this valve is movedto the right side.The 4th clutchpressure(4.1)
from the 3-4 shift valve becomesthe 4th clutch pressure(40) at the manual valve.The 4th clutch pressure(401
is
appliedto the 4th clutch,and the 4th clutchis engaged.
Fluidflows by way of:
- Linepressure(4)* CPBValve- Line Pressure(5)+ 1-2Shift
Valve- Linepressure(5)* 2-3 ShiftValve
- LinePressure(5)- 3-4 ShiftValve- 4th Clutchpressure(41)+
ManualValve_ 4th Clutchpressure(40)
* 4th Clutch
The hydraulicpressurealso flows to the lst clutch.However,no power is transmittedbecauseof the
one-waycrutch
as in 2nd and 3rd gear.
NOTE:When used,"|eft" or "right,,indicatesdirectionon the hydrauliccircuit.
1 4-30
L
E Position
pressure(1) changesto the
The flow of fluid through the torque conveftercircuitis the same as in E position The line
(3')at the 'l-2shift valve
pressure
(3)
line
to
the
pressure
changes
line pressure(3)and flows to the l-2 shift valve.The iine
(Reverserangeposition)and uncoversthe port to
and flows to the servovalve.The servovalveis movedto the right side
1-2shiftvalveflows throughthe servovalveto
pressure
the
from
The
line
{3')
allow line pressure{3") to the manualvalve,
pressure(40)is appliedto the 4th clutch,and
(40).
4th
clutch
pressure
The
clutch
the
4th
the manualvalve and changes
the 4th clutchis engaged,
ReverseInhibitor Control
(10 km/h)'the PCMoutputsthe
Whenthe E positionis selectedwhile the vehicleis movingforwardat spe€dsover 6 mph
oFF,shift controlsolenoid
1stspeedsignalto shift controlsolenoidvalvesA and B; shiftcontrolsolenoidvalveA is turned
port
line pressure(3') to the
stop
to
valve B is turned ON. The 1-2 shift valve is moved to the right side and coversthe
(40)
pressure
is not appliedto the
servovalve.The line pressure(3' )is not appliedto the servovalve,and the 4th clutch
4th clutch, as a result, power is not transmitted to the reversedirection'
'left" or "right" indicatesdirectionon the hydrauliccircuit'
When used.
14-31
Description
HydraulicFlow (cont'd)
lll Position
The flow of fluid through the torque convertercircuitis the same as in E position.The line pressure(1) changes
to the
line pressure(3)and flows to the l-2 shift valve.The line pressure(3)changesto the line pressure(3,)at
the 1-2shift valve
and flows to the servovalve.The servovalveis movedto the right side (Reverserangeposition)and uncovers port
the
to
allow line pressure(3") to the manualvalveas in @ position.The line pressure(3") from the servovalveis Intercepted
by
the manualvalve.However,hydraulicpressureis not suppliedto the clutches,and the power is not transmitted.
NOTE:When used,"|eft" or "right" indicatesdirectionon the hydrauliccircuit.
14-32
Lock-upSystem
\
Lock-upClutch
1.
Ooeration(clutchonl
with the lock-upclutch on, the fluid in the chamber betweenthe torque convertercover and the lock-uppiston is drained
off, and the converterfluid exertspressurethrough the pistonagainstthe torque convertercover,As a result,the convener turbine is lockedto the conveftercover.The effect is to bypassthe converter,therebyplacingthe vehiclein direct drive
PISTON
LOCK.UP
DAMPERSPRING
The power flows by way ot:
Engine
{
Driveplate
i
Torqueconvertercover
I
Lock-uppiston
Damperspring
I
Turbine
Mainshaft
ODeration{clutch off}
"clutch on." As a result,the lock-uppiston moves away from
With the lock-upclutch off, the fluid flows in the reverseof
the convertercover,and the torque converterlock-upis releassd.
TURBNE
Engine
t
Driveplate
I
Torqueconvenercover
{
Pump
I
Turbine
TOROUECOI{VERTER
COVER
\
Mainshaft
(cont'd)
MAINSHAFT
14-33
Description
Lock-upSystem(cont'd)
In B.rlposition,in 3rd and 4th, and lDl_positionin 3rd.
pressurized
fluid is drajnedfrom the back of the torque
converterthrough a fluid passage.causingthe lock-up
pistonto be held againstthe torque convenercover.As
this takesplace,the mainshaftrotatesat the samespeed
as the engine crankshaft,Togetherwith the hydraulic
c o n t r o l ,t h e P C M o p t i m i z e dt h e t i m i n g o f t h e l o c k _ u p
system.Under certainconditions,the lock_upclutch is
appliedduringdeceleration,
in 3rd and 4th gear.
The lock-upsystemcontrolsthe rangeof lock_upaccord_
ing to lock-upcontrol solenoidvalvesA and B. and the
linearsolenoid.When lock-upcontrolsolenoidvalvesA
and B activate,modulator pressurechanges.Lock_up
controlsolenoidvalvesA and B and the linearsolenoid
a r e m o u n t e do n t h e o u t s i d eo f t h e t o r q u e c o n v e r t e r
housing.and are controlledby the pclvl.
TOROUECONVERTER
.
LOCK.UPCONTROL
VALVE
Lock-upConditions/Lock-upControl SolenoidValves/
LinearSolenoid Pressure
A
B
OFF
OFF
High
Lock-up.Half
ON
Dutyoperation
OFF- ON
Lock-up.Full
ON
ON
High
Lock-up
during
deceleration
ON
Dutyoperation
OFF* ON
Low
Lock-up
Conditions
Lock-upOFF
TOROUECONVERTER
CHECI(VALVE
RELIEFVAI-VE
Lock-upControl
Solenoid Valve
Lineal
Solenoid
Pressure
LOCK.UPCONTROL
SOLENOIDVALVE
MODULATORPRESSURE
LOCK.UPTIMING
VALVE
^
VALVE
r______rr
r cooLER RELTEF
.--
LINEARSOLENOIDPRESSURE
ATFPUMP
14-34
I
No Lock-up
.
.
.
Lock-upControlSolenoidValveA: OFF
Lock-upControlSolenoidValveB: OFF
High
LinearSolenoidPressure:
fluid regulatedby the modulatorworks
The pressurized
on both endsof the lock-upshiftvalve.Underthis condition, the pressuresworking on both ends of the lock-up
shift valveare equal,the lock-upshift valve is movedto
the right side by the tensionof the valve spring alone.
The fluid from the ATF pump will flow through the left
side of the lock-upclutchto the torqueconvener;that is,
the lock-upclutchis in OFFcondition.
TOROUE
CONVERTER
"left" or "right" indicatesdirection
NOTE:When used,
circuit.
on the hydraulic
LOCK.UPCONTROL
SOLENOIDVALVE
MOOULATORPRESSURE
RELIEFVALVE
LOCK-UPTIMING
VALVE
LINEARSOLENOIOPRESSURE
9
L
] I COOLER RELIEF VALVE
ATFPUMP
(cont'd)
14-35
Description
Lock-upSystem(cont'dl
Half Lock-up
.
Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValve8: DutyOperation
OFF- ON
LinearSolenoidPressure:
Low
The PCMswitchesthe solenoidvalveA on to releasethe
modulatorpressurein the left cavityof the lock_upshift
valve.The modulatorpressurein the right cavityof the
lock-upshift valve overcomesthe springforce;thus the
lock-upshift valveis movedto the leftside.
The line pressureis then separatedinto the two pasTOROUE
CONVERTER
sagesto the torque converter:
Torque ConverterInner pressure:enters into right
sadeto engagelock-upclutch
TorqueConverterBackpressure:entersinto left side
to diseogagelock-upclutch
LOCK.UPCONTROL
VALVE
The back pressure(F2)is regulatedby the lock-upcontrol valve, whereasthe position of the lock-uptiming
valve is determinedby the linearsolenoidDressureand
LOCK.UP
CONTROL tensionof the valvespring.Also the positionof the lock_
up control valve is determined by the back pressureof
SOI.TNOID
VALVE
the
lock-upcontrol valve, torque converter pressurereg_
A
8
ulatedby the torqueconvertercheckvalve,and modula_
tor pressuredeterminedby the lock-upcontrolsolenoid
valve B. The PCMswitchesthe lock-upcontrolsolenoid
valve B on and off rapidly{duty operation}undercertain
conditions to regulate the back pressure(F2)to lock the
torque convener properly.
TOROUECONVERTER
CHECKVAI-VE
NOTE:When used, "left" or "right" indicatesdirection
on the hvdrauliccircuit.
MODULATOR
PRESSURE
RELIEF VALVE
LOCK-UPTIMING
VALVE
^
cooLERRELTEF
valvE
L____J'r
LINEARSOLENOTD
PRESSURE
ATF PUMP
14-36
Full Lock-up
. Lock-upControlSolenoidValveA: ON
. Lock-upControlSolenoidValveB: ON
o LinearSolenoidPressure:
High
W h e n t h e v e h i c l es p e e df u r t h e r i n c r e a s e st.h e l i n e a r
s o l e n o i dp r e s s u r ei s i n c r e a s e dt o h i g h i n a c c o r d a n c e
with the linearsolenoidcontrolledbv the PCM.
T h e l o c k - u pt i m i n g v a l v e o v e r c o m e st h e s p r i n g f o r c e
and moves to the left side. Also, this valve closesthe
fluid port leadingto the left side of the lock-upcontrol
Under this condition.the modulatorpressurein the left
s i d e o f t h e l o c k - u pc o n t r o l v a l v e h a d a l r e a d y b e e n
releasedby the lock-upcontrol solenoid valve B; the
lock-upcontrol valve js moved to the left side. As this
t a k e s p l a c e ,t h e t o r q u e c o n v e r t e r b a c k p r e s s u r ei s
releasedfully. causingthe lock-upclutchto be engaged
fully.
TOROUECONVERTER
LOCK.UPCONTROL
SOLENOIDVALVE
"|eft" or "right" indicatesdirection
NOTE:When used,
on the hvdrauliccircuit.
MODULATORPRESSURE
RELIEFVALVE
LOCK.UPTIMING
VALVE
'r
LINEARSOLENOIOPRESSURE
vALvE
,-.r' cooLERRELTEF
ATFPUMP
{cont'd)
14-37
Description
Lock-upSystem(cont'dl
DecelerationLock-up
.
.
Lock-upControlSolenoidValveA: ON
Lock-upControlSolenoidValveB: DutyOperation
OFF- ON
a LinearSolenoidPressure:
Low
The PCM switchessolenoidvalve B on and off rapidly
u n d e r c e r t a i nc o n d i t i o n sT
. h e s l i g h t l o c k - u pa n d h a l f
lock-upregionsare maintainedso as to lock the torque
converterproperly.
NOTE:When used, "left" or "right" indicatesdirection
on the hydrauliccircuit,
TOROUECONVERTER
LOCK-UPCONTROL
SOLENOIDVALVE
MOOULATORPRESSURE
RELIEFVALVE
LOCK.UP
TIMING
VALVE
LINEARSOLENOIDPRESSURE
COOLERRELIEFVALVE
ATF STRAINER
ATFPUMP
1434
ComponentLocations
CONTROL
POWERTRAIN
MODULE(PCM)
TRANSAXLE{A/TI
GEARPOSITIONSWITCH
COUNI€RSHAFT
SPEEDSENSOR
SOI,TNOIDVALVE
ASSEMBLY
SOLENOIDVALVE
ASSEMBLY
SPEEDSENSOR
1+39
PGMGircuitDiagram(A/T ControlSystem:'96 - 98 Modelsl
-HOODFUSE/RELAY
UNDEfl
BOX
U N D E RD A S H
N o . l 3( 1 5 A ) FUSE/REIAY
8OX
(80A1N0.42
No.41
l40A)
No.47{7.5A)
/8LU
YEUBLK
c10
424
Arp
Np
BtK
At0
Btx
423
lon,^o l r,, lotrr
'96:BLU/BED
'97,'98rGFN/BLK
l 6lt l 3]t lot*
824 t88 tB17
'96:GRN 8LU
GAUGE
ASSEMBTY
A,TGEAR
POSITION
INDICATOR
'96:BLU/RED
'97,'98:
GRN/8L
LTGRN
BLK/BTU
F-
BTK/BI.U
F_wHr
F-
GRN
GRN
f-
GRN
BLU
F-
Bru
RED
GRNiELK
NorE: :ro5v
t
: r o1 2 v
T
T T T
YEL
GRN BLU
CONNECTOR
SERVICE
CHECK
NCSG ILS-
l
ISHA
ISHB
ltc A
ltc B
WHT
RED
t
ILS+
l
l
'
It Tl
l
l
T
II
Lo-l
MAINSHAFT
SENSOR
SPEED
BRNiBLK
-UP CONTROL
SHIF'CONTROL LOCK
VALVE
VALVE SOLENOIO
SOTENOID
ASSEMELY
ASSEMEI-Y
I
-
G1 0 1
PCMTerminelLocations
14-41
PCMTerminalVoltage/MeasuringGonditions('96 - 9g Models)
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shown for the connectorterminalsthat relateto the A"/Tcontrol
system.The other PCMterminalvoltageand measuringconditionsare describedin sectionI l.
A l32P)Conn€ctot
B I25P)Connector
C (31P)Conngctor
D (16P)Connector
PCMCONNECTOR
A I32P}
Terminal Numbor
Signal
Dcacription
MoasuringConditions/Te.minalVoltage
- see section 1I -
A1 to A8
A9
LG1
Ground
A10
PG1
Ground
A11
IGPl
Power supply system
412 to A2l
With ignitionswitchON (ll):8atteryvoltage
With ignition switch OFF:0 V
- see section I I -
Ground
423
PG2
Ground
A'24
IGP2
Power supply system
A25 to A32
With ignitionswitchON (ll):Batteryvoltage
With ignition switch OFF:0 V
- seesectionl1 -
PCMCONNECTORB (25P}
Terminal Number
Signal
B1
LS-
Description
MeasuringConditions/T6rminalVoltage
Linearsolenoidpower supply
negativeelectrode
lgnitionswitchON (ll):Pulsingsigna.
Linearsolenoidpowersupply
positive electrode
lgnitionswitchON (ll):Pulsingsignal
SHA
ShittcontrolsolenoidvalveA
control
In 2nd gear and 3rd gear in E, E position,
and in @, @ position:Batteryvoltage
In lst gearand 4th gear in E. E position:0 V
B4
LCB
Lock-upcontrol solenoid valve B
control
Whenfull lock-up:Batteryvoltage
When half lock-up:Pulsingsignal
B5
LCA
Lock-upcontrolsol€noidvalveA
control
When lock-upis ON: Batteryvoltage
With no lock-up:0 V
82
86 to 87
B8
B gt o 8 1 0
14-42
Not used
ATP D3
IVT g6ar positionswitch@ position signalinput
Not used
l n E p o s i t i o n ;O V
In otherthan E position:Batteryvoltage
I
PCMCONNECTORB {25P1{cont'dl
Measuring Conditions/TerminalVohage
Description
TerminalNumber
Signal
811
SHB
Shift controlsolenoidvalveB
control
B't2
SLU
Interlockcontrol
813
D4 IND
D4 Indicatorlight control
When ignitionswitchis firstturnedON (ll):
Batteryvoltage for two seconds
In E position:Bafteryvoltage
B't4
NMSG
Mainshaftspeedsensorground
Always:0 V
E tc
NM
Mainshaftspeedsensorsignal
input
Dependingon enginespeed:Pulsingsignal
When engineis stopped:0 V
816
ATP R
Ay'Tgear position switch E
positionsignalinput
I n E p o s i t i o n0: V
In otherthan E position:Batteryvoltage
817
ATP 2
A/T gear position switch E position signalinput
I n E p o s i t i o n0 :V
Battery
voltage
In orherthanE position:
position,
In 1stgearand 2nd gear in -q1,q11
and in E] position:Batteryvoltage
[Dr-position:0 V
In 3rd gearand 4th gear in lD.J,
When ignitionswitchis ON (ll),brakepedal
deoressedand accelerator
Dedalreleased:0 V
Not used
8 1 8t o 8 2 1
s22
NCSG
Countershattspeedsensorground
Alwaysr0 V
B23
NC
speedsensorsignal
Countershaft
input
Dependingon vehiclespeed:Pulsingsignal
Whenvehicleis stopped:0 V
B24
ATP D4
Ay'Tgear position switch lor position signalinput
A,/Tgear position switch E and
N positionsignalsinput
InEposition:0V
In otherthan 6 position:5 V
ATP NP
:
I n E a n dE p o s i t i o n0sV
Batteryvoltage
In otherthanE andN] positions:
C {31P)
PCMCONNECTOR
TerminalNumber
Signal
Description
- seesection11 -
Cl to C6
c1
Servicechecksignal
With ignition switch ON (ll) and servicecheck
connectoroDen;5 V
With ignition switch ON (ll) and servicecheck
connectorconnectedwith sDecialtool: 0 V
- seesection11-
Back-uppower system
Always batteryvoltage
- seesection'11-
C8 to Cg
c10
Measuring Conditions/TerminalVoltage
VBU
C 1 1t o C 3 1
D (16P}
PCM CONNECTOR
TerminalNumber
Signal
Description
- seesection11-
Dl to D4
D5
D 6t o D 1 6
MeasuringConditions/TerminalVoltage
STOPSW
Brakeswitchsignalinput
Batteryvoltage
Brakepedaldepressed:
0V
Brakepedalreleased:
- seesection1 l -
14-43
PCMGircuitDiagram(A/T GontrolSystem:'99- 00 Models)
UNOEF
DASI
FL]SE/FELAY
BOX
ta T06 TDr.
UISEF,DASH
FISSIELYmX
r,Jo
25(75A)
GAUGE
ISSEMBLY
Lr GRN -----l
L
l"--
eultru----iF
LTGRll
INT€RLOCK
CCNTFOL
uN|l
erk€Lu
ert*rll
r-->l
l__
14-44
sL!
I
I
I STARTEF
CONNECTOF
1r6P)
Y
II
I
SPEEO
SENSOF
f7
II
I
I
ECI
"*ttot**" 1*u)
ttt*'"
,5-,
I
II
SHIFICONTFOL
solEt€to vALvE
ASSEMSLY
fl**',*"
I
BLK
I
G401
PCMTerminalVoltage/Measuring
Conditions('99- 00 Models)
A/T ControlSystem
The PCMterminalvoltageand measuringcondjtionsare shownfor the connectorterminalsthat are relatedto the A//Tcontrol system,The other PCMterminalvoltageand measuringconditionsare describedin section,11.
PCMConnoctorTgrminrl Locations
PCMCONNECTOR
A {32PI
Terminal Numbel
A10
Signal
5L5
A14
D4 IND
428
ILU
A.32
STOPSW
Description
M€asuring Conditions/TerminalVoltage
Servicechecksignal
With ignitionswitchON (ll)and servicecheck
connectoropen:Approx, 5 V
With ignitionswitchON (ll)and servicecheck
connectorconnectedwith sDecialtool: 0 V
E indicatorlight control
When ignitionswitchis first turnedON (ll):
ApDrox. 10 V for two seconds
In E position:Approx.1OV
InterlockControl
When ignitionswitchON (ll),brakepedal
pedalrereaseo:
depressed,
and accelerator
Batteryvoltage
Brakeswitchsignalinput
Brakepedal depressed:battery voltage
Brakeoedalreleased:0V
PCMCONNECTOR
8 (25P}
Terminal Number
Signal
B1
!GP1
Power supply system
PGl
Ground
B8
LS AM
B9
Descdption
MeasuringCondhions/TorminalVoltag6
With ignitionswitchON (ll):Batteryvoltage
With ignition switch OFF:0 V
Linearsolenoidpowersupply
negativeelectrode
With ignitionswitchON (ll):Pulsingsignal
IGP2
Power supply system
With ignition switch ON (ll): Bafteryvoltage
With ignition switch OFF:0 V
810
PG2
Ground
917
LS AP
B20
14-46
With ignitionswitchON (ll):Pulsingsignal
Ground
VBU
822
Linearsolenoidpower supply
positiveelectrode
Back-uppowersupply
Ground
Always battery voltage
D {16P)
FCM CONNECTOR
D1
LCA
Lock-upcontrolsolenoidvalveA
control
When lock-upis ON: Batteryvoltage
With no lock-up:0 V
SHB
ShiftcontrolsolenoidvalveB
control
In E position,in 1stand 2nd gearin E, E
position: Batteryvoltage
ln 3rd gear in E, E, in 4th gear in E posit i o n ; 0V
LCB
Lock-upcontrolsolenoidvalveB
control
Whenfull lock-up:Batteryvoltage
With half lock-up:Pulsingsignal
Not used
D4
D5
VB SOL
D6
ATP R
SHA
o
Measuring Conditions/TorminalVohage
Signal
D3
\
Do3cription
Terminal Number
Lock-upcontrolsolenoids,shift
controlsolenoidsand linear
solenoidpower supplyelectrode
with ignitionswitchoN (ll):Batteryvoltage
With ignitionswitchOFF:0 V
Ay'Tgear position switch
E positioninput
tnEposition:0V
Approx.10V
In otherthanE position:
ShiftcontrolsolenoidvalveA
control
In E] position,in 2nd and 3rd gearin p!, [Q]
position: Batteryvoltage
In 1stgear in E, @ position,in 4th gear in El
Dosition:0 V
D8
ATP D3
A/T gear position switch
E positioninput
In E position:0V
In otherthan @ position:Approx.10 V
D9
ATP D4
Ay'Tgear position switch
E position switch
0V
In El position:
Approx.5 V
In otherthanE position:
D10
NC
Countershaftspeedsensorsignal
input
Dependingon vehiclespeed:Pulsingsignal
Whenvehicleis stooped:0 V
D11
NM
Mainshaftspeedsensorsignal
Inpur
Dependingon enginespeed:Pulsingsignal
When engineis stopped:0 V
D't2
NMSG
Mainshaftspeedsensorground
D13
ATP NP
Ay'Tgear position switch E and
E positioninput
:
I n E a n dE p o s i t i o n0sV
Approx.10V
In otherthanE andE positions:
D14
AfP 2
Ay'Tgear position switch
E positioninput
tnEposition;0V
Approx.10V
In otherthanE position:
D16
NCSG
Countershaftspeed sensor
ground
14-47
Troubleshooting Procedures
Chcckingthe DiagnosticTrouble Code IDTC)
with an OBD ll Scan tool or Honda PGM Tester
when the PCMsensesan abnormalityin the input or output systems,the pl indicatorlight in the gauge assemblywill
blink.When the 16PData Link Connector(DLC)(locatedunder the dash on the driver,sside) is connectedto the OBD ll
ScanTool or HondaPGM Testeras shown,the scantool or testerwill indicatethe DiagnosticTroubleCode (DTC)when
the ignitionswitchis turnedON{ll).
OBD ll SCANTOOLor
HONDAPGMTESTER
DAYALINKCONNECTOR
{16P}
lf the El indicatorlight or the MIL hasbeenreportedon, or lf a driveabilityproblemis suspected,
follow this procedure:
1. Connectthe OBD ll ScanTool (conformingto SAE J19781or HondaPGMTesterto rhe 16p DLC.(Seethe OBD ll Scan
Tool or HondaPGMTesteruser'smanualfor specificinstructions.lf you are usingthe HondaPGMTester,makesure it
is set to the SAE DTCtype.)
2. Turn the ignitionswitchON (lll, and observethe DTCon the screen,
3, Recordall fuel and emissionDTCS,A/T DTCS,and freezedata.
4 lf there is a fuel and emissionsDTC,first checkthefuel and emissionssystemas indicatedbythe DTC(exceptfor DTC
P0700).DTCP0700meansthere is one or more A,/TDTC,and no problemswere detectedin the fuel and emissionscircuit of the PCM.
5. Write down the radiostationoresets.
6. Resetthe memorywith the PGMTesteror by removingthe BACKUP fuse in the passenger's
under-dashfuse/relaybox
for more than 10 seconds.
7. Drivethe vehiclefor severalminutesat speedsover 30 mph (50 km/hr),and then recheckfor DTCS.lf the A"/TDTC
returns,go to the Symptom-toComponentCharton pages14-52and 14-53for'96 - 98 models,and pages14-54and
14-55for the'99 - 00 models,lf the DTCdoes not return,there was an intermittentproblemwithin the circuit.Make
sureall pins and terminalsin the circuitare tight, and then go to step g.
8. Resetthe radiopresetstations,and setthe clock.
14-44
Chockingth€ DiagnosticTroubleCode (DTCI
with the ServicoCheckConneqtorand Sp€cialTool
Whenthe PCMsensesan abnormalityin the inputor outputsystems,the @ indicatorlight in the gaugeassemblywill blink
When the Service CheckConnector(locat€d under the dash on the passengsrside) is connectedwith the special tool as
TroubleCode(DTC)when the ignitionswitchis turnedON (ll).
shown,the E indicatorlightwill blinkthe Diagnostic
When the E indicator light has been reported on, connectthe ServiceCheckConnectorwith the specialtoo'.
Thenturn ON (ll)the ignitionswitchand obssrvethe E indicatortight.
GAUGEASSEMBLY
SERVICE
CHECK
CONNECTOR
I2PI
CONNECTOB
07PAZ-0010100
Codes 1 through 9 are indicated by individual short blinks, Codes 10 and above are indicat€d by a sories of long and short
blinks.One long blink equals1Oshort blinks.Add the long and short blinkstogetherto determineth€ code.After determining the code, refer to the electricalsystem Symptom-to Component Chart on pages 1+52 and 1+53 for'96 98 mod'99
00 models.
els,and 14-54and 14-55for the
Short blink loncel
S€r DTC1
s.. DTC2
Long blink
Short blink
lfiYa tim.!,
S€c DTC 15
(cont'd)
14-49
TroubleshootingProcedures
(cont'dl
1.
Removethe kickpanelon the passenger's
side {seesection20}.
2.
Removethe PCM.and turn the PCMover.
Inspectthe circuit on the PCMaccordingto the troubleshootingflowchart with the spocialtools and a digital multimeter as shown.
How lo Use tha BackprobeSet
Connectthe backprobeadaptersto the stackingpatchcords,and connectthe cords to a multimeter.Usingthe wire
insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until it comesin contactwith the terminalend ofthe wire.
BACKPROSE
BACKPROBE
SET
07saz- (xtl(xtoA
{two required)
DIGITALMULNMEIER
(Comm€rcially6vailabl€l
-aHM-32-003
or equival€nt
14-5 0
PCMResetProcedure
1. Turn the ignitionswitchoff.
2.
Removethe BACKUPfuse (7.5A) from the under-hoodfuse/relaybox for
'10secondsto resetthe PCM'
NOTE:
the radio
. Disconnecting
the BACKUP fuse also cancelsthe radio presetstationsand clock setting Make note of
you
them
reset
can
presetsbeforeremovingthe luse so
. in" gCfUmemorycan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
Final Procedure
NOTE:This proceduremust be done afterany troubleshooting.
1. Turn the ignitionswitchOFF.
2.
Resetthe PcM.
3.
tool from
the oBD ll scan Tool or HondaPGMTesterfrom the DataLinkconnector,or removethe special
Disconnect
the ServiceCheckConnector.
4.
Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting'
5'ToVerifytheprob|emisrepaired,test.drivetheVehic|eforseveralminutesatspeedsover30mph(48km/h).
14-51
Symptom-to-Component
Ghart
ElectricalSystem-'gG - 98 Models
E Indicaior
Light
MIL
P1753
fl)
Blinks
ON
Lock-upcontrolsolenoidvalveA
P1758
\21
Blinks
ON
Lock-upcontrolsolenoidvalveB
P1705
(51
Blinks
ON
Ay'Tgear position switch (short to groundl
P1706
(6)
OFF
ON
A,/Tgear position switch (open)
P0753
l7l
Blinks
ON
ShiftcontrolsolenoidvalveA
P0758
{8)
Elinks
ON
ShiftcontrolsolenoidvalveB
POl20
(9)
Blinks
ON
Countershaftspeed sensor
P0715
{15)
'96 - 97
models:
OFF
'98 model:
Blinks
ON
P1768
{16)
Blinks
ON
P0740
(40)
OFF
ON
P0730
(41)
OFF
ON
DTCII
Dotection ltem
Page
14-56
14-58
14-60
14-62
14-64
14-66
14-68
Mainshaftspeedsensor
P0700*,
(none)
*1: The DTCin the parentheses
is
14-70
Linearsolenoid
Lock-upcontrol system
Shift control system
't4-72
14-74
14-75
Automatictransmissioncontrolsvstemin the pGM-Fl
control svstem
the code E indicatorlight indicateswhen the DataLinkconnectoris connectedto the
Honda PGM Tester.
*2: Wheneverthe HondaPGM
Testeror ScanTool detectsan automatictransmissioncontrolsystemDTC,p07OO
will be
set in the PGM-FIcontrol svstem.
14-52
lf the self-diagnostic
l-d indicatorlight does not blink,performan inspectionaccordingto the table below.
SYmPtom
Inspection
E indicatorlight does not come on tor two secondsafterignition
switchis first turnedON {ll}.
E indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis ON (ll).
Shift levercannotbe movedfrom @ positionwith the brakepedal
depressed.
Ref.Page
11-16
14-78
Inspection
't4-79
to recreatethe symptom by test-drivNOTE:lf a customerdescribesthe symptomfor code Pl706 {6),it will be necessary
DTC.
recheck
the
then
ing,
14-53
Symptom-to-Component
Chart
ElectricalSystem-'99 - 00 Models
DTC*I
E Indicator
Light
MIL
P1753
fi)
Blinks
ON
Lock-upcontrolsolenoidvalveA
P1758
t2l
Blinks
ON
Lock-upcontrolsolenoidvalveB
P1705
{5}
Blinks
ON
Ay'Tgear position switch {short to ground)
P1706
(6)
OFF
ON
y'VTgear position switch {open)
P0753
\71
Blinks
ON
ShiftcontrolsolenoidvalveA
P0758
(8)
Blinks
ON
Shift control solenoid valve B
P0720
(9)
Blinks
ON
Countershaftspeed sensor
P0715
(15)
Bl i n k s
ON
P1768
(16)
Blinks
ON
PO740
(40)
OFF
ON
Lock-upcontrol system
P0730
(41)
OFF
ON
Shift control svstem
P0700*,
(none)
OFF
Dotostion ltem
Mainshaftspeedsensor
Linearsolenoid
Page
'14-80
14-82
14-84
14-81
14-89
14-9r
r4-93
14-95
't 4-97
14-99
14-100
Automatic transmissioncontrol system in the pGM_Fl
controt svstem
*1: The DTc in the parentheses
is the code E indicator tight indicateswhen the Data Link connector is connected
to the
Honda PGM Tester.
*2: Whenever the Honda PGM Tester
or scan Tool detects an automatic transmission control system DTc, p07oowill be
set in the PGM-FIcontrol svstem
14-54
E indicatorlight does not blinkand followingsymptomsappear,performan inspectionaccordingto
lf the self-diagnostic
the table below.
page
Reference
1."""". y{*fu
fiSh,
E i"dl.r."
14-101
oN (ll).
lE indicatorlight does not come on for two secondsafterignitionswitchis first turned
Shift levercannotbe movedfrom E positionwith the brakepedaldeprsssed'
14-102
14-104
14-55
ElectricalTroubleshooting(,96- gg Models)
Troubleshooting
Flowchart- Lock-upcontrorsorenoidVarveA
NOTE:Recordallfreezedata beforeyou troubleshoot.
. OBD ll Scrn Toot indicatesCode
P1753.
. S e l f - d i a g n o s i s@ i n d i c a t o r
light blinks once.
Po$ible Cau3e
. Disconnecledlock-up control
solenoidvalvo A connector
. Short or open in lock-uDcontrol
solenoidvalv€ A wire
. Fauliy lock-up contlol solonoid
valve A
PCMCONNECTORS
Checkfor a Short to Powo.:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32p)and B
( 2 5 P )c o n n s g l 6 p s1 r q - t h a
PCM.
3. Turnthe ignitionswjtchON 0t).
4, Measurethe voltagebetween
the 85 and Ag or A22 termi
nals.
A l32P)
Wire sideof femaleterminals
Repair shoit to power in the wire
betw€en the 85 terminal and thg
lock-up coDtrol tolenoid valve A.
Mea3ureLock-upControl Solenoid Valve A RGislance:
'1. Turn
the ignitionswitchOFF.
2. Measure the resistance
betweenthe 85 and A9 or A22
terminals.
ls the resistance
12- 25 O?
To page'14-57
Checklor looso PCM conn€ctoB.
lf nece$.ry, substituto a knowngood aolonoid valve ass€.nblvol
PCMend rech6ck.
Frompage14-56
PCMCONNECIOBS
Ch6ck Lock-up Control Solenoid
Valve A tor a Short Cilcuiti
1. Disconnectthe 2P connector
lrom the lock-upcontrol solenoid valveassemblY.
2. Check for continuity between
the 85 and Ag or A22 terminats.
Wire sideof lem6leterminals
Ropair 3hort to giound in iha wila
b.twoqn th6 85 terminrl rnd tho
locl-up control 3olanoid valvo A.
LOCK.UPCONTROL
SOrINOID CONNECTOR
lml
-,f
(o)
Mo..ura Lock-up Control Sole'
noid Velve A Reri3tanc. at tho
SolenoidConn6cto.:
Measure the resistancebetween
the No. 2 terminalof the lock-up
control solenoidconnectorand
body ground.
ls the resistance12_ 25 O?
YEL
I
Teaminalsideof maloterminals
Chock for opan in tha wit.
ba(w.an tha 85 torminll lnd the
lock-uocontrol lolanoid vtlYa A.
Roplscetho lock"up cont.ol 3ol€_
noid vllvo arsembly.
14-57
ElectricalTroubleshooting('96 - 9g Modelsl
TroubleshootingFtowchart- Lock-upcontrol sorenoidVarveB
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicrtes Code
P1758.
. Self-diagnosisE indicrtor light
blinkstwice.
PossibleCause
. Disconnectedlock-up control
solenoid valve B connector
' Short or open in lock-upcontrol
solonoid valve B whe
. Faulty lock-up control solenoid
valve B
PCMCONNECTORS
Checkfor a Shon to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32p)and B
( 2 5 P )c o n n e c t o r sf r o m t h e
PCM,
3. Turnthe ignitionswitchON t).
4. Measurethe voltage between
the 84 and A9 or A22 terminals.
A {32P)
Wire sideof femaleterminals
Repeir short to power in the wire
between the 84 teiminal and the
lock-up control solenoid valve B.
MoasureLock-upControl Solenoid Valve B Resistance:
1. Turnthe ignitionswitchOFF.
2. Measure the resistance
b e t w e e nt h e 8 4 a n d A g o r
A22terminals.
ls the resistance
12- 25 O?
To page 14-59
Check for loose FCM connectors,
lf necessary, substitute a knowngood solenoid valve assembly ol
P1CMand rech6ck.
Frompage14 58
PCMCONNECTORS
Check Lock-up Control Solenoid
Valve B for a Short Circuh:
1. Disconnectthe 2P connector
from the lock-uPcontrolsole'
noid valveassefibly.
2. Checkfor continuitybetween
the 84 and A9 or A22 termanals,
WiresideoI lemaleterminals
ls therecontinuity?
Rgprir 3hort to ground in tho wite
Hwoon the 84 torminal and the
lock-uocontlol solonoidvalvs B.
LOCK.UPCONTROL
SOLENOIDCONNECTOR
IFl;II
-r:-]
Measu.o Lock-uP Control Sole'
noid Valve I Resistance at tho
SolenoidConnector:
Measurethe resistancebetween
the No. 1 terminalo{ the lock-up
control solenoid connectorand
body ground.
12- 25 O?
ls the resistance
6nn/eLKfi
I
Terminalsidoot maleterminals
Chcck tor opcn in the wirs
b€tlve.n the 84 ierminal and tho
lock-upconttol solonoidvllvc B.
Reolacethe lock'up control solenoid valve assemblY.
14-59
ElectricalTroubleshooting('96 - 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Shortl
NOTE:Recordallfreezedatabeforeyou troubleshoot.
' OBD ll Scln Toot indic.tes Cod6
P1705.
. Sofidi.gno3b E indicato] tighr
blinksfivatim...
Observo th. A/T Go.r po3ition
Indicator:
1. Turnthe ignitionswitchON l).
2. Observethe A"/Tgear position
i n d i c a t o r ,a n d s h i t t t o e a c h
posttron,
Do any indicatoGstay on
when the shift lever is not in
those positions?
Poiriblo Caus6
. Short in A/T go.. position
awhch wira
. FauhyA/T goa. position swhch
NOTE:Code P1705(5) is causedwhen
the PCM receives two g e a r p o s i t i o n
inputsat the sametime.
Tho sy3tem b OK.t this timo.
Checkth6 wilc harnari for damrga.
PCMCONNECTORS
M.r.ur. ATP R Vohlge:
1. Shiftto all positionsotherthan
E.
2. Nileasurethe voltage between
the 816 and Ag or A22 torminats,
ls there batteryvoltage?
Check for short in tha wiro
bstwacn the 816 tcrminal and th6
A/T go.r porition rwitch or A/T
g..r position indicltor. It wira i3
OK, ch.ck for loo!€ FCfit connocto13. lf nacetaary, subrtitute a
known€ood Pcllt and roa|rsck.
Meesur. ATP NP Vohage:
1. Shiftto allpositionsoth€rthan
EorE.
2. Moasurethe voltage between
the 825 and A9 or A22 termi
nats.
M.Gur. ATP D4 Voltago:
1. Shiftto allpositionsotherthan
lD.l.
2. Measurethe voltage betw€en
rhe 824 and Ag or A22 terminals.
ls there approx. 5 V?
YES
To page14-6':
14-60
Check for short in the wire
b.tw..n th6 B:I5torminrt and th.
A/T gclr poahion indicator. o. .
short in tha wirrs between th.
A/T gclr position indicator rnd
the A/T gerr poiition switch. lf
wir.3 r.o OK, chack tor looso
PCM conn.ctorr. It n.cosarry.
sub.tituto a known-good pCM
.nd r.chock.
Check tor 3hort in tho wiro
bc{wocn the 824 terminrl and tho
A/T ge.r poiition switch. lI wile
ia OK, chock tor loo3o plCM conncctoaa. It nacossarv,sublthute a
known-good PCMand rech€ck.
Wiresideof femaleterminals
PCMCONNECTORS
From page 14-60
'96:GRN'97- 98:PNX
MeasuroATP D3 Voltage:
1. Shiftto all positionsotherthan
tr.
2. Measurethe voltage between
the 88 and A9 or A22 terminals.
B (25P1
Wire sideot femaleterminals
ls there batteryvoltage?
Ch.ck tor short in the wire
botwoen tho 88 terminal and ihe
A/T goar position 3witch ol A/T
gosr position indicator, ll wirc is
OK, chock for loo3€PCM connector3. lf nece3rary, substituta a
known-good PCMlnd roch€ck
Morsuro ATP2Voltage:
1. Shiftto all positionsotherthan
6t
2. Measurc the voltage between
the 817 and Ag or A22 termln6ls.
ls there batteryvoltage?
Check for short in the wile
b€twesn the B'l 7 terminal and the
A/T ge.r pGition switch or A/T
gear po3ition indicator. lf wire i3
OK, check for loo3o rcM connec'
to13. lf necossarY, substitute a
known-goodPICMand recheck.
check for loose PCMconnectors.
lf noc*sarY. sub3titute a known_
good PCMand r.chock.
14-61
ElectricalTroubleshooting('96- gg Modelsl
TroubleshootingFlowchart- A/T GearpositionSwitch (Open)
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
P1706.
. Self-di.gnosk E indicatortight
blinks six timos.
PossibleCauso
. DisconnectedA/T gear position
switch conn€ctor
. Open in A/T gear position
switch wire
. FaultyA/T gear position switch
PCMCONNECTORS
MoasureATP I Voltage:
1. Turnthe ignitionswitchON 1 ).
2. Shiftto E position.
3. Measurethe voltagebetween
the B'f6 and Ag ot A22 tetminats.
Wire side of female terminals
Ropai. op€n in the wire betwe€n
the Bl6 terminal.nd the A/T gear
position swhch.
Measur€ATP NP Voltage:
1. Shiftto E or E position.
2. Measurethe voltagebetween
the 825 and A9 or A22 termi,
nals,
Repeir open in the wir€ between
tho B25terminal and th6 A/T geer
position indicator or tho A/T 96.r
position 3witch.
MeasureATP 04 Voltege:
1. Shiftto E position.
2. Measurethe voltagebetween
the 824 and A9 or A22 termi
nals,
ls there voltage?
NO
To page 14 63
1+62
Rcpair open in the wire between
tto 82{ to.minal and th6 A/T geat
lrosition 3witch.
Frompage14-62
PCMCONNECTORS
'95: GRN37 -'98: PNK
MeasureATP 03 Voltagei
1. Shiftto E Position.
the voltagebetween
2. lvteasure
the 88 and A9 or A22 terminals.
Wire sideof femaleterminals
Ropairopen in tho wils between
the 88 terminal .nd tho A/T goar
oosition switch
Mea3ur. ATP2Vohage:
1. Shiftto E Position.
2. Measurethe voltage between
the 817 and Ag or A22 termi'
nals,
Repairopen in the wirc botweon
the B17terminalrnd the A/T
geer poaition 3witch.
Chockfor loose PCM conn€ctoB.
lf nec*sary, sub3titute e known'
good PCMand rocheck.
14-63
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- Shift GontrolSolenoidValveA
NOTE:Recordall freezedata beforeyou troubleshoot.
' OBD ll ScanTool indicatesCode
P0753.
. Sett{iagnosis E indicatorlight
blinks seventim6.
Po$ible Cau3e
. D i s c o n n e c t e ds h i f t c o n t r o l
solenoidvalve A connector
. Short oi open in shift control
solenoidvalve A wire
. Faulty shirt control solenoid
PCMCONNECTORS
Checktor a Short to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
{ 2 5P i c o n n e c t o r st r o m t h e
PCM.
3. Turnthe ignitionswitchON {ll).
4. Measurethe voltage between
the 83 and A9 orA22 terminals.
A t32Pl
Wire sideol femaleterminals
Repairshort to powe. in the wir6
between the 83 terminal .nd the
shift control solonoid valvo A.
Moa3ure Shift Control Solenoid
Valve A Resistanc€:
1. Turnthe ignitionswitchOFF.
2, Measure the resistance
betweenthe 83 and A9 or A22
terminals.
ls the resistance
12- 25 0?
To page14-65
Ch€ckfor loose PCMconnectors.
lf n€c6srry, subatitute a knowngood solenoid valve a3,semblyor
PCMend rocheck.
Frompage14-64
PCMCONNECTORS
Check Shift Control Sol.noid
v.lve A loi a Short Circuh:
'1. Disconnectthe 2P connector
from the shift control solenoid
valveassemblY.
2. Checkfor continuitybetween
the 83 and Ag or A22terminals.
Wiresideo{ femaleterminals
Roprir shon to ground in th. wil.
b.tw€on th. B:t t.rmin.l rnd tho
ihift conLol aolonoid valvc A
SHIFTCONTROLSOLENOID
CONNECTOR
----!=--
FI-I1
=r==--
Mea3ur. Shift Control Solonoid
v.lvo A Rgistance !t tho solendd
Connoc'tor:
Measurethe resistancebetween
the No. l terminalofth€shiftcon_
trol solenoid connectorand body
ground.
alurvEL5f
II
Terminalsideol maleterminals
12- 25 O?
ls the resistance
Chack to. open in th. rtir.
b.t^raan tha 8:l Lrtnlnll tnd tho
thift conlrol 3olanoid valva A.
14-65
ElectricalTroubleshooting('96 - g8 Modelsl
TroubleshootingFlowchart- Shift ControlSolenoidValveB
NOTE:Recordallfreezedatabeforeyou troubleshoot,
. OBD ll ScanTool indic.tes Code
P0758.
. Solt-diagnosisE indicatorlight
blinks eight times.
PossibleCause
' Disconnected shift control
solenoidvalve I connectol
. Short or open in shift control
solenoidvalve B wire
. Faulty shift control 30lenoid
valve B
PCMCONNECTORS
Chockfor a Short to Power:
1. Turnthe ignitionswatchOFF.
2. Disconnect
the A (32P)and B
(25P)connectors
from the PCM.
3. Turnthe ignitionswitch ON (ll).
4. Measurethe voltagebetween
the 811 and Ag or A22 terminals,
A t32P)
Wire sideot femaleterminals
Repairshort to powar in the wire
botwcen the 811 torminal and
the shift control solenoidvalve 8.
Measure Shift Cont.ol Solenoid
Valve B Resktance:
1. Turnthe ignitionswitchOFF.
2 , M e a su r e t h e r e s i s t a n c e
b e t w e e nt h e B l l a n d A 9 o r
A22terminals.
ls the resistance
12- 25 O?
To page 14 67
Checl for loose PiCM connector3.
lf nec€ssary, sub3titute a knowngood solenoid v.lve assembly ol
PCM and recheck.
Frompage14-66
PCMCONNECTORS
C h e c kS h i f t C o n l r o l S o l € n o i d
valve B tor a Short Circuit:
1. Disconnectthe 2P connector
trom the shift control solenoid
valveassembly.
2. Checkfor continuitybetween
the 811 and Ag or A22 terminals,
, 2 ll r .
5
Wire sideof femaleterminals
ls therecontinuity?
Replir shon to ground in th€ wire
betwe.n the 811 terminal and the
3hift control solenord valvo B.
SHIFTCONTROLSOLENOID
CONNECTOR
GRN/WHT
Measure Shift Control Solenoid
vrlve B Resistanceat the Solenoid Connector:
Measurethe resistancebetween
the No.2 terminaloftheshiftcon
trol solenoid connectorand body
ground.
12 25 O?
ls the resistance
Terminalsideol maleterminals
Check tor ooen in the wire
betw..n thc 81 1 t€tminal ard tha
shift control solonoidvrlv6 B.
14-67
ElectricalTroubleshooting('gO- 98 Modelsl
TroubleshootingFlowchart- CountershaftSpeedSensor
NOTE;Recordallfreezedata beforeyou troubleshoot.
. OBOll Scln Tool indicat6 Code
m7z).
. S6lt-dirgnosis E indic.tol
light blink! nin. tim6,
Po$iblo Causa
' Loosg or laulty conncction
botwocn tho PCM and c.i hrrn1't!
' Disconnoctad countorahott
lpo€{ san3or oonnoctot
. Short or opon in countorshaft
speed lonsor wire
. F ulty counte.lhalt spe6d s6nsol
ls the countershaftspoedsensor
installedproperly?
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
lFI,]1
-F=r
9 l
Moa3ureCountoEhaft Sp€ed S6nsor Reaktanc€ at tho Son3or Connoctor
1. Disconnectthe 2P connector
trom the countershaftspged
sensorconnector,
2. Measurethe resistanceof the
countershaftsDeedsensor,
L_l
Terminalsideol maleterminals
ls the resistance400 - 600 0?
PCMCONNECTOR
B I25P}
Chock Countersh.ft Spood Scr|3ol
for a Shoft Circuit:
1. Disconnectthe B {25P)con
nectorfrom the PCM.
2. Check for continuity between
the body groundand the 823
t e r m i n a la n d 8 2 2 t e r m i n a l
individually.
Wiresideof temaleterminals
Repai. .hort in th. wiroa b.t$re€n
tho 823 lnd 822 torminals .nd
lho counteBhaft lpocd aenro..
To page 14-69
14-68
l
PCMCONNECTOR
8 I25PI
MeasureCounteFhaftSp€€dS6nsor Resistance:
1. Connect the countershaft
speedsensor2P connector,
2, Measure the resistance
between the B23and 822 tel
mtnals.
Wire sideoI femaleterminals
ls the resistance400- 600 0?
Repair looso terminal ol opon in
the wiro3 between th6 823 and
822 terminal3 and the countershaft soeedaen3or.
Checktor looscrcM connestors.
ll nocessary,
sub3titutea knowngoodPCMandrecheck.
14-69
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- MainshaftSpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
m715.
. S e l f - d i r g n o s i 3E i n d i c a t o r
light indicstesCode 15.
Po$ible Cause
. Disconnect€dmainshaft sD€ed
Sensor@nnoctot
. Short or open in mainshatt
sJt€eds6nsoawire
. Faulty mainshaftlpeed s6nso.
N O T E :C o d e P 0 7 1 5( 1 5 )o n t h e P C M
doesn'talwaysmeanthere'san electrical
problemin the mainshaftor countershaft
s p e e ds e n s o rc i r c u i t ;c o d e P 0 7 1 5( 1 5 )
may also indicatea mechanicalproblem
in the transmission.
Checkthe mainshaftand countershaftspeedsensorinstallation.
Are the mainshaftand countershaft
speedsensorinstalledproperly?
MAINSHAFTSPEEO
SENSORCONNECTOR
MoasureMainshaftSpoedSgnsol
Rosistanceat the Sensor Conn€ctor:
1. Disconnectthe 2P connector
from the mainshaftspeedsensor connector.
2. Measurethe resistance
ot the
mainshaftspeedsensor.
Terminalsideof maleterminals
ls the resistance400 600 O?
PCMCONNECTOR
B I25PI
Check Mainshaft Sp6ed Sensor
for a Short Circuil:
1. Disconnect
the B {25P)connec'
tor lrom the PCM.
2. Checkfor continuitybetween
bodygroundand 815terminal
and the 814terminalindividu,
ls therecontinuity?
To page 14-71
14-70
Repai. shon in the wi.os bstwoen
the 815 and 814 te.minals and
the mainshatt .Dood 3ensor.
Wiresideof femaleterminals
Frompage14-70
B I25PI
PCMCONNECTOR
Mea3uroMain3haftspeed sensor
Resistance:
1. Connectthe ma;nshaftsPeed
sensol2Pconnector,
2 . [ / l e a s ur e t h e r e s i s t a n c e
betweenthe 815 and 814 ter_
minals.
ls the resistance400- 600 O?
Run the Electical TrouH€.hooting
Flowcirrt for cod. P0720l9l.
Check for loose P1CMconnoctors.
ll n€cesslrY,3ubstitute a known'
good PCMand racheck.
Wire sideoI femaletermlnals
MAINSHAFTSPEEDSENSOR
CONNECTOR
CheckNM wire Continuityl
1. Disconnectthe 2P connector
from the mainshaftspeedsen'
sor connector.
2. Checkfor continuitybetween
the 815terminaland the No. 1
terminal of the mainshaft
speedsensorconnector.
Rgpsi. opon in thc wira bctwg€n
the 815 torminrl and th6.tain_
shatt soeodlensoa,
CheckNMSGWire ContinuitYr
Checkfor continuity between the
814 terminaland the No.2 termi
nal of the mainshaftsp€edsensor
connector,
Repairopen in the wira botwGon
the 814 terminal and lhe main'
shsft spo€d 3en3or.
Checkfor loo3o PCMconnoctoB.
ll neca$8ry, subditute a knowngood PCMand rgchock.
14-71
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- LinearSolenoid
NOTE:Recordall freezedata beforevou troubleshoot,
OBOll ScanTool indicatesCode
P176a.
S e l f - d i a g n o s i 3E i n d i c a t o r
light indicatesCode 16,
Po$ible Caus6
. DisconnoctodlineaJ solonoid
connectot
. Short or open in linoar solenoid
' Faultylinoar solonoid
CONNECTOR
LINEARSOLENOID
l;r]l
TT
Measure Linear Solenoid Resistance at the SolenoidConnecto.:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 2P connector
lrom the linearsolenoidcon
nector,
3. Measurethe resistance
ofthe
linearsolenoid.
YL I I
Terminalsideol maleterminals
ls the resistance
approx.5.0O?
PCMCONNECTOR
B I25PI
WHT
RED
CheckLinearSolenoidfor a Shon
Circuit:
1. Disconnect
the B 125P)
connector from the PCM.
2. Checkfor continuitybetween
the body ground and the B1
terminaland 82 terminalindavidually.
Wiresideof femaleterminals
Repair short in the wires bgtwoen
the Bl and 82 terminab and the
lineti solsnoid.
Meaaure Linoar Solenoid RGi3tanc€:
1 . C o n n e c t h e l i n e a rs o l e n o i d
connector.
2 , M e a su r e t h e r e s i s t a n c e
betweenthe 81 and 82 terminals,
ls the resistance
approx.5.0O?
To page14-73
14-72
Ropair looso terminal or open in
the wires botwe€n the 81 and 82
telminals end the linear solenoid.
Ftom page 14-72
PCMCONNECTOR
A I32P}
Checkthe G.ound Circuit:
Checkfor continuitybetweenthe
A9 and A10terminals.
. Rapair opan in the wiro
botweon th6 tormin.b Ag rnd
A10and G101.
. Raprir looc€ iunction connrc{or.
. R.p.ir poor ground {G101}.
Wirosideof t6maleterminals
Chock tor 100!6 PCM connectors.
ll nocessary,substituto a knowngood PCMand r6ch6ck.
14-73
ElectricalTroubleshooting('96 - 98 Models)
TroubleshootingFlowchart- Lock-upControlSystem
NOTE:Recordall freezedata beforevou troubleshoot.
. OBD ll Sc6n Tool indicatG Code
PossibleCause
m7{0.
. Self-diagnosis
E indicatorlight
indicatesCode40.
Faulty Lock-upcont.ol system
Checktor Another Code:
Checkwhether the OBD ll scan
tool or the E indicato,light
indicates
anothercode.
Doesthe OBDll scantool or
the E indicatorlight indicate
anothercode?
Tast Line Pressure:
M e a s u r et h e l i n e p r e s s u r e( s e e
page14-119and 14-120).
Perform lhe Troublo3hooiing
Flowchart tor the indicated
Code(s).Recheckfor cod. P07il0
lilol aftor iroubl€3hooting.
NOTE:Do not continuewith this troublesnoonno
until the causesof any
otherDTCShavebeencorrected.
Repairtho hydreulicaystem a3
necessary{3eepage 14-119).
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve Assembly and
R6check;
1 . B e p l a c et h e l o c k u p c o n t r o l
solenoidvalve Ay'Bassembly
(seepage14-105).
2. Turn the ignitaonswitch OFF
and reset the PCM by remov
ing the BACKUP (7.5A) fuse
in the underhood fuse/relay
box for morethan 10seconds,
3. Usingthe scantool, checkto
be sure that the enginecool
a n t t e m p e r a t u r ei s i n 1 7 6 ' F
(80'C)and above.
4 . D r i v et h e v e h i c l ea t 5 5 m p h
(88 km/h)constantlyfor more
than one minute.
5. Recheck
for codeP0740(40).
Doesthe OBDll scantool
indicatecode P0740{40)?
14-74
The systom k OK at this time.
TroubleshootingFlowchart- Shift ControlSystem
NOTE:Recordall freezedata beforevou troubleshoot.
. OBD ll ScanTool indicatesCode
P0730.
. S e l l - d i a g n o s i sE i n d i c a t o r
light indicatesCodeill.
PossibleCause
Faultyshift control system
Checktor Another Coder
C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e E , i n d i c a t o rl i g h t
indicateanothercode.
Doesthe oBD ll scantool or
tightindi
the E indicato'.
cateanothercode?
Perlorm ths Troubleshooling
Flowch.rt for the indic.t.d
Code(sl.Rechecktor code m730
l4'lI atter troubleshooting.
until the causesot any
NOTE:Do not continuewith this troubleshooting
other DTCShave beencorrected.
Test lst, 2nd, 3rd and 4th Clutch
Pressure:
Measurethe 1st,2nd,3rd and 4th
clutchpressure(seepage 14119
t h r u1 4 - 1 2 1 ) .
ls eachclutchpressurewithin
the servicelimit?
Ropair the hydrlulic systom !s
necessary{see page 14-119 and
11-1211.
ReplaceShift Control Solenoid
valve Assembly,Linear Solenoid
Assamblyand Rechock:
1 . R e p l a c et h e s h i f t c o n t r o l
solenoidvalve A'/Bassembly
(seepage14-106).
2 . R e p l a c et h e l i n e a rs o l e n o i d
assemblylseepage14 108).
3. Turn the ignition switch OFF
and resetthe PCMmemory by
removingthe EACKUP (7.5A)
tuse in the under hood fuse/
relaybox for more than l0
seconds,
4 . D r i v et h e v e h i c l ea t o v e r 1 2
mph (20 km/h)in 1st,2nd,3rd
and 4th gearfor morethan 30
secondsat P1 position.
tor codeP0730(41).
5. Recheck
Doesthe OBDll scantool or
the Ed indicatortightindi
catecodeP0730{41)?
The swt6m is OK et this time.
ElectricalTroubleshooting('96 - 98 Models)
TroubleshootingFlowchart- E IndicatorLight DoesNot GomeOn
Tha E indicator light does nol
come on when the ignition swhch
is first turned ON (lll. {lt should
come on tol about two s€conds.l
Chockthe SeJvicoCheckConnector:
Make sure the specialtool (SCS
SeryiceConneclor)is not connected to the servicecheckconnector.
ls the specialtool (SCSService
Connector)connectedto the ser
vice checkconnector?
Disconnectthe special tool trom
thc sarvice check connoctor and
rocheck.
Checkth6 E indicator Light:
Shift to lD.l oosition.
Checktor loose PCM connecto6.
ll nece3sary, sub.titute a knowngood FCM and r.chock.
PCMCONNECTOR
A I32PI
Checkthe Ground Circuit:
'1. Turnthe ignition
switchOFF.
2. Disconnecrthe A {32P}connector lrom the PCM.
3. Check for continuity between
the A9 terminal and body
ground and the A22 terminal
and body ground.
Wire sideof femaleterminals
Repair op6n in tho wirgs
between tho A9 ot M2 torminalsand G101.
Rcpairpoor glound {G101).
To page14-77
14-76
Frompage14-76
A I32PI
PCMCONNECTOR
Measure Powor Supply Cilcuit
Voltage:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltagebetween
t e r m i n a l sA 9 a n d A 1 1 a n d
b e t w e e nt e r m i n a l sA 2 2 a n d
424.
Wiresideof {emaleterminals
RGpairopon or short in the wire
boiween the A11 andlot Ml lor'
minals,the PGM-Flm.in rel.Y,
end the tu36 box.
Mo.sure D4 IND Voltago:
1. Turn the ignitionswitchOFF.
2. Connectthe A {32P}connector
to the PCM.
3. Connecla digital multitester
to the B13and Ag or A22 terminals,
4. Turn the ignition switch ON (ll)
and makesure that the voltage
is availablefor two seconds.
BRN/BLK
BRN/BLK
'96:BLU/RED
,97,'98:GRN/BLK
Chack tor opan in thc wita
bctwoon tha 813 larminal and
th. gauge ar!.mbly. lf wi.c i!
OK, chock for . frulty E indicator light bulb or a l.uhy g.ug.
a.!.mbly printod circuit bolrd.
Chock for loose PCM connoctort.
Chocktho A/T gGatpolition
switch. lI n6ca$sry, substitute a
known-good PCMand rochock.
14-77
ElectricalTroubleshooting('96 - 98 Models)
TroubleshootingFlowchart- E IndicatorLight On Constantly
Th6 E indicstor light is on const.ntly {not blinkingl whenevei
the ignition switch is ON lll).
PCMCONNECTOR
B (25P)
Measure04 IND Voltage:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the B 125P)
connector from the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
t h e 8 1 3 t e r m i n a la n d b o d y
ground,
Wire sideof lemaleterminals
Repair3hort to pow€. in the wiro
between the 813 terminal end
thc gauge asiombly.
Meaiure ATP Dil Voltage:
1. Turnthe ignitionswitchOFF.
2. Connectthe I (25P)connector
to the PCM.
3. Turn the ignitionswitchON (ll).
4. Shifttoany positionotherthan
5. Measurethe voltagebetween
t h e 8 2 4 t e r m i n a la n d b o d y
ground.
Checkfor a short to ground on tho
wir6. It wire i3 OK, .eplac6 the A/T
goar po3ition indbator,
14-7 A
l
!
a
TroubleshootingFlowchart- BrakeSwitch Signal
Symptom
Shift lever cannol b€ moved f.om
B pGition with the brako podrl
depr8sed.
CheckBrako Light Operation:
Deoressthe brakepedal.
Are the brakelights ON?
Rop.ir faulty braks switch cilcuit
lsos soction231.
PCM CONNECTORS
MeasureSToP SW Vohag€:
1. Turnthe ignitionswitchOFF.
the A l32P)and D
2. Disconnect
{ l 6 P ) c o n n e c t o r sf r o m t h o
PCM.
3. Measurethe voltage belween
the D5 and A9 or A22 terminals with the brake Pedal
depressod.
Wire sideof lemaleterminals
ls there batteryvoltage?
. Brakeswitch 3ign.l is OK.
. Ch6cklor looao PCMoonnoctors.
It nocassary,aubctilute a knowngood PCM and r€check.
. Inspoctthe brake switch circuit
{s6esection 231.
Rap.i. opon in the wira bctn oen
tha 05 terminal and tho btrkc
lwitdr.
ElectricalTroubleshooting('99 - 00 Models)
TroubleshootingFlowchart- Lock-upControlSolenoidValveA
\
NOTE: Recordall freezedata before vou troubleshoot.
. OBD ll ScanTool indic.t6 Code
P1753.
. S e l f - d i a g n o s i s@ i n d i c a t o r
light blink3 once.
Checklor a Short to Power:
L Turnthe ignitionswitchOFF.
2. Disconnect
the B (25P)and D
( 1 6 P )c o n n e c t o r sl r o m t h e
PCt\4.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltage between
the Dl and 820 or 822 terminats.
PossibleCause
. Disconnoctedlock-uD control
solenoid valve A/B alsembly
connector
. Short or opon in lock-upconkol
solenoid valv6 A wire
. Faulty lock-up control solenoid
valva A
' Open in VB SOLwire
FCM CONNECTORS
LGl IBRN/BLXI
B (2sPt
Measu.e Lock-up Cont.ol Solenoid V.lvo A R63btanc6:
1. Turnthe ignitionswitchOFF.
2. Measure the resistance
between the Dl and 820 or
822terminals.
LGl (BRN/BLKI
MeasureVB SOLVohage:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltage between
the D5 and 820 or 822 terminals.
Check for blown No. 15 17.5Al
fu3€ in the undordash fuse/raby
box. l{ th€ tusa ii OK, r.pair opon
in the wira b€twoen th€ 05 torftinal and thc und€r{ash fuso/r€lay
box.
14-80
ll D {16P1
LG2 IBRN/8LK)
To page 1+81
I t25Pt
Checkto.loose tarminalfit in the
PCM connecloa3.ll necessary,
substilute a known-good PCM
and rocheck.
LG2 (BRN/BLK)
Wire sideot femaleterminals
Ropairshort to powcr in the wire
bstwoon tho Dl tolminal and the
lock-upcor|lrol lolonoid valvo A.
ls the resistance
12- 25 O?
ll D {16P1
B (25Pt
D (16P1
a
B {25P}
PCMCONNECTOR
Frompage14-80
Checklor continuity between the
8 2 0 t e r m i n a la n d b o d y g r o u n d ,
a n d b e t w e e nt h e B 2 2 t e r m i n a l
and body ground.
I.G1(BRN/BLKI
Wiresideof l6maleterminals
Ropair opon in thc wircs betwe6n
the 820 lnd 822 tolminals .nd
ground {G10ll, and tepair Pool
ground (G10'l).
PCM OONI{ECTORS
Check Lock-up Cont.ol Solonoid
valve A for a Shon Cilcuit:
1. Disconnectthe 2P connector
trom the lock-upcontrol solenoid valve ry'Bassembly.
2. Check for continuity betlv€en
th6 D1 and 820 or 822 terminals.
ll o l16P)
B (25p)
IBRN/BLK}
LG2IBRN/BLK}
Wire side ot femaleterminals
R6p.ir 3hort to glound in thc
wir. b.two.n the Dl torn|in.l
ard th. lock-up conttol iol.noid
valva A.
LOCK.UPCO TROLSOTINOIDVALVE
A/B ASSEMBLYCON]TECTOR
I2P}
Maasuro Lock-up Control Sol.noid Vllve A Ro.istance at tho
SolanoidConn6ctor:
Measure the resistancebetween
the No. 2 terminal of the lock-up
control solenoidvalve y'y'Bassembly connectorand body ground.
]F]AL
r-f-
I
LCA {YEu
(o)
Y
I
'12
ls the resistance - 25 O?
R6placotho lock-up control solo_
noid valve A/B.$6mblY.
Terminalsideof maleterminals
Chack for opon in tho wiro
botweon the Dl t..minal and tho
lock-upcontrol solenoidYalvaA.
14-A1
ElectricalTroubleshooting('99 - 00 Models)
TroubleshootingFlowchart- Lock-upControlSolenoidValveB
NOTE|Recordallfreezedata beforeyou troubleshoot.
' OBD ll ScanTool indic.tes Code
P1758.
. S e l f - d i a g n o s i sE i n d i c a t o r
light blinks twice.
Chackfor a Short to Power:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the I (25P)and D
( 1 6 P )c o n n e c t o r sf r o m t h e
PCM.
3. lurn the ignitionswitchON (ll).
4. Measurethe voltage between
the D3 and 820 ot 822 tetminals,
PossiblaCause
. Oisconnectedlock-uD control
solenoid velve A/B assembly
connector
. Short or open in lock-upcontrol
solenoid valv€ B wire
. Faulty lock-up control solenoid
valve B
' Open in VB SOLwire
B t2sP)
Repairshort to power in the wire
between the D3 terminal and the
lock-upcontlol solenoidvalve B.
MeasureLock-upControl Solenoid Vdlve I R8i3tance:
1. Turnthe ignitionswitchOFF.
2, Measure the resistance
between the D3 and 820 or
822terminals.
ls the resistance
12- 25 O?
rcM CONNECTORS
Wiresideol femaleterminals
I {2sPt
B (25P1
Chockfor loose te.minal fit in the
PCM connectors. It necessary,
substitute a known-good PCM
end recheck.
14-82
ll D (16Pt
To page 14-83
MeasureVB SOLVoltago:
1. Turnthe ignitionswitchON lll).
2. Measurethe voltage between
the D5 and 820 or 822 terminals.
ls there batteryvoltage?
ll D t15P)
Checkfor blown No. 15 {7.5 Al
fus€ in the under-dashluse/reley
box. It the fuse is OK, repair open
in the wir6 between th6 DStermi
nal and the under-dashfuse/reby
oox,
D t16Pt
B (25PI
PCMCONNECTOR
Frompage14-82
51 6
2
3
l0 1 1 /
Checkfor continuitYbetweenthe
8 2 0 t e r m i n a la n d b o d y g r o u n d ,
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground
LG2 (BRN/BLKI
LG1 (BRN/BLK)
o
I
15
o
Wiresideof femaleterminals
Repairopen in the wires between
the 820 and 822 terminals and
ground |G101),and repair Pool
ground(G1011.
Check Lock-up Control Solenoid
Valve B lor a Short Cilcuit:
1. Disconnectthe 2P connector
controlsolefrom the lock_uP
noid vaiveA/B assemblY.
2. Checkfor continuitybetween
the D3 and 820 or 822 termi
nals.
B (25P1
Rep.ir short to ground in lho
wire between lhe D3 terminal
and the lock-up contlol solenoid
valve B.
-
llo t16Pt
Wire sideof femaleterminals
LOCK.UPCONTROLSOLENOIDVALVE
(2PI
A/B ASSEMBLYCONNECTOR
MeasureLock-upControl Sol6'
noid Valve B Resistanceat the
Sol6noidConn€ctor:
Measurethe resistancebetween
the No. 1 terminalof the lockuP
control solenoidvalve A'lBassem_
bly connectorand body ground-
t;T J
llt z
! ] 4
LC B (GRN/BLKII
t
(o)
YI
12- 25 0?
ls the resistance
Repl.ce the lock-up control 3olc
noid valve A/B a$emblY.
Terminalsideof maletermrnals
Ch6ck {or open in the wire
between the D3 terminal dnd ihe
lock-upcontrol sol€noid valve B.
14-83
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicrtB Code
P1?05.
. S o l t - d i a g n o 3 i 3E i n d i c a t o r
light blink. tive times.
Observothe A/T Gear Position
Indicetori
1. Turnthe ignitionswitchON fit).
2. Observethe lVT gear position
indicator,and shift each posi,
!on separately.
Doesany indicatorstayon
when the shiftleveris not in
that position?
Po$ible Cause
' Short in A/T go.r position
swhch wire
. FaultyA/T goar position switch
NOTE:Code P1705(5) is causedwhen
t h e P C M r e c e i v e dt w o g e a r p o s i t i o n
inputsat the sametime.
The sFtom is OK at thi3 time.
Check the wi.e harnessfor damaga.
Do all gearpositionindicators
go out?
PCM CONNECTORS
B {25P1
MoasureATP R Voltage:
1. Shiftto all positionsotherthan
E.
LGl (BRN/BLK)
2. Measurethe voltagebetween
the DGand 82Oo( 822 terfiinats.
ls there batteryvoltage?
To page14-85
14-84
llD (16P1
LG2 (BRN/BLKI
Wiresideof femaleterminals
Check tor short in the wire
batwoen tha DB terminal and the
A/T go.r porhion switch or A/T
g6ar po3ition indicator, and
chock for opon in the wires
between the B20 and B22 t€rmin.ls and body ground (G10 . tf
wir€c rro OK, chsck fo. loo3e telftinal fit in the FCM connectors.ll
noceisary, substiiute e knowngood FCM and r€check.
Frompage14-84
B {25P)
Measule ATP NP Voltage:
1. Shiftto all positionsotherthan
31115
2
l6 8 1 1 2 tV-st7 / \ 1 67 I 9 1 0 t 1 2
10n\/
pl orE.
2. Measurethe voltage between
the D13and 820 or 822terminals.
PCMCONNECTORS
o t16Pl
o zlzz /l/1,/
L---{O--l
I
LGl (BRN/BLK)
113
\a
TI
t9
ATP NP (LT GRN)
\=/
LG2 {BRN/BLKI
ls there bafteryvoltage?
,/t\_
Check for ahott in lhe wire
between ths D13 torminal and
tho A/T go.r PGition iwitci, and
in rho E .nd E polition signal
wires Mwgon tho A/T gsar Posi'
tion indicrtor and th. A/T gGar
po3ition 3witch. ll wiJ.! .ro OK,
check lor loose torminal fit in the
PCM connoctor3.lf nocet3.rY,
substitute . known-good PCM
and r6check.
Wirc sideo{ femaletermlnals
g t25P)
MeasureATPD4voh.g€:
otherthan
1. Shifttoallpositions
E
9 10
2. Measurethe voltage between
the Dg and 820 or 822 terminals.
8l
3 115
111/ t6l/ 17
) W
20
(BRN/8IJ()
LGl
D t16P)
Wl/l
+
5
l2
l sl t l a
1 12
'3111/ll
ATP D4 IYEL)
LG2(BBN/BLKI
-<_
ls there approx. 5 V?
Ch.ck lor 3hort in ths wilo
betweon tho lxl termin.l and tho
A/T ge.r pGhion switch. It wites
are OK. chock fo. looao t€rminal
fit in the PCM conn.ctoB. lf noc_
.*sary, sulFtitute a known-good
PCM.nd rechock.
Moa3ureATP D3 Vohsge:
1. Shiftto all positionsotherthan
tr.
2. Measurethe voltage between
the D8 and 820 or 822 terminals.
ls there batteryvoltage?
LGl IBRN/BLK)
LG2 (BRN/BLK}
Check tor 3hort in the wits
betweon the D8 torminal and the
A/T goer position switch or A/T
gcar position indicltor. It wires
are OK, check for loo3€ torminal
fit in tho FCM conn€ctoG. lf nec_
a3$ry, 3ubatitute e known'good
PCM and r.check.
To page l4'86
14-85
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)(cont,dl
FCM CONNECTORS
B {25P)
MeasuleATP 2 Vohage:
1. Shiftto all positionsotherthan
l
2. Measurethe voltage between
the D14and 820 or 822terminals,
1 2
8
[Ll
9 1 0 1 / 1 1 3/ 151/)11
,/ 20
LGl (BRN/BLK}
D l16Pl
1
2 3
5
7 8 9 t 0 1 12
ATP 2 {BLUI
Wiresideof femaleterminals
ls there batteryvoltage?
Ch6ckfor loose terminal fit in the
PCM connoctors. lf necessary,
substitute a known-good PCM
and recheck.
14-86
Check for short in the wire
between the D14 terminal and
the A/T gear position switch or
A/T ge.r position indicator. It
wires aaeOK, checkloa loose terminal th in ths PCMconnectors.ll
necessary,substitute a knowngood FCM and recheck.
TroubleshootingFlowchart- A/T GearPositionSwitch (Open)
NOTE:Recordallfreezedata beforeyou troubleshoot.
. OBOll ScanTool indicatd Codc
P1706.
' S s l f - d i a g n o s i sE i n d i c a t o r
light blink3 six tim6.
Po$ible Cause
. DisconnectodA/T goar position
switch conngdor
. Open in A/T gear position
switch wire
. Fautty Aft gear poshion switch
Test the Ay'Tgear position switch
(seesection23).
PCMCONNECTORS
B(25Pt
MoasureATP R Volt.ge:
'1. Turnthe ignitionswitchON ('l).
2. Shift to E position.
3. Measurethe voltage between
the D6 and 820 ot 822 termi'
nals.
IARN/BLK)
llDtl6Pl
LG2IBRN/BLKI
Wire sideof lemaleterminals
Repoiropon in the wire bitween
the D6 torminll and the A/T go.r
position switch.
D (16P1
MeasuroATP NP Volt ge:
1. Shiftto E or E position.
2. Measlre the voltage between
the D13and 820 or 822 terminals,
I
2
{
't0 1 1 /
LG1 {BBN/BLKI
6
t5l/
,|
2 3
1 8 9
5
12
ATP NP (LT GRNI
Ropairop€n in thc wire betwoon
the D13terminrl and the A/T
ge.r position switch.
(cont'd)
Io page14-88
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- A/T GearpositionSwitch Open{cont,d)
Frompage14-87
PCMCONNECTORS
B l2sPl
Moalure ATP 04 Vohago:
1. Shiftto pll position.
2. Measurethe voltage between
the Dg and 820 or 822 termi
nals.
D {16P)
1 2
415 6
I
9 10 11)./
t5l/ 11
zo ztzzll//l
fj r-cz]_c;l
tgaNlelxr
1 8 9
LGl {BRN/BI.KI
12
ATP D4 (YEL}
Wire sideof lemaleterminals
Repair opon in the wire betweon
the lrg terminal and the A/T goat
poshion switch.
MeasureATP D3 Vohage:
1. Shiftto l& position.
2. Measurethe voltagebetween
the D8 and 820 or 822 terminats.
1
hsr),41
I.G1IERN/BLKI
LG2IBRN/BLKI
Reprir opcn in the wirc b?twoen
the D8 terminrl and tho A/T goar
Dositiontwitch.
B (25P1
Mersurc ATP 2 Voltage:
1. Shiftto E position.
2. Measurethe voltage between
the Dl4 and 820 or 822 terminals,
I
2
9 10 11)/
LGl IBRN/BLKI
Reprir opon in the wire betweon
tho Dl4 te.minal rnd the A/T
go.r position switch.
Ch6cktor loose terminal tit in the
PCM connectors. ll necossery,
subslitute . known-good pCM
and recheck.
14-88
D {16P}
5l l6l/ 8
Itsln
7 8 9
12
ATP 2 IBLUI
TroubleshootingFlowchart- Shift ControlSolenoidValveA
NOTE:RecordallJreezedata beforeyou troubleshoot.
. OBD ll ScanTool indic.ts6 Code
Pot53.
. Solt-diagno.isE indicrtot light
blinks seven time6.
Chock tor a Short to Power:
1. Turnthe ignitionswitchOFF.
the g (25P)and D
2. Disconnect
( 1 6 P )c o n n e c l o r sf r o m t h e
PCM,
3. Turn the ignirionswitchON (ll)
,1. Measurethe voltage between
the D7 and 820 or 822 termi
nals,
PossibleCru3.
' Disconnectod 3hift control
solonoid valva A/B a33emblY
connactot
. Short or opon in shift cont.ol
solonoidvalvo A wits
. Faulty shift control .olenoid
. op.n in vB SOLwi.e
PCM CONNECTOBS
ll D {16P)
I t25Pt
LG1{BRN/BLK} LG2IBRN/BLKI
Wire side of female terminals
Rcpairshort to powet in the wile
b€t^reen tho D7 termin.l .nd the
shift control aolonoid valve A.
Mee3ur. Shift Control Solonoid
Valve A Roaisttnce:
1. Turnthe ignitionswitchOFF.
2. Measure the resistance
between the D7 and 820 or
822 terminals.
LGl IBRN/BI-K)
ls the resistance12 - 25 O?
LG2IBBN/BLK)
To page 14-90
BrzsPt
o trQil
Me.3uro vB SOLVoh.ge:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltage between
the D5 and 820 or 822 terminals.
ls there bafteryvoltage?
Checkfor loose t6tminalfit in th€
PCM connoctors. It necessary,
substitute e known-good PCM
and rechock.
Check tor blown No. 15 17.5A)
fuse in tho underdaah fula/rol.Y
box. ll the tusr is OK, .epair oPen
in th. wiio betwe.n the D5 ter'
min.l and th. underdssh tuso/
relav box.
(cont'd)
14-89
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveA (cont,O)
Frompage14-89
PCMCONNECTOR
B {25P}
Checklor continuitybetweenthe
820 terminal and body ground,
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
LGl (BRN/BLKI
Repair open in ihe wires
between th€ 820 and 822 termin a l s e n d g r o u n d { G 1 0 l l .a n d
repa,rpoor ground{G101}.
Wiresideof femaleterminals
Check Shitt Control Solenoid
Valve B for a Short Circuit:
1. Disconnectthe 2P connector
from the shiltcontrolsolenoid
valve A,/Bassembly.
2. Checklor continuitybetween
the D7 and 820 or 822 termi,
nals.
rcM CONNECTORS
Bt25Pt
LGl {BBN/BLKI
ls therecontinuity?
R€pairshort to ground in the wiie
bartwe€nthe D7 te.minal and the
shift control solonoidvalveA.
Meesuro Shift Control Solenoid
Valve A RGistance at the Solenoid
Connector:
Measurethe resistancebetween
t h e N o . 1 t e r m i n a lo f t h e s h i f t
c o n t r oI s o l e n o i d v a l v e A / B
a s s e m b t yc o n n e c t o ra n d b o d y
grounct,
ls the resistance
12 25 O?
Check for open in the wire
between the D7 termindl and the
shift control 3olonoidvalve A.
14-90
llD t16Pt
LG2 (BRN/BLKI
Wiresideof femaleterminals
SHIFTCONTROLSO|'INOID VALVE
A/B ASSEMBLYCONNECTOR
I2PI
SHA {BLU/YELI
Repl.ce tho shift control solenoid
valve A/B rss€mblv.
TroubleshootingFlowchart- Shift ControtSolenoidValveB
NOTE:Recordall freezedatabeforeyou troubleshoot.
. OBD ll ScanTool indic.l6 Code
P0758.
' Self-diagnosbEl indicatorlight
blinkseighl tim6.
Checktor a Shortto Power:
1. Turnthe ignitionswitchOFF
the B (25P)and D
2. Disconnect
( 1 6 P )c o n n e c t o r fsr o m t h e
PCM.
3. Turnthe ignitionswitchON (lli.
4. Measurethe voltage between
the D2 and 820 or 822 termi
nals,
PossiblgCause
. Disconnectgd ihilt control
solenoidvalve A/B conneciot
r Short or oDen in shift conlrol
3olgnoidvrlve B wito
. Faulty 3hift control solenoid
velve B
. Op€n in VB SOLwire
B (25Pt
rcM CONNECTORS
-
I lD {16P)
LGl IBRN/BLKI LG2IBRN/BLK)
Wiresideof {emaleterminals
Repaft3hon to Powor in the wir€
b€tirvoonthe D2 termin.l and the
3hift control solenoid valve B.
M€asure Shift Control Solenoid
Valve B R6isttnce:
1. Turnthe ignitionswitchOFF
2. Measure the resistance
between the D2 and 820 or
822 terminals.
LGi (BRi|/BLKI LG2IBRN/8LK)
12- 25 O?
ls the resistance
To page14-92
B {25P1
D (t6Pl
Me.sure VB SOLVohage:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltage between
the D5 and 820 or 822 termi'
nars.
ls there battery voltage?
Checkfor loo3eterminal fit in the
PCM connectols. lf necossarY,
substitute a known_goodPCM
and rocheck,
Checklol blown No 15 {7.5 Al
fuse in the under-d.sh luae/rolav
box. ll the fuse is OK, repair open
in ihe wire between tho D5 terminal and the under'dashfus€/
relav box.
(cont'd)
14-91
ElectricalTroubleshoot:ng('gg - 00 Models)
TroubleshootingFlowchart- Shift ControlSolenoidValveB (cont,dl
Frompage'14-91
PCMCONNECTOR
A {25PI
Checkfor continuity between the
8 2 0 t e r m i n a la n d b o d y g r o u n d ,
a n d b e t w e e nt h e 8 2 2 t e r m i n a l
and body ground.
LGl (BRN/BLK)
Ropair opan in the wirgs
b.twocn the 820 rnd 822 te.mi,
n.ls and ground lG10t), and
..p.ir poor ground lG10t).
Wiresid€ot femaleterminals
Check Shift Control Sol.noid
Vrlve B tor a Short Ci.cuit:
1. Disconnectthe 2P connector
from the shift control solenoid
valve A/B assembly.
2. Checkfor continuitybetween
the D2 and 820 or 822 terminals.
FCM CONNECTORS
SH B (GRN/WHTI
B(25P1
IBRN/BLKI
Repair3hort to ground in tho wire
botw.en tha 02 torminsl and the
shift com.ol rolonoid v.lv. B.
Meaiuro Shift Cont.ol Solonoid
Vrlve B Raailtrnca at the Solonoid
Conn€c,toa:
Messure the r€sistancebelween
t h e N o . 2 t e r m i n a lo f t h e 6 h i f t
control solenoid valve A/B
a s s e m b l yc o n n e c t o ra n d b o d y
ground.
-
llDt
LG2IBRN/BLK)
Wire sideof temaleterminals
SHIFT@NTROL SOENOID VALVE
(2PI
A/A ASSEMBLYCONNECTOR
. - _
1 ) 2
-.T-
I sne tcanlwxrt
(o
YI
ls the resistance
12- 25 O?
Chack for open in the wi.e
betwoon th€ D2 termin.l and the
3hift control lolanoid valv6 8.
14-92
R.pl.co th. 3hift control lolenoid
v!lv. A/8.lsombly.
Terminal
sideoI maleterminals
TroubleshootingFlowchart- CountershaftSpeedSensor
NOTE: Recordall freezedata beforeyou troubleshoot
. OBD ll ScanTool indicat6 Code
PO720.
. Self-diagnosisE indicatorlight
blinks nin6times.
C h e c kt h e c o u n t e r s h a f st P e e d
sensorinstallation,and check it
lor damage.
ls the countershaftspeedsensor
installedproperly,and not damaged?
Po$iblo Cause
. Loos€ or fsulty conneclion
between the PCM and vehicle
hainoss
' Disconnectod countersh.ft
spoed senaof connoctor
. Short or opgn in counteBhaft
3Deedaensorwire
. Faulty counloEhaft 3p€ed sen'
soa
Reinstallor replaceand rechock.
COUNTERSHAFfSPEED
SENSORCONNESTOR
Measurg Counlershatt SPeed
Sgn3ol R6istance at tho Son3ol
Connector:
1. Disconnectthe 2P connector
from the countershaftsPeed
sensor.
2, MeasurocountershaftsPeed
sensorresistancaat the sensor
connector.
TerminalsideoI maleterminals
ls the resistance400- 600 O?
D I16PI
FCM CONNECTOR
Chcck CounteEh.tt SPeed Sen'
sor lor a Short Circuit:
1 . D i s c o n n e ct th e D { 1 6 P )c o n
nectortrom the PCM.
2. Checklor continuitybetween
body groundand the D10ter_
minal and D16 terminal individ!ally.
NCIBLUI
Wire sideof temaleterminals
R6oai. short in tl|€ wi.6a bstwa€n
the D10 and D16 t.rminali end
tho countdthatt rP€od senaor.
rconl c
To page 14 94
1+93
ElectricalTroubleshooting('gg - 00 Modelsl
TroubleshootingFlowchart- CountershaftSpeedSensor(cont,d)
Frompage14-93
Measure CounteJahaft Speed
SensorCircuittor an Open:
1. Connect the countershalt
speedsensorconnector,
2. Measure the resistance
betweenthe Dl0 and D16ter
mtnats.
PCMCONNECTOR
D I16PI
Wiresideof femaleterminals
ls the resistance400 - 600 O?
Checkfor loose t.rminal frt in the
PCM connectors. It necalsary,
3ubstitute a known-good PCM
and recheck.
14-94
Roptir loo.€ t6.minal or opan in
th6 wir€! betwo€n lho D10 lnd
D16 t.rmina13and the count.rshatt apaadaaNor.
TroubleshootingFlowchart- MainshaftSpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
m715.
. Sell-diagno3isE indicator indicatesCode 15.
PossibleCausg
. Diaconn€ctedmainshaft spoed
sen3orconnector
'Short or open in mainshaft
sDeed sen3or wile
. Faulty main3haltspeedsensor
NOTE:Code P0715(15)on the PCMdoesn't
problemin
alwaysmean there'san electrrcal
the mainshaftor countershaftspeed sensor
circuit;code P0715{15) may also indicatea
problemin the transmissjonAny
mechanical
p r o b l e mc a u s i n gi r r e g u l a rc o u n t e r s h a ft to
mainshalt speed differencecan cause thls
code.
Checkthe mainshaftand countershatt speedsensorsinstallation,
and checkthem for damage.
Are the mainshaftand countershaft
speedsensorinstalledproperly,
and not damaged?
Rsinalallor replaceand rocheck.
MAINSI{AFTSPEED
SENSORCONNECTOR
Mea3u.e Meinshalt SPeod
Sensor Residance al the Sen3or
Connector:
1. Disconnectthe 2P connector
f r o m t h e m a i n s h a f ts P e e d
sensor.
2, Nreasuremainshaftspeedsen_
sor resistanceat the sensor
connector.
l.TT
ll ,.
(- io- l l
t
l
TerminalsideoI maleterminals
ls the resistance400- 600 O?
D (16P)
PCMCONNECTOR
Check Mainshaft Sp.ed Sen3o.
for a Short Circult:
1. Disconnectthe D (16P)connectortrom the PCM.
2. Checklor continuitybetween
body groundand the D11ter'
m i n a la n d D 1 2t e r m i n a il n d i
vidually.
NMSG (WHT)
Wiresideof femaleterminals
ls therecontinuity?
Bopair 3hort in the wiros b€twe€n
the 011 and D12 termin.ls rnd
th€ main3hett sp€€d aensoa.
(cont'd)
To page 14 96
14-95
ElectricalTroubleshooting('gg - 00 Models)
TroubleshootingFlowchart- MainshaftSpeedSensor(cont,dl
Frompagel4-95
PCMCONNECTOR
D {16PI
Measure Mainshatt Speed
SensorResistance:
1. Connectthe mainshaftspeed
sensorconnector.
2. Measurethe resistancebetween the Dl1 and D12terminats.
/)
2 3
NMSG {WHTI
6 18
rghrll [e]
(
NM IREDI
I
Wire sideof femaleterminals
ls the resistance400- 600 0?
Run the Electricel Troubl€shooting
Flowchart lor cod6 m?m l9).
Ch€ck lor loo.o te.minol fit in th6
PCM connectors. lf necossary,
substitute r known-good PCM
end .echeck.
CheckNM Wire Continuity:
1. Disconnectthe 2P connector
from the mainshaftspeedsensor.
2. Checkfor continuitybetween
the D11terminaland the No.2
terminal ot the mainshaft
speedsensorconnector,
23
1
5
6 7 8
t1v
NM (REDI
o
MAINSHAFTSPEED
SENSOROONNECTOR
Ropair opon in the wiro lratwoen
tho Dll tsrminal and tha main3hatt spe€d sensor.
CheckNMSG Wire Continuity:
Checkfor continuity betweenthe
Dl2 terminaland the No. 1 terminal of the mainshaftspoedsen-
RED
Wire sideof femaleterminals
6 1 78
t1v
9
ll
12
Io
NMSG IWHTI
WHT
1
Repai. open in the wire betwoen
the D12 terminal and the meinshaft 3peodsansor.
CheckIor loose terminal fit in the
PCM connectors. lf necesaary.
substitute a known-good PCM
and recheck.
14-96
TroubleshootingFlowchart- LinearSolenoid
NOTE: Recordall freezedata before you troubleshoot.
. OBD ll Scln Tool indic.t.t Codo
P1768.
. Self-diagnosisE indicltol indicat6 Cods 16.
Moasur. VB SOLVoltago:
1. Turnthe ignitionswitchOFF.
the B {25P)and D
2. Disconnect
( 1 6 P )c o n n e c t o r sf r o m t h e
PCM.
3. Turn the ignitionswitchON (lll.
4. Measurethe voltage between
the D5 and 820 or 822 terminals.
Poitibl. Cau3.
. DisconnactedlinoaJ tolanoid
connaclol
. Shorl or opon in linolr solonoid
. Flulty linoar 3olenoid
. ODonin VB SOLwit.
. ODenin PG lino
PCftI @NNECTORS
D {16P1
B t25Pl
Wire side ol female terminals
Ropair opan or thort in dla wi.9
hrw..n th. D5 t.rminrl .nd th.
und.r-d.rh fu ta/r.l.y box.
PCM OONNECTORB I25PI
Ch.ck th. Ground Circuit:
1. Turnthe ignitionswitchOFF.
2. Checklor continuity betwoen
the terminals82 and 822 and
b e t w e e nt e r m i n a l s8 1 0 a n d
820.
Rapair opal| in tfr wi|! batlwao
th. tcrrnln.l. 82, B10, B:20..nd
BZI .id Gt01. R.p.ir poor ground
tG10rl.
Linea. Solenoid
M.!sure
Rcai3tancc rt tha Solanoid
Conn6ctor:
the linearsolenoid
1. Disconnect
connectol,
2. Measurethe resistanceof the
linearsolenoid.
LGT(BNN/BLKI
LG2 {BBN/BLKI
Wir6 side of Iemale terminals
LINEAFSOITNOIDOONNECTOR
Flr-11
=T=T
o l
Y
I
L_l
ls the resistanceapprox. 5 O?
Terminalsideof mal€termanals
To page 14-98
(cont'd)
1+97
ElectricalTroubleshooting('99 - 00 Modelsl
TroubleshootingFlowchart- LinearSolenoid(cont'dl
Frompage14 97
Check Linea. Solenoid tor a
Short Ci.cuit:
Checkfor continuitybetweenthe
body groundand the 88 terminal
and B17terminalindividually.
PCMCONNECTOR
A {25PI
Repairshon in the wir6 between
th€ 88 and 817 terminals and the
lin€arsolenoid,
Wire sideof femaleterminals
Measure Linear Solenoid
Resistance:
1 . C o n n e c t h e l i n e a rs o l e n o i d
connector,
2 . M e a su r e t h e r e s i s t a n c e
betweenthe Bg and 817 ter
mtnals,
ls the resistance
approx.5.0O?
Checkfor loose terminal tit in the
PCM conn€ctors, lf necessary,
substitut6 a known-good PCM
and recheck.
14-9 8
LSAM(WHTI
Repair loose te.minal or open in
the wire botwoenthe 88 .nd Bl7
t.rmin.b end the linoar3olenoid.
TroubleshootingFlowchart- Lock-upControlSystem
NOTE:Recordall freezedata beforevou troubleshoot.
OBD ll ScanTool indicatesCode
m14/J.
S€lf-diagnosis.D4lindicalorlight
indicatesCode40.
Possibl€Cause
Faulty Lock-upcontrol sy3tem
Checkfor Another Code:
C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e : E i n d i c a t o rl i g h t
indicatesanothercode,
ooesthe OBDll scantool or
rhe E indicatorlight indicate
anothercode?
Test Line Pressure:
M e a s u r et h e l i n e p r e s s u r e( s e e
p a g e1 4 1 1 9a n d 1 4 - 1 2 0 ) .
ls the lanepressurewithinthe
servicelimit?
P e r f o r mt h e T r o u b l e s h o o t i n g
Flowchart tor the indicated
Codels|. Rocheckto. code P0740
(40).fter troublBhooting.
until the causesof any
NOTE:Do not continuewith this troubleshooting
other DTCShave beencorrected.
Repairthe hydrrulic sy3tem as
n6c6ssary(seepage 14-1191.
R e p l a c et h e L o c k - u p C o n t r o l
Solenoid Valve Assembly and
Recheck:
1 . R e p l a c et h e l o c k - u pc o n t r o l
solenoidvalve A/B assembly
(seepage14-105).
2. Turn the ignition switch OFF
and reset the PCM by remov
ing the EACKUP (7.5A) fuse
in the underhood {use/relay
box for morethan 10seconds.
3. Usingthe scantool, checkto
be sure that the enginecoola n t t e m p e r a t u r ei s i n 1 7 6 ' F
(80'C)and above.
4 . D r i v et h e v e h i c l ea t 5 5 m p h
(88 km/h)constantlyfor more
than one minute,
for codeP0740{40).
5. Recheck
Doesthe OBDll scantool
indicatecodeP0740(40)?
The svstem i3 OK .t this time.
14-99
ElectricalTroubleshooting('99 - 00 Modelsl
TroubleshootingFlowchart- Shift ControlSystem
NOTE:Recordallfreezedata beforeyou troubleshoot.
. OBD ll ScanTool indicrtd Code
m730.
. S e l f - d i r g n o s i sE i n d i c a t o r
light indicst€. Codo41.
Po33ibl.Crus6
Frulty 3hift control ryrtom
Checkfor Anoth€. Code:
C h e c kw h e t h e rt h e O B D l l s c a n
t o o l o r t h e E i n d i c a t o rl i g h t
indicateanothercode.
DoestheOBDllscantool or
the E indicatorlight indicate anothercode?
Prrf orm tho Troublc!hooting
Flowch.rt for th. indicrt.d
Cod.l3l. R.ch.ck tor cod. m730
141|.tt r troubldhootlng.
NOTE:Do not continuewith this lroubleshootinguntil the causesot any
other OTCShave beon corrected.
Test 13t, 2nd, 3rd .nd 4th Clutch
Prglture:
Measurethe 1st,2nd,3rdand 4th
clutchpressure(seepage 14-119
t h r u1 4 1 2 1 ) .
ls each clutch pressurewithin
the servicelimit?
R.prir tho hydrlulic ayrtam aa
n.c.3t..y lr.o p!9. lil-119 rnd
1+1211.
Roplace Shift Control Solenoid
Valve Asembly. Linoar Sol.noid
Assembly.nd Recheck:
1 . R e p l a c et h e s h i f t c o n t r o l
solenoidvalve A/B assembly
(seepage14-106).
2 . R e p l a c et h e l i n e a rs o l e n o i d
assembly{seepage14-108}.
3. Turn the ignitionswitch OFF
and resetthe PCMmemory by
removingthe BACKUP (7.5A)
fuse in the under-hoodfuse/
relaybox for more than 10
seconds,
4 . D r i v et h e v e h i c l ea t o v e r 1 2
mph (20 kn/h) in 1st,2nd, 3rd
and 4th gear lo. more than 30
secondsat lPll position.
5. Recheck
for codeP0730(41).
DoestheOBDIlscantool or
the E ;ndicatorlight indicatecodeP0730(41)?
14-100
Th. sFtcm b OK .t this time.
TroubleshootingFlowchart- El IndicatorLight On Constantly
The Dll indicator lighi is on constantly {not blinking)whenever
the ignition switch is ON (lll.
A I32P)
PCMCONNECTOR
MoasureD4 IND Voltage:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A { 3 2 P }c o n nectorfrom the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
t h e A 1 4t e r m i n a a
l ndbody
ground.
Repsirshort to power in the wire
between the A14 torminal and
the gauge assembly.
MeasureATP D4 Voltagel
1. Turnthe ignitionswitchOFF.
2. Connectthe A (32P)connec
tor to the PCM.
3. Turnthe ignitionswitchON (ll).
4 . S h i t t t o a n y p o s i t i o no t h e r
than [ql.
5. Measurethe voltagebetween
t h e D 9 t e r m i n a la n d b o d y
ground.
ls thereapprox.5 V?
Test the A/T gear position switch
( s e es e c t i o n 2 3 ) .
CheckIor a short to ground in
the wire betweon the D9 terminal and A/T gear position switch.
It wire is OK, substitute a knowngood PCMand recheck.
Wiresideof lemaleterrnanals
D {16P)
PCMCONNECTOR
2
6 1
t{
e11(
5
12
Iro
ATPD' (YELI
Wire sideof femaleterminals
ElectricalTroubleshooting('99 - 00 Models)
TroubleshootingFlowchart- E IndicatorLight DoesNot ComeOn
The Pll indicator light does not
come on when the ignition
switch is fi.st turned ON (ll). llt
should come on for about two
seconda.l
Check the Service Check Connector:
Makesure the specialtool (SCS
ServiceConnector)is not connected to the servicecheckconnector?
ls the specialtool{SCSService
Connector)
is not connected
to
the seNicecheckconnector.
Disconnectthe special tool from
the service check connector and
r6check.
Checkthe Dll lndicator Lighti
Shiftto d position.
Doesthe @ indicatorlight
comeon?
Checkfor looseterminal fit in the
PCM connecto13.It necessary.
sub3titute a known-good PCM
and recheck.
FCM CONNECTOR
B (25P}
Checkthe Ground Circuit:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e B ( 2 5 P )c o n nectorfrom the PCM.
3. Checkfor continuitybetween
t h e 8 2 0 t e r m i n a la n d b o d y
ground,and betweenthe 822
terminaland body ground.
i
2
9 10
t 5
q
6
t7
LGl {8RN/ALKI
LG2 {BRN/8LK}
o) (o
Repair open in the wires
between the B20 rnd 822 termi, nd
n a l sa n d g r o u n d( G 1 0 1 ) a
rep.ir poor ground (G1011.
Wire sideol temaleterminals
Measure Power Supply Circuit
Voltage:
1. Turnthe ignitionswitchON {ll}.
2. Measurethe voltagebetween
terminals B1 and 822 and
b e t w e e nt e r m i n a l s B g a n d
820.
LGl IBNN/BLK}
Repair open or short in the wi.o
between th6 81 and/or 89 terminals and the PGM-FImain relav,
and between th€ PGM-FImain
r€ley rnd the under-hoodtus€/
relay box.
To page14''103
14-102
LG2 {BRN/BLK)
Frompage14-102
PCMCONNECTORS
Measu.e D4 IND Voltago:
1. Turnthe ignitionswitchOFF.
2. Connectthe B (2SPiconnector
to the PCM.
3. Connecta digital multimeter
to the A14 and 820 or 822 ter4. Turnthe ignitionswitchON (ll),
and makesurethat voltageis
for two seconds.
available
Wire sideol femaleterminals
Chock for ooon in tho wite
between the A't4 tsrminal .nd
the gauge.3s.mbly. ll wite i3
OK, chock to. a t.ulty indicator
light bulb or. feulty gaugc
e336mblyp.inted circuit board.
CheckD4 IND lor a Short Citcuit:
Checklor continuity betweenthe
A14terminaland bodyground.
ls therecontinuity?
Rop.ir short in thc wirg b€twoen
th. Al4 tormin.l .nd tho gaugo
a$ombly. ll wiro is OK. chock
tho gsugo a3rambly.
Checkfo. loose terminal tit in thc
PCM connectoB. Chock the A/T
gear position switch. It ncce3sary, substitute a known-good
PCMand rechock.
14-103
('99- 00 Modelsl
ElectricalTroubleshooting
TroubleshootingFlowchart- BrakeSwitch Signal
Shift lever cannot be moved trom
E position with tho b.ake pedal
depressod.
CheckBrake Light Operation:
Depressthe brakepedal.
Are the brakellghtsON?
Repairt ulty brake switch circuit
{sees€ction23}.
PCMCONNECTORS
B {25P)
Mea3ureSTOPSW Vohage:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (32P)and B
{ 2 5 P }c o n n e c t o r sf r o m t h e
PCM,
3. Measurethe voltagebetween
the A32 and 820 or 822termin a l s w i t h t h e b r a k ep e d a l
depressed.
Wire side of female terminals
ls therebatteryvoltage?
. Brak€switch sign.l is OK.
. Check for loose terminal fil in
lhe PCM conn€ctors. lf necessary. substitute a known-good
PICMand recheck.
. InsDectthe breke 3witch circuit
lsee section231.
14-104
Repairopen in the wire betwsen
the A32 terminal rnd tho brrk6
switch.
Lock-upGontrol SolenoidValve A/B Assembly
Test
Replacement
'1, Disconnectthe 2P connectorfrom the tocK-upcontrol solenoidvalve1y'8assembly.
NOTE:Lock-upcontrolsolenoidvalvesA and I must bs
removed/replacedas an assembly.
TERMINAL
SIOEOF
MALETERMINALS
1.
R e m o v et h e m o u n t i n gb o l t s a n d l o c k - u pc o n t r o l
solenoidvalveAy'Bassemblv.
6 r 1 . 0m m
1 2 N . m( 1 . 2k g f . m , 8 . 7l b l . f t l
/:'-
Cleanthe mountingsurface
and fluid psssages.
LOCK.UP
CONTROL
VALVEA/B
SOLENOID
ASSEMBLY
Measure the resistancebetween the No. 2 terminal
(solenoidvalve A) of the lock-upcontrol solenoid
valveconnectorand body ground,and betweenthe
No. 1 terminal(solenoidvalveBl and body ground.
STANDARD:12 - 25 O
Cleanthe mounting surfaceand fluid passagesof
th6 lock-upcontrol solenoid valve assembly,and
instsll a new lock-upcontrol sol€noid valve Ay'Bwith
a new filtsr/gask€t.
Checkthe connector for rust, dirt or oil, and raconnect it securely.
Replacethe lock-upcontrol solenoidvalve assembly if the resistanceis out of specification.
lf the resistanceis within the standard,connectthe
No. 1 terminalof the lock-upcontrolsolenoidvalve
connectorto the battery positiveterminal. A clicking
soundshouldbe heard.Connsctthe No. 2 terminalto
the batterypositiveterminal.A clickingsound should
be heard. Replacethe lock-upcontrol solenoid valve
assemblyif no clickingsoundis heard.
1+105
Shift Control SolenoidValve A/B Assembly
Test
Replacement
1.
NOTE: Shift control solenoid valves A and B must be
removed/replaced
as an assembly.
Disconnectthe 2P connectorfrom the shift control
solenoidvalveA,/Bassemblv.
1.
Removethe mountingboltsand shiftcontrolsolenoid
valveA,/Bassembly.
5xL0mm
12 N.m
(1.2kgf.m,8.7lbf.ft)
SHIFTCONTROL
VALVEA/B
SOLENOID
ASSEMBLY
N4easure
the resistancebetweenthe No. 1 terminal
(solenoidvalveA) of the shift controlsolenoidvalve
connectorand body ground,and betweenthe No. 2
terminal(solenoidvalveB) and body ground.
STANDARD:12 - 25 O
Replacethe shift controlsolenoidvalve assemblyif
is out of specification,
the resistance
lf the resistanceis within the standard,connectthe
No. 1 te.minal of the shift control solenoid valve
connectorto the batterypositiveterminal.A clicking
sound should be heard.Connectthe No. 2 terminal
to the battery positive terminal. A clicking sound
should be heard.Replacethe shift control solenoid
valveassemblyif no clickingsound is heard.
14-106
CONNECTOR
BRACKET
FILTER/GASKET
Cleanthe mountingsurface
Beplace.
and fluid passages.
Cleanthe mounting surfaceand fluid passagesof
t h e s h i f t c o n t r o l s o l e n o i d v a l v e a s s e m b l y ,a n d
installa new shift controlsolenoidvalveAy'Bwith a
new filter/gasket
and the clamp bracket.
Checkthe connectorfor rust. dirt or oil. and reconnect it securelv,
LinearSolenoid Assembly
Test
1.
lf not, removethe linearsolenoidassembly.
the linearsolenoidconnector.
Disconnect
Checkthat the linearsolenoidfluid passageIor dust
or dirt.
LINEARSOLENOID
1.
C o n n e c t h e N o . 2 t e r m i n a lo f t h e l i n e a rs o l e n o i d
connectorto the batterypositiveterminaland connectthe No, 1 terminalto the batterynegativetermanal.Checkthat the valvemoves.
Disconnectone of the batteryterminalsand check
that the valvereleases.
NOTE:You can see the valve movementthrough
the fluid passagein the mountingsurfaceof the linear solenoidassembly.
LINEAR
SOLENOID
Measurethe resistancebetweenthe No. 1 and the
No. 2 terminalsof the linearsolenoidconnector.
STANDARD:applox. 5 O
replacethe
lf the resistanceis out of specification,
linearsolenoidassembly.
4.
Connectthe No. 2 terminalof the linsarsolenoidconnector to the batterv positive terminal and connect
the No. 1 terminalto the batterynegativeterminal A
clickingsoundshouldbe heard.
VALVE
lf the valvebinds,or movessluggishly,or the linear
solenoiddoesnot operate,replacethe linearsolenoid
assembly.
14-107
LinearSolenoidAssembly
Mainshaft/Countershaft
Speed Sensors
Replacement
Replacement
1.
't. Removethe mm
6
bolt and the countershaftspeed
Removethe mountingbolts and the linearsolenoid
assemory.
themounting
surface
Clean
andfluid passages.
sensorfrom the rightside cover.
6 x 1 . 0m m
1 2N.m (1.2kgf.m, COUNTERSI{AFT
8.7rbf ft)
SPEEDSENSOR
6x1.0mm
12 N.m 11.2kgl m,
8.7 tbf.ftl
\
\
O.RING
Replace.
\
/ ,
%/E:)
MAINSHAFT
SPEED
SENSOR
@
@
GASKET
LINEAR
SOLENOID
ASSEMELY
MAINSHAFTSPEED
SENSOBWAS}IER
(D16Y7enginel
6x1.0mm
12 N.m (1.2kgf m,
8.7 tbf.ft)
Cleanthe mountingsurfaceand fluid passageof the
linearsolenoidassemblyand transmissionhousing.
Removethe 6 mm bolt and the mainshaftsDeed
sensorfrom the transmissionhousino.
Installa new linear solenoidassemblywith a new
gasl(et.
Replacethe O-ringwith a new one beforeinstalling
the countershaftspeedsensoror th€ mainshaftspeed
sensor.
NOTE;Do not pinch the gasketwhen installingthe
linearsolenoid;makesurethat the gasketis installed
properlyin the mountinggrooveof the linearsolenoid.
Checkthe linearsolenoidconnectorfor rust,dirt or
oil, and connectit securely,
14-108
NOTE:Installthemainshaftspeedsensorwasheron
the mainshaftspeed sensor.The mainshaftspeed
sensorwasher is used on models with the D'|6Y7
engine.
Symptom-to-ComponentChart
HydraulicSystem
C h e c kt h e s e i t e m s o n t h e
P R O B A B L EC A U S E L i s t
SYMPTOM
Engineruns,but vehicledoesnot move in any gear.
Vehiclemovesin E, E, but not in lrl, pr-, position.
movesin Dl, E, El,lut notin E position.
Vehicle
Vehiclemovesin -o1],@, @, Uutnot in E position.
Vehiclemovesin E position.
idlevibration.
Excessive
flareson startingotf in E, [Dl]position
Pooracceleration;
Stallrpm hiqh in !!1, p!1,E position.
C h e c kl h e s e l e m s o n
the NOTESLIst
1.2,3,5,6,7.36,38
K , L ,R ,S
6, 8, 9, 10,30, 54
c,M,o
6,11,12.24
4 , 6 , 1 4 ,1 5
C,L
10,12,13,14,16,29,33,34,35
C,D
c,L,o
4 ,5 ,4 1 4
,a
1 . 2 ,1 9 , 3 2 , 3 6
1 , 2 , 3 , 6 , 3 44,1
6. 8. 10
K,L,R
6,12
C,D
C,D
14
N
No shift
11, 32. 45,41, 48
19,20,40,48,49
G,L
Failsto shiftin 81, pll position;from lst to 3rd gear
22,49
F a i l st o s h i f t i n 0 3 , D . o o s i t i o n ; f r o m l s t t o 4 t h q e a r
22.23,48
Erraticupshifting.
1'2 upshift,2-3 upshift,3-4 upshift
58
stall rom hioh in D.r, lD,loosition.
5t"[ rprnrsn ^ a"t"t-at
1-2upshift
3'4 upshift
Harshupshift{1 2).
Harshupshift(2'3).
Harsh upshift (3'4).
21,48
22,t9
23,la
12,19,20,29.50,51,57.54
13,19,20,24,27, 29,50.51, 51, 58
14,19,20,25,28,29.50,51, 51, I
C,D,E,H,L
C , D ,E ,I , L
19, 20. 24, 43,54, 57, 58
12,19,20,25,43,55,57,5A
13,19,20,26,43,56,57,58
o
Flareson 2-3 upshift.
Flareson 3-4 upshift.
Excessive
shockon 2-3uPshift.
Excessive
shockon 3-4 uPshift.
Lateshiftfrom El positionto Lq! or &l position.
Lateshiftfrom E positionto E position.
1 3 ,1 9 , 2 0 , 2 4 . 2 1 , 5 1
14,19. 20,25.24,51
13.19,20,24,27. 43.50.51, 58
14,19,20,25.2A,8, 50,51, 58
F I
10,30
4 , 1 4 ,2 1 , 5 3
o
K,L,O
Harshdownshift(2-1)
Harshdownshift(3-2).
Harshdownshift(4-3).
C,D,E,H
C, D, E, I
E,L,N
E,L,N
E,L,N
in all shiftleverpositions
Noisefrom transmission
2,31
V e h i c l e d o e s n o t a c c e l e t a t em o r e t h a n 3 1 m p h { 5 0 k m / h )
17
shift lever does not operate smoothly.
P
will not shiftintoparkin [a]position
Transmission
6, 39
19,48,49
6, 18,39
S t a l l r p m h i g h ; a l l c l u t c h p r e s s u r e sa r e i n s p e c i f i c a t i o n .
41
D,K,O
Lockup clutchdoesnot disengage.
Lockup clutchdoesnot operatesmoothly.
19,44,45,46.41,50,51.54
19,41,44,45,46,47,50,51,58
L
Lock-upclutchdoesnot engage.
Vibrationin all positions
19,41,4t, 15,46,41,50, 51,57,58
F a i l st o s h i f t ; s t u c k i n 4 t h g e a r .
F I
(cont'd)
The followingsymptomscan be caused
by improperrepairor assembly
Checktheseitems,onth€^
CAUSEDUETO
PROBABLE
List
IMPROPER
REPAIR
Vehiclecreepsin N position.
R 1 ,R 2
Vehicledoes not move in &l or Pll position.
locksup in E position.
Transmission
R4
drag in transmission.
Excessive
R6
vibration,rpm related.
Excessive
R7
Noisewith wheelsmovingonlY.
R5
Main sealpops out.
R8
Variousshiftingproblems.
R 9 ,R l O
ltemson the
NOTESList
R 3 ,R 1 1
K,R
REPAIR
CAUSEDUETO IMPROPER
PROBABLE
lmproperclutchclearance.
lmpropergearclearance.
Parkleverinstalledupsidedown.
one-way{sprag)clutchinstalledupsidedown.
Reverseselectorhub installedupsidedown.
ATF pump binding.
Torqueconverternot fully seatedin ATF pump.
Main sealimproperlyinstalled.
Springsimproperlyinstalled.
Valvesimproperlyinstalled.
Shiftfork bolt not installed.
14-11
Symptom-to-ComponentChart
HydraulicSystem(cont'dl
Seeflushingprocedure,page 14-187and 188.
set idle rpm in gearto specifiedidle speed.lf still no good,adjustmotor mountsas outlinedin engine
sectionof this manual.
lf the largeclutchpistonO-ringis broken,inspectthe pistongroovefor rough machining.
lf the clutchpackis seizedor is excessively
worn. inspectthe otherclutchesfor wear,and checkthe orifice
controlvalves,CPCvalveand linearsolenoidfor free movement.
lf the linearsolenoidis stuck,inspectthe clutchesfor wear.
G.
lf the l-2 shift valveis stuckclosed,the transmissionwill not upshift.lf stuckopen,the transmissionhas
no 1stgear.
n,
lf the znd orificecontrolvalveis stuck.inspectthe 2nd and 3rd clutchoacksfor wear.
lf the 3-4 orificecontrolvalveis stuck,inspectthe 3rd and 4th clutchoacksfor wear.
lf the clutchpressurecontrolvalveis stuckclosed,the transmissionwill not shift out of 1stgear.
lmproperalignmentor main valvebody and torqueconverterhousingmay causeATF pump seizure.The
symptomsare mostlyan rpm-related
tickingnoiseor a high-pitchedsqueak.
lf the ATF straineris cloggedwith particlesof steelor aluminum,inspectthe ATF pump and differential
pinionshaft.lf both are OK and no causefor the contaminationis found,replacethe torqueconverter.
lf the l st clutchfeed pipe guide in the end cover is scoredby the mainshaft,inspectthe ball bearingfor
excessivemovementin the transmissionhousing.lf oK, replacethe end coveras it is dented.The o-rino
underthe guide is probablyworn.
Replace
the mainshaftif the bushingfor the 4th feedpipeis looseor damaged.lf the 4th feedpipeis danF
aged or out of round, replacethe right side cover.
Replace
the mainshaftif the bushingfor the 1stfeedpipeis looseor damaged.lf the 1stfeedpipeis darnagedor out of round,replaceit.
A worn or damagedspragclutchis mostlya resultof shiftingthe transmissionin
the wheelsrotatein reverse,suchas rockingthe vehiclein snow.
or E positionwhile
Inspectthe framefor collisiondamage.
Inspectfor damageand wear:
1. Reverseselectorgearteethchamfers.
2. Engagement
teethchamfersof countershaft4th and reversegear.
3. Shiftfork for scuffmarksin center.
4. Differentialpinionshaftfor wear u nder pinion gears.
5. Bottomof 3rd clutchfor swirl marks.
Replaceitems1,2,3 and 4 if worn or damaged.lf transmission
makesa clicking,grindingorwhirringnoise,
alsoreplacemainshaft4th gear,reverseidlergear.and countershaft
4th gearin additionto 1, 2, 3 or 4.
lf differentialpinion shaft is worn, overhauldifferentialassembly,and replaceATF strainer,and thoroughly
cleantransmission,
flushtorqueconverter,
coolerand lines.
lf bottom of 3rd clutchis swirled and transmissionmakesgear noise,replacethe countershaftand final driven
gear.
Be very carefulnot to damagethe torqueconverterhousingwhen replacingthe main ball bearing,you
may also damagethe ATF pump when you torquedown the main valvebody.Thiswill resultin ATF pump
seizureif not detected.Usethe oroperroors.
Installthe main sealflush with the torqueconverterhousing.lf you push it into the torqueconverter
housinguntil it bottomsout, it will blockthe fluid returnpassageand resultin damage.
14-1 1 2
Road Test
NOTE:Warm up the engineto normaloperatingtemperature (the radiatorfan comeson)'
1. Apply parkingbrakeand blockthe wheels.Start the engine,then shift to E positionwhile depressingthe brake
pedaland releaseit suddenly.The engineshouldnot stall'
Dedal,Depressthe accelerator
2. Repeatsametest in E Position.
3. Test-drivethe vehicleon a flat road in the E position.Checkthat the shift pointsoccurat approximatespeedsshown
in the table.Also checkfor abnormalnoiseand clutchslippage.
the throttleopening
NOTE:Throttlepositionsensorvoltagerepresents
a. Unboltthe PCMfor roadtesting;referto page14-50.
b. Setthedigitalmultimeterto checkthe th rottlepositionsensorvoltagebetweenPCMterminals;
. '96 - 98 models:D1 {+)and A9 (-) or 422 (-}.
. ' 9 9- 0 0 m o d e l sC
: 2 7( + )a n d B 2 0 t - )o r B 2 2 { - } .
BACKPROBE
ADAPTER
SET
BACKPROBE
07sAz- 001oq)A
{tworequiredl
DIGIIAL MULTIMETER
lCommerciallyavailable)
KS-AHM-32-003,
or equivalenl
'96 - 98 Modelsr
c (31P}
I (25P1
Wire sideol temaleterminals
'9!t - 00 Models:
A t32Pt
PCMCONNECTORS
c (31P)
B t25Pl
D (16P)
LG1IBRN/BLK)
Wire side ol female terminals
1+113
Road Test
(cont'dl
.91Position:Dl6Y7 engine
.
Upshift
Throttle Opening
Throttlepositionsensor
voltage:0.75V
Throttlepositionsensor
v o l t a g e : 2 . 2V5
Fully-opened
throttle
Throttlepositionsensor
voltage:4.5V
Unit of speed
lst + znd
2nd * 3rd
mph
9-12
20-23
28-32
21-24
km/h
15-19
32-37
45-52
34-39
mph
3rd t
Lock-upON
4th
40-45
62-67
't08
99 -
95 - 104
1 0 1- ' t 1 2
km/h
34-40
mph
33-38
km/h
53-61
Unit of speed
Lock-upOFF
'lth + 3rd
mph
't9 - 22
1 7- 2 0
6-9(3rd+lst)
km/h
30-35
27-32
10- 15 (3rd+ 1st)
mpn
95 - 105
85-95
54-61
25-30
km/h
153- 169
1 3 7- 1 5 3
87-98
40-48
Unit of speed
lst + 2nd
2nd - 3rd
3rd + 4th
Lock-up ON
mph
9-12
20-23
2A-32
2 1- 2 4
km/h
32-37
45-52
34-39
mpn
15-19
2 1- 2 5
40-45
km/h
34-40
59-65
9 5- 1 0 4
99 - 108
mph
32-37
6 2- 7 0
96 - 107
9 5- 1 0 6
km/h
52-60
1 0 0- 1 1 3
't55-
't53- '170
Unit ot speed
Lock-upOFF
'lth + 3rd
mph
19-22
1 7- 2 0
6-9(3rd+ 1st)
km/h
30-35
27-32
l0 - 15 (3rd+ lst)
mpn
9 1- 1 0 1
km/h
'147- 163
102-115
99 - 109
'159- 176
163- 180
Downshift
Throftle Opening
Fullyclosedthrottle
Throttlepositionsensor
voltage:0.5V
Fully-opened
throttle
Throttlepositionsensor
voltage:4.5V
3rd + 2nd
2nd t
lst
-q1Position: DI6YBengine
.
Upshift
Throttle Opening
Throftlepositionsensor
voltage:0.75V
Throttlepositionsensor
v o l t a g e : 2 . 2V5
Fully-opened
throttle
Throttlepositionsensor
voltage:4.5V
112
Downshift
Throttle Opening
Fully-closed
throttle
Throttlepositionsensor
voltage:0.5V
Fullyopenedthrottle
Throttlepositionsensor
voltage:4.5V
NOTE:
. Lock-upON:The lock-upcontrolsolenoidvalveA turns ON.
. Lock-upOFF:The lock-upcontrolsolenoidvalveA turns OFF.
14-114
3rd+2nd
I
54-61
1 3 7- 1 5 3
87-98
2nd+lst
25-30
I
40-48
then shift from Dl positionto Z position The
Accelerateto about 35 mph (57 km/h)so the transmlssionis in 4th,
braking'
engine
vehicleshouldimmediatelybeginslowingdown from
CAUTION: Do not shift from -91or
the transmission.
-Ddposition to
damage
E position at speeds ov6r 63 mph {100 km/hl; You mav
positions'
Checkfor abnormalnoiseand clutchslippagein the following
E (2ndGear)Position
clutchslippage.
from a stop at full throttle.checkthat there is no abnormalnoiseor
ll Accelerate
posirion'
b. Upshiftsand downshiftsshouldnot occurwith the selectorin this
Position
E (Reverse)
and clutchslippage'
i"cceleratefrom a stop at fullthrottle,and checkfor abnormalnoise
Test in B (Park)Position
into E position Beleasethe brake;the veh'
Parkthe vehicleon slope(approx.l6'), applythe parkingbrake'and shift
cle shou,dnol move
1+115
Stall Speed
Test
CAUTION:
. To prev€nt transmissiondamage,do not t6st stall speedfor more than
ro sgcondsat a time.
. Do not shift the levor while raising the engine speed.
. Bo sule lo remove the pressuregauge betoro testing stall speed.
'1.
Engagethe parkingbrake,and blockthe front wheels.
2.
Connecta tachometerto the engine,and startthe engine.
3.
Makesurethe Ay'Cswitchis OFF.
4.
After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan
5.
Fullydepressthe brakepedaland accelerator
for 6 to g seconds,and noteenginespeed.
6.
Allow two minutesfor cooling,then repeatthe test in @ and @ positions.
comeson). shift into E position.
NOTE:
. Stallspeedtestsshouldbe usedfor diagnosticpurposesonly,
. Stallspeedshouldbe the samein o., E and positions.
E
Stall Spsed RPM:
Specification:2.700rpm
ServiceLimit: 2,550- 2,850rDm
TROUBLE
PROBABLECAUSE
Stallrpm high in D., E and E positions
.
.
.
.
Stallrpm high in El position
Stallrpm high in E posirion
. Slippageof 4th ctutch
. Slippageof 2nd clutch
. Slippageof lst clut"tr or. t"t g""io*-*"y
"lut"h
. Engineoutput low
. Torqueconverterone-wayclutchslipping
Stallrpm high in E position
Stallrpm low in LDa
. El and E positrons
14-1 1 6
Low fluid levelor ATF pump outDur
CloggedATF strainer
Pressureregulatorvalvesluckcloseo
Slippingclutch
Fluid Level
Ghecking
NOTE: Keep all foreign particlesout of the transmissron.
1.
7.
Insertthe dipstickbackinto the transmissionin the
directionshown.
Warm up the engineto normal operatingtemperature (the radiatorfan comeson)
FRONT
Parkthe vehicleon the level ground, then turn off
the engrne.
Removethe dipstick(yellow loop) from the transmission.and wipe it with a cleancloth.
Insertthe dipstickinto the transmrssron
Installthedipstickin the extent
of the directionshown.
DIPSTICKIYELLOWLOOPI
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l l t
s h o u l d b e b e t w e e nt h e u p p e r m a r k a n d l o w e r
marks.
K
L
UPPERMABK
LOWERMARK
lf the levelis belowthe lower mark,pour the recomm e n d e df l u i d i n t o t h e t i l l e r h o l e t o b r i n g i t t o t h e
upper mark. Always use GenuineHonda Premium
FormulaAutomaticTransmissionFluid (ATF).Using
a non-HondaATFcan affectshift quality
14-117
Fluid Level
Changing
NOT€: Keep all foreign particlesout of the transmission.
'1.
Bringthe transmissionup to operatingtemperature
(the radiatorfan comeson) by drivingthe vehicle.
Parkthe vehicleon the level ground, and turn the
engine off.
R e m o v et h e d r a i n p l u g . a n d d r a i n t h e a u t o m a t i c
transmissionfluid (ATF).
NOTE:lf a coolerflusheris to be used,seepage 14187and 14-188.
TRANSMISgION
ENDOOVER
DNAINPLUG
1 8x 1 . 5m m
49 N.m (5.0kgtm, 36lbf.ftl
SEALINGWASHER
Replace.
Reinstallthe drain plug with a new sealingwasher,
then refill the transmissionwith the recommended
fluid into the filler hole to the upper mark on the
d i p s t i c k .A l w a y s u s e G e n u i n e H o n d a p r e m i u m
FormulaAutomaticTransmissionFluid (ATF).Using
a non-HondaATFcan aftectshift quality.
Automatic TransmissionFluid Capacity:
2.7 | |'2.9US ql,2.a lmp qtl at Ghlnging
5.9 f 16.2US qt. 5.2 lmp qt) at overhaul
1 4- 1 1 A
PressureTesting
@
I While testing, be caroful of th€ rotating front wheels.
.
Make sure lifts, iacks, and satoty stands are placod properly (seesection 1)'
CAUTION:
. Beforoiesting, be sure the transmissionfluid is tilled to tho proper level'
. Warm up tho engine before testing'
1.
Raisethe vehicle(seesection1).
2.
Warm up the engine,then stopthe engineand connecta tachometer'
3.
Connectthe oil pressuregaugesto eachinspectionhole.
TOROUE:18 N.m (1.8 kgf'm, 13 lbnft)
to entel
cAUTloN: connact the oil pressurogauges securely;be suro not to allow dust and other foreign Parlicles
the inspestion holos'
GAUGE
A/T OILPRESSURE
SETw/PANEL
07t06- 0020400
HOSE
A/T OIL PRESSURE
ADAPTER
07Mru - PY0120
(4 requiJedl
GAUGE
A/T LOWPRESSURE
SETWPANEL
07406- 0070300
HOSE
A/T OIL PBESSURE
2210mm
OTMAJ- PY4{)llA
14roquircdl
Startthe engine,and measurethe respectiveptessureas follows'
a LinePressure
. 1st Clutch Pressure
. 2nd,3rd and 4th ClutchPressure
Installa new washerand the sealingbolt in the inspectionhole.and tightento the specifiedtorque'
TOROUE:l8 N.m (1.8 kgf'm,13lbf'ft)
NOTE:Do not reuseold sealingwashers;alwaysreplacewashers'
(cont'd)
14-119
PressureTesting
(cont'd)
Line Pressure/1stClutch PressurcMeasurement
1.
Setthe parkingbrake,and btockboth rearwheelssecurely.
2.
Startthe engine,and run it at 2,OOO
rpm.
3.
Shiftto N or E position,then measureline pressure.
NoTE: Higherpressuremay be indicatedif measurements
are made in shift leverpositionsotherthan @ or @ posi
tron.
4.
Shiftto tq;lposition,hold the engineat 2,000rpm, and measure1stcrutchpressure.
1STCLUTCHPRESSURE
INSPECTION
HOLE
(Markedwith "1")
LOCK.UPCONTROL
SOLENOIDVALVEA/8
ASSEMBLY
VALVEA/B ASSEMBLY
PRESSURE
Line
1stClutch
14-120
SHIFTLEVER
POS|TtON
SYMPTOM
PROBABLE
CAUSE
FLUIDPRESSURE
Standard
N orE
No (or low)
lrne pressure
Torqueconverter,
ATF pump,pressure regutator.
torqueconverter
checkvalve
D;l
Noor low 1st
pressure
1 s tC l u t c h
830 - 880 kPa
{8.5- 9.0 kgf/cm?,
120- 130psi)
ServiceLimit
780 kPa
(8.0kgf/cm' ,110psi)
2nd, 3rd and 4th Clutch PressureMeasurement
1. Setthe parkingbrake,and blockboth rearwheelssecurely'
2. Startthe engine,and run it the engineat 2,000rpm'
pressure
3. Shiftto E position,then measure2nd clutch
pressure
4. Shiftto El position,then measure3rdclutch
pressure'
5. Shiftto E position,then measure4th clutch
pressure'
6. Shiftto E position,then measure4th clutch
2ND CLUTCHPR€SSURE
HOLE
INSPECTION
HOI'E
INSPECTION
(Markedwith "3")
FLUIDPRESSURE
SHIFTLEVER
PRESSURE POStT|()N
SYMPTOM
PROBABLECAUSE
2nd Clutch
tr
No or low 2nd
pressure
2nd Clutch
3rd Clutch
tr
No or low 3rd
pressure
3rd Clutch
p.l
No or low 4th
presSure
4th clurch
4th clutch
E
standard
800 (8.21208'10(8.3120-
I
sorviqe Limit
850 kPa
8.7 kgflcm',
120psi)
760 kPa
(7.7kgf/cm' ,110Psil
860 kPa
8.8 kgt/cm',
130psi)
760 kPa
(7.8kgt/cm',110Psi)
Servo Valve or 4th
Clutch
1+121
Transmission
Removal
@
Maks sure lifts, iacks and safety stands are placed
properly, and hoist bracket ate aftached to the cor_
rec{ position on the engine lsee section 1).
Apply parking brake and block rear whoels so vehicle
will not roll off stands and fall on you while working
under it.
4.
Removethe transmissiongroundcable,and discon_
nectthe lock-upcontrolsolenoidconnector.
CAUTION: Use tender covers to avoid damaging painted surfaces.
1,
Disconnectthe battery negative(_) terminal from
the battery,then removethe positive(+)terminal.
2.
Removethe intakeair duct.
D16Y7engins:
Removethe intakeair duct and resonator.
LOCK.UPCONTROL
SOLENOIDCONNECTOR
D16Y8engine:
Removethe intakeair duct and the air cleanerhousing assembly,
3.
Removethe starter cables and cable holder from
the starter motor.
5,
Disconnectthe vehiclespeedsensor(VSS)connec_
tor and the countershaft
speedsensorconnector.
MOTORCABLE
VEHICLE
SPEED
MOTORCABLE
14-122
6.
Removethe transmissionhousing mounting bolts
and the rearenginemountingbolt.
8.
DRAINPLUG
18 x 1.5mm
'9 N m t5 o kgf'm' 36 lbf'ft|
MOUNTINGBOLTS
7.
the shiftcontrolsolenoid,the linearsoleDisconnect
noid,and the mainshaftspeedsensorconnectors'
9.
SHIFTCONTROL
SOLENOIDCONNECTOR
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e a u t o m a t i c
t r a n s m i s s i o nf l u i d ( A T F ) .R e i n s t a ltlh e d r a i n p l u g
with a new sealingwasher.
Replace.
Remove the splash shield.
LINEARSOLENOID
CONNECTOR
SPLASHSHIELD
BRACKET
{cont'd)
14-123
Transmission
Removal(cont'd)
'10. Remove
the cotter pins and castlenuts, th€n separate
the balljoints from the lower arms (seesection 1gl.
16. Removethe shift cablecover.then removethe shift
cableby removingthe controllever,
DAMPERPINCHBOLT
CAUTION: Take car6 not to bond the shift cable.
NUT
FORK BOLT
FORI(
COTTER
PIN
Replace.
WASHER
11. Removethe right damper fork bolt. th€n separate
right damperfork and dampor.
1 2 . Prythe right and left driveshaftsout ofthe differential.
1a
Pullon the inboardjoint to removethe right and left
drivsshafts(seesection 16).
1 4 . Tie plastic bags over the driveshaftonds.
NOTE: Coat all precisionfinished surfaceswith clean
engineoil.
t9.
1 7 . Removethe right front mounvbracket.
1 8 . Remove the ATF cooler hoses at the ATF cooler
lines.Tufn the ends of the ATF cooler hosesuo to
preventATF from flowing out, then plug the ATF
cooler hosgsand lines.
NOTE: Checkfor any sign of leakageat the hose
ioints.
Removethe exhaustpipe A,
NOTE: Dl6YB engine is shown; D16y7 engine is
similar.
SELF-LOCKING
NUT
Replace.
14-124
EXHAUSTPIPEA
MOUNT/BRACKET
19. Removethe engine stiffener and the torque converter cover.
23. Placea jack under the transmission.and ra6a :'.
transmissioniust enoughto take weight otf ol tF.
mounts.then removethe transmissionmounl
TRANSMISSION
MOUNTBRACKET
COVER
20. Removethe eight drive plate bolts one at a tlme
while rotatingthe crankshaftpulley.
2 1 . Removethe distributor.
Attacha hoistingbracketto the engine,then lift the
engineslightly.
24. Removethe transmissionhousing mounting bolts
and the rearenginemountingbolts.
25. Pull the transmissionaway from the engineuntil it
clearsthe 14 mm dowel pins, then lower it on the
transmissionjack.
TRANSMISSIONHOUSING
HOIST
BRACKET
lf necessary,removethe torque converteranc:"
startermotor.
1+16
lllustrated Index
Transmission/End
Cover
a-'tEO
14-126
O ROLLER
O COLLAR
O o-RINGReplace.
@ FEEDPIPEFLANGE
@ O-RINGReplace.
@ SNAP RING
€) 3RD CLUTCHFEEDPIPE
LOCKNUT(FLANGENUT)
€) COUNTERSHAFT
23 x 1.25mm Replace.
o coNlcAL SPRINGWASHERReplace.
@ PARKGEAR
@ ONE.WAYCLUTCH
lST GEAR
@ COUNTERSHAFT
@ NEEDLEBEARING
lST GEARCOLLAR
@ COUNTERSHAFT
@ o-RlNGs Replace.
@ ENDcovER GASKETReplace.
E) DOWELPINS
@ PARKPAWLSTOP
@ LocK WASHERReplace.
@ PARKSTOPSelectivepart
€D PARKLEVER
@ PARKLEVERSPRING
€D DRAINPLUG
€) SEALINGWASHERReplace
@ o-RINGReplace.
SPEEDSENSOR
@ COUNTERSHAFT
PAWL
PARK
@)
@ PARKPAWLSPRING
@ PARKPAWLSHAFT
@ LINEARSOLENOIDASSEMBLY
@ LINEARSOLENOIDGASKETREPIACE.
@)END COVER
@ lsT CLUTCHFEEDPIPE
@ O-RINGSReplace.
@ FEEDPIPEFLANGE
C) SNAP BING
@ MAINSHAFTLOCKNUT(FLANGENUTI 21 x 1 25 mm
Replace.
@ CONICALSPRINGWASHERRePlace
@)lST CLUTCHASSEMBLY
@ o-RlNGs Replace.
€) THRUSTWASHER
@)THRUSTNEEDLEBEARING
@ NEEDLEBEARING
@ MAINSHAFTlST GEAR
@ MAINSHAFTlST GEARCOLLAR
@)ATF COOLERLINE
@ SEAUNGWASHERSReplace.
@ LINEBOLT
@ ATF DIFSTICK
@ ATF COOLERLINE
@ UNE BOLT
@ SEALINGWASHERSReplace.
@ VEHICTTSPEEDSENSOR
@ O-RINGReplace.
TOROUESPECIFICATIONS
Bolt/Nut No.
6B
8F
12A.
'l8D
2'tM
23C
Torque Value
Size
'12N'm (1.2kgim,8.7 lbift)
14 N.m (1.4kgf.m,10 lbf'ft)
22 N.m (2.2 kgf.m, 16 lbf'ft)
28 N.m (2.9 kgf.m, 21 lbf'ft)
49 N.m (5.0 kgf.m, 36 lbf'ft)
78 N.m (8.0 kgf'm, 58 lbf'ft)
103N.m {10.5kgf'm,75.9lbift)
6x1.0mm
6x1.0mm
8 x 1 , 2 5m m
1 2x 1 . 2 5m m
1 8x 1 . 5m m
2 1 x 1 . 2 5m m
2 3 x 1 . 2 5m m
Remarks
Linebolt
Drainplug
Mainshattlocknut:Left-handthreads
locknut:
Countershaft
Left-handthreads
14-127
lllustrated Index
Transmission
Housing
6A
I
e
:!_..
14-128
Replace,
O LocKWASHER
SHIFTFORK
O REVERSE
REVERSE
GEARCOLLAR
O COUNTERSHAFT
REVERSE
GEAR
G) COUNTERSHAFT
BEARING
@ NEEDLE
SELECTOR
@ REVERSE
HUB
SELECTOR
REVERSE
O
4THGEAR
@ COUNTERSHAFT
BEARING
O NEEDLE
28 mm Selectivepart
GOLLAR,
@ DISTANCE
2ND
O COUNTERSHAFT GEAR
@ THRUSTNEEDIEBEARING
3RDGEAR
@ COUNTERSHAFT
BEARING
@ NEEDLE
3RDGEARCOLLAR
@ COUNTEBSHAFT
NEEDLE
BEAFING
@ THRUST
WASHER
O SPLINED
ASSEMBLY
@ 3RDCLUTCH
Replace.
@ O-RtNGs
@ COUNTERSHAFT
@ SNAPRING
WASHER
@ THRUST
BEARING
NEEDTE
€) THRUST
GEAR
4TH
GEAR/REVERSE
MATNSHAFT
@}
BEARINGS
@iNEEDLE
EEARING
@ THRUSTNEEDLE
4THGEARCOLLAR
@)MAINSHAFT
ASSEMBLY
@ 2ND/4THCLUTCH
@ o-RlNGsReplace.
x 55 mm Sel€ctivepart
WASHER,36.5
@ THRUST
BEARING
@ THRUSTNEEDLE
zNDGEAR
@ MAINSHAFT
BEARING
@ NEEDLE
BEARING
NEEDLE
@ THRUST
@ MAINSHAFI
@ S€ALINGRINGS,35 mm
RING,29mm
@ SEALING
@}NEEDIEBEARING
@ SETRING
VALVEA/B ASSEMSLY
SOLENOID
@ sHrFTCONTROL
BRACKET
CLAMP
@ HARNESS
Replace.
FILTER/GASKET
SOI"ENOID
@ SHIFTCOI,ITROL
BFACKET
@ CONNECTOR
HANGER
TNANSMISSION
@D
CAP
@ BREATHER
SPEED
SENSOR
@ MAINSHAFT
WASHER
SPEED
SENSOR
{Dl6Y' ongine}
@ MATNSHAFT
O-RING
Replace.
@
@ SNAPRING
BEARING
HOUSING
TRANSMISSION
@ MAINSHAFT
HOUSING
BEARING
TRANSMISSION
@ OOUNIERSHAFT
ASSEMBLY
IDLERGEARSHAFTHOLDER
@ REVERSE
BEARING
@ NEEDI.E
SEAL
Replace.
olL
@
@ SETRING,fll mm Selectivepart
HouslNG
@rnANsMrssloN
IDI."ER
GEAR
@ REVERSE
@ DowELPINS
Replace.
HOUSING
GASKET
@ TRANSMISSION
ASSEMBLY
@ DIFFERENfIAL
@ OILSEALReplace.
HOUSING
@ TOROUECONVERTER
TOROUESPECIFICANONS
Boh/Nut No.
Torquovalue
Size
6B
10A
12 N.m {1.2kgf.m,8.7lbf.ft)
14 N.m (1.4kgf'm,10lbf'ft)
44 N.m (4.5 kgf.m, 33 lbf'ft)
6x1.0mm
6x1.0mm
1 0x 1 . 2 5m m
Romarks
14-129
lllustrated lndex
TorqueConverterHousing/ValveBody
to\
\*
14-130
O ATF FEEDPIPE
O ATF STRAINER
O SERVOBODY
'99 - 00 modelsservobody has integrallymolded
servodetent.
@ SERVOSEPARATORPLATE
(' SECONDARYVALVE BODY
@ DOWELP|NS
O SECONDARYSEPARATORPLATE
@ SERVODETENTBASE('96 -'98 models)
O ATF FEEDPIPES
(D ATF FEEDPIPES
O SHAFTSTOP
@ CONTROLSHAFT
€D DETENTARM SPRING
@ DETENTARM
(9 DETENTARM SHAFT
@ FILTERReplace.
(? CHECKBALLS
CHECKVALVE
@ TOROUECONVERTER
CHECKVALVE SPRING
CONVERTER
TOROUE
@
@ DOWELPINS
@ LOCK.UPVALVE BODY
@ LOCK-UPSEPARATORPLATE
VALVE BODY
@ REGULATOR
PINS
DOWEL
@}
@ COOLERRELIEFVALVE SPRING
@ COOLERRELIEFVALVE
@ O-RINGReplace.
@ STATORSHAFT
@ STOPSHAFT
@ ATF FEEDPIPE
@ MAIN VALVE BODY
@ ATF PUMP DRIVENGEARSHAFT
@ ATF PUMP DRIVENGEAR
@ DOWELPINS
65)ATF PUMP DRIVEGEAR
MAIN SEPARATORPLATE
SUCTIONPIPECOLLAR
ATF MAGNET
HOUSING
TOROUECONVERTER
COUNTERSHAFT
BEARING
@ ATF GUIDEPLATE
HOUSING
@ ToRoUE CONVERTER
@ OILSEALReplace.
HOUSING
@ MAINSHAFTTOROUECONVERTER
BEARING
@)olL SEALReplace.
@ LOCK-UPCONTROLSOLENOIDFILTER/GASKET
Reolace.
@ LOCK-UPCONIROL SOLENOIDVALVEA/B ASSEMELY
@ CONNECTORBRACKET
@
@
@
@
TOROUESPECIFICANONS
Bolt/Nut No.
Torque Valug
Siz€
12 N.m (1.2kgf.m,8.7lbnft)
6x1,0mm
Remarkg
14-131
End Cover
Removal
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair,
. Blow out all passages,
. When removingthe right sidecover,replacethe following:
- O-rings
- Mainshaftand countershaftlocknuts
- Conicalspringwashgrs
- End cover gasket
- Lockwasher
- Sealingwashers
6 x 1.0mm BOLT
13 Bolts
ENDCOVER
PARKITVER
LOCKWASHER
PARKPAWL
tST GEAFCOLLAR
LINEAOLT
COUI{TERSI{AFT
SEALINGWASHERS
14-132
1.
Removethe 13 bolts securingthe end cover,then
removethe cover.
5 . Removethe specialtool from the mainshaftafter
removingthe locknuts.
Slipthe specialtool onto the mainshaftas shown.
6 . Removethe 1stclutchand mainshaft1stgearassem
bly and mainshaft1stgearcollarfrom the mainshaft.
HOLOER
MAINSHAFT
- PFs0101
07GAB
7. Removethe parkpawl.springand shaft.
8. Removethe parkleverfrom the controlshaft.
9. Using a universaltwo-jaw puller, removethe park
g e a r , o n e w a y c l u t c h a n d c o u n t e r s h a f t1 s t g e a r
assemory.
PULLER
(CommerciallYavailable)
PARKGEAR
Engagethe parkpawl with the parkgear.
4.
Cut the locktabs of the mainshaftand countershaft
locknutsusing a chiselas shown. then removethe
locknutsand conicalspringwashers
CAUTION: Keep all of lhe chiseled particles out of
the transmission.
NOTE:
. Mainshaftand countershaftlocknuts have lefthandthreads.
. Alwayswear safetyglasses.
1 0 . Removethe needle bearing and the countershaft
1stgearcollarfrom the countershaft
1 1 . Removethe ATF coolerlinesand ATFdipstick.
cHrs€L
LOCKNUT
LOCKTA8
14-133
Transmission
Housing
Removal
TRANSMISSIONHOUSING
MOUNTINGBOLTS
1 8B o l t s
TRANSMISSION
HANGER
TRANSMISSION
HOUSING
MAINSHAFT
SUB.ASSEMBLY
MAINSHAFT
SENSORWASHER
lD16Y7engine)
SUB.ASSEMBLY
MAINSHAFT
SPEEDSENSOR
TRANSMISSION
HOUSINGGASKET
DIFFEBENTIAL
ASSEMBLY
TOROUE
CONVERTER
HOUSING
14-134
Torque ConverterHousing/ValveBody
Removal
ATF FEEOPIP€
PIN
LOCK-UPVALVE
BODY
6x1.0mm
SERVODETENT
BASE
LOCK-UPSEPARATOR
PLATE
ATFFEED
PIPES
REGULATOR
VALVESODY
DOWELPIN
COOLERRELIEFVAL
STRAINER
CONTROL
SHAFT
DETENT
ARM SHAFT
DETENT
ARM
SERVOEODY
SEPARATON
ATF FEEDPIPE
6x1.0mm
5 Eolts
MAIN VAL
BODY
ATFPUMP
GEARSHAFT
ATF PUMP
DRIVEN
MAIN SEPARA
PLATE
6x1.0mm
3 Eolts
VALVEBODY
PIN
SECONDARY
SEPARATOR
PLATE
NOTE:The illustrationshowsthe '96 - 98 models,the '99 - 00 modelsdo not havethe servodetentbase;the servodetent
is integralwith the servobody.
14-136
NOTE;
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry with compressedair.
. Blow out all passages.
. When removingthe valvebody,replacethe O-ring.
1 3 . C I e a nt h e i n l e t o p e n i n go f t h e A T F s t r a i n e rt h o r oughly with compressedair. then checkthat it is in
good condition,and the inletopeningis not clogged.
l, Removethe ATF feed pipes from the servo body,
secondaryvalvebody and main valvebody.
For'96 - 98 models:Removethe ATF strainerand
servo detent base (two bolts).
For'99 - 00 models:Removethe ATF strainer(one
bolt).
Removethe servo body and servo separatorplate
{'96- 98 models:sevenbolts,'99- 00 models:eight
bolts).
INLETOPENING
Removethe secondaryvalve body, shaft stop and
secondaryseparatorplate(threebolts).
Removethe lock-upvalve body and separatorplate
{sevenbolts).
Removethe regulatorvalvebody (one boltl.
7 . Removethe stator shaft and stop shaft.
1 4 . Test the filter by pouring clean ATF fluid through
the inlet opening. Beplacethe ATF strainerif it is
cloggedor damaged.
NOTE:The ATF str8inercan be reused if it is not
clogged.
Removethe detentspringfrom the detentarm. then
remove the control shaft from the to.que converter
housing.
Removethe detentarm and detent arm shaft from
the main valvebody.
1 0 . Removethe main valvebody (five bolts).
NOTE:Do not let the eight checkballsfall outofthe
m a i n v a l v e b o d y w h e n r e m o v i n gt h e m a i n v a l v e
body.
't'1. Removethe ATF pump drivengear shaft,then remove
the ATF pump gears.
12. Removethe main separatorplate and two dowel
pins.
14-137
Valve Caps
Description
C a p sw i t h o n e p r o j e c t e dt i p a n d o n e f l a t e n d a r e
installedwith the flat end toward the inside of the
valve body.
Capswith a projectedtip on each end are installed
w i t h t h e s m a l l e rt i p t o w a r d t h e i n s i d eo f t h e v a l v e
body.The smalltip is a springguide.
Toward outside of valvo body.
Capswith hollow ends are installedwith the hollow
end awayfrom the insideofthe valvebody.
Capswith notchedends are installedwith the notch
towardthe insideof the valvebody.
Capswith flat ends and a holethroughthe centerare
installedwith the smaller hole toward the inside of
the valvebodv.
Toward outsido of valve bodv.
Efla
Toward insido ot valvo body.
C a p s w i t h o n e p r o j e c t e dt i p a n d h o l l o w e n d a r e
installedwith the tip toward the inside of the valve
body.The tip is a springguide.
Towa.d outside o, valv6 bodv.
Toward inlido ot valve bodv,
Capswith flat ends and a groovearoundthe cap are
installedwith the groovedside toward the outsideof
the valvebody.
Toward oulsido of valv6 body.
"-\"h
,A
\za9
Sectional view.
Toward insid€ of valv6 bodv.
14-138
Toward insido ol valvo body.
Valve Body
Repair
NOTE:This repair is only necessaryif one or more of
the valvesin a valve body do not slidesmoothlyin their
bores.You may use this procedureto free the valvesin
the valvebodies.
5.
Coatthe valvewith ATF,then drop ir into its bore.
It should drop to the bonom of the bore under its
own weight.lf not, repeatstep 4, then retest.
1 . S o a k a s h e e t o f # 6 0 0 a b r a s i v ep a p e r i n A T F f o r
about30 minutes.
2.
Removethe #600 paper and thoroughly wash the
entirevalve body in solvent.then dry it with compressedair.
Carefullytap the valve body so the stickingvalve
dropsout of its bore.
C A U T I O N :l t m a y b € n e c e s s a r yt o u s e a s m a l l
screwdriver to pry the valve free. Be careful not to
scratchthe bore whh the screwdriver.
3.
4.
Inspectthe valvefor any scuff marks.Use the ATFsoaked#600 paper to polishoff any burrs that are
on the valve,then wash the valvein solventand dry
it with compressedair.
VALVE BODY
-M
W
paper,and insert
Roll up half a sheetof ATF-soaked
it in the valvebore of the stickingvalve.
Twistthe paperslightly,so that it unrollsand fits the
b o r e t i g h t l y ,t h e n p o l i s ht h e b o r e b y t w i s t i n gt h e
paperas you push it in and out.
CAUTION: The valve body is aluminum and doesn't
require much polishing to remove any burrs,
ATF-soaked
#600 abrasive Paper
7.
Removethe valve.then thoroughlyclean it and the
valve body with solvent. Dry all parts with compressedair. then reassembleusing ATF as a lubri
cant.
14-139
Valve
Assembly
NOTE:
Coat all parts with ATF before assembly.
.
.
Set the spring in the valve and installit in the valve
body. Push the spring in with a screwdriver,then
installthe springseat.
Installthe valve, valve spring and cap in the valve
body and securewith the roller.
-_^?=w_
5-'--------P/
=/
/-\ (-,.1\)
,.
l_/1
)
SPRIITGSEAT
VALVE BODY
VALVE BODY
Installthe valve,springand cap in the valvebody.
Pushthe cap,then installtheclip.
VALVE AODY
VALVE
SPRING
14-140
ATFPump
Inspection
1.
Installthe ATF pump gears and ATF pump driven
gearshaft in the main valve body
2.
Measurethe side clearanceof the ATF pump drave
and drivengears.
ATF Pump GearsSide {Radial)Clearance:
Standard (New):
ATF Pump Drive Gear
0.105- 0.1325mm {0.004- 0.q)5 in}
ATF Pump Drivsn Gear
0.035- 0.0625mm (0.0014- 0.0025inl
NOTE:
. Lubricateall partswith ATF during inspection.
. Installthe ATF pump drivengearwith its grooved
and chamferedsidefacingup as shown.
GEAR
ATFPUMPORIVEN
Groovedand chamfe.edside
MAIN VALVESOOY
YZ]
o?
ATF PUMP
DRIVEGEAR
ATF PUMP
DRIVENGEAR
Inspectteethfor wear and damage
lnspect
teethforwearanddamage.
3.
MAIN VALVE BODY
Removethe ATF pump driven gear shaft. Measure
the thrust clearanceof the ATF pump driven gearto-valve bodY.
ATF Pump Drive/Drivon Gear Thrust {Axial} Cloarance:
Standard (Now): 0.03- 0.05 mm 10'001- 0.002inl
SorviceLimit: 0.07 mm (0.003in)
1+141
Main Valve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages.
. Replacethe valvebody as an assemblyif any pans are worn or damaged.
. Checkall valvesfor free movement.lf anyfail toslidefreely,seeValveBody Repaironpage,l4-139.
. Coatall partswith ATF duringassembly.
CAUTION: Do not use a magnet to removs tha check balls; it may magnetizothe balls.
I.2 SHIFTVALVE
CPBVALVE
VALVECAPCLIP
ORIFICE
CONTROLVALVE
BALLS,8
lST ACCUMULATOR
CHOKE
MODULATOR
VALVE
RELIEFVALVE
VALVE
MAIN VALVEEODY
Inspectfor wear,scratches
and scoring.
SEBVOCONTROLVAL
VALVECAP
14-142
CHECKBALL
CHECKBALLS
w
CHECKBALLS
MAIN VALVEBODY
(Sectionalviewl
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard (New)
No.
o
@
@
@
@
@
Springs
Reliefvalvespring
Modulatorvalvespring
CPBvalvespring
1-2shiftvalvespring
2nd orificecontrolvalvespring
Servocontrolvalvespring
Wire Dia.
1 . 1( 0 . 0 4 3 )
'1.4(0.055)
0.9 (0.035)
0.9 (0.035)
0.7 (0.028)
1.0(0.039)
o.D.
8.6 (0.342)
9.4 (0.374)
8.1 t0.3221
7.6 {0.302)
6.6 (0.262)
8.'t to.322l
Free Length
3 7 . 1( 1 . 4 6 1 )
35.0(1.378)
47.2(1.8s8)
4 1 . 3( 1 . 6 2 6 1
34.8(1.370)
52.1t2.O51l
No. ot Coils
13.4
10.9
1C?
'15.3
22.0
20.8
1+143
SecondaryValve Body
Disassembly/lnspection/Reassembly
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner.and drywith compressedair, Blowoutall passages.
. Replacethe secondaryvalvebody kit. P/N27700- P4R- 315 (Thesecondaryvalve body kit includesthe linearsolenoid
assembly)if any partsare worn or damaged.
. Checkallvalvesfor free movement.lf anyfailto slidefreely,seeValveBodyRepaironpage14-139,
. Coatall partswith ATF duringassembly.
. The CPCvalveis installedin the secondaryvalvebody, held in placeby the lockbolt.
2.3 SHIFTVALVE
3.4 SHIFTVAL
.TH EXHAUSTVALVE
LOCKBOLT
CAUTION:Do not move.
SECONDARY
VALVEBODY
Inspectfor wear,scratches
6nd
scoring.
3-'l ORIFICE
CONTROLVAL
VALVE
SPRINGSPECIFICATIONS
U n i t :m m ( i n )
Standard {New)
Springs
No.
Wire Dia.
o
ra,
.n
3-4shift valvespring
2-3shift valvespring
4th exhaustvalvespring
3-4orificecontrolvalvespring
14-144
0.910.035)
0.9{0.035)
0.9{0.035)
0.7{0.028)
o.D.
7.6 (0.302)
7.6 (0.302)
6.1 10.2421
6.6 (0.262)
FreeLongth
57.O12.2441
57.O12.2441
36.4(1.433)
37.5(1.476)
No. of Coils
26.8
26.8
24.6
RegulatorValveBody
Disassembly/lnspection/Reassembly
NOTE:
. cleanall partsthoroughlyin solventor carburetorcleaner,and drywith compressedair. Blowoutall passages
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. checkallvalvesfor free movement.lf anyfail toslidetreely,seevalve Body Repaironpage1+139.
1.
Holdthe regulatorspringcap in placewhile removingthe stop bolt. once the stop bolt is removed.releasethe spring
cap slowly.
CAUTION: The regulator 3pring cap can pop out when the stop boh is removod'
2.
is the reverseorderofths disassemblyprocedure.
Reassembly
NOTE:
o Coatall partswith ATF duringassembly.
. Align the hole in the regulatorspringcap with the hole in the valve body,then pressthe springcap into the valve
body,and tightenthe stop bolt.
\
STOPBOLT
6x1.0mm
12 N.m 11.2
^/^'ou*'oRsPRrNGcAP
*N@
8.7 tbf.lrl
VALVEBODY
REGULATOR
Inspectlor wear, scratches
and scorlng.
REGULATOR
VALVE
\=f
-.-*
*fi
/F
cooLERRELlEFvALVr"r?
^LvE//
cHEcKv
roRouEcoNvERrER
{
a-tLocK.uPcoNrRoLvALVE
ry
v^r* "r**::f\
vi{LvEcAp
SPRINGSPECIFICANONS
Unit:mm (in)
Standard (Now)
No,
o
o
@
@
@
Springe
RegulatorvalvesPringA
RegulatorvalvespringB
Statorreactionspring
Coolerreliefvalvespring
Torqueconvertercheckvalvespring
Lock-upcontrolvalvesPring
Wire Dia.
1.8{0.07' r)
1.8(0.071)
4.5(0.177)
1.0(0.039)
1.0(0.039)
0.7 (0.028)
o.D.
'r4.7(0.584)
9.6 (0.381)
35.4(1.407)
8.4{0.334)
8.4 {0.334}
6.6{0.262}
Free Lengrth
87.8(3.457)
44.0(1.732)
30.3(1.193)
3 3 . 8( 1 . 3 3 1 )
33.811.3311
38.0{1.4961
No. of Coils
11.0
1.9
8.2
a.2
't4.1
14-145
Servo Body
Disassembly/lnspection/Reassembly
NOTEI
. clean all partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Blow out all passages.
. Replacethe valvebody as an assemblyif any partsare worn or damaged.
. Coatall partswith ATFduringassembly.
. Replacethe O-rings.
. The servobody showsthe '96- 98 models:the '99 - 00 modelshavean integrallymoldedservodetent.
SERVO
BODY
I n s p e c tf o r w e a r , s c r a t c h e sa n d s c o r i n g .
,______.g
1l
v
"-------'g
I
ZruO
lCCUr,irUr-nrOn
---rrr___-p
O.RING
Replace.
n\='l
3,ii11---------*5
1STACCUMULATOR
PISTON
^rrr4
3ROACCUMULATOR
PISTON
4TH ACCUMULATOR
PISTON
SNAPRINGS
SPRINGSPECIFICATIONS
No.
U n i t :m m ( i n )
Standard {New)
Springs
Wire Dia.
o
(a
@)
o
@
'Ist accumulatorspring
4th accumulatorspringA
4th accumulatorspringB
3rd accumulatorspringA
3rd accumulatorspringB
2nd accumulatorspringC
2nd accumulatorspringA
2nd accumulatorspring B
14-146
2.1(0.083)
2 . 6( 0 . 1 0 2 )
2 . 3( 0 . 0 9 1 )
2 . 8( 0 . 1 1 0 )
2.210.0871
2.2 t0.0a7l
2.4 (0.094)
'1.6(0.063)
o.D.
16.0(0.636)
17.0(0.676)
10.2lo.402J
1 7 . 5( 0 . 6 9 5 )
31.0 11.220)
14.5(0.576)
2 9 . 0( 1 . 1 5 2 )
9.0 (0.358)
FreeLength
89.1(3.s08)
87.0(3.425)
5 1 . 6( 2 . 0 3 1 )
89.3(3.516)
3 5 . 1( 1 . 3 8 2 )
68.012.677)
39.0(1.535)
20.7(0.815)
No. of Coils
14.2
13.8
'13.9
Lock-upValve BodY
Disassembly/lnspection/Reassembly
NOTE:
with compressedair' Blow out all passages'
. Cleanall pans thoroughlyin solventor carburetorcleaner'and dry
a Replacethe valvebody as an assemblyif any partsare worn or d€maged'
ValveBody Repaironpage14-'139'
. Checkallvalvesfor free movement ttanytaitio stlaefreely'see
. Coatall partswith ATF duringassembly
LOCK.UPVALVEBODY
Inspectfor wear,scratches
and sconng.
VALVECAP
LOCK-UPTIMINGVAL
U n i t :m m ( i n )
SPRINGSPECIFICATIONS
Lock-upshiftvalvesPrang
Lock-uptiming valvesPrlng
7.6 (0.302)
8 . 1( 0 . 3 1 9 )
73.1 t2.902J
ao.7 13.'1771
14-147
Mainshaft
Disassembly/lnspestion/Reassembly
NOTE:
. Lubricateall partswith ATF during reassembly.
.Inspectthethrustneedlebearingsandtheneedlebearingsforgallingandroughmovement,
. Beforeinstallingthe O-rings,wrap the shaftsplineswith tapeto preventdamagingthe O_rings.
. Locknuthasleft-handthreads.
LOCKNUT{FLANGENUTI
21 x 1.25mm
78 N.m (8.0 kgl.m,58 lbt.ftt
Replace.
Left-handthreads
CONICALSPRINGWASHER
Reolace.
SNAP RING
THRUST WASHER
MAINSHAFT
Checksplinesfor excessive
wear and oamage.
Check bearingsurtacefor scoring,
scratchesand excessivewear.
THRUSTWASHER
4TH GEAN
THRUST NEEDLE
BEARING
BEARING
BEARINGS
1ST GEAR
THRUST NEEDLE
BEABING
1ST GEAR
COLLAR
4TH GEAR COLLAR
TRANSMISSION
HOUSINGBEARING
O-RINGS
Replace.
THRUSTWASHER,36.5 x 55 mm
Selectivepart.
THRUSTNEEDLE
EEARING
Install the sealing ring
mating faces as shown,
RING,
29 mm
NEEDLEBEARING
SETRING
14-148
O-RINGS
Replace.
THRUST NEEOI.E
BEARING
2ND/4TH CLUTCH
ASSEMBLY
SEALINGRINGS,
35 mm
lST CLUTCH
ASSEMBLY
2NO GEAB
NEEDLEBEABING
THRUSTNEEDLE
BEARING
Inspection
3.
a ClearanceMeasurement
NOTE: Lubricateall parts with ATF during assembly.
1,
Removethe mainshaftbearingfrom the transmission housing(seePage14-1741.
2.
Assembleths parts below on the mainshaft.
Torquethe mainshaftlocknutto 29 N'm (3.0kgf'm,
22 tbt,ftl.
NOTE:Mainshaftlocknuthas left-handthreads.
NOTE:Do not assemblethe O-ringsduring inspectlon.
LOCKNUT
CONICAL SPRIIIGWASHER
lST CLUTCHASSEMBLY
TXRUSTWASHER
SNAP RING
29 N'm t3.0 kgl'm, 22 lbt'ft)
Hold 2nd gear againstthe 2nd clutch'then measure
the clearancebetween 2nd gear and 3rd gear with a
feelergauge.
1STGEARCOLLAR
NOTE: Take measurementsin at least three places,
and use the av€rageas the actual clearance'
TRA SMISSION
HOUSII{GBEARING
STANDARD:0.05- 0.13 mm 10.002- 0.005in)
THRUSTWASHER
4TI{ GEARCOLLAR
2ND/4THCLUTCH
ASSEMBLY
THRUSTWASHER
36.5 x 55 mm
Selectivepart.
THBUSTNEEDLE
BEARING
2ND GEAR
AEABII{G
IHRUST NEEDLE
BEARING
THRUST WASHER,
36.5 x 55 mm
MAINSHAFT
(cont'd)
1+149
Mainshaft
Inspection(cont'd)
5.
l f t h e c l e a r a n c ei s o u t o f t o l e r a n c e ,r e m o v e t h e
thrustwasherand measurethe thickness.
THRUST
WASHER
6.
Selectand installa new washer,then recheck.
THRUSTWASHER36.5 x 55 mm
No.
1
4
Part Number
Thickness
90441- P4P- 010
4.00mm (0.157in)
90442-P4P-010
4 . 0 5m m ( 0 . 1 5 9
in)
90443-P4P-010
4 . 1 0m m ( 0 . ' 1 6i1n )
90444-P4P-010
4 . 1 5m m ( 0 . 1 6 3
in)
90445-P4P-010
4.20mm (0.165in)
90446-P4P-010
4.25mm (0.167in)
7
90447-P4P-010
4.30mm (0.169in)
8
90448-P4P-010
4 . 3 5m m ( 0 . 1 7 1i n )
90449-P4P-010
4 . 4 0m m ( 0 . 1 7 3
in)
90450-P4P-000
4 . 4 5m m ( 0 . 1 7 5
in)
10
7 . After replacingthe thrust washer, make sure the
clearanceis within tolerance.
14-150
Countershaft
Disassembly/lnspection/Reassembly
NOTE:
. Lubricateall partswith ATF beforereassembly'
gallingand rough movement'
. tnrp"",,n",t -"t needlebearingsand the needlebearingsfor
preventdamagingthe O-rings
to
tape
with
splines
the
shaft
wrap
O-rings.
. Beforeinstallingthe
. Locknuthas left-handthreads
LOCKNUT(FLANGENUT}
23 x 1.25mm
103 N.m
{10.5 kgf'm, 75.9 lbf'tt)
Replace.
L e f t ' h a n d lhreads
SPRING
CONTCAL
WASHER
Replace.
GEAR
REVERSE
GEAR
CLUTCH
NEEDLEBEARING
SELECTOR
1ST GEAR
SELECTOR
BEARING
4TH GEAR
NEEDLEBEARING
lST GEAR COLLAR
DISTANCECOLLAS,
28 mm
Selective pa .
TRANSMISSION
HOUSINGBEARING
2'{D GEAR
COUNYERSHAFT
Check splineslor excesslve
wear and damage
Checkbearingsurfacefor scoring'
scratchesand excessivewear'
THRUST NEEDLE
BEARING
3RD GEAB
NEEDLEBEARING
3RD GEAR COLLAR
THRUST NEEDLEEEARING
SPLINEOWASHER
3RD CLUTCH ASSEMBLY
Replace.
1+151
Countershaft
Disassembly/Reassembly
1.
Using a hydraulicpress,pressout the countershaft
while supporting4th gear.
NOTE:Placean attachmentbetweenthe pressand
the countershaft
to preventdamageto the shaft.
CAUTION: Do not allow the countershaftto fall and
hit the g.ound when pressedclear.
2.
Assemblethe parts on the countershaftas shown
oetow.
NOTE;
. Lubricateall partswith ATFduringassembly.
. Beforeinstallingthe O-rings,wrap the shaft splines
with tapeto preventdamagingthe O_rings.
4TH GEAR
NEEDLEEEARING
DISTANCECOLLAR, 28 mm
Selective part.
2ND GEAR
THRUSTNEEOLEBEARING
3RD GEAR
NEEDI.EEEARING
3RO GEAR COLLAR
THRUST NE€OLEBEARING
SPLINEDWASHER
3RD CLUTCH ASSEMBLY
O.RINGS
Replace.
COUNTERSHAFT
14-152
Inspection
3.
Installthe reverseselectorhub on the countershaft
sub-assembly,and then pressthe reverseselector
hub usingthe specialtool and a pressas shown'
Measurement
r Clearance
NOTE;Lubricateall partswith ATFduringassembly
1.
Removethe countershaftbearingfrom the transmissionhousing(seepage l4-174)
2.
Installthepartsbelowon the countershaftusinglhe
specialtool and a pressas describedon this page
NOTE:Do not assemblethe O-ringsduring inspection.
REVERSESELECTOR
HUB
4TH GEAR
NEEDLEBEARING
DISTANCECOLLAR, 28 mm
SelectavePart.
2ND GEAR
THRUST NEEDLEBEARING
3RD GEAR
BEARING
3RD GEAR COLLAR
THBUST NEEDLEBEARING
SPLINEOWASHER
3RD CLUTCH ASSEMBLY
(conl'd)
14-153
Gountershaft
(cont'dl
Inspection
3.
I n s t a l lt h e p a r t s b e l o w o n t h e c o u n t e r s h a fst u b a s s e m b t yt,h e n t o r q u et h e l o c k n u t o 2 9 N . m ( 3 . 0
kql.m , 22 blf.ftt .
4.
Measurethe clearancebetweenthe 2nd gear and
the 28 mm distancecollarwith a feelergauge.
NOTE:Takemeasurements
in at leastthree places.
and usethe averageas the actuarctearance.
NOTE:Countershaft
locknuthas left handthreads.
STANDAFD:
0.10- 0.18mm {0.004- 0.002inl
LOCKNUT
Left hand threads
CONICALSPRING
WASHER
PARKGEAR/ONE.WAY
CLUTCH/1ST
GEAR
ASSEMBLY
NEEOLE
BEARING
OISTANCECOLLAR,28 mm
.IST GEAR COLLAR
TRANSMISSION
HOUSING
BEARING
(=)-----'
v
REVERSE
GEAR
COLLAR
lf the clearanceis out of tolerance.removethe 2g
mm distancecollarand measurethe width.
S e l e c ta n d i n s t a l la n e w d i s t a n c ec o l l a r ,t h e n
recheck.
DISTANCECOLLAR,28 mm
No.
Part Numb€r
widrh
1
90503-PCg-000
3 9 . 0 0m m ( 1 . 5 3 5i n )
2
90504-PCg-000
3 9 . 1 0m m { 1 . 5 3 9i n )
90505-PCg-000
3 9 . 2 0m m ( 1 . 5 4 3
in)
7.
14-154
90507-PCg-000
3 9 . 3 0m m { 1 . 5 4 7i n )
90508-PC9-000
3 9 . 0 5m m ( 1 . 5 3 7
in)
90509-PCg-000
39.15
m m ( 1 . 5 4 i1n )
7
90510-PCg-000
3 9 . 2 5m m ( 1 . 5 4 5
in)
I
90511-PCg-000
3 8 . 9 0m m ( 1 . 5 3 1i n )
90512-PCg-000
3 8 . 9 5m m ( 1 . 5 3 3
in)
Afret selectinga new distancecollar, recheckthe
clearanceand makesure it is within tolerance.
One-way Clutch
Disassembly/lnspection/Reassembly
1.
Separatecountershaft1st gear from the park gear
by turningthe parkgear in the directionshown
3.
Inspectthe partsas followsl
PARKGEAR
Inspeclthe parkgear
for wear and scorrng.
lST GEAR
COUNTERSHAFT
2.
Removethe one-wayclutchby prying it up with the
end of a screwdriver.
1STGEAR
COUNTERSHAFT
ONE-WAYCLUTCH
Inspectthe one-way
clutch for damageand
laulty movement.
ONE-WAY CLUTCH
NOTE:lnstallin this direction.
lST GEAB
Inspectcountershaltlst gear
for wearanclscorlng.
After the partsare assembled,hold countershaft1st
gear and turn the park gear in the directionshown
to be sure it turns freely.Also make sure the park
gear does not turn in the oppositedirection.
ONE'WAY CLUTCH
COUNTERSHAFTlST GEAR
SCREWORIVER
14-155
Clutch
lllustratedIndex(A4RA,B4RATransmission)
3RDCLUTCH
CLUTCH
DRUM
O-RINGS
Beplace. CLUTCHptSTON
CLUTCHEND
PLATE
SNAPRING
lST CLUTCH
CLUTCHEND
SNAPRING
SPRINGRETAINER
RETUNNSPRING
CLUTCHDRUM
CLUTCHPLATES
Standardthickness:
1.6mm (0.063in)
CHECKVALV€
14-156
2NDi4TH CLUTCH
SNAPRING
CLUTCHPISTON
DISCSPRING
SNAP RING
SPRINGRETAINER
RETURNSPRING
CHECKVALVE
O.RINGS
Replace.
4TH CLUTCHDRUM
CLUTCHPLATES
Standardthickness:O-RINGS
2.0mm {0.079in)
Replace.
SNAPRING
14-157
Clutch
lllustratedIndex(M4RATransmission)
3RD CLUTCH
CLUTCH
DRUM
CLUTCHPISTON
DISCSPRING
CLUTCIIEND
rST CLUTCH
CLUTCHE D
SI{AP RIiIG
CLUTCHPLATES
Standardthickness:
1.6mm (0.063in)
CHECKVALVE
14-158
SNAPRING
2ND/4THCLUTCH
CLUTCH
PISTON
VALVE
2.0mm (0.079in)
2ND CLUTCH
DRUM
CLUTCHPISTON
RETURNSPRING
RETURNSPRING
\l-.
SNAPRING
14-159
Clutch
Disassembly
1 . Removethe snap ring. then removethe clutchend
plate,clutchdiscsand plates.
3.
Installthespecialtools as shown.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40,t 00
SCREWDRIVER
SNAP RING
2.
Removethe discspring.
NOTE:Except2nd clutch.
DISC SPRING
CLUTCH
COMPRESSOR
AOLTASSEMBLY
07GAE- PG4tt200
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX()100
o1
07HAE- P150100
ol
O'GAE - FG4O2OA
CLUTCH SPRING
COMPRESSOR
ATTACIIMENT
oTLAE-PX40100
1
CLUTCI{ DRUM
CLUTCH
COMPRESSOR
BOLTASSEMBLY
07GAE - PG/O200
OTGAE- PG4O2OA
14-160
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- Px/Ol00
ot
07HAE- PLs0100
CAUTION: lf eithd end of the 3pocialtool issotoveran
area ot the spring rstainer which is unsupport€d by tho
return spring, tho r€tain€l may be damagod. Bo eure the
special tool is adiusted to have full contact with tha
spring retainor.
5.
Removethe snap ring. Then removethe specialtools,
spring retainerand returnspring.
Do not sat horo.
SPRINGRETAIItIER
Wrap a shop rag aroundthe clutchdrum, and apply
air pressureto the ATF passageto remove the pisron.
Placea finger tip on the other end while applying
air pressure.
OSHA.APPROVED
SPRINGRETAINER
4.
Compfessthe returnsprang.
PISTON
14-161
Clutch
Reassembly
NOTE:
. C l e a na l l p a r t st h o r o u g h liyn s o l v e not r c a r b u r e t o r
cleaner,and dry them with compressedair.
Blow out all passages.
a Lubricateall partswith ATF beforereassembly.
1 . Inspectthe checkvalve;if it's loose,replacethe pisto n.
3.
Installthe pistonin the clutchdrum, Apply pressure
and rotateto ensureproperseating,
NOTE:Lubricatethe pistonO-ringwith ATF before
installing.
CAUTION: Do not pinch the O-ring by insta ing the
piston with too much force.
CLUTCIIDRUM
CHECKVALVE
2.
Installnew O-ringson the clutchpiston.
I n s t a l lt h e r e t u r ns p r i n g a n d s p r i n g r e t a i n e r a
, nd
positionthe snap ring on the retainer.
O RINGS
CLUTCI{DRUM
PISTON
14-162
5.
CAUTION:lf eithe. end of the sDecialtool is set
over an area of the spring retainer which is unsupported by the rsturn spring, the ietainer may be
damaged. Bs sure the specialtool is adjusted to
have full contact with the spring retainer.
Installthe specialtools as shown.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
or
07HAE- P150100
Sot hsro.
Do not sot hore.
SPECIAL TOOL
CLUTCH SPRING
COMPRESSOR
ATTACHMENT
07LAE-PX40100
RETAINER
6.
Compressthe returnspring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX4010o
CLUTCHSPRING
COMPRESSOR
BOLTASSEMBLY
07GAE- PG40200
07HAE- PL50100
O7GAE. PG4O2OA
(cont'd)
14-163
Glutch
(cont'd)
Reassembly
7.
Installthe
s n a pr i n g .
1 0 . Soakthe clutchdiscsthoroughlyin ATF for a minimum of 30 minutes.
l l . Startingwith a clutch plate, alternatelyinstall the
clutch platesand discs.Installthe clutch end plate
with flat side toward the disc.
NOTE:Beforeinstallingthe platesand discs,make
sure the insideof the clutchdrum is free of din or
other foreign mafter.
CLUTCHENDPLATE
Installin this direcrion.
SNAP RING
8.
Removsthe specialtools.
o
Installthe discspring.
NOTE: Installthe disc spring in the direction
shown, except 2nd clutch.
12. Installthesnap ring.
SCREWDRIVER
SNAP RING
14-164
13. Measurethe clearancebetweenthe clutchend plate
and top discwith a dial indicator'Zero the dial indicatorwith the clutchend plateloweredand lift it up
to the snap ring. The distancethat the clutch end
platemovesis the clearancebetweenthe clutchend
plateand top disc.
in at leastthree places,
NOTE|Takemeasurements
and usethe averageas the actualclearance.
Clutch End Plste-to-TopDisc Clearance:
SerYiceLimit
Clutch
0.650.650.400.40-
1st
2nd
3rd
4th
0.85mm (0.0260.85mm (0.0260.60mm (0.0160.60mm (0.016-
0.033in)
0.033in)
0.024in)
0.024in)
OIAL INDICATOR
CLUTCHEND PLATE
A4RA,g4RA Transmission:
Plate No.
,l
2
J
4
5
6
1
8
q
Plate No.
3
'l
.'
q
10
11
't2
Clearance
13
14
15
'16
CLUTCHDISC
17
18
1 4 . l f t h e c l e a r a n c ei s n o t w i t h i n t h e s e r v i c el i m i t s ,
select a new clutch end plate from the following
table.
22551- P4R- 003
22552-P4R-003
22553-P4R-003
22554-P4R-003
22555-P4R-003
22556-P4R-003
22557-P4B-OO3
22558-P4R-003
22559-P4R-003
Thickness
in)
2 . 1m m ( 0 . 0 8 3
2.2 mm (0.087in)
2 . 3m m ( 0 . 0 9 1i n )
2.4 mm (0.094in)
2.5 mm (0.098in)
2 . 6m m ( 0 . 1 0 2i n )
2 . 7m m { 0 . 1 0 6i n )
2 . 8m m { 0 . 1 1 0i n )
'14
2 , 9m m ( 0 . 1 i n )
M,IRATransmi$ion:
1
CLUTCHEND
PLATE
Part Number
Part Number
22551- PCg- 000
22552-PCg-000
22553-PCg-000
22554-PCg-000
22555-PCg-000
22555-PCg-000
22557-PCg-000
22558-PCg-000
22559-PCg-000
22560-PCg-000
22561- PCg- 000
22562-PCg-000
22563-PCg-000
22574- P4V- 003
22561- P4V- 003
22562- P4V- 003
22563-P4V-003
22564-P4V-003
Thickness
2.4 mm (0.094in)
2.5 mm (0.098in)
2 . 6m m { 0 . 1 0 2i n )
in)
2 . 7m m ( 0 . 1 0 6
2 . 8m m ( 0 . 1 1 0i n )
2 . 9m m ( 0 . 1 1 4i n )
3 . 0m m { 0 . 1 1 8i n )
in)
3 . 1m m ( 0 . 1 2 2
in)
3 . 2m m ( 0 . 1 2 6
3 . 3m m ( 0 . 1 3 0i n )
2 . 1m m ( 0 . 0 8 2i n )
2.2 mm {0.086in)
2.3 mm (0.090in)
in)
3 . 4m m ( 0 . 1 3 4
3 . 5m m ( 0 . 1 3 8i n )
3 . 6m m ( 0 . 1 4 2i n )
in)
3 . 7m m ( 0 . 1 4 6
in)
3 . 8m m ( 0 . 1 5 0
15. After replacingthe clutchend plate.make sure that
the clearanceis within tolerance.
NOTE: lf the thickestclutch end plate is installed,
but the clearanceis still over the standard,replace
the clutchdiscsand clutchplates.
PLATENUMBER
Thickn6ss
CLUTCHENO PLATE
14-165
Differential
lllustratedlndex
SET RING, 80 mrrt
efef
BOLT
1 0 r 1 . 0m m
'10'l N'm (10.3 k91.m,74.5 lbf.ftl
Left-hand threads
FINALDRIVENGEAR
Inspecttor excessivewear.
Installin this direction.
BALL BEARING
Inspectfor faulty movement.
DIFFERENTIALCARRIER
Insoectfor cracks,
ROLLER,5x10mm
ORIVE
SPEEDOMETER
GEAR
lnstallin this direction.
SNAP RING
Installin this direction.
EALL BEARING
Inspectfor faulty movement-
14-166
Backlashlnspection
1.
Placedifferentialassemblyon V-blocksand install
both axles.
BearingReplacement
NOTE: Checkbearingsfor wear and rough rotation.lf
bearingsare OK, removalis not necessary.
1,
Removebearingsusinga bearingpuller.
BEARINGPULLER
(Commerci6lly
available)
Checkbacklashof both piniongears
Standard {Now): 0.05- 0.15 mm {0.002- 0.006in)
lf backlashis out of tolerance,replacethe differential carrier.
2.
Installnew bearingsusingthe specialtoolas shown.
14-167
Differential
DifferentialCarrierReplacement
L
Removethe final driven gear from the differential
carrier.
5.
NOTE: The final driven gear bolts have left-hand
threads.
Align the hookedend of the snap ring with the pinion shaft as shown,then installthe snap ring in the
differentialcarrier groovs.
Hookedend
SNAPRING
Installin this
Install
thisdirection.
direclon.
Pry the snap ring off differentialcarrier,then remove
the speedometer
drivegearand 5 x 10 mm roller.
SNAP RING
SPNI G PIN
Installthe final drivengear,then tightenthe boltsto
the specifiedtorque.
TOROUE:101 N.m (10.3kgf'm, 74.5 lbf.ftl
NOTE: The final driven gear bolts have left-hand
threads.
3.
Installthe 5 x l0 mm rollerin the differentialcarrier,
BOLTS
1 0 r 1 . Om m
1Ol t{.m 11O.3kgf.m,
74.5 lbl.frl
Left-hand rhreads
FINALDRIVEN
GEAR
lnstallin this
direction.
DIFFERENTIAL
CARRIER
Installthe speedometerdrive gear with its chamfered side facingthe carrier.Align the cutouton the
bore of the speedometerdrive gear with the 5 x 10
mm roller.
14-168,
7.
Install a new ball bearing (se€ page 14-157).
Glearance
Oil SealInstallation/Side
OilSealRemoval
1.
1.
Remov€the differentialassembly.
2,
Removethe oil sealfrom the transmissionhousing,
Installa 2.50mm (0.098in) set ring,80 mm in transmissionhousing.
NOTE:Do not installthe oil sealvet.
RING,80 mm
TRAITISMISSlON
HOUS|l{G
OIL SEAL
Roplace.
R e m o v et h e o i l s e a l f r o m t h s t o r q u e c o n v e r t e r
housing.
OIL SEAL
Replace.
TOROUECONVERTEF
HOUSING
Installthe differentialassemblyinto the torqueconverterhousingusingthe specialtoolas shown.
I n s t a l lt h e t r a n s m i s s i o nh o u s i n ga n d t i g h t e nt h e
bolts{seepage 14-178and 14-179).
{cont'd)
14-169
Differential
(cont'd)
Oil SealInstallation/Side
Clearance
4.
Tap on the transmissionhousingside of the differentialassemblywith the specialtool to seatthe differentialassemblyin the torqueconverterhousing.
5.
N4easure
the clearancebetweenthe 80 mm set ring
and outer race of the ball bearinoin the transmiss i o nh o u s i n g .
STANDARD:
0 - 0.15mm (0 - 0.006inl
DRIVER40 mm l.D.
SET RING,80 mm
BALL BEARING
lf the clearanceis more than the standard,selecta
new set ring from the table,and install:
SETRING,80 mm
Part Number
90414-689-000
904r5-689-000
90416-689-000
90417-689-000
90418-689-000
904r9-PH8-000
Thickness
2.50mm (0.098in)
2 . 6 0m m { 0 . 1 0 2i n )
2 . 7 0m m { 0 . 1 0 6i n )
2 . 8 0m m ( 0 . 1 1 0i n )
2 . 9 0m m ( 0 . 1 1 4i n )
3 . 0 0m m ( 0 . 1 1 8i n )
NOTE:lf the clearancemeasuredin step 5 is standard, it is not necessaryto perform steps 7 and 8.
7.
Removethe transmissionhousing.
Replacethe 2.50mm (0.098in) 80 mm set ring with
the one of the correctthicknessselectedin step6.
14-170
9. lnstallthe new oil seal flush with the transmission
housjngusing the specialtools as shown
DRIVER
077i(} - 0010000
PILOT.
26x30mm
07JAO- PH80200
DRIVERATTACHMENT,68 mm
079i17-6110501
10. lnstall the new oil seal flush with the torque converterhousingusingthe specialtoolsas shown
DRIVER
07749- 0010000
14-171
TorqueConverterHousingBearings
MainshaftBearing/OilSealReplacement
1.
Removethe mainshaftbearingand oil seal using
the specialtools as shown.
2.
Drive in the new mainshaft bearing until it bottoms
in the housingusingthe specialtools as shown.
DRIVER
077€ - 0010000
3/8"16 SLIOE
HAMMER
ADJUSTAELEBEARING
PULLER,25 - ilo mm
07736- A01000a
lnstallthe new oil sealflush with the housingusing
the specialtools as shown.
DBIVER
07749 - 0o l0(xt0
ATTACHMENT,
72x75 mfi
07746- 0010600
1 4-1 7 2
CountershaftBearingReplacement
'1. Removethe countershaftbearingusing the special
tools as snown.
3,/8'.16SLIDEHAMMER
{Commerciallv
available)
AOJUSTABLE
BEARING
PULLER,
25-{Omm
07736- A0'1000A
2.
5.
Installthe ATF guide plate.
Drive the new bearing into the housing using the
specialtools as shown.
ATTACHMENT,
62x68mm
0 - 0.03 mm
(0 - 0.001inl
14-173
TransmissionHousingBearings
Mainshaft/Countershaft
BearingsReplacement
L
To removethe mainshaftand countershaftbearings
from the transmissionhousing,expand each snap
ring with snap ring pliers,then pushthe bearingout
usingthe specialtools and a pressas shown.
Expandeach snap ring with snap ring pliers,insert
t h e n e w b e a r i n gp a r t - w a yi n t o t h e h o u s i n gu s i n g
the specialtools and a press as shown, Installthe
bearingwith the groovefacingoutsidethe housing.
N O T E : D o n o t r e m o v et h e s n a p r i n g s u n l e s si t ' s
necessary
to cleanthe groovesin the housing.
NOTE:Coatall partswith ATF.
Releasethe pliers,then push the bearingdown into
the housinguntil the ring snapsin placearoundit.
PRESS
07749- 0010000
\
DRIVER
07749- 0010000
ATTACHMENT,
62x68mm
07746-
IRN
{L{r.)n
\bZ
MAINSHAFTBEARING
DFIVEB
07749- 0010000
TTACHMENT
ATTACHMENT
. Mainshaft Bearing Removaluse:
ATTACHMENT,72 x 75 mm
077/16- 0010600
. Counte6haft Bsaring Removaluse:
ATTACHMENT,62 x 68 mm
07746- 0010500
After installingthe bearingverifythe following:
.
.
The snap ring is seatedin the bearingand housing grooves.
The ring end gap is correct.
ENDGAP:0-7mm
(0- 0.28in)
ATTACHMENT
. Mainshaft BearingInstallation us€:
ATTACHMENT.72 x 75 mm
07746- 0010600
. Countershaft Bearing Installation use:
ATTACHMENT,62 x 68 mm
077/16- 0010500
14-174
SNAP RING
Park Stop
Reverseldler Gear
Inspection/Adiustment
lnstallation
1,
'1.
lnstallthe reverseidler gear.
Setthe parkleverin the E position.
Measure the distance between the park pawl shaft
and the parkleverrollerpin as ahown.
STANDARD:72.9- 73.9 mm 12.87- 2.91 inl
/A\
Measuring
\v
Installthe reverseidler gear shaftholderand needle
bearinginto the transmissionhousing,then tighten
the bolts.
6 x 1.0 mm
12 N.m ll .2 kgf'm,
8.7 tbf.ftl
PARKPAWL
SHAFT
lf the measurementis out of tolerance,selectand
i n s t a l lt h e a p p r o p r i a t ep a r k s t o p f r o m t h e t a b l e
Delow.
PARKSTOP
PARKSTOP
Mark
I
GEAR
Part Numb€r
Lr
12
2 4 5 3 7 - P A g - 0 0 3 1 1 . 0 0m m
(0.433in)
11.0m
0 m
(0.433
in)
2 4 5 3 8 - P A g - 0 0 3 1 0 . 8 0m m
(0.425in)
10.65mm
(0.419
in)
2 4 5 3 9 - P A g - 0 0 3 1 0 . 6 0m m
(0.417
in)
1 0 . 3 0m m
(0.406in)
After replacingthe park stop, make sure the distanceis within tolerance.
14-175
Transmission
Reasembly
NOTE;
. Coat all parts with ATF.
. Beplacethe followingparts:
- O-rings
- Lockwashers
- Gaskets
- Mainshaftand countershaftlocknutsand conical
springwashers
- Sealingwashers
TOROUE:l2 N.m (1.2 ksf'm,8.7 lbf.ft)
6 x 'l.0 mm
7 Bolts
LOCK.UPVALVE
BODY
LOCK.UPSEPARATOR
PLATE
FEEDPIPE:A
DOWELPINS.2
6xl.0mm
1 Bolt
ATF STRAINER
ATFFEED
PIPES:
a
REGULATOR
VALVE
BODY
DOWELPINS.
6x1.0mm
7 Bolts
COOIERRELIEFVALVE
SERVOBODY
TOROUECONVENIER
CHECKVALVE
STATORSHAFT
SERVOSEPARATOR
PLAYE
O.RING
STOPSHAFT
ATF FEEOPIPE:H
5x1.0mm
5 Bolts
MAIN VALVEBODY
ATF PUMP
GEARSHAFT
SECONOARY
SEPARATORPLATE
ATF PUMPDFIVEN
GEAR
MAIN SEPARATOR
PLATE
'
DOWELPINS,
TOROUECONVERTER
HOUSING
/
-
CONTROL
SHAFI
t'se- oo^od"t"t
7r(
lli
tri
NOTE:The illustrationshows the'96 - 98 modsls,the'99 - 00 modelsdo not havethe servo
detentbase;the servo
detentis integralwiththe servobodv.
1 4-1 7 6
Downloaded from www.Manualslib.com manuals search engine
1 . Installthe ATF magnetand suctionpipe collarin the
torqueconverterhousing.if necessary.
lnstallthe main seDaratorplate and the two dowel
pins on the torqueconverterhousang.
Installthe ATF pump drive gear,ATF pump driven
gear and ATF pump driven gear shafton the torque
converter housing.
NOTE; Install the ATF pump driven gear with its
groovedand chamferedsidetacingdown.
ATFPUMP
a
For '96 - 98 models: Installthe servo detent base
and the ATF strainer(two boltsl.
For'99 - 00 models: Installthe ATF strainer (one
bolt).
1 0 . Tightenthe five bolts on the main valve body to 12
N.m ('1.2kgf.m,8.7lbf.ft).
Makesure the ATF pump drive gear and ATF pump
drivengearshaft move smoothlY'
1 1 . lf the ATF pump drive gsar and ATF pump driven
gear shaft do not move freely, loosen ths five bolts
the valve
on the main valve body, and disassemble
bodies.
Realignthe ATF pump driven gear shaft and reassemble the valve bodies,then retighten the bolts to the
specifiedtorque,
ATF PUMPDRIVEN
GEARSHAFT
ATF PUMP
DRIVENGEAR
Groovedand chamfered
side taces separalor
plate.
4.
Installthe servo body and separatorplate on the
secondaryvalve body ('95 - 98 models: seven bolts.
'99 - 00 models:eight boltsl.
MAIN SEPARATOR
PLATE
CAUTION: Fsilule to align tho ATF pump driven
goar shaft corr.ctly will rscuh in a s€izedATF pump
drive goar or ATF pump d ven gear shaft.
Loosely install the main valve body with five bolts.
Make sure the ATF pump drive gear rotatessmoothly
in the normal operating direction and the ATF pump
driven gear shaft moves smoothly in the axial and
normaloperatingdirections.
Install the secondaryvalve body, separatorplate
and two dowel pinson the main valvebody.
NOTE:Do not installthebolts.
6.
7.
Installthe controlshaft in the housingwith the control shaftand manualvalvetogether.
lnstall the detent arm and arm shaft in the main
valve body, then hook the detentarm springto the
detent arm,
PLATE
SERVOSEPARATOR
PUMP
1 2 . Installthe stator shaft and stop shaft.
't3. Installthe bolts and the shaftstop on the secondary
valve body, then tighten the bolts (three boltsl.
DETENTARM SPRING
DETENT
MANUAL VALVE
1 4 . Installthe torqueconvertercheckvalve,coolerrelief
valveand valvespringsin the regulatorvalve body.
then install the regulatorvalve body on the main
valve bodv (one bolt).
1 5 . Installthe lock-upvalve body on the regulatorvalve
bodv (sevenbolts).
Installthe ATF feed pipes in the main valve bodY,
the threeATF feed pipesin the secondaryvalveand
the four ATFfeed pipesin the servobody. (cont'dl
14-177
Transmission
(cont'd)
Reassembly
TRANSMISSION
HANGER
*''
TRANSMISSIONHOUSING
MOUNTINGBOLTS
10 x 1.25mm
4{ N.m {4.5 kg{.m,33 lbI.ft)
Ufln
MAINSHAFT
SUB.ASSEMBLY
TRANSMISSION
HOUSING
REVERSE
GEAR
COLLAR
$*U./
REVERSE
GEAR
_\,]ffil
MAINSHAFTSPEED
SENSOR
WASHER
(D16Y7engine)
LOCKWASHER
SHIFTFORK
COUNTERSHAFT
SUB.ASSEMBLY
MAINSHAFT
SPEED
OIFFER€NTIAL
ASSEMBLY
TRANSMISSION
HOUSINGGASKET
TOROUECONVERTER
HOUSING
14-178
1 7 . l n s t a l lt h e r e v e r s ei d l e r g e a r a n d t h e g e a r s h a f t
h o l d e r( s e ep a g e1 4 - 1 7 5 ) .
reversegear
2 1 . lnstallthe needlebearing,countershaft
and reversegearcollaron the countershaft.
1 8 . lnstallthe differentialassemblyin the torque converterhousing.
22. Align the spring pin on the control shaft with the
1 9 . A s s e m b l et h e m a i n s h a f ts u b - a s s e m b l ya n d t h e
c o u n t e r s h a fst u b - a s s e m b l yt ,h e n i n s t a l lt h e m
togetherin the torqueconverterhouslng
transmissionhousinggrooveby turningthe control
shaft.
SPRINGPIN
CONTROLSHAFT
MAINSHAFT
SUB-ASSEMBLY
COUNTERSHAFT
SUB.ASSEMBLY
Installthe two dowel pins and a new gasketon the
torqueconverterhousing.
24. Placethe transmissionhousingon the torque converterhousing.
20, Turn the shift fork so the large chamferedhole is
tacing the fork bolt hole, then install the shift fork
with the reverseselector,and tighten the lock bolt'
Bendthe locktab againstthe bolt head
SHIFTFORK
LOCKWASHER
Replace.
CAUTION: Make sure that lhe mainshaft speed
sensor is not installed on the transmission housing
before installing the transmission housing on the
torque conv€rter housing.
l n s t a l lt h e t r a n s m i s s i o nh o u s i n gm o u n t i n g b o l t s
a l o n g w i t h t h e t r a n s m i s s i o nh a n g e r ,t h e n t i g h t e n
the bolts in two or more steps in the sequenceas
shown.
TOROUE:,l,t N'm l{.5 kgf'm, 33 lbf'ft}
TRANSMISSION
HANGER
6 x 1.0mm
4 N.m
('l.4 kgl'm, 1O lbt'ft)
Large chamtered hole
o
(cont'di
14-179
Transmission
(cont'dl
Reassembly
26. Slipthe specialtool onto the mainshaftas shown,
MAINSHAFTHOLDER
07GAB- PF50101
3 1 . I n s t a l lt h e m a i n s h a f t1 s t g e a r c o l l a ro n t h e m a i n _
shaft.
32. Wrap the shaft splineswith tape to preventthe Orings,then installnew O-ringson the mainshaft,
33. Assemblethe thrust washer,thrust needlebearing,
needle bearing,and mainshaft?st gear in the lst
clutchassembly,then installthem on the mainshaft.
34. Installnew conicalspring washersand locknutson
eachshaft.
27. Installtheparkleveron the controlshaft.
28. A s s e m b l et h e o n e - w a yc l u t c h a n d t h e p a r k g e a r
with the countershaftlst gear(seepage l4-1S5).
CAUTION: Install the conical spring washers in the
direction shown.
MAINSHAFT
LOCKNUT
Left handthreads
29. Installthe countershaftlst gear collar.needlebear_
ing, and the countershaft1stgearlparkgear assembly
on the countershaft.
lSTCLUTCH
ASSEMBLY
PARK
GEAR
CONICAL
SPRING
WASHERS
installin thisdirection.
35. Tightenthe locknutsto the specifiedtorque.
30. Installthe park pawl shaft, spring, pawl, and pawl
stop on the transmissionhousing,then engagethe
parkpawlwith the parkgear.
NOTE:
. D o n o t u s e a n i m p a c t w r e n c h .A l w a v s u s e a
torque w.ench to tighten the locknut.
. Mainshaftand countershaftlocknuts have left_
handthreads.
TOROUE:
MAINSHAFT
78 N.m (8.0 kgf.m, 58 tbf.ft)
COUNTERSHAFTt03 N.m 1r0.5kgf.m, 75.9 tbt.ftl
14-180
36. Removethe specialtool from mainshaft,then stake
eachlocknutusinga 3.5 mm punchas shown'
40. Instslltheend coverwith two dowel pinsandanew
gasket(thirteen bolts)'
TOROUE:12 N'm (1.2tgf'm. 8.7 lbf'ft}
COUNTERSHAFT
LOCKNUT
0.7- 1.2mm
(0.03- 0.05 in)
ENDCOVER
a'f
Set the park lever in the El position, then verify that
the park Pawl engagesthe Parkgear
38. lf the Dawl does not engagefully, checkthe park
ao
4 1 . lnstall the ATF cooler lines with new sealing wash9rs.
pawl stop clearance(see page 14-175).
TOROUE:28 N.m {2.9 kgf'm. 21 lbt'ft1
Tighten the lock boll and bend the lock tab'
Installthe ATF diPstick.
Erl.Omm
14 t{.m (1.4 kgf'm, 10 tbl.ftl
\.-
(o)
LOCK
WASHEF
14-181
Torque Converter/Driveplate
6x1.0mm
12 N.m (1.2 kgt.m, 8.7 lbf.ft)
74 N.m 17.5 kgl.m, 54 lbf.ftl
Torque in a ctisscaossoattern.
@
@
/
E PLATE
14-182
Transmission
lnstallation
1.
Flushthe ATF cooler as describedon page l4-187
and 14-188.
Installthe transmissionmount bracket.
6.
12 x 1.25mm
6il N.m {6.5 kgf.m, a7 lbf'ft)
Install the torque converter assembly securely with
a new O-ringon the mainshaft
45 N.m {4.5 kgf.m,
MOTOR
STARTER
14 mm DOWELPIN
TOROUE
CONVERTER
O-RING
Replace
PIN
lil mm DOWEL
lnstall the starter motor on the torque converter
housing,then installthe two 14 mm dowsl pins in
the torqueconverterhousing.
Placethe transmissionon a jack,and raiseit to the
engineassemblylevel.
Attach the transmissionto the engine,then install
two transmissionhousingmounting bolts and two
rearenginemountingbolts.
REARENGINE
BOLTS
MOUNNNG
1,1r15mm
TRANSMISSIONHOUSING
MOUNTINGBOLTS
12x 1.25mm
47 tbf frl
64 N.m {6.5
12 x 1.25mm
74 N.m (7.5 kgf.m,
54 tbt.fr)
TRANSMISSIONMOUNT
Installthe remainingtransmissionhousing mounting boltsand remainingrearenginemountingbolt.
7.
REARENGINE
MOUNTINGBOLT
14 x 1.5mm
el N.m (8.5 kgt'm,
61 tbl.ft)
Replace.
&| N.m 18.5kgf m, 61 lbf'ft]
Replace.
WASHER
HOUSING
MOUNTINGBOLTS
12 x 1.25mm
g N m (6.5kgf m, 'l? lblftl
ENGINE
MOUNTING
BRACKET
8.
Remove the transmission jack.
(cont'd)
JACK
14-183
Transmission
Installation(cont'dl
9. Attach the torque converter to the drive plate with
eight drive plateboltsand torqueas follows:
Rotatethe crankshaftpulleyas necessaryto tighten
the bolts to 1/2 of the specified torque. then to the
final torque, in a crisscrosspattern.
After tighteningthe last bolt, checkthat the crankshaft rotatesfreely.
14. Installthe control lever with a new lock washerto
the controlshaft,then installthe shift cablecover.
CAUION: Taks care not to bend the shift cable.
SHIFTCABLE
TOROUE:12 N.m {1.2 kgl.m, 8.7 tbt{r}
10x 1.25mm
4,r N.m 14.5kgf.m,33 lbtft)
L(rcK WASHER
Replace.
6x1.0mm
12 N.m (1.2kgt m,
8.7 rbt ft)
8 x 1,25r'|m
22N-m
12.2tgt m. 16lbnftl
SHIFT CAAE COVER
x 1.0mm
tit N.m11.4kgtm,
10tbr,ft,
I \ 1.25mm
2/t N.m {2.4kg{.m,
17 tbt ftl
CONVERTEB
COVER
10. Installthe torque convener cover and the €ngine
stiffener.
'11. Tighten
the crsnkshaft pull€y bolt, if necessary(see
section61.
12. Connectthe ATF cooler hosesto the ATF cooler lines
(seepage1,t192).
15. lnstallthe exhaustpipeA.
NOTE: D16Y8engine is shown; D16y/ engine is sim_
ilar.
ATF COOIIR
UNE
Replace.
10 x 1.25mm
a,l N.m {4.5kgl.m,
33 rbt.ftt
RIGHTFRONT
12 x 1.25mm
MOUNT/BRACKET6.t N.m (6.5kg{.m,
47 tbt ftl
13. Installthe rightfront mounvbracket.
14-1A4
GASKET
Replace.
SELF.LOCKING
NUT
Replace.
8 x 1.25mm
22 N.m {2.2 kgl.m, 16lbtfrl
SELF.LOCKING
NUT
Replace.
10 x 1.25mm
54 N.m (5.5 lgf.m,
40 tbt ftl
NUT
Replace.
8 x 1.25mm
16 N.m {1.6kgI.m,
12 tbf.ft)
16. Installa new set ring on the end of eachdriveshaft'
17. Installtheright and left driveshafts(seessction16)
CAUTION: Whil6 installing the driveshafE in the
diffarential, be surs not lo allow du3t and othor foreign particl€s to enler into the transmission.
NOTE:
. Cleanthe areaswhere the driveshaftscontactthe
transmission(differential)thoroughly with solvent or carburetorcleaner,and dry with compressedair.
. Turn the right and left steeringknucklefully outward, and slide each driveshaft into the differential until you feel its set ring clip engagethe side
gear.
18. Installthe damperfork,then installthe rightand left
ball jointsto the eachlower arm with the castlenuts
and new cotter Plns.
20. Connectthe mainshaftspeedsensor,the linearsolenoid and the shift controlsolenoidconnectors.
SOLENOIO
SHIFTCONTROL
CONNECTOR
LINEAR
SOITNO|o
CONNECTOR
6 r 1.0mrn
12 N.m (1.219f.m,
E.7lbf.frl
DAMPERPINCHBOLT
10 x 1.25 mm
a3 N.m l4.iakgf.m,
32 tbl.ftl
CONNECTOR
21. Connectthe countershaftspeed sensor and the vehicle speedsensor (VSS)connectors.
SPEED
VEHICI..E
CONNECTOR
SENSOR
4l
NUT
SELF.LOCKING
12 x 1.25mm
6il N.m t6.5 kgf'm, il7 lbf ftl
Replace.
COTTER
CASTLENUT
Replace.
12 x 1,25mm
49 59 N.m
{5.0- 6.0 kgf m, 36 - iB lbf'ft|
19. Install the splash shield.
COUNTERSHAFT
SPEEDSENSOR
CONNECTOR
(cont'dl
14-185
Transmission
Installation{cont'd)
Connectthe lock-upcontrolsolenoidconnector.and
installthe transmissiongroundcable.
24. Installtheintakeair duct.
D16Y7engine:
Installthe intakeair duct and the resonaror.
6 x '1.0mm
12N.m{1.2kgf.m,8.7lbl.ft}
D16Y8engine:
lnstallthe intakeair duct and the air cleanerhous_
angassembly.
25. Refillthe transmissionwith ATF (seepage 14_1.18).
26. Connectthe positive(+) cable first. then the negative (-) cable to the battery.
27. Checkthe ignitiontiming (seesection23).
28. Startthe engine.Setthe parkingbrake,and shift the
transmissionthrough all gears.three times. Check
the shift cableadjustment(seepage14_190).
TRANSMISSION
GROUNDCABLE
LOCK.UPCONTROL
SOLENOIDCONNECTOR
Connectthe stanercableson the stanermotor.and
installthe cableholder.
NOTE; When installingthe starter cable terminal.
makesurethat the crimpedside of the ring terminal
is facingout (seesection23).
6x1.0mm
12 N.m 11.2kg{.m.8.7tbtftl
{0.9kg'f.m,7 lbf.ftl
STARTERCAELE
14-186
29, Checkthe front wheelalignment(seesection1g).
3 0 . L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
cooling fan comes on) with the transmissionin N
or @ position,then turn it off and checkthe fluid
level(seepage 14- 7).
31. Roadtest as describedon pages14-113thru ,14_116.
CoolerFlushing
To prevent iniury to.face and eyas, always
!!!@
glasses
ot a face shield when using the
safetv
-ea.
transmissionflusher.
7. With the water and air valvesoff, attachthe water and
to the flusher'lHotwaterif available.)
air suDolies
NOTE:This procedureshouldbe performedbeforereinstallingthe transmission.
1.
Checkthe tool and hosesfor wear and cracksbefore
using.lf wear or cracksare found,replacethe hoses
beforeusing.
Usingthe measuringcup,fill the tankwith 2'l ounces
(approximately2/3 full) of biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contarner.
the tank
Securethe flusherfiller cap, and pressurize
(5 6 kpa
829
550
between
with compressedair to
120Psi).
80
8.45kgflcm' .
8, Turn on the flusherwater valve so water will flow
throughthe coolerfor 10 seconds.
NOTE:The air line shouldbe equippedwith a water
trap to ensurea dry air system.
NOTE;lf water does not tlow throughthe cooler,it
is completelyplugged.cannotbe flushed,and must
be replaced.
Hangthe tool underthe vehicle.
Attach the tank's dischargehose to the return line
of the transmissioncoolerusinga clamp.
Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamP
IMPORTANT:
Securelyclampthe oppositeend oJthe drain hoseto a
bucketor floor drain.
TRANSMtssroN
I
9. Depressthe trigger to mix the flushing fluid into the
water flow. Usethe wire clip to hold the trigger down'
1 0 . While flushingwith the water and flushingfluid for
two minutes,turn the air valve on for five seconds
everv 15- 20 secondsto createa surgingaction'
MAX 845 kpa{8.45kgf/cm' ,120psi)
AIR PRESSURE:
' 1 1 .Turn the water valve off. Releasethe trigger,then
reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps8 through 10'
12, Releasethe trigger,and rinsethe coolerwith water
onlv for one minute
13. Turn the water valveoff, and turn off the water supply
14. Turn the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Residualmobturo in tho cooler or pipas
can damagethe transmksion'
{r Water
TRANSMISSIONCOOLER
FLUSHER
{Commcrci.llYavail.blel
Kent-MooreJ384O5'A
or equivelent
15. Removethe flusherfrom the coolerline.Attachthe
drain hoseto a contalner.
16. Installthe transmission,and leavethe drain hose
attachedto the coolerline
{cont'd)
14-187
Transmission
CoolerFlushing(cont'dl
1 7 . Makesurethe transmissionis in the E position.
Fill the transmissionwith ATF, and run the engine
for 30 secondsor until approximately0.95f (1.0US
qt.,0.8lmp qt.) is discharged.
TOOL MAINTENANCE
1.
1 8 . Removethe drain hose, and reconnectthe cooler
returnhoseto the transmission(seepage l4-192).
Empty and rinseafter each use.Fill the can with water
and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
2.
1 9 . Refillthe transmissionwith ATF to the oroDerlevel
(seepage 14-118).
lf dischargeliquiddoes not foam,the orificemay be
blocked.
3.
To clean,disconnectthe plumbingfrom the tank at
the largecouplingnut.
FILLERCAP
ORIFICE
GRT{G
Removethe in-line filter from the dischargeside and
clean if necessary.
The fluid orifice is tocatedbehind the filter.
Clean it with the pick stored in the bottom of the
t a n k h a n d l e ,o r b l o w i t c l e a n w i t h a i r . S e c u r e l v
reassembleall Darts.
14-18A
Shift Cable
Removal/lnstallation
!@@
seqtion1).
Make sure lifts are placed properly (see
1.
Removethe front console(seesection20).
2.
Shift to E position,then removethe lock pin Jrom
the adjuster.
4.
Removethe shift cableholder.
5.
Bemovethe shift cablecover.
6.
Removethe control Iever from the control shaft,
then remove the shift cable. Take care not to bend
it
the cablewhen removing/installing
I x '1.25mm
22 N.m
12.2kgl'm.
16 tbl.ftl
SHIFTCABLEHOLDER
SHIFTCABLE
LOCKWASHER
Replace.
CONTBOLLEVER
7.
SHIFTCABI.f
7 N.m
(07kst'm,5lbl'ftl
3,
6x1.0mm
12 N.m
('1.2ksf.m,
8.7 rbtftl
6 x 'l.0mm
14 N.m
(!.il kgt.m. 10lbl.ftl
lnstall the shift cable in the reverseorder of removal'
C h e c kt h e c a b l e a d j u s t m e n to n r e a s s e m b l y( s e e
page 14-190).
Remove the shift cable bracket.
SHIFTCABLE
BRACKET
6x1.0mm
9.8 N.m
{1.0kgf m, 7.2
14-189
Shift Cable
Adjustment
@
section1).
Make sure lifts are ptaced properly (see
1.
Removethe front console(seesectionZ0l.
2.
Shift to @ position.then removethe lock pin from
the adiuster.
3 . C h e c kt h a t t h e h o l e i n t h e a d j u s t e r i s p e r f e c t l y
alignedwith the hole in the shift cable.There are
two holes in the adjuster.They are positioned90.
apart to allow cable adjustmentin 1/4 turn increments.
Cable
Too Short
Cable
Too Long
Exact
Alignment
4. lf the hole is not perfectly aligned, loosen the locknut on the adjusterand adjustas required.
5. Tightenthe tocknutto 7 N.m (0.7kgf.m,5 tbf.ft).
6. Installthe lock pin on the adjuster.lf you feel the
lock pin binding as you reinstallit, the cableis still
out of adjustmentand must be readjusted.
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d j u s t e r
securetv.
7 N.m (0.7kgtm.
5 tbtftl
8. Move the shift lever to each gear, and verify that the
shift positionindicatorfollows the automatictransaxlegear positionswitch.
9 . S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
gears. lf any gear does not work properly, refer to
(seepage 14-109thru 1'4-'112).
troubleshooting
10. Insertthe ignition key into the key cylinderon the
Ay'Tgear positionindicatorpanel,and verifythat the
shift lock leveris released.
14-190
Shift Lever
PUSHKNOBSPRING
SCBEW
N.m {0.3kgtm.2 lbf ft)
threadlocksealant
Apply non-hardening
SCREW
3 N.m {0.3kgifm,2 lblft)
SILICONEGREASE
GEARPOSITIONINDICATORPANEL
COVER
BUSHING
-61
SHIFTINDICATOR
SILICONEGREASE
LEVER
SHIFTLOCK
SCREW
3 N.m {0.3
SHIFTLEVERASSEMBLY
g
2/""*"
,.@
*
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbt.ft)
-Rt
_.\__r.\
\ooru.r.,
A/T GEARPOSITION
PLATE
A/T GEARPOSITIONSWITCH
SHIFTLEVERBRACKETBASE
SHIFTLEVER
BASECOLLAA
6x1.0mm
9.8 N.m 11.0kgf.m.7.2lbf.ft)
14-191
Shift Indicator Panel
Adiustment
'1.
Checkthat the index mark on the indicatoralions
with the N mark on the shift indicatorpanelwhen
the transmissionis in NEUTRAL.
ATFCoolerHoses
Connection
1.
Connectthe ATFcoolerhosesto the ATFcoolerlines
and ATF cooler,and securethem with the clips as
shown.
INDEXMARK
TRANSMISSION
3 N.m {0.3 kgf.m, 2lbt.ftl
lf not aligned.removethe front console{seesection
20t.
Removethe shift indicatorpanel mounting screws
and adjustby movingthe panel,
NOTE:Wheneverthe shift indicatorpanelis removed,
reinstallthepanelas describedabove,
14-192
CLIP
ContinuouslyVariableTransmission(CVTI
. . . . . . . . . . . . . .1. 4
. -194
S p e c i aTlo o l s
. . . . . . . . . . . . . . . . .1. 4
. .- 1 9 5
Description
Brake/Planetary
Clutches/Reverse
. . . . . . . . . .1 4 - 1 9 8
Gear/Pulleys
p o w e rF l o w
..............1
, .4. .-.2. 0 0
ElectronicControlSYstem
......14-203
(,96- 98 Modets)
ElectronicControl System
" 14-205
('99- oo Models)
14-208
'.......
HydraulicControl
'14-212
.'..-.....'...
HydraulicFlow
.....-...'.'
14-222
ParkMechanism
EleqtricalSystom
ComponentLocations
'96 - 98 Models
""""""' 14-224
,99- 00 Modets
14-225
.............
14-226
TCM CircuitDiagram('96- 98 Models).............
TCM Terminal Voltage/
MeasuringCondiiions('96- 98 Models) '....14-228
PcM CircuitOiaqram '99
14-230
{A/TControlSystem: - 00 Models}...--....
Conditions
PCMTerminalVoltage/Measuring
('99- 00 Models)
.'.'...14-232
A/4 ControlSystem
'14-234
... . .........',........."'
Procedures
Troubleshooting
Chart
Symptom-to-ComPonent
'14-234
'96 - 98 Models......'.....
ElectricalSystem'11-210
ElectricalSystem-'99 - 00 Models..'....-..-.
Troubleshooting
Electrical
Flowcharts
Troubleshooting
"""'11-242
('96- 98 Models)
Flowchart
Troubleshooting
......14-265
('99- 0OModets)
Solenoid
LinearSolenoids/lnhibitor
. . . . . .1. 4 - 2 9 f
T e s t. . . . . . . . . . . . . . . . . . . . . . . . .
Gear
Pulley/Secondary
DrivePulley/Driven
Shaft Speed Sensors
.14-292
.........'......
Replacement
Start Clutch Control
StartClutchCalibrationProcedure...........,. 14-293
HydraulicSYstem
Chart
Symptom-to-ComPonent
'.'.......14-294
HydraulicSystem
. . . . . . . . . . . . . . . . . . . .1. 4
. .-.2. .9. .6
R o a dT e s t
StallSpeed
......14-294
Test.........................
FluidLevel
.......14-299
Checking/Changing
14-300
.................
Testing
Pressure
LowerValveBodYAssemblY
. . . . . . . . . . , . .1.4 - 3 0 2
Replacement
ATF Filter
.....14-303
Removal/lnstallation
Transmission
Transmission
14-304
.
R e m o v a.l . . . . . . . . . .
lllustratedIndex
ValveBodY
Transmission/Lower
. . . . . . . . . . . . .1. .4. -. 3 0 8
Assembly
... 14-310
Housing
Housing/Flywheel
Transmission
14-312
ntermediateHousing ..........'.'....
EndCover/f
TransmissionHousing/
Lower Valve Body Assembly
.. " 14-314
R e m o v a l. . . . . . . . . . ' . . . .
Housing
TransmissionHousing/Flywhesl
........1+316
Removal.................
Housing
EndCover/lntermediate
14-318
Removal.........,...............
Body
Valve
Manual
.'.'.'.....14-320
Disassembly/lnspection/Reassemblv
Forward Clutch
. .2. .1.
l l t u s t r a t eIdn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .4.-. 3
14-322
..................
Disassemblv
, ,, . ',','......14-324
Reassemblv
SecondaryGear Shaft
25 x 35 mm ThrustShim Selection..'.'....-...14-324
Differential
14-329
lllustratedlndex ...,.....................,.,...-.-.-...'...
.-....14-329
BacklashInspection
....'...14-330
BearingReplacement......'........'....'...
14-330
DifferentialCarrierReplacement........'........
14-331
...........
Oil SealRemoval
14-331
.
.
.......
Clearance
Oil SealInstallation/Side
FlywheelHousingInputShaftOil Seal
...'.'..14-333
.....,....
Replacement
TransmissionHousingBearings
Driven Pulley Shaft Bearing
14-334
. ...................'..
...................'.
Replacenient
Bearing
Shaft
SecondaryGear
. ........14-335
. ..........
......................
Reolacbment
FlywheelHousing Beating
SecondaryGear Shaft Bearing
R e o 1 a c e m e n t . . . . . . . . . . . . . . . . . . , . . . . . . . . .1. .4.-. 3
. .3. .5. . . . . . . . . .
Bearing
RingGear
. . . . . . .1.4 - 3 3 6
Replacement.........
Control Shaft Assembly
.................'.....1
. .4. .-.3. 3 6
R e m o v a l / l n s t a l l a t.i .o. n
Transmission
14-338
..................
Reassembly
Plate .. . ....... ......... . ....-.....'.'...14-341
Flywheel/Drive
Transmission
14-348
.....................
lnstalation
.'.........14-352
CoolerFlushing
shift cable
Removal/lnstallation....'........." """ 14-354
. . . . . . . ' . . . . . . .1. 4 - 3 5 5
Adjustment
. . . . . . . . . . . . . . . . . .1
. .4. .' .3.5, .6
S h i f tL e v e r
Shift IndicatorPanel
..............1
. .4 - 3 5 7
Adjustment
ATF Cooler/Hoses
.... 14-357
l n s t al l a t i o n. . . . . . , , . . . . . .
SpecialTools
Ref. No.
Tool Number
I
o
@
alr *
@
o
@
6l
@
o
@
@-"
@
@
@
o
@
07GAE- PG40200
07JAD- PH80200
07LAE- PX40100
07PM- 0010100
07sM- 0010004
07TAE- P4V01l0
07TAE- P4V0120
07TAE- P4V0130
07tvlAJ- PY4011A
07MAJ- PY40l20
07406- 0020400
07406- 0070300
07736- A0r 0004
07746- 0010100
07746- 0010500
07746- 0010600
07746- 0030100
07749- 0010000
ClutchSpringCompressorBoltAssembly
Pilot.26 x 30 mm
ClutchSpringCompressorAttachment
SCSServiceConnector
BackprobeSet
ReverseBrakeSpringCompressor
Stan ClutchRemover
Stan ClutchInstaller
A/T Oil PressureHose,2210mm
Ay'TOil PressureHose,Adapter
Ay'TOil Pressurecauge Set Wpanel
Ay'TLow PressureGaugew/panel
AdjustableBearingPuller,25 - 40 mm
Attachment,32 x 35 mm
Attachment,62 x 68 mm
Attachment,72 x 75 mm
Driver40 mm l.D.
Driver
0 7 9 4 7- 6 1 1 0 5 0 1
01947 - 6340201
Driver Aftachment,68 mm
DriverAttachment,58 x 72 mm
't4-322,325
I
1
2
I
a
,l
14-333
14-322,325
't4-235,293
14-236,
296
r4-319,339
't 4-311
14-342,343
't4-300
1
1
14-300
14-300
14-300
14-335
14-333,
336
14-335
14-334,
335
14-330,
331
14-333,
334,335,
336
14-333
14-333
1
,1
1
1
'1
I
1
1
*07HAE- PL5010lcan be usedas a substitute.
**Must be usedwith commercially-available
3/8.,- 16 slidehammer.
E*E
o
e
1:,'Jt*
dAt:-
@
IR
>.'.--t-'- t'
\;4
aio
@
14-194
o
e'
18l
io(313
@
@
@
@
Description
controlledautomatictransmissionwith drive and driv
The ContinuouslyVariableTransmission(CVT)is an electronically
en Oullevs,and a steelbelt.The CVTprovidesnon stagespeedsforward and one reverse.The entireunit is positionedin
l i n ew i t ht h e e n g i n e .
Transmission
Aroundthe outsideof the flywheelis a ring gear which mesheswith the starterpinion when the engineis being staned.
The transmissionhasfour parallelshafts:the input shaft,the drive pulleyshaft.the drivenpulleyshaft,and the secondary
The drive pulleyshaftand the drivenpulleyshaftconsistof
gearshaft.The input shaftis in linewith the enginecrankshaft.
pulleys.
pulleys
steel
belt.
are linkedby the
Both
movableand fixed face
The input shaft includesthe sun gear.The drive pulleyshaft includesthe forwardclutchwhich mountsthe carrierassembly on the forwardclutchdrum. The carrierassemblyincludesthe piniongearswhich meshwith the sun gearand the ring
gear.The ring gear hasa hub-mountedreversebrakedisc.
The drivenpulleyshaft includesthe startclutchand the secondarydrive gearwhich is integralwith the parkgear'The secondary gear shaft is positionedbetweenthe secondarydrive gear and the final driven gear.The secondarygear shaft
includesthe secondarydriven gear which servesto changethe rotationdirection.becausethe drive pulleyshaft and the
driven oullev shaft rotate the same direction.When certain combinationsof planetarygears in the transmissionare
engagedby the clutchesand the reversebrake,power is transmittedfrom the drive pulleyshaftto the driven pulleyshaft
to provideE, E, E, and El.
ElectronicControl
'96 - 98 Models:
The electroniccontrolsystemconsistsof the TransmissionControlModule (TCM),sensors,three linearsolenoids,and a
controlledunderall conditions'
inhibitorsolenoid.Shiftingis electronically
the
dashboard,
behind
the kickpanelon the driver'sside.
is
located
below
The TCM
'99 - 00 Models:
The electroniccontrol svstem consistsof a PowertrainControl Module (PCM),sensors,three linear solenoidsand an
controlledunderall conditions.A GradeLogicControlSystemto controlshiftinhibitorsolenoid.Shiftingis electronically
position
or descendinga slope.
vehicle
is
ascending
while the
ing in E
side.
The PCMis locatedbelowthe dashboard,underthe kickpanelon the passenger's
HydraulicControl
The lower valve body assemblyincludesthe main valve body,the PressureLow (PL)reguiatorvalvebody,the shift valve
body, the start clutch control valve body, and the secondaryvalve body. They are positionedon the lower part of the
t r a n s m i s s i ohno u s i n g .
The main valvebody containsthe PressureHigh (PH)controlvalve,the lubricationvalve,and the pitot regulatorvalve.
The secondaryvalve body containsthe PH regulatorvalve,the clutchreducingvalve,the startclutchvalve accumulator,
and the shift inhibitorvalve.The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrol valve
which is ioinedto the PH,PLcontrollinearsolenoid.The inhibitorsolenoidvalveis boltedon the PLregulatorvalvebody.
The shift valvebody containsthe shiftvalveand the shift controlvalve.which is joinedto the shift controllinearsolenoid.
The startclutchcontrolvalve body containsthe startclutchcontrolvalve,which is joinedto the startclutchcontrollinear
solenoid.The linearsolenoidsand the inhibitorsolenoidare controlledby the TCM or PCM.The manualvalvebody which
containsthe manualvalveand the reverseinhibitorvalve,is boltedon the intermediatehousing.
The ATF pump assemblyis locatedon the transmissionhousing,and is linkedwith the input shaft by the sprocketsand
feed pipes,and the reversebrakereceives
the sprocketchain.The pulleysand the clutchreceivefluid from their respective
fluid from internalhydrauliccircuit.
Shift Control Mechanism
Inputfrom varioussensorslocatedthroughoutthe vehicledetermineswhich linearsolenoidthe TCM or PCMwill activate.
Activatingthe shift controllinearsolenoidchangesthe shift controlvalve pressure,causingthe shift valveto move.This
pressurizes
the drive pulley pressureto the drive pulleyand the driven pulley pressureto the driven pulleyand changes
their effectivepulleyratio.Activatingthe startclutchcontrollinearsolenoidmovesthe startclutchcontrolvalve.The start
clutch control valve uncovers the port, providing pressure to the start clutch to engage it
(cont'd)
14-195
Downloaded
from www.Manualslib.com manuals search engine
,!
Description
(cont'd)
Gear Sel€stion
The shift leverhassix positions:@ pARK,E REVERSE,
g SECOND,
E NEUTRAL,
and El LOW.
E DR|VE,
Poshion
De3cription
E PARK
Frontwheelslocked;parkpawl engagedwith the parkgearon the drivenpulleyshaft.The start
clutch and the forward clutch released.
E REVEBSE
Reverse;reversebrake engaged.
E NEUTRAL
Neutral;the start clutch and the forward clutch released.
D DRIVE
Generaldriving;the transmissionautomatically
adjuststo keepthe engineat the bestspeedfor
drivingconditions.
E SECOND
For rapid accelsrationat highway speeds;the transmissionshifts into a lower range of ratios for
better accelerationand increasedengine braking.
E LOW
Forenginebrakingand powerfor climbinO;the transmissionshiftsinto the lowestrangeof the
ralros.
Staning is possibleonly in E and E positionsthrough the use of a slid6-type,neutrafsafety switch.
Automrtic Transaxle{A/T} Gear Position Indicltor
The A-lTgear position indicator in the instrument panel shows which gear has been selectedwithout having to look down
at the console.
14-196
STEELBELT
STARTCLUTCH
INPUTSHAFT
DRIVEPULLEY
ATF FILTER
14-197
Description
Clutches/Reverse
Brake/Planetary
Gear/Pulleys
Clulches/ReverseBrake
T h e C V T u s e st h e h y d r a u l i c a l l y - a c t u a tcel u
d t c h e sa n d b r a k et o e n g a g eo r d i s e n g a g et h e t r a n s m i s s i o n
g e a r s .W h e n
hydraulicpressureis introducedinto the clutchdrum and the reversebrakepistoncavity,the clutchpistonand the reverse
brakepiston move.This pressesthe frictiondjscsand the steelplatestogether,lockingthem so they don't slip. Poweris
then transmittedthrough the engagedclutch packto its hub-mountedgear. and through engagedring gear to pinion
gears.
Likewise,when the hydraulicpressureis bled from the clutchpackand the reversebrakepistoncavity,the pistonreleases
the frictiondiscsand the steelplates,and they are free to slidepasteach.This allowsthe gearto spin independently
on its
shaft,transmittingno power.
Start Clutch
The startclutch,which is locatedat the end of the drivenpulleyshaft,engages/disengages
the secondarydrive gear.
The startclutchis suppliedhydraulicpressureby its ATFfeed pipeswithin the driven pulleyshaft.
Forward Clutch
The forwardclutch,which is locatedat the end of the drive pulleyshaft,engages/disengages
the sun gear.
The forwardclutchis suppliedhydraulicpressureby its ATFfeed pipewithin the drive pulleyshaft.
ReverseBrake
The reversebrake,which is locatedinsidethe inte.mediatehousingaroundthe ring gear,locksthe ring gear in E position. The reversebrakediscsare mountedto the ring gear and the reversebrakeplatesare mountedto the intermediate
housing.The reversebrakeis suppliedhydraulicpressureby a circuitconnectedto the internalhydrauliccircuit.
PlanetaryGear
The planetarygearconsistsof a sun gear,a carrierassembly,and a ring gear.The sun gear is connectedto the input shaft
with splines.The pinion gearsare mountedto the carrierwhich is mountedto the fo.ward clutchdrum. The sun gear
inputsthe enginepower via the input shaftto the planetarygear,and the carrieroutputsthe enginepower.The ring gear
is only usedfor switchingthe rotationdirectionof the pullevshafts,
In E. E, and E positions(forwardrange),the pinion gearsdon't rotateand revolvewith the sun gear, so the carrier
rotates.In E] positjon{reverserange),the reversebrakelocksthe ring gear and the sun gear drivesthe pinion gearsto
rotate.The pinion gearsrotateand revolvein the oppositedirectionfrom the rotationdirectionof the sun gear,and the
carrierrotateswith piniongear revolution.
Pulleys
Eachpulley consistsof a movableface and a fixed face, and the effectivepulley .atio changeswith engine speed.The
drive pulleyand the drivenpulleyare linkedby the steelbelt.
To achievea low pulley ratio, high hydraulicpressureworks on the movableface of the driven pulleyand reducesthe
effectivediameterof the drive pulley.and a lower hydraulicpressureworks on the movableface of the drive pulleyto
eliminatethe steelbelt slippage.To achievea high pulleyratio,high hydraulicpressureworks on the movablefaceof the
drive pulleyand reducesthe eifectivediameterof the driven pulley,and a lower hydraulicpressureworkson the movable
faceof the drivenpulleyto eliminatethe steelbelt slippage.
14-198
ATF PUMP
DRIVENSPROCKET
ATF PUMP
DRIVEPULLEY
RING GEAR
REVERSE
BRAKE
PISTON
FORWARDCLUTCH
BEVERSEBRAKE
CARRIER
FLYWHEEL
RINGGEAR
DRIVEPLATE
PLANETARY
PINIONGEARS
INPUTSHAFT
ATFPUMP
DRIVECHAIN
ATF PUMP
DRIVESPROCKET
DRIVENPULLEY
SHAFT
STARTCLUTCH
FINALDRIVEGEAR
DRIVENPULLEY
GEAR
SECONDARY
SHAFT
a-i___
STEELBELT
il
DRIVEGEAR
SECONDARY
PARKGEAR
14-199
Description
PowerFlow
E Position
.
.
.
StartClutch:released
ForwardClutch:released
ReverseBrake:released
Hydraulicpressureis not appliedto the startclutch.forwardclutch,and the reversebrake.Poweris not transmittedto the
secondarydrive gear.
E Position
. StartClutch:released
. ForwardClutch:released
a ReverseBrake;released
Hydraulic pressureis not applied to the start clutch, forward clutch, and the reversebrake.Power is not transmitted to the
secondarydrive gear. The secondarydrive gear is locked by the park pawl interlockingthe park gea..
FI-YWHEEL
FORWARD
INPUTSHAFT
SUN GEAR
STARTCLUTCH
ORIVENPULLEY
FINALORIVE
GEAR
PARKGEAR
FINALDRIVENGEAR
14-200
E, E, and E Positions{Forward Rangel
. Start Clutch:engaged
. ForwardClutch:engaged
o ReverseBrake:released
1, The hydraulicpressureis appliedto the forward clutch and the start clutch,and the sun gear drives the torward
clutch.
2.
The torwardclutchdrivesthe drive pulleVshaft.which drivesthe drivenpulleyshaft linkedby the steelbelt.
3,
The drivenpulleyshaftdrivesthe secondarydrive gear,via the startclutch.
4.
Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.
NOTE:The working hydraulicpressureon the movablefaceof eachshaftdependson the throttleopeningposition.
FLYWHEEL
DRIVEPULI.fY
STEELAELT
CLUTCH
INPUTSHAFT
STARTCLUTCH
DRIVEN
SECONDARY
GEAR
(cont'd)
FINAL DRIVENGEAR
14-201
Description
Power Flow (cont'd)
E Position
.
.
.
Start Clutch:engaged
ForwardClutch:released
ReverseBrake:engaged
1. The hydraulicpressureis appliedto the reversebrakeand the startclutch.The sun gear drivesthe piniongears,and
the piniongearsrevolvearoundthe sun gear.The carrierassemblyrotatesin the oppositedirectionfrom the rotation
directionof the sun gear.
2.
The carrierassemblydrivesthe drive pulleyshaft via the forward clutchdrum, and the drive pulleyshaft drivesthe
drivenpulleyshaftlinkedby the steelbelt.
3.
The drivenpulleyshaftdrivesthe secondarydrive gearvia the startclutch.
4.
Poweris transmittedto the secondarydrivengear,which drivesthe final drivengear.
DRIVEPULLEY
STEELEELT
REVERSE
BRAKE
DRIVE
PULLEY
CARRIER
ASSEMBLY
INPUTSHAFT
SUN GEAR
PINIONGEAB
RINGGEAB
STABTCLUTCH
DRIVENPULLEY
SECONDARY
DRIVE
GEAR
FINAL
GEAB
SECONDARY
ORIVEN
GEAR
FINALORIVEN
GEAR
14-202
ElectronicControlSystem('96- 98 Modelsl
(TcM),sensors,three linearsolenoids,and an
The electroniccontrolsystemconsistsof the Transmissioncontrol Module
controlledunderall conditions
inhibitorsolenoid.Shiftingis electronically
The TCIMis locatedbelowthe dashboard,behindthe kickpanelon the driver'sside'
when the vehicleis
The TcN4controlsthe transmissionto reduceenginespeedand retainthe engine'scoolingefficiency
drivenwith Iull throttleacceleration
t h, e T C M r e g u l a t e st h e p u l l e yh y d r a u l i cp r e s s u r et o
y r i v e na t f u l l t h r o t t l ea c c e l e r a t i o n
l f t h e v e h i c l ei s c o n t i n u o u s l d
and retainsthe designedcoolingefficiencyAfter
speed
increasethe pulleyratio,which,as the result.reducesthe engine
the pulleyratioto the originalratio.
increases
the
TCM
for
a
while,
the vehiclehas beendrivenat a lower enginespeed
cut
off
the rvc clutch{if the A!/cis on) and
EcM
to
to
the
a
signal
sends
position,
the
TcM
For smooth startingin the E
position'
to
the
is
shifted
E
the
transmission
rpm
when
900
speed
to
engine
the
increases
properly.the TCM regulates
The start clutchfunctionsto make smooth startingpossible.To let the start clutchfunction
position'
in
the
pressure
memorized
E
negative
entine's
the startclutchhydraulicpressurebasedon the
:
:
z
z
z
S*ond.ry
G..r Sh:ft
(cont'd)
14-203
Description
ElectronicControlSystem('gG- 98 Modelsl(cont'dl
Circuit Diagramand Terminal Locations
GNITIONSWITCN
Pri- PtcoNTnoL
LrN ns0LtN0t0
SIAiT CLUTCH
CONTSOL
LINEAFSOLENOID
:
MAP(PBI
g
s61
E
rtDiRxo
g
sHtFT
CONmOI
LINIAftSOLENOID
TM8
scs
i\\c-...............-+B
BFAXELIGHT
PAS|(ING
8MI(E SWITCH
i\--------.--_ rcr
1
14
14-204
2
3
5
17
1
20
8
I
1 0 1 1 't2
23
2
26 12 1 3 t 4
5
7
t6 17 18
8
9
20
10
ElectronicGontrolSystem('99- 00 Modelsl
(PCM).sensors,three linearsolenoidsand an
The electroniccontrotsystemconststsof a Powertraincontrol Module
controlledunderall conditionsA GradeLogiccontrol systemto controlshiftinhibitorsolenoid.shifting is electronically
ing in E positionwhile the vehicleis ascendingor descendinga slope'
fn"pCVirlocatedbelowthedashboard,underthekickpanelonthepassenger'sside'
is
to reduceenginespeedand retainthe engine'scoolingefficiencywhen the vehicle
The pCM controlsthe transmassion
drivenwith full throftleacceleration
the pulley hydraulicpressureto
lf the vehicle is continuouslydriven at lull throttle acceleration,the PCM regulates
the
designedcoolingefficiencyAfter
retains
and
increasethe pulleyratiowhich. as the result,reducesthe enginespeed
pulley
ratioto the originalratio'
the
increases
PCM
while,
the
the vehiclehas beendrivenat a lowerenginespeedfor a
the enginespeedto
(if
increases
on)
and
A/c
is
the
,Vc
clutch
off
the
PcM
cuts
position,
the
i"i ".nl",rr startingin the E
900 rpm when the transmissionis shiftedto the E position'
functionproperly,the PcM regulates
The start clutchfunctionsto make smooth startingpossible.To let the start clutch
in the E position'
pressure
memorized
the startclutchhydraulicpressurebasedon the engine'snegative
FCM
s*o.d.ry
G..t Sh.h
(cont'd)
14-205
Description
ElectronicControlSystem('99- 00 Modelsl(cont'dl
Grade Logic Control System
How it works:
The PcM comparesactual driving conditionswith memorizeddriving conditions.basedon the input from the vehicle
speedsensor,the throttlepositionsensor,the manifoldabsolutepressuresensor,the enginecoolanttemperaturesensor,
the brakeswitchsignal,and the shift leverpositionsignal,to controlshiftingwhile the vehicleis ascendingor descending
a slope.
AscendingControl
When the PCM determinesthat the vehicleis climbing a hill in E position,the system selectsthe most suitableshift
schedule(pulleyratio)accordingto the magnitudeof a gradient.so the vehiclecan run smooth and have more power
when needed.Thereare threeascendingmodeswith differentshift schedulesaccordingto the magnitudeot a gradientin
the PCM.
DescendingControl
when the PCMdeterminesthat the vehicleis going down a hill in E position.the systemselectsthe most suitableshift
schedule(pulley ratio) accordingto the magnitudeof a gradient.This, in combinstionwith engine braking,achieves
smoothdrivingwhen the vehicleis descending,Thereare three descendingmodeswith differentshift schedulesaccording to the magnitudeof a gradientin the PCM.
14-206
-'99
Circuit Diagram and Terminal Locations
- 00 Models
IGN1TIONSWTCH
PH.PLCOiTSOL
SOLEI€ID
LINEAF
IGPl
SIAFTCLIJICHCOTITROL
LINEiFSOLET€IO
vcc2
TPS
SHIFICONTNOT
SOLEI{OIO
LINEAR
INNIBTOFSOLETIOIO
14-207
Description
HydraulicControl
The hydrauliccontrolsystemis controlledby the ATF pump.the valves,and the solenoids.The ATF pump
is drivenby the
input shaft.The ATF pump and the input shaft are linkedby the ATF pump drive chain and the
sprockets,The inhibitor
solenoidvalve and the linearsolenoids.which are locatedon their valve body, are controlledby the
TCM or pcM. Fluid
from the ATF pump flows throughthe PH regulatorvalveto maintainspecifiedpressureto the drive pulley,
the driven pulley,and the manualvalve,
The lower valve body assemblyincludesthe main valve body,the PL regulatorvalve body,the shift
valvebody,the start
clutchcontrolvalvebody,and the secondaryvalvebodv.
Main Valve Eody
The main valvebody containsthe pH controlvalve,the rubricationvalve,and the pitot regulatorvalve.
PH Control Valve
The PHcontrolvalvesuppliesPHcontrolpressure(PHCIin accordance
with the pH-pLcontrolpressure(HLc),and supplies PH control pressureto the PH regulatorvalve,which also regulatssPH pressure.
At kick-down,it increasespH
controlpressurewhich increases
the high (PH)pressure.This shortensthe shift speedby releasingthe reverseinhibitor
pressure(Rl)fromthe inhibitorsolenoidvalve.
LubricationValve
The lubricationvalvecontrolsthe lubricationpressureto eachshaftand maintainslubricationpressure.
Whenrne pressure is too high,the spring is compressed.
This movesthe lubricationvalveand opensthe fluid leakpassage.
Pitot Regulalor Valv6
The pitot regulatorvalvecontrolsthe startclutchpressure(SC)in accordance
with the enginespeed,when the electronic controlsystemis faulw.
MAIN VAIVE
BODY
14-208
SecondaryValve Body
valve accumulator'
The secondaryvalve body containsthe PH regulatorvalve.the clutchreducingvalve' the start clutch
and the shift inhibitorvalve
PH RegulatorValve
pump. and suppliesPH pressureto the
The pi regulatorvalve maintainshydraulicpressuresuppliedfrom the ATF
PH regulatorvalveby the PH control
the
pressure
at
is
regulated
hvdrauliccontrolcircuitand the lubricationcircuit.PH
pressure(PHC)from the PH controlvalve.
Cluteh ReducingValvo
the clutch reducing pressure
The clutch reducing valve receivesPH pressurefrom the PH regulator valve and regulates
clutchcontrolvalve'and
the
start
(cR)
and
valve
pressure
manual
to
the
(cR).The clutchreducingvalvesuppliesclutch
solenoidvalve'
inhibitor
the
and
valve,
control
shift
pressure
valve.
the
control
suppliessignalpressureto the PH-PL
Start Clutch Valv€ Accumulator
the hydraulicpressurethat is suppliedto the startclutch'
The startclutchvatveaccumutatorstabilizes
Shift Inhibitor Valve
from electroniccontrol to hydraulic
The shift inhibitor valve switchesthe fluid passageto switch the start clutch control
pressure(cR) to the pitot regulator
reducing
clutch
suppliss
lt
also
is
faulty.
system
control
electronic
control when the
valveand the pitot lubricationpipe.
START CLUTCHVALVE
SECONDARYVALVE
BODY
SHIFTINHIBITOEVALVE
VALVE
REDUCING
VAL
PH REGULATOR
(cont'd)
14-209
Description
HydraulicControl{cont'dl
PL RegulatorValve Body
The PL regulatorvalve body containsthe PL regulatorvalve and the PH-PLcontrolvalve.which is joined wirh the pH-pL
controllinearsolenoid.The inhibitorsolenoidis boltedon the pL regulatorvalvebody.
.
PL RegulatorValve
The PL regulatorvalvesupplieslow p.essure(pL)to the pulleyto eliminatesteelbelt slippage.
The PL pressureis controlledby the pH-pLcontrolpressure(HLC).
.
PH-PLControl Valve
The PH-PLcontrolvalve controlsthe PL regulatorvalve accordingto enginetorque.The PH-PLcontrolvalvesuoolies
PH-PLcontrolpressure(HLC)to the PH controlvalveto regulatePH pressurehigherthan pL pressure.The pH-pLcontrol valveis controlledby the PH-PLcontrollinearsolenoid.which is controlledby the TcM or pcM,
.
InhibitorSolenoid
The inhibitorsolenoidcontrolsthe reverseinhibitorvalveby turningon and off. Also,the inhibitorsolenoad
controlspH
controlpressure(PHC)by applyingreverseinhibitorpressure(Rl)to the PHcontrolvalve.The inhibitorsolenoidis controlledby the TCM or Pclvl.
Start Clutch Control Valv€ Body
The startclutchcontrolvalve body containsthe startclutchcontrolvalve.Both are joinedto the stan clutchcontrollinear
solenoid.
.
Start Clutch Control Valve
The startclutchcontrolvalvecontrolsstartclutchengagementaccordingto the throttleopening.The start clutchcon,
trol valveis controlledby the stan clutchcontrollinearsolenoid,which is controlledbv the TCM o. pCM.
STARTCLUTCHCONTROL
vAt-vE
LOWERVALVEBODY
ASSEMBI-Y
PH.PLCONTROL
LINEARSOLENOID
14-210
Shift Valve BodY
linearsolenoro.
shift controlvalve.Bothare ioinedto the shiftcontrol
The shiftvalvebody containsthe shift valveand the
r tl'ft1il1rf"",""
pH
Theshiftvarvedistributes
varve.
(sV)fromtheshiftcontror
by shiftvarvepressure
is controred
pi""aur" "nO PL pressureto drive pulleyand the driven
t
pulley'to shiftthe transmission'
t*"rilf:::lr';ivarve
opening and vehicle speed rhe shift
contrors the shift varve in accordancewith the throttre
When the elecsolenoid,which is controlledby the TcM or PcM
controlvalveis convorr"ouv ti" "iirt "ontrol linear
port
leadingthe
the
uncover
to
valve
"witchesthe shift inhibitor
tronic controlsystemis faulty,t;; snift controtuutue
pitot regulatorpressureto the startclutch
SHIFTCONTROL
CONTROLVALVE
VALVEBODY
inhibitorvarve.Themanuatvarvebodvis bortedto the
varveandthe reverse
the manuar
T;J:"i"""1ff"t""ilody contains
intermediatehouslng
.
ManualValve
position'
the fluid passageaccordingto the shift lever
uncovers/covers
The manualvalvemechanicallY
'
(Rl). lt interceptsthe hvdraulic circuit to the
is contro ed by the reverse inhibitor pressure
ff:e;;;.'::'?Xftl::T",*
at speedsover approximatelv6 mph (10 km/h)'
reversebrakewhile the vehicleis movingforward
REV€RSEINHIBITOR
VALVE
MANUAL VALVE
BODY
MANUALVALVE
14-211
Description
HydraulicFlow
GeneralChart of Hydraulic prossure
'Shift Valve
. ShiftinhibitorVatve
PH REGULATOR
VALVE
NO.
cc
coL
DESCRIPTION
OF PRESSURE
NO.
DESCRIPTION
OF PRESSURE
CLUTCHCONTROL
PP
PITOTPIPE
ATF COOLER
PR
PITOTREGULATOR
CLUTCHREDUCING
RCC
RECIRCULATION
DN
DRIVENPULLEY
DR
DRIVEPULLEY
RVS
REVERSE
BRAKE
FWD
FORWARD
CLUTCH
sc
STARTCLUTCH
HLC
PH-PLCONTROL
sl
SHIFTII"IHlBITOR
LUB
LUBBICATION
PH
PRESSURE
HIGH
PHC
PL
14-212
PHCONTROL
PRESSURE
LOW
RI
SUC
REVERSE
INHIBITOR
SUCTII'N
SHIFTVALVE
X
LEAK
E Position
Astheengineturns.theATFpumpa|sostartstooperate.F|uidfromtheATFpumpf|owstothePHregu|atorva|veandt
c|Utchreducingva|ve.ThePHregu|atorva|veregu|ateshighpressure(PH).andsendittotheshiftVa|veandthePLr
latorvalve.Thehighpressure(PH)flowstothemovablefaceofthedrivenpulleyviatheshiftvalve'andturnsintolow
pressure(PL)atthePLregu|atorva|ve.Thelowpressure(PL}f|owstothemovab|e'aceofthedrivepu||eYviatheshif
valve.At this time, the pulleyratio remarnslow'
T h e h i g h p r e s s u r e ( p x ) u e c o m e s t t r e c t u t c h r e d u c i n g p r e s s u r e ( C R ) a t t h e c | uvalve'
t c h r eand
d u cthe
i n gshift
va|V
e . T h evalve'
c | u t cand
hreducing
control
valve'the PH-PLcontrol
sure (CR)flows to the startclutchcont'oi uatt". tn"lt"n'al
is interceptedbYthose valves
pressureis not appliedto the clutchesand reversebrake'
Underthis condition,hydraulac
(cont'd)
14-213
Description
HydraulicFlow(cont'dl
lll position, at low spo€d range
The flow of fluid up to the drive pulley,the driven pulley,and the
clutchreducingvalve is the same as in El position.The
pulleyratio is low becausethe drivenpulleyreceiveshigh pressure(PH),
and the drive pulleyreceiveslow pressure(pL),
The clutchreducingpressure{cR) flows throughthe manualvalve
to the forwaroclutch,ttrenforwardciulcn is engaged.
The forwardclutchthen drivesthe drive pulleyshaft,which drives
the d(ven pu ey shaft.
Also' clutch reducingpressure{cR) flows to the start clutch
control valve, and becomesclutch control pressure
{cc).
clutch control pressure(cc) becomesstart clutch pressure(sc) at
the shift inhibitorvalve.stan clutchpressure{sc) is
appliedto the startclutchto engagethe startclutch.
14-214
E position, at middle sPeedrange
Asthespeedofthevehic|ereachestheprescribedVa|ue,theshiftcontro||inearsolenoidisactivatedbytheTcMorPc
T h e s h i f t c o n t r o | | i n e a r s o | e n o r o c o n t r o I s t t r e s n i f t c o n t r o I V a | v e(SV)
t o a c t i v a t shift
e s h icontrol
ftVa|ve
p r e sShift
s u r evalve
( S V ) 'pressure
c|utchreducing
valve
at the
shift valve pressure
sure (CR)trom the clutchreduclngvalve becomes
( S V ) f l o w s t o t h e | e f t " n o o t t r ' " s t ' i t t u " t u e . t h e s h i f t V a | V e t o t h e r i g h t s i d e a n d p oport
s i t i o n i n g i tlow
i n t hpressure
e m i d d |(PL)
e o f ito
t sthe
trave|.The
leading
tiHl a ,tr" pulleys,and uncoversthe
shiftvalvecoversth" pon ao",oo nLior".irr"
middle'
in
the
pulley
is
ratio
pressure(PL).At this time, the
pu eys.The drive pu ey and tne oriJenpriLy |."""iu" to*
clutch'
start
the
Pressureremainsto applythe forwardclutchand
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
(cont'd)
14-215
Description
HydraulicFlow (cont'd)
@ position, at high spe6d range
As the speedof the vehiclereachesthe prescribedvalue,the
shift controllinearsol€noidmovesthe shift controrvatveto
increaseshift valve pressure(SV)at the left end of the shift valve.
ttre srrit vatvemovesto the right side comparedto its
positionat the middle pulley ratio.The shift valve uncovers
the port leadinghigh pressure(pxito ttre d.ve puley and
uncoversthe port leadinglow pressure(PL)to the drivenpulley.
The drive pu|ey receiveshigh pressure(pH)and the driven pulleyreceiveslow pressure(pL).The pulleyratiois high.
Pressureremainsto applythe forwardclutchand the startclutch,
NOTE:When used,"left,,or,,right" indicatesdirectionon the hydraulic
circuit.
14-216
E position
pulley'and the clutchreducingvalve is the sameas in E position The
The flow of fluid up to the drive pulley,the driven
and the drive pulleyreceiveslow pressure{PL).
pulleyratio is low b"car"" tt " o riu",i'prti"vi"""v"" t'igtrpressure.(pH)
(RVS)to the
the port that leadsreversebrakepressure
The manualvalve is shiftedinto the B position,and it uncovers
(Rl)is
pressure
inhibitor
reverse
and
PcM,
meansof the TcM or
reverseinhibitorvalve.The inhibitoiJenoid turns off by
a p p l i e d t o t h e r i g h t e n d o f t h e , " u " , " " i n t , i u i . o , u , | v e . T h e r e v e r s e i n h i b i t o r v a |pressure
v e m o v e(cR)
s t o tbecomes
he|eftsid
e , a n dbrake
uncoversth
reverse
clutch reducing
port that leadsreversebrakepr"a"ur" tivst,o,he reversebrake.
ring
the
The reversebrakeis engaged,and it locks
pressure(RVS)at the manuat*r"-, "nJ tro*" to the reversebrake.
gear.
"|eft" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
(cont'd)
14-217
Description
HydraulicFlow(cont'dl
E position
ReverseInhibitor Conirol
lf the E positionis selectedwhile the veiicle is moving forward
at speedsover 6 mph (10 km/h),the inhibitorsolenoid
doesn'tturn off by meansof the TcM or PCM Reverseinhibitorpressure(Rl)
is not appliedto the reverseinhibitorvalve
as the reverseinhibitorsolenoidturns on. The reverseinhibitor
valve is kepton the right side,and coversthe pon ro srop
reversebrakepressure{RVS}to the reversebrakefrom the
manualvalve.Reversebrike pressure(RVs)i; not appried
to
the reversebrake,and power is not transmittedto the reverse
direction.
NOTE:When used,"left,' or,,right,,indicatesdirectionon the hydraulic
circuit.
14-218
E position
position'
pulley' and the clutch reducingvalve is the same as in E
The flow of fluid up to the drive pulley,the driven
and is
valve'
controlvalve,the manualvalve,and the shift control
Clutchreducingpressure(CR)t'"*" i" ii" startclut;h
interceptedbYthosevalves.
to the clutchesand reversebraKe'
Underihis condition,hydraulicpressureis not applied
fr
--l
-
4t1.1
'rltll
,
1
(cont'd)
14-219
Description
HydraulicFlow (cont'd)
lll position, when th€ electroniccontrol system is fauhy.
when the electroniccontrolsvstem(linearsolenoidsand sensors)is faulty,
the transmissionusesthe pitot pipe pressure
(PP)to 311o-rh" u"hicleto drive.
when all linearsolenoidsand sensorsare off becauseof a faulty electronrc
controlsystem,clutchreducingpressure(cR)
flows to the startclutchcontrolvalve,the manualvalve,the PH-PLcontrol
valve,and the shift controlvalve.clutch reducing pressure(cR) becomesshift varvepressure(sV) at the shift contror
varve,and shift varvepressure{sv) is appriedto
the left end of the shift valve and the right end of the shift inhibitorvalve.
The shift valve movesto the right side.and
uncoversthe pon that leadshigh pressure(PH)to the drive pulleyand
uncoversthe po.t tlr"t r""1" ro,,"-pressure
(pL)to
the driven pulley At this time, the pulley ratio is high, The shift inhibitorvalve
movesto the left side,and uncoversthe
port that leadsshift inhibitorpressure(Sll to the pitot lubricationpipe
and the pitot regulatorvalve.tne prtot lubrication
pipe dischargesfluid insideof the pitot flange,and discharged
fluid entersinto the pitot pipe and it is appliedto the left
end of the pitot regulatorvalve.The pitot regulatorvalve moveslo the
right side,and uncoversthe port that leadspitot
regulatorpressure(PR)to the shift inhibitorvalve.Pitot regulatorpressure
{pR)becomesstartclutchpressure{sc1at the
shift inhibitorvalve,and is appliedto the stan clutch.The stan clutch
rs engaged.The forwardclutch pressure(FWD)is
appliedto the forwardcrutch,and the forwardcrutchis engaged.This alows
the vehicreto drive.
NOTE:When used."|eft" or ,,right',indicatesdirectionon the hydraulic
circuit.
14-220
system is faulty'
E] position, when the elestronicGontrol
pulley'and the startclutchis the sameas in El position
The flow of tluid up to the drive pulley,the driven
pressure{RVS}to the
it uncoversthe port that leadsreversebrake
The manualvalve is shiftedinto the lE position'and
valve becauseof
inhibitor
reverse
(Rl)is appliedto.the right end of the
reverseinhibitorvalve.Reverse,"nlu-i,"ip*r""i"
a f a u l t y i n h i b i t o r s o l e n o i d . T h e ' " t ' " , " " i n f t i U i t o ' v a l v e m o v e s t o t h(cR)
e l e fbecomes
t s i d e ' a nreverse
d u n c o vbrake
e r s t hpressure
e p o r t t h(RVS)
a t l e aat
d sthe
reverse
reducingpressure
brakepressure{RVS)to the ,"u"r." ir"t"- cru,ch
vehigear'This allowsthe
reversebrakeis engagedand locksthe ring
manualvalve,and,lows to the ,e\r"rs" lr"re. ttre
cle to drive in reverse.
"left" or "right" indicatesdirectionon the hydrauliccircuit'
NOTE:When used,
14-221
Description
ParkMechanism
The park mechanismlocksthe transmissionby engagingthe park pawl with
the park gear which is integralwith the secondarydrive gear'The secondarydrive gear engageswith the secondarydrivengear
which engageswit-hthe final driven
gear.
shiftingto E positioncausesthe parkcone (installedat the end of the parkrod) press
to
the park pawl onto the parkgear.
Evenif the end of the park pawl rideson the top of the parkgearteeth,slight
movementof the vehiclewill causethe park
pawl and the parkgearto mesh with eachother completely
becausethe parkcone receivesthe tensionfrom the parkrod
spring The park pawl receivesthe tension(whichactsto separatethe park pawl
from the park gear)from the park pawl
spring.
STARTCLUTCH
PARKPAWI-
PABKGEAR
PARKCONE
PARKPAWL
PARKROO
SPRING
14-222
PARK ROD
Component Locations
36 - 98 Models
BRAKESWITCH
ENGINECONTROL
MODULEIECMI
AUTOMATICTRANSAXLE(A/T}
GEARPOSITIONSWITCI{
SECONDARY
GEARSHAFT
SPEEOSENSOR
MANIFOLDABSOLUTE
IMAPI SENSOR
THROTTI.IPOSITION{TPI
SENSOR
VEHICLESPEEOSENSOR
{vss}
/i/ i
DRIVENPULLEY
SPEEDSENSOR
,' / ,','4
$r,
,i/:1
i,,
t"--.---.-
-_,-:-_a.--:
il
INHIBITOR SOLENOID
STARTCLUTCHCONTROL
LINEARSOLENOID
PH.PLCONTROL
LINEARSOLENOID
PULLEY
SPEEDSENSOR
SHIFTCONTROL
LINEARSOLENOTD
14-224
h
'99 - 00 Models
CONTROL
AUTOMATIC TRANSAXLE IA/TI
GEARPOS]TIONSW]TCH
SECONDANYGEAR SHAFT
SPEEDSENSOR
MANIFOLDABSOLUTE
IMAPI SENSOR
THROTTLEPOS]TIONITP)
SENSOR
VEHICLESPEEDSENSOR
tvss)
DNVENPUL]-EY
SENSOR
SPEED
STARTCLUTCHCONTROL
LINEARSOIENOID
PH.PLCONTBOL
LINEABSOLENOIO
PULLEY
SPEEDSENSOR
SHIFTCONTROL
LINEARSOLENOIO
14-225
TCM CircuitDiagram('96- 98 Modelsl
U N D E NH
. O O DF U S E ] R E LBAO
YX
No.521l5A)
l
N o . 4 ll 8 0 A ) N o . 4 7 ( 7 . 5 A )
PARKING
BRAKE
I
swrTcH
lG1
sToP
swT
A / TG E A R
POSITION
INDICATOR
YI
I
I
i
I
I
GnN,4,vHT
Tot 2v
V
I
I
I
UNDER
OASH
FUSE/RELAY
80X
I G N I T I OCNO I L
GRN/REO
, t ,I
HBR(
sw-
-
I
BI-U
rsl
rur
LTGRN
ELKiBI-U
RED
GRN/BLK
8LK
I
I
Tl
G401
G404
14-226
cRN---l
F-----
GnN
Bru-J
F------
61U
NoTEiif
T
:ro 5V
: T ot 2 v
^ A ',o
J'
I
GRY
WHT/REDELUMHT
B2O
I
T
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I
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l
wirr
,
'r-|
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wHTqED I
l
PNUSLK I
PNK,BLU 1
T
T
T
J wxitnro I eruxialrI
r-T'
_
r
r
-r_
-T
L
-T-
-T-r
T
nro,wHr
I
nroieru
_
L
I
T
T
cnN
--
B6
B7
LB5
wHT
T
PNK
T
T
BLKMHTI
T
I
|
|
|
|
l
l
T -.T-. T
'i|
Lli:"*l
BLUIEL^^.,1,.
YFt -_..1_.-.
GRN{WHT-...1_...
GRNiBIK
PNKiBLU GBN,^vEt
T
I
GRN/BLK
G8N/YEL J
I
| c*Hl**t I
pr'rxisLr I
l
t
l
J
l
T
'i'
I sLU'i^'Hr
I
l
l
PNK7BLU
I GBN/YEI
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l
+. L'
il
GRN/BIK
t l
-t P-
BRN/BLK
l
d
s
t
g
@
@
@
l
e
]
SEigY#ISBniho,
3FIYE,',X!b'J
SFiYbtt"','J8i0ft 3il[ip' T
BLK
rNHrBlT0R
I
SOLENOID
I
I
5PEE'sENsoR
!8[$fo,o !'$,'Afl]: !'8$nlo'ol
I
n-:
I
G1 0 1
G1 0 1
-
TCMTeflnlnalLocations
X
><
2
14
3
5
17
TCM-A (26P)Connertor
7
20
10
'11
2
2 5 26
5
14
6
7
17 18
10
8
20
,/1,/
T C M- B l 2 2 P ) C o n n e d o r
14-227
TCMTerminalVoltage/Measuring
Gonditions
('96- 98 Modelsl
TCM Terminal Loc.tions
2
1
4
1 1 1 5 16 1 7
20
8
9 1 0 1 1 12 1 3
23
25 26
TCM-Al25P)Connecto.
TCM-B(22P)Connectot
TCM CONNECTOR A (26P}
TerminalNumbet
Signal
A1
SCLS_
Stanclutchcontrollinearsolenoid
powersupplynegativeelectrode
Engineidling,E position:
Approx. 0.4 V
HLC LS-
PH-PLcontrol linearsolenoidDower
supply negative electrode
Engineidling,E position:
Approx.0.7V
Engineidling,E position:
Approx.0.8V
A4
LG1
NE
A6
A7
ATP L
A8
ATPS
A9
ATP D
Ar0
ATP NP
A11
ATP R
A.12
tGl
A13
PG1
414
A15
HLCLS+
A16
SH LS+
417
Dsscription
Shiftcontrollinearsolenoidoower
supplynegativeelectrode
Ground
Enginespeedsignalinput
Not used
A/f gear positionswitchEl position
signalinput
ly'T gearpositionswitchE position
signalinput
A{/Tgear positionswitchE position
signalinput
A,/TgearpositionswitchE or E
positionsignalsinput
A,/Tgear positionswitchE position
signalinput
Powersupplysystem
Ground
Startclutchcontrollinea.solenoid
powersupplypositiveelectrode
PH-PLcontrolline8|.solenoidpower
supplypositiveelectrode
Shift control linear solonoid oower
supply positive electrode
A18
Ground
Not used
A19
Not used
420
D IND
A2'l
VBU
Not used
Back-uppower system
Not used
tG1
Powersupplysystem
PG1
Ground
424
14-228
Withenginerunning:Pulsingsignal
InEposition:OV
In otherthanEl position:Approx.1OV
In lg position:0 V
In otherthanE position:
Approx.10V
In lll position:0 V
In otherthanE position:
Approx.10V
InEorEposition:oV
In otherthanE orE position:
Approx.1OV
In lE position:0 V
In otherthanE position:
Approx.1OV
With ignitionswitchON (ll):Baneryvoltsge
With ignitionswitchOFF:0 V
Engineidling,E position:
Approx.2.5V
Engineidling,El position:
Approx.5.0V
Engineidling,E position:
Approx.6.0V
When l9l indicator light comes on: Approx. jO V
When lll indicatorlighr OFF:0 V
Not used
422
A.25
E indicatorlight control
MoasuringConditions/Torminsl
Vohrgo
Alwaysbatteryvoltage
With ignition switch ON (lt):Bafteryvoltage
With ignitionswitch OFF:0 V
TCM CONNECTORB (22P}
Terminal Numbel
Signal
B1
S O LI N H
82
MAP(PB)
B3
B4
TPS
VSS
TMB
81
TMA
B8
N D NS G
NDN
B9
810
NDR
811
812
813
STOPSW
Inhibitorsolenoidcontrol
-M
Pressure
IMAP)
anifold Absolr-rte
sensorsignalinPUt
Not used
-Throttle
Position(TP)sensorsignal
input
VehicleSpeed Sensor(VSS)signal
Inpur
Data communicationwith ECM:
Transmissioncontrol data outpUt
Data communicationwith EClvl:
PGM Fl control data inPut
Driven pulley speedsensorground
Driven pulley speedsensorsignal
input
Drivepulleyspeedsensorsignal
Input
Not used
BrakeswitchsignalinPut
Datacommunication:
DIAG-H
(TXD/RXD) Diagnostictrouble code outPut
814
816
VEL SG
Secondarygear shaft speedsensor
grouno
Drive pulley speedsensorground
Parkingbrakeswitch signal inPut
N D RS G
819
B20
821
VREF
With ignition swltch uN {ll,: l-ulslng slgnal
ln other thTnE and E position:Pulsingsignal
-tn
ottrerttranE anaE position:Pulsingsignal
With brakepedaldepressed:Batteryvoltage
0V
With brakepedalreleased:
Wittr ignitio.rs*itct' ON (ll):Approx 5.0 V
on vehiclespeed:Pulsingsignal
Depending
0V
Whenvehicleis stoPped:
gearshaftspeedsensor
Secondary
signalinput
HBRKSW
With ignitionswitch ON (ll) and throftlefully open:
4 . 1 4- 4 . 4 2V
With ignition switch ON (ll) and throttle fully
closed:0.44- 0.56V
With ignition switch ON (ll) and rotatingfront
wheels0
r -5Vcycle
With ignilion swltch UN lll): rulslng slgnar
With ignition switch ON (ll) and servicecheck
connectoroPen:APProx.5 V
With iqnition switch ON (ll) and servicecheck
"onn"itot. connect"dwith specialtool: 0 V
VEL
817
With inhibitorsolenoidON: Bafteryvoltage
With inhibitorsolenoidOFF:0 V
With iqnition switch ON (ll):Approx.2.5 V
With e;gine adling:Approx. 1.0V (dependingon
enginespeed)
Se-ice ctrectsignat
815
818
Measuring Conditions/Terminal Voltage
Description
Not used
+5 V relerence
Not used
Not used
With parkingbrakelever pulledr0 V
With parking brakelever released:Batteryvoltage
With ignitionswitchON (ll):Approx 5 V
PCMCircuitDiagram(A/T ControlSystem:'gg - 00 Models)
tGNtTtc{l
SWTCH
UNDER.OASN
FUSF]NEUY
8OI
UADEFD'SI
FUSSFEUY
8OX
r{o.2s(7 5A)
iPrE: T
rosv
I N
lD
,:-^1 GETBPOSITIoi{
14-230
EI€INE
COOLTI'II
TEUPEFATUFE
SENSOF
SPEED
SEllsoF
Y
I
I
I
T I
.-l-
tI
GFN8U
l
t
u00u
t
I
t
l
EE
l
iflfl.S$'
ilillfSIft,' *fl&'u''!l^"
soLEl€|0
l
J-
H
I NHIEITOR
I soLEr,roro
I
:
14-231
PGMTerminalVoltage/Measuring
Conditions('99- 00 Modelsl
A/T ControlSystem
The PCMterminalvoltageand measuringconditionsare shownfor the connectorterminalsthat are relatedto the A/T control system.The other PCMterminalvoltageand measuringconditionsare describedin section11.
PICMConnoctorTerminrl Location3
Terminal Number
Signal
A7
ATP D
A,/Tgear position switch
E positioninput
InEposition:OV
In otherthan E] position:Approx.1OV
A9
ATP NP
A/T gear position switch
@ and S positionsinput
In E andEl positions:
0V
In otherthanE] andE position:
Approx.1OV
Timing and adjustmentservice
checksignal
With ignitionswitchON {ll} and servicecheck
connectoroDen:5 V
With ignitionswitchON (ll) and servicecheck
connectorconnectedwith soecialtool:0v
In E position;OV
In otherthan E position:Approx.10 V
A10
ATP L
STOPSW
Descriplion
A,/Tgear position switch
I positioninput
Brakeswitchsignaloutput
MeasuringCondhions/TorminalVoltage
Brakepedal depressed:Batteryvoltage
Brakepedalreleased:0 V
PCMCONNECTORB I25P}
Terminal Number
Signal
B1
IGPl
Powersupplycircuitfrom main
relay
82
PG1
Ground
B8
HLCLSM
B9
IGP2
Powersupplycircuitfrom main
relay
810
PG2
Ground
817
HLCLSP
PH-PLcontrollinearsolenoid
power supplypositiveelectrode
818
SC LSM
Startclutchcontrollinear
solenoidpower supplynegative
electrode
Description
LGI
Ground
821
VBU
Back-uppowersupply
825
14-232
With ignitionswitchON (lll: Batteryvoltage
With ignitionswitchOFF:0 V
PH-PLcontrollinearsolenoid
power supply neqativeelectrode
s20
B22
MoasuringCondhions/TerminalVohage
With ignitionswitchON (lll: Batteryvoltage
With ignitionswitchOFF:0V
With ignitionswitchON {ll):Pulsingsignal
Always battery voltage
Ground
SC LSP
Stan clutchcontrollinear
solenoidpowersupplypositive
electrode
With ignition switch ON (ll): Pulsing signal
\
a
D {16P)
PCMCONNECTOR
TerminalNumbs]
Signal
D1
VEL
02
Description
Measuring Conditions/TerminalVoltage
Secondarygearshaftspeed
sensorsignalinput
Dependingon vehiclespeed:Pulsingsignal
APProx.0 V
Whenvehicleis stoPPed:
S O LI N H
lnhibitorsolenoidcontrol
With inhibitorsolenoidON: Batteryvoltage
With inhibitorsolenoidOFF:0 V
D3
SH LSM
Shift controllinearsolenoid
power supplynegativeelectrode
D4
SH LSP
Shift controllinearsolenoid
power supplypositiveelectrode
With ignitionswitchON (ll):Pulsingsignal
D5
VB SOL
Powersupplyfor solenoidvalves
With ignitionswitchON (ll):Bafteryvoltage
With ignitionswitchOFF:0V
D6
ATP R
A,/Tgear position switch E
positioninput
InEposition:0V
In otherthan B position;Approx.10 V
D]
V E LS G
SecondarygearshaftsPeed
sensorground
Not used
D8
Not used
D9
D10
NDN
Drivenpulleyspeedsensorsignal
anput
In otherthan E and E position:Pulsingsignal
D11
NDR
ln otherthan E and E position:Pulsingsignal
D12
N D RS G
Drivenpulleyspeedsensorsignal
input
Drivepulleyspeedsensorground
D13
ATPS
A,/Tgear position switch E
positioninput
D14
D IND
D indicatorlight control
I n E p o s i t i o n0: V
In otherthan E position:Batteryvoltage
When ignitionswitchis firstturnedON (ll):
Batteryvoltage for two seconds
In E position:Batteryvoltage
Not used
D15
D16
NDN SG
Drivenpulleyspeedsensor
ground
14-233
TroubleshootingProcedures
l. How To BeginTroubleshooting
When the E indicatorlight has been reportedon, use the appropriateprocedurebelow to diagnoseand repatrthe
proDlem.
A . W h e nt h e @ i n d i c a t olri g h th a sc o m eo n :
l
connectthe HondaPGM Testeror an oBD ll ScanTool to the 16PData Link Connector(DLc) locatednearthe left
kickpanel.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
3 . Checkthe DTC and note it. Also checkand note
the freezeframedata.
R e f e rt o t h e D i a g n o s t i T
c r o u b l eC o d eC h a r ta n d
b e g i nt r o u b l e s h o o t i n g .
o0\e--loo
INOICATOR
LIGHT
NOTE:SeetheOBDll ScanTool or HondaPGMTesteruser'smanualsfor specificoperatinginstructions.
Some PGM-FIproblemswill also makethe E indicatorlight come on. After repairingthe pGM-Flsystem,disconnectthe
BACKUP fuse (7.5Al in the under-hoodfuse/relaybox for more than l0 secondsto resetthe TCM or PCMmemory,rnen
recheck.
NOTE:Disconnecting
the BACKUP fuse also cancelsthe radio presetstationsand the clock setting.Make note of the
radiopresetsbeforeremovingthe fuse so you can resetthem,
OATALINKCONNECTOB
I16P}
14-234
connectedto the
B. DTCSwill be indicatedby the blinkingof the E indicatorlight with the SCSserviceconnector
(2P)
on the passen
the
dash
under
is
located
(The
Check
Connector
Service
ServiceCheckConnectoras shown.
(ll).
ON
switch
ger'ssideof the vehicle.)Turn the ignition
i
i
i:j
,,,/
CONNECTOR
{2PI
CONNECTOR
07PAZ- 00101(x)
aboveare indicatedby a seriesof long and short
codes 1 through9 are indicatedby individualshon btinks.codes 10 and
b|inks.one|ongblinkequa|sloshortb|inks.Addthe|ongandshortb|inkstogethertodeterminethecode.After
m i n i n g t h e c o d e , r e f e r t o t h e e | e c t r i c a | s y s t e'99
msymptom-to-componentchartonpagesl4-238and14.239forthe,96_9
- 00 models
models,and on pages14-240and 14'241for the
Shorl blink (oncc)
Soc DTCI
Sor DTC2
Long blink
Short blinks |tive tim€sl
Scc DTCI5
the PGM-FIsystem,disconnectthe
some pGM-Ftproblemswi atso makethe E indicatorlight come on. After repairing
BACKUPfuse(7.5A)intheUnder.hoodfuse/re|ayboxformorethanl0secondstoresettheTcMorPcMmemory
recheck.
(cont'd)
14-235
TroubleshootingProcedures
(cont'd)
C. lf the inspectionfor a particularcode requiresvoltageor resistance
checksat the TCM or PCMconnectors,remove
the driver'sside kick panel,and unbolt the TCM, and at the PCMconnectors,removethe passenger'sside kick
panel,and unbolt the PCM.Turn the ignitionswitchOFF,and connectthe backprobesetsand a digitalmultimeter
as describedbelow.Checkthe systemaccordingto the proceduredescribedfor the appropriatecode(s)listedon
the followingpages.
6x1.0mm
9.9N.m{1.0kgt m,
6 x 'l,0 mm
9.EN.m (1.0 kgf.m,
7.2 rbtftt
How to use lhe Backprob€SE{
Connect the backprobeadaptersto the stacking patch cords, and connect the cords to a multimeter, Using the wire
insulationas a guide for the contouredtip of the backprobeadapter,gently slidethe tip into the connectorfrom the
wire side until comesin contactwith the terminalend of the wire.
BACI(PROBESET
07saz- 001txtoa
Itwo requirodl
ADAPTER
coRo
14-236
DIGITALMULTIMETER
(Commarciallyavsibblel
KS-AHM-32-(x)3,
or oquivalent
ll. TCM ResetPlocedure
1. Turn the ignitionswitchoff.
2. Removethe BACKUp fuse (7.5A) from the under-hoodfuse/relaybox for 10 secondsto resetthe TCM or PCM.
NOTE:
. Disconnecting
the BACKUPfuse also cancelstheradio presetstationsand the clocksetting Makenole ofthe radio
presetsbeforeremovingthe fuse so you can resetthem
BACKUP
t7.sAl FusE
.
The TCM or PCMcan also be clearedby usingthe OBD ll ScanTool or HondaPGMTester'
OBD ll SCANTOOLo.
PGMTESTER
{16PI
DATALINKCONNECTOR
lll. Final Procedut€
NOTE:This proceduremust be done afterany troubleshooting
'1.Turn the ignitionswitchoff.
2. Resetthe TcM or PCM.
the OBD ll ScanTool or HondaPGMTesterfrom the DataLink Connector(16P),or removethe specialtool
3. Disconnect
from the ServiceCheckConnector.
4. Turn the ignitionswitchON (ll),and setthe radiopresetsand clocksetting.
14-237
Symptom-to-Component
Chart
ElectricalSystem-'96 - 98 Models
DTC*
O Indicator
Light
MIL
P1790
(3)
Blinks
ON
P179'l
(4)
Blinks
ON
Vehiclespeedsensor
P1705
(5)
Blinks
ON
Ay'Tgear position switch (short to groundl
P1706
(6)
OFF
ON
A/T gear position switch {open)
P0725
(11)
Blinks
ON
P1793
112l
Blinks
ON
Manifoldabsolutepressuresensor
P1 8 7 0
(30)
Blinks
ON
Shiftcontrollinearsolenoid
P'1873
(311
Blinks
ON
PH-PLcontrollinearsolenoid
P1879
(32)
Blinks
ON
Startclutchcontrollinearsotenoid
Blinks
ON
Blinks
ON
Drivepulleyspeedsensor
P1886
(35)
Blinks
ON
Driven pulley speed sensor
P1888
(36)
Blinks
ON
Secondarygear shaftspeedsensor
(37)
Blinks
ON
P1890
l42l
Blinks
ON
P1891
(43)
Blinks
ON
P1882
P1885
(34)
T to55
Detectionltem
Throttlepositionsensor
lgnitioncoil
Inhibitorsolenoid
ECMor TCM
Shift controlsystem
Start clutch control svstem
Page
14-242
14-243
't
4-244
14-246
14-248
14-249
14-250
14-25'l
14-252
14-253
1l-Zb4
14-255
14-256
14-257
14-259
14-260
*: The DTCin parentheses
is the code @ indicatorlight indicateswhen the DataLinkConnectoris connectedto the Honda
PGMTester.
14-23a
lf the self-diagnostic
E indicatorlight does not blink,performan inspectionaccordingto the table below.
Symptom
E indicatorlight does not come on for two secondsafterignitionswitch
is firstturn on (ll).
E indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis on (ll).
Inspection
Ref.page
14-262
14-264
NOTE:
. lf a customerdescribedthe symptomfor code P1706(6),it will be necessaryto recreatethe symptom by test driving,
then recheckthe DTC.
lf so, repairthe
. Sometimethe E indicatorlight and the MalfunctionIndicatorlamp (MlL)may come on simultaneously.
pGM-Flsystem accordingto the DTc, then reset the memory by removing the BACK uP fuse in the under-hood
(50 km/h)'then
fuse/relaybox for more than 10 seconds.Drivethe vehiclefor severalminutesat a speedover 30 mph
recheckthe DTC.
14-239
Symptom-to-Com
ponentChart
ElectricalSystem-'99 - 00 Models
E Indicatot
Lighr
MIL
P1705
(5)
Elinks
ON
A,/Tgear positionswitch(shortto grouno,
P1706
(6)
OFF
ON
A"/Tgear position switch (open)
P1870
(30)
Blinks
ON
Shiftcontrollinearsolenoid
P1873
(31)
Blinks
ON
PH-PLcontrollinearsolenoid
P1879
t32l
Blinks
ON
Stan clutchcontrollinearsolenoid
P1882
(33)
Blinks
ON
Inhibitorsolenoid
P1885
(34)
Blinks
ON
Drivepulleyspeedsensol
P1886
(35)
Blinks
ON
Drivenpulleyspeedsensor
P1888
(36)
Blinks
ON
Secondarygear shaft speed sensor
P1890
\421
Blinks
ON
Shift control system
P1891
(43)
Blinks
ON
Start clutch control system
DTCT
r: The DTc in parentheses
is the
PGM Tester.
14-240
Detostion ltem
Page
14-265
14-26€
14-271
14-213
14-215
't4-277
't
4-279
14-281
14-283
14-245
14-286
codeE indicatorlight indicateswhen the DataLinkconnectoris connectedto the Honda
table below.
lf the self-diagnostic
E indicatorlight does not blink.performan inspectionaccordingto the
SYmPtom
IDIindicatorlight does not come on for two secondsafter ignitionswitch
is firstturnedON (ll).
lE1indicatorlight is on constantly(not blinking)wheneverthe ignition
switchis ON {ll).
Inspection
Ref.page
14-284
14-290
NOTE:
by test driving,
. lf a customerdescribedthe symptomfor code Pl706 (6),it will be necessaryto recreatethe symptom
then recheckthe DTC.
lf so, repair
. iometimes, tfre E indicatorlight and the MalfunctionIndicatorlamp (MlL) may come on simultaneously
in
the underfuse
RADIO
BACK
UP
the
removing
by
the PGM-Flsystemaccordrngto the DTC,then resetthe memory
km/h)'
then
mph
30
{50
over
at
a
speed
minutes
for
several
the
car
Drive
hood fuse/relaybox for more than 10 seconds.
recheckthe DTC.
14-241
ElectricalTroubleshooting('96- 98 Modelsl
TroubleshootingFlowchart- Throttleposition(Tpl Sensor
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBOll ScanTool indic.tes Code
P1790.
. Self-diagnosisE indicator light
blinks three times.
PossibleCause
. Disconnectedthroftle position
(TPl3ensorconnoctol
. Short or open in TP sensorwire
. FauhyTP sensol
Checklor Anothar Code or MIL
Blinking:
1. Turnthe ignitionswitchON 1 ).
2. Checkwhetherthe OBD ll scan
tool indicatesanothercode or
the MalfunctionIndicatorLamp
(MlL)blinks(seesecrion11).
Doesthe OBDll scantool indicate
anothercode
oristhe MILblinking?
Repairthe PGM-FIsystom (3ee
section 111.
TCM CONNECTORS
MeasureVREFVoltage:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the A (26P)and B
{ 2 2 P }c o n n e c t o r sl r o m t h e
TCM.
3. Turn the ignition switch ON
{fl).
4. Measurethe voltage bet\iveen
the 820 and A13 or 426 terminals,
ls lhereapprox.5 V?
BLK
WHT/RED
Wire s;deof femaleterminals
Repairopen or short in thc wire
b,stween the Bao tcrminal rnd the
ECM.
MeasureTPS Voltago:
Measurethe voltagebetweenthe
B4 and A13 or 426 terminals.
ls there0.4- 0.6V?
Checkfor loose TCM connectors.
lf necessary,substitute a knowngood TCM and r6check.
A {26P1
Repail open in the wire tr€tweon
the Erl t6.minal ind the TP sen3o..
(VSS)
TroubleshootingFlowchart - Vehicle Speed Sensor
NOTE:Recordall freezedata beforeyou troubleshoot'
. OBD ll ScanTool indicatesCode
P1791.
. Setf-diagno3isE indicato. light
blinks tour times.
Po$ribleCtuse
. D i s c o n n e c t e dv e h i c l e s p e e d
sensor (VSS)connectol
. Short or open in VSS wire
' Faulty VSS
Refer to seclion 23 for vehicle
soeedsensor IVSSItest
Check the VSS Voltage:
1 . R a i s et h e v e h i c l e
2 . S h i f t t h e t r a n s m i s s i o nt o l E
posrtlon.
3 . D i s c o n n e c tt h e A ( 2 6 P )a n d B
(22P) connectors from the
@
. Make sure lifts, iacks,and sal€tYstands are placedproperly lsoe section 1)'
. Set the parking brake securelv,and block the rear wheels'
. iacr upile rront or the vehicle,and support it with safety st'nds'
TCM CONNECTORS
TCM.
4 . T u r n t h e i g n i t i o ns w i t c h O N { l l ) .
5. Rotate the front wheel and
check for the voltage between
the 85 and 413 or A26 terminals. Blockthe other wheel so
at does not turn
Wire sideof femaleterminals
D o e s 0 V a n d a p p r o x5 V o r m o r e
appearalternatelY?
Check for oP€n in the wire
between the 85 terminal and the
vehicle speed sensor {VSS}. lf
wire is OK, check the vSS (see
soction23).
Checkfor loos€ TCM connedors
lI nec€ssary,substitute a known'
good TCM and recheck.
14-243
ElectricalTroubleshooting('96- 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Short)
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
P1705.
. Seif-diagnosis@ indicator light
blinksfive times.
Obsorvethe A/T gear position
indicetor:
1 . T u r n t h e i g n i t i o ns w i t c hO N
1[).
2. Observetho Ay'Tgear position
i n d i c a t o r ,a n d s h i f t t o e a c h
positionseparately.
Do any jndicatorsstayon when the
sh;ft leveris not in that position?
PosribleCause
. Short in A/T go.r position
switch wire
. Faulty A/T g€ar polition switch
NOTE: Code P1705(5)is causedwhen
t h e T C M r e c e i v e st w o g e a r p o s i t i o n
Inputsat the sametime.
Th6 lyrtcm i3 OK at thi. tima.
Check the wi.s hamels for drm.
ag9.
TCM CONNECTOR
A {26P}
MeasureATP R Vohage:
1. Shiftto all positionsotherthan
E.
2. Measurethe voltage between
the 411 and A13 or A26terminats.
ls thereapprox.10V?
MeasureATP NP Volt.ge:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than @ or @.
2. Measurethe voltage between
the A10 and 413 or 426 terminals,
ls thereapprox.10V?
Check for sho.t in tho wire
b€twoonthe Al1 t rminaland th6
A/l ge.r polhion switch or A/T
gear position indicstor. lf wilo is
OK check for loos6 TCM conncctora. It nocassery, subrtitute a
known-good TCM and r€chsck.
Ch.ck tor 3hort in th€ wirc
b€twe€n thc Al0 termin.l and
the A/T 96r. porition indicrtor,
or a short in the wilea b?twecn
tho A/T gerr porition indic.to.
and the A/T geer position
switch. It wires ar6 OK, chsck for
loose TCM conn.clols. ll nccNe3sa.y, substituto a known-good
TCM rnd locheck.
Measure ATP O Vohage:
1 . S h i f t t o a l l p o s i t i o n so t h e r t h a n
E,
2. Measurethe voltagebetween
the Ag and A13 or 426 termi
nals.
l s t h e r e a p p r o x . ' 1 0V ?
To page14-245
14-244
Checl tor short in the wire
lr€tweon tho A9 terminal and the
A/T g6a. position 3witch. lf wire
b OK. check tor loos€ TCM connectors. lf nocelsary, substhute a
known-goodTCM and rechack.
Wire sideof femaleterminals
A (26P)
TCM CONNECTOR
From page l4-244
Measure ATP S Vollage:
1 . S h i f t t o a l l P o s i t i o n so t h e r t h a n
2. Measure the voltage between
the A8 and A13 or A26 termi
nals.
Wire sideof femaletermanals
ls thereapprox.10V?
Check lor shott in the wire
between the A8 terminal and the
A/T gea. Position switch or the
A/T gearpositionindicator.lf wire
is OK, check for loose TCM con_
nectors. lI necessary,substitute a
known-goodTCM and recheck.
MeasureATP L Voltage:
'1. Shiftto all positionsotherthan
E-
2, Measurethe voltagebetween
the A7 and A13 or A26 terminals.
ls thereapprox.10V?
Check for short in the wi.e
between the A7 terminal and the
A/T gear position switch or the
A/T gear position indicator. lf wire
b OK. check for loose TCM connectors. ff necessary,substilute a
known-goodTCM and recheck.
Checklor loose TCM connectors.
lf necessary.substitute a known'
good TCM and recheck.
14-245
ElectricalTroubleshooting(,96- 9g Models)
TroubleshootingFlowchart- A/T GearpositionSwitch (Openf
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanToot indicat* Code
P1706,
. Solf-diagnosisE indicator tight
blinb six times.
Pos.riblsCause
. DisconnoctedA/T gear position
switch connector
. Open in A/T gear position switch
. Faulty A/T gear position switch
TCM CONNECTOR
A I26PI
Measule ATP R Volt.gei
1. Turn the ignitionswitch ON l).
2. Shifito E position.
3. Measurethe voltage between
the A11 and 413 or ,426terminals.
Repairopen in tho wire betwoen
lhe A11 terminaland the A/T
goar po3ition switch.
MeasureATP NP Volt.gei
1. Shifrto E orE position.
2. Measurethe voltage betlveen
the A10 and A13 or 426 termi
nals.
Repairopen in the wiro between
the A10 terminal.nd tho A/T
gea. poshion swhch.
MeasureATP D Vohage:
1. Shiftto E position.
2. Measurethe voltagebetween
the Ag and A'13or 426 termi-
Repairopen in the wire lretween
the A9 terminel and the A/T gear
position 3witch.
To page14-Z4j
14-246
Wiresideof femaleterminals
A l26p)
TCM CONNECTOR
From page 14 246
MoasureATP S Voltage:
1. Shiftto E Position
2. Measurethe voltagebetween
the A8 and 413 or 426 termi
nals,
Bepair open in the wir€ between
the A8 t€rminal and the A/T gear
position switch.
Wire sideof femaleterminals
MeasureATP L Vohage:
1. Shiftto E Position
2. Measurethe voltagebetween
the A7 and A13 or 426 terminals.
Repairopen in the wire between
the A7 terminal and the A/T geal
Dositionswitch
Chocktor loose TCM connectors.
lf necessary,substitute a l(nowngood TCM and recheck,
14-247
ElectricalTroubleshooting('96- 9g Models)
TroubleshootingFlowchart- lgnitionCoil
NOTE:Recordall freezedata beforeyou troubleshoot,
. OBD ll ScanTool indicatesCode
POl25.
. Soll-diagnosisE indicarol light
indicatesCode 11.
Po3ribleCause
. Dbconnected ignition coil connectol
. Short o. op6n ignition coil wire
' F.ulty ignition coil
MeasureNE Voltrge:
1. Disconnectthe A {26p) con
nectorfrom the TCM.
2. Startthe engine.
3. Measurethe voltagebetween
the A5 and 413 or A26 terminals,
Wire sideot femaleterminals
ls there battery voltage?
Check for loose TCM connector.
It nec$sery. substilute a knowngood TCM and .echeck.
R6p.i. open or short in the wire
b€lween the A5 te.minsl and tho
ignhion coil. It wir€ b OK, check
the ignition coil test lsoc aoction
23t.
Sensor
TroubleshootingFlowchart- ManifoldAbsolutePressure{MAPI
NOTE:Recordall freezedata beforeyou troubleshoot
. OBD ll ScanTool indicatesCode
P1793,
. self-diagno3b E indicato. light
indicat€sCode 12.
PG.iblo Cau3€
. Dkconnoctodmanilold .bsoluto
ore33urcIMAP) sensor connoc'
lor
. Short or opcn in MAP s.nsor
MAP sen3or
Chock tor Another Cod€ or MIL
Blinking:
1. Turnthe ignitionswitchON (ll).
2. Checkwhetherthe OBD ll scan
tool indicatesanother code or
the Mal{unctionIndicatorLamP
(MlL)blinks(ssesection11).
Doesthe OBDllscan tool indicate
anothercodeor isthe lVlLblinkin9?
TCM CONNECTORS
MeasureVREFvoltage:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A (26P)and B
( 2 2 P )c o n n e c t o r st r o m t h e
TCM.
3. Turn the ignitionswitchON (ll).
4, Measurethe voltage between
the B2Oand A13 or A26termr
nals.
WHT/RED
Wire sideof femaleterminals
lsthereaPprox.5V?
R€pair opon or 3hort in the wire
botwoan the 820 t€.minal and
the EcM.
MsasureMAP IPB)volt.ge:
Measurethe voltage betlveenthe
82 and A13 or 426 terminals.
ls thereapprox.3 V?
Repair opon ot shorl in the wiro
betwesn the 82 torminal end th€
MAP sensol.
Checkfor loo3eTCM conn€stors.
lf nec*sarY, sub3titute a known'
good TCM and rechock.
14-249
ElectricalTroubleshooting(,96- 9g Modelsl
TroubleshootingFlowchart- Shift ControlLinearSolenoid
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanToot indicatesCode
P1870.
. Selt-dirgnosis[d indic.tor tight
indicatosCode30.
PossibleCause
' Disconnected3olenoid h.rn€is
connoctor
. Short or open in 3hift control
linear solenoidwire
. Faulty shift control linear solenoid
SOLENOIDHARNESS
8P CONNECTOR
BLU/WHT
MeasureShift ControlLinoarSolenoid Resistanceat the Solenoid
HarnessConnector:
1. Disconnectthe 8p connector
fromthe solenoidharnesscon
nector.
2 , M e a s ur e t h e r e s i s t a n c e
betlveenthe No. 3 and the No.
7 terminalsofthe solenoidhaF
nessconnector.
GRN/YEL
Terminal stde of male terminals
ls the resistance
3.8- 6.8O?
TCM CONNECTOR
A I26PI
Check Shift Controt Linear Sotenoid for a Short Circuit:
1 . D i s c o n n e ct th e A ( 2 6 p )c o n ,
nectorfrom the TCM.
2. Checkfor continuitybetween
body ground and the A3 ter
minal and the A16 terminal
individually.
Wiresideof femaleterminals
Repair shon in tho wire6 betweon
the A3 and A16 termin.ts lnd tho
body ground.
GRN/YEL
M e a s u r eS h i t t C o n t r o l L i n e . r
SolenoidResistance:
1. Connectthe 8P connectorto
the solenoidharnessconnec,
tor.
2 , M e a su r e t h e r e s i s t a n c e
betweenthe 43 and A16 ter-
ls the resistance
3.8 6.8O?
Chockfor loose TCM connectorc.
ll necessary,substitute a knowngood TCM and recheck.
14-250
l l 1 2 l :1
5
IriGlx 1 7
8LU/YEL
Repairloose terminal oa open in
the wires between the 43 and
A16 terminal3and the solenoid
harnessconnector.
7
2t)
8
9 10 1 1 12 13
23
25 26
Troub|eshootingF|owchart_PH-PLControJLinearSo|enoid
NOTE| Recordall treezedata beforeyou troubleshoot
. OBD ll ScanTool indicatesCodo
P1873.
. sef-diagnosis E indicalor light
indicat6 Code 31.
Possiblecause
' Disconnectedsolenoid harness
connectof
. Short or oPen in PH_PLcontrol
linear solenoidwire
. FaultyPH-PLcontrol linear sole_
noid
SOLENOIOHARNESS
8P CONNECTOR
Measure PH-PLControl Linear
Solenoid Resistanceat the Sole_
noid HatnessConnectot:
1. Disconnectthe 8P connector
confrom the solenoidharness
nector,
2. Measure the resistance
betweenthe No 2 and the No.
6 terminalsofthe solenoidhar
nessconnector'
GRN/WHT
PNK/BLK
Terminalsideof maletermlnals
3.8- 6.80?
ls the resistance
A (26P)
TCM CONNECTOR
o
Check PH-PLControl Lineer
Solenoidfor a Short Circuit:
1 . D i s c o n n e ct th e A 1 2 6 P c) o n nectorlrom the TCM
2. Checkfor continuitybetween
body ground and the A2 ter
minal and the A15terminal
individually.
I
PNK/BLK
2
3
5
4
1 1 't5 1 6 1 7
I
7
8
20
/,,/
10 l 1 1 2 13
23
25 26
IGRN/wHr
o
Wire side ol female terminals
Repair short in th€ wires
between the A2 and A15 lermi_
nals and the body glound.
*r}l
Measute PH-PLControl Linear
SolenoidResi3tance:
1. Connectthe 8P connectorto
the solenoidharnessconnector,
2 , M e a su r e t h e r e s l s l a n c e
betweenthe ,q2 and A15 ter_
3.8-6 8 O?
lsthe resistance
PNK/8LK
t'T,
E[
3
a 5
16
I
20
9 1 0 1 1 12 1 3
23
25 26
GRN/WHT
Rep.il loose tetminal or oPen in
th6 wires betwccn the A2 and
A15 lerminals and the solenoid
harnessconn€ctol.
Checkfor loose TCM connactors
lf neceasery,Substitutea knowngood TCM and rechock.
14-251
ElectricalTroubleshooting('96- gg Modelsl
Troubleshooting
Flowchart- start clutchcontrolLinearsolenoid
NOTE: Recordall freezedata before you t.oubleshoot.
. OBOll ScanTool indicatG Code
P1879.
. Self-dilgno.is E indicator light
indiclt$ Code32.
Po$iblo C.u.o
' Di3aonnoctodsolanoid harncat
connactol
. Short or opon in start clutch
control linoar tolanoid wira
. Faulty ttart clutch control lino.r
solanoid
Me.suro Sta.t Clutch Control
LinearSolenoid Rosirtrnco st th.
SolenoidHrrn6rs Connecto.:
1. Disconnectthe 8P connector
from the solenoidharnessconnector.
2, Measure the resistance
betweenthe No. 4 and the No.
8 terminalsotthe solenoidharnessconnectot.
SOLENOIDHARNESS
8P CONNECTOR
YEL
PNK/BLU
Terminalsideof maleterminals
ls the resistance
3.8- 6.80?
TCM CONNECTOR
A I26P}
Chock Start Clutch Control Linoar Solenoidtor a Short Circuit:
1. Disconnectthe A (26p) con,
nectorfrom the TcM.
2. Checklor continuity between
body ground and the A1 terr n i n a la n d l h e A l i l t e r m i n a l
individually.
Wiresideof femaleterminals
Raprir 3hort in tha wira3
b.ftvcen tho A1 .nd Atil t .mi.
n.l. .nd thr body ground.
-{r-
Measure Stan Clutch Cont.ol
LineerSolenoidF6aist.ncei
1. Connectthe 8P connectorto
the solenoidharnessconnector.
2 . M e a su r e t h e r e s i s t a n c e
betweenthe 41 and Al4 terminals,
ls the resistance
3.8- 6.8O?
Checkfor loose TCM connecto.s.
lf necessary, substitute a knowngood TCM and iecheck.
14-252
PNK/BLU
E
2 3 a 5
a 15 t 6 1 '
YEL
Rcplir loose tcrminal or oDcn in
thG wiras b.tween the Al rnd
Ala torminal3 rnd tha 3olanoid
hamaas connactor.
1
20
I
9 1 0 l l 12 13
a
25 2G
TroubleshootingFlowchart- InhibitorSolenoid
NOTE:Recordall treezedata betoreyou troubleshoot
. OBD ll ScanTool indic.td Code
P1882.
. Selt-di.gnGis E indicator lighl
indic.tos Code 33.
Po$ibls Cause
. Dbconnected solenoid hatness
connedor
' Short or opon in inhibitor sole'
noid wire
. Faultv inhibitor solenoid
SOLENOIDHARNESS
8P CONNECTOR
Mea3ureInhibhorSolenoidResidance at the sol€noid Harness
Connector:
1. Disconnectthe 8P connector
f r o m t h e s o l e n o i dh a r n e s s
connector.
2. Measure the reslstance
betlveenthe No 5 terminal of
the solenoidharnessconnector and body ground.
Terminalsideof maleterminals
11.7- 21 0 0?
ls the resistance
Check Inhibitor Solenoid lor a
Short Circuii:
1 . D i s c o n n e ctth e B ( 2 2 P )c o n nectorfrom the TCM.
2. Check for continuity between
t h e B 1 t e r m i n a la n d b o d y
gro!no.
Wire sideof femaleterminals
Repairrhort in the wire ltetwegn
the 81 dnd the bodY ground.
Mea$rr€ Inhibitor Solenoid ResBt'
anoe:
1. Connectthe 8P connectorto
the solenoidharnessconnec_
IOr.
2. Measure the resistance
betweenthe Bl and body
ground.
11.7- 21.0O?
ls the resistance
Reoair loose terminal or open in
the wire betwean the 81 and the
solenoid hame3sconnector'
Ch6ckfor loose TCM connectors.
ll necessary, substhule a known_
good TCM and techeck.
14-253
ElectricalTroubleshooting{'96 - 9g Models)
TroubleshootingFlowchart- DrivepulleySpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot,
' OBD ll ScanTool indicatesCode
P1885.
. Self-diagnosisE indicator tight
indicatesCode34.
Po$ible Cause
. Oisconn€cted drive pulley speed
sensorconnector
. Shon or op€n in drive pulley
spgedsonsorwire
. Faulty drive pulley spoed s.nsot
C h e c kt h e d r i v e p u l l e y s p e e d s e n ,
sor installation.
ls the drivepulleyspeedsensor installedproperly?
ORIVEPULLEYSPEED
SENSOR2P CONNECTOR
M6a3ureDrive PulleySp€ed S€nsor Resistanceai the Seosor Connectot:
1. Disconnectthe 2P connector
from the drive pulley speed
sensorconnector.
2. Measurethe resistance
of the
drivepulleyspeedsensor.
lT_ T---_l
-rr
lt 9l
1 | 2 tl
t| ]--+i
L_t
TerminalsideoI maleterminals
ls the resistance350 - 600 O?
TCM CONNECTOR
8 I22PI
REO/BLUJ ( l
Check Orive Pulley Speed Sensor tor a Short Circuit:
1. Disconnect
the B (22P)connectortromthe TCM.
2. Checkfor continuitybetveen
body groundand the 810 term i n a la n d 8 1 7 t e r m i n a il n d i
vidually.
2
4 5 6
8 9 10
1 2 1 3 t 4 15 1 6 1 7 1 8
20
GRN
o
Rspair shon in the wi.es botwoen
the Bl0 and 817 te.minals and
the driva pulloy 3peod 3eniol.
Wiresideof femaleterminals
Measure Drive Pulley Sp€€d Sensor Re3istance:
1. Connectthe drivepulleyspeed
sensor2P connector.
2 , M e a su r e t h e r e s i s t a n c e
betweenthe 810 and 817 termtnals.
REO/8LU
1
ls the resistance
350- 600O?
Check tor looso TCM connoctor.
ll necessary,substituto a knowngood TCM and recheck.
14-254
Repair loos6 t.rmin.l or open in
th. wiros botweon tho Bl0 and
817 torminals and thg driva pulley sp€gd sensor.
2
1
5
12 1311 15 1 6
iliI;W1M
tdil)lil/l
GRN
v
TroubleshootingFlowchart- DrivenPulleySpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot'
. OBD ll ScanTool indicatesCode
P1886.
. Sell-diagnosisE indicator light
indicatesCode 35.
Po3sibleCause
. D i s c o n n e c t e dd t i v e n P u l l e Y
so6edsensorconnector
. Short or open in driven PulleY
apeedsen3orwire
. Faulty driven PulloYsPeod 3en-
DRIVENPULLEYSPEEO
SENSOR2P CONNECTOR
ls the drivenPulleyspeedsensor installedproPerlY?
l-_r| 1 2 l
:-
M€asure Driven Pulley SP€edSen_
sor Resbt nce at the SensorConneclof:
1. Disconnectthe 2P connector
from the driven PUlleyspeed
sensorconnectol.
ot the
2. Measurethe resistance
drivenpulleyspeedsensor.
tt 9t
L_.1
Terminalsideof maletermrnals
350 6000?
ls the resistance
I l22p)
TCM CONNECTOR
WHT
REO/BLU
^\,
Check Driven Pulley Speed Sensor {or a Short Circuit:
1. Disconnectthe B (22P)connec_
tor from the TCM.
2. Checkfor continuitybetween
body ground and the BB ter
minaland 89 terminalindivid'
8 9 10
6
'17
'16
20
18
12 13 1 a 15
1
Repair sho.t in the wiles between
lhe 88 and Bg lerminals tnd the
driven pulleY3Peed3€nsor.
2
a
Wire side oI female terminals
RED/BLU] WHT
o
Measure Driven Pulley SPeedS€nsor Reistance:
1 . C o n n e c t h e d r i v e nP u l l e Y
speedsensor2P connector'
2 . M e a s ur e t h e r e s i s t a n c e
betweenthe 88 and Bg terml_
nals.
350- 600O?
ls the resistance
o
1
2
1
6
12 1 3 1 a 1 5 1 6 1 7 1 8
10
8
20
Repair loos€ terminal or oPen in
the wires between the Bg and Bg
torminals and the dtiven Pulley
3D6eO S6n50a,
Check lor loose TCM connector.
lf necessary,substitute a known_
good TCM and rechack.
14-255
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
P1888.
. Selt-diagnosisIq indicator light
indicatesCode 36.
Po$ible Cause
. Disconnectedsecondarygeal
shaft speodsen3orconnectol
. Short ol open in s€condary gear
shaft spe€d sen3or wiro
. Faulty secondary gear shatt
speeds€nsor
Checkthe secondarygear shaft
speedsensorinstallation.
SECONDARY
GEARSHAFTSPEED
SENSOR2P CONNECIOR
ls the secondary
gearshaftspeed
sensorinstalledproperly?
llll;ll
MeasureSecondaryGear Sheft
Speod Sensor R8istance at the
SensorConnector:
1. Disconnectthe 2P connector
from the secondarygearshaft
speedsensorconnector.
2. Measurethe resistance
ol the
secondarygear shalt speed
T_T
l @
t
l
LJ
Terminals i d e o f m a l e t e r m i n a l s
ls the resistance
350- 6000?
TCM CONNECTOR
B {22P}
Check Counterchaft Speed Sonsor for a Short Circuit:
1. Disconnectthe B 122P)connec
torfromtheTCM.
2. Checkfor continuitybetween
body groundand the 815 ter
m i n a la n d 8 1 6 t e r m i n a il n d i
vidually.
ls therecontinuity?
I
14-256
5
6
9 10
20
ORN/BLU
-
D (o.
Repair short in the wir€6 bctuveen
th. 815 and 816 torminrls.nd
the s€condary ge.r shaft speod
Wire sideof femaletermanals
1
a 5 6 7 8 I 10
1 2 13 1 4 1 5 1 5 1 7 1 8
20
A
I
2 . M e a su r e t h e r e s i s t a n c e
betweenthe 815 and 816 te.
mrnals.
Check lor loose TCM connector.
lf n€cessary, substitute a knowngood TCM and recheck.
1
WHT/REDT
Measu.e Secondary Gear Shatt
Speed Sensor Resistance:
1. Connectthe secondarygear
shaftspeedsensor2P connec-
ls the resistance
350 600O?
2
12 131 a 15 16 1 7 18
WHT/REI
Reprir loose terminal or opcn in
the wires between the 815 and
8'16terminals and the secondary
g€ar shaft sp€ed s€nsor,
ORN/BLU
TroubleshootingFlowchart- TMA and TMB Signals
NOTE:Recordall freezedatabeforeyou troubleshoot'
. OBD ll Scsn Tool indicate3Codo
P1655.
. Self-diagnosbE indicator light
indicalesCod6 37.
PossibleCause
. Shorl or op.n in TMA wi.o
botwo6n 87 terminal and ECM
. Short or open in TMB wiro
bdtwoon BGto.min.l .nd ECM
. F.ulty ECM
. FaultyTCM
CheckTMA Wire Continuity:
1. Turnthe ignitionswitchOFF.
2- Disconnectthe I (22P)connectorlrom the TCM
3 . D i s c o n n e ct th e c ( 3 1 P )c o n '
nectorfrom the ECM
4. Checkfor continuitybetween
t h e 8 7 t e r m i n a lo f t h e T C M
and the Cg terminaloI the
ECM,
B (22P)
TCM CONNECTOR
GRY
a
2
I
o
9 10
8
5
12 1311 1 5 16 17 18
20
C 13lPI
ECMCONNECTOR
GRY
1
2 3 a
1 112 t 3 l a
l8 9r0
5 6
18/
16
/
29130/
WiresideoI temaleterminals
Ropail open in the wire betwcen
the TCM and the ECM.
::)
Check TMA Wir€ for a Short Circuit:
Checkfor continuitybetweenthe
87 terminalof the TCM or the Cg
t e r m i n a lo l t h e E C M a n d b o d y
ground.
I
2
a 5 6
12 t 3 1 4 1 5 1 6 1 7 1 8
8
9 10
20
check rhe EcM:
1 . R e c o n n e ctth e C ( 3 1 P )c o n '
nector to lhe ECM, and the B
(22P)connectorto the TCM
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltage between
t h e C 9 t e r m i n a lo I t h e E C M
and body ground.
ls thereapprox.10V?
Chocktor loose ECMconnectors.
lf nscossary,subdituta a known'
good ECM.nd lecheck.
(cont'd)
To page14 258
14-257
ElectricalTroubleshooting('96- 98 Models)
TroubleshootingFlowchart- TMA and TMB Sigrrals(cont,d)
from page14 257
TCM CONNECTOR
8 {22P}
CheckTMB Wire Continuity:
1. Turnthe ignirionswitchOFF.
2. Disconnect
the C (31P)connec,
tor from the ECM,and the I
(22P)connectorfrom the TCM.
3. Checkfor continuitybetween
t h e 8 6 t e r m i n a lo l t h e T C M
a n d t h e C 3 0 t e r m i n a lo f t h e
ECM,
PNK
2
6
I
12 1314
o
7 t 8
16 17 18
10
I
20
ECMCONNECTOR
C 131P}
2
a
5 6 7
12 1 3 l a
ll
Repairopen in the wire betwe€n
rhe TcM and the EcM.
8 I 10
17118
/l/l
)/)/l/l )aol'ol/
PNK
Wire sideof femaleterminals
Check TMB Wire tor a Short Circuit:
Checkfor continuitybetweenthe
8 6 t e r m i n a lo t t h e T C M o r t h e
C 3 0 t e r m i n a lo t t h e E C M a n d
body ground.
PNK
2
4
5
6
o
,
12 1 3 1 1 1 5 1 6 1 1 1E
8
9 10
20
ls therecontinuity?
Checkthe TCM:
1 . R e c o n n e ctth e B ( 2 2 p )c o n nectorto the TCM, and the C
(31P)connectorto the ECM.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltage between
t h e B 6 t e r m i n a to f t h e T C M
and body ground.
ls thereapprox.S V?
Checkfor loose TCM connoctors.
lf necessary,substitute e lnowngood TCM and recheck.
Downloaded from www.Manualslib.com manuals search engine
PNK
2
1 5
7 8
10
1 2 13 1 4 1 5 1 6 1 7 1 8
20
TroubleshootingFlowchart- Shift ControlSystem
NOTE:Recordall freezedata beforeyou troubleshoot.
OgD ll ScanTool indicatesCode
P'1890.
Self-diagnosi3E indicator light
indicatesCode 42.
Po$ible Cause
Faulty 3hift control system
Checkfor Anolhet Code:
C h e c kw h e t h e rt h e E i n d i c a t o r
lightindicatesanothercode.
ls the E indicator light indi
cate another code?
P e r t o r mt h e T r o u b l e s h o o l i n g
Flowchrrt to. th€ indicet.d
Codelsl.
CheckStall SpeedRPM:
M e a s u r et h e s t a l l s p e e dR P M
(seepage14-298).
ls the stallspeedover 3,500rpm?
l s t h e s l a l l s p e e d b e l o w 2 . 0 o 0r p m )
T e s t - d r i v ea n d C h e c k En g i n e
Speed:
1 . D r i v et h e v e h i c l ea t 3 0 m P h
(50 km/h) constantlYfor sev_
eral manutes.
2. Checkthe enginespeed
ls the engine speed within the
s p e c i f i c a t i o n( s e e p a g e 1 4 2 9 6
and 14 297\?
14-259
ElectricalTroubleshooting('96 - 98 Models)
TroubleshootingFlowchart- Start ClutchControlSystem
NOTE:Recordall freezedata beforeyou troubleshoot.
OBOll ScanTool indic.le3 Cod6
P1891.
Solt-diagnosisE indicator light
indicatesCode(1.
Po$ible Ceuaa
Frulty start clutch cont.ol 3ystem
Checkfor Another Codo:
C h e c kw h e t h e rt h e @ i n d i c a t o r
light indicatesanothercode.
ls the E indicatorlightindicateanothercode?
Poiform tho Troublcahootlng
Flowchrrt lor the indicat.d
Code(sl.
Test Strrt Clutch Oper.tion:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 8P connector
from the solenoidharnesscon,
nector.
3. Start the engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
moves.
Rcplacath. strrt dudt r$amt ly.
CheckCreepingSpe€d:
1. Turnthe ignitionswitchOFF.
2. Reconnectthe 8P connectorto
the solenoidharnessconnector,
3. Start the engin6,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
creeps,and chockthe creepIng speed.
Does the vehicle move and is
the creepingspeed approx.3
mph (5 km/h)?
To page 14-261
14-260
From page 14 260
CheckStall Speed RPM:
Measurethe stallspeedRPM(see
page14'298).
ls the stallspeedover3,500rpm?
Warm Up Engine and Recheck
Failure:
1 . W a r m u P t h e e n g i n et o n o r '
m a l o p e r a t i n gt e m P e r a t u r e
(theradiatorfan comeson)
2. Checkwhetherthe startclutch
problemappearsagain.
Doesthe problemappear?
The svstem is OK at this time.
rl,
14-261
ElectricalTroubleshooting('96- 98 Modelsl
TroubleshootingFlowchart- Pl IndicatorLight DoesNot GomeOn
The E Indicator light does not
come on when the ignition switch
is tirst turned ON {ll). {lt should
come on for aboul two s€conds,)
Chockthe ServiceCheckConneclot:
Make sure the specialtool (SCS
S e r v i c eC o n n e c t o ri)s n o t c o n
nectedto the seryicecheckcon
nector,
ls the specialtool (SCSService
Connector)
connected
to the servicecheckconnector?
Disconn€ctthe sDecialtool from
the seruicecheck connector and
recheck.
Checkthe E IndicatorLight:
Shift to [5] oosition.
Doesthe E indicatorlight
comeon?
Checkfo. loose TCM connectors.
lf neceasary, substitute a knowngood TCM .nd rochock.
A {26P)
TCM CONNECTOR
BLI
Ch€ckth6 Ground Circuit:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A 1 2 6 P c) o n nectorfrom the TCM.
3. Checktor continuitybetween
t h e A 1 3 t e r m i n a la n d b o d y
ground and the 426 terminal
and body ground.
I
1
2
3 a 5
1a 15 16 17
8 9 1 0 1 t 12
20
23
Downloaded from www.Manualslib.com manuals search engine
rt
o
.Repair open in the wires
betwoon lhe A13 or A26 terminel3and G101.
. Repai.poorground{G1011.
14-262
25
nl
8LK
Wire side of female terminals
To page14-263
l-
Ftom page14 262
A I26P)
TCM CONNECTOR
BLK/WHT
Measure Powet SUPPIYCi.cuit
Voltage:
1. TurntheignitionswitchON (ll)
2. Measurethe voltagebetween
t e r m i n a lA
s 1 2a n d A 1 3a n d
b e t w e e nt e r m i n a l sA 2 5 a n d
426.
a
2
r
BLK
1 0 1 1 12 13
25 26
23
7
20
14 t5 16 17
I
A
BLK/WHT
I
BLK
I
Wire sideof femaleterminals
ls there batteryvoltage?
Repair open or short in the wire
between the A'12andlor Ms lerminrls and the under-dashfuse
DOX,
MeasureD IND Voltage:
1. Turnthe ignitionswitchOFF
2. connect the A (26P)connec
tor to the TcM.
3. Connecta digkal multitester
to the A20and A'13or A26ter
minals.
4. Turnthe ignitionswitchON (ll),
and makesure that the voltage
for two seconds.
is available
GRN/BLK
Check tor opon in the wire
between the A20 l6rminal and
the gaug€ assembly. It the wite
is OK, check tor a faultY ipl indicalor light bulb or a faulty gauge
assemblyprir ed circuit boatd.
CheckD INOfor an Shott Circuit:
1. Turnthe ignitionswitchOFF
2 . D i s c o n n e ct th e A ( 2 6 P )c o n nectorfrom the TCM.
3. Checkfor continuitybetween
the A20terminalandthe No.I
terminalof the gaugeassembly connector(seesection23).
A (25P}
TCM CONNECTOR
1
2
8
a 5
20
1 l 15 16 1 7
9 1 0 1 1 12 1 3
25 26
23
GRN/BLK
GAUGEASSEMBLY
14PCONNECTOR
Bepair open in the wire between
the A20 terminal and the gauge
assembly.
o
a 5
7
8
9 10
1 1 12
GRN/BLK
Checktor looso TCM connecto.s.
C h e c kt h e A / T g e . r P o s i t i o n
switch. lf nec6ssary,substitute a
known-goodTCM and r€check
Wire side of female terminals
14
ElectricalTroubleshooting('96 - 98 Modelsl
TroubleshootingFlowchart- lq IndicatorLight On Constantly
The E indic.tor light is on constantly {not blinking}whonever
the ignilion switch is ON llll.
TCM CONNECTOR
A {26PI
MeasureD INOVoltage:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e A ( 2 6 P )c o n '
nectorfrom the TCM.
3. Turnthe ignitionswitchON (ll).
4, Measurethe voltagebetween
t h e A 2 0 t e r m i n a la n d b o d y
ground,
2 3 4
1a 15 16 1 7
7
1 0 l l 12 13
23
25 26
8
20
GRN/BLK
Wiresideof femaleterminals
Repeir3hort to power in thc wire
between tho A20 terminal and
ihe gauge ass€mbly.
MeasureATP DVohage:
1. Turnthe ignitionswitchOFF.
2. Connectthe A (26P)connector to the TCM.
3. Turnthe ignitionswitchON (ll).
4. Shift to any positionotherthan
YEL
1
E,
5. Measurethe voltagebetween
t h e A 9 t e r m i n a la n d b o d y
ground.
Check tor a short to ground on
the wire. ll wire is OK, .epl.ce
the A/T gear position indic.tor.
14-264
2
3
a
1a t5 16 17
5
7
20
8 9 1 0 1 t 12 1 3
a
25 26
ElectricalTroubleshooting('99- 00 Models)
TroubleshootingFlowchart- A/T GearPositionSwitch (Short)
NOTE:Recordall freezedata beforeyou troubleshoot.
. oBD ll scln lool indicats code
P't705.
. Self-diagnosbE indicator light
blinksfivetim€s.
Obseive tho A/T Gear Polition
lndicetor:
1. Turnthe ignitionswitchON (ll).
2. Observethe A,/Tgear positaon
indicator,and shift oach Position separately.
Doesany indicatorstay on
when the shiftleveris not an
that position?
Po3sibleCause
. Short in A/T gear po3ition 3witch
. F.ulty A/T ge6r Positionswitch
NOTE: Code P1705(5)is causedwhen
t h e P C M r e c e i v e dt w o g e a r P o s i t i o n
inputsat the sametime.
Tho ry3t6m is OK at this tims.
Check th€ wiro hsrno!! tor
damage.
PCMCONNECTORS
Bt25Pt
llO(16P1
M.Furo ATP R Vohtge:
1. Shift to all positionsother than
E.
2. Measurethe voltage between
the D6 and 820 or 822 termi'
nals,
ls thereapprox.10V?
LGl (BRN/8LKI LG2(BRN/8LKI
Wire sideof femaleterminals
Chock for lhort in tho wit€
betwe€n the D6 telminal and thg
A/T ge.r position 3witch or A/T
gear po3ition indicttoi, !nd
chcck for open in the witgs
botwo€n the 820 lnd 822 tetmi_
F
n.ls and body g.ound (G1011.
wiro3 ere OK, checktor loo3oter'
minal fit in the PrCMconnoctors.
ll n6c€3sary, 3ubstitute a knowngood PCMand rochock.
(cont'd)
To page14 266
14-265
ElectricalTroubleshooting('99- 00 Models)
Troubfeshooting Flowcharl -
AIT Gear Position Switch {Short) {cont,d}
Frompage14 265
MeasureATP NP Voltage:
'1. Shiftto all positions
otherthan
EorI
2. Measurethe voltagebetween
the A9 and 820 or 922 te(minals.
jl
A t32Pl
B {25P)
LGl IBRN/BLK)
LG2 {BRN/BLK}
Wire sideof femaleterminals
ls thereapprox.10V?
Me.sure ATP D Vohago:
1 . S h i f t t o a l l p o s i t i o n so t h e r
t h a nE .
2. Measurethe voltage between
the 47 and 820 ot 822 tet-r'inals,
Check for short in the wire
betwoen ths Ag terminal and the
A/T gerr position switch, .nd in
the E .nd E position3ignal
wiros botween the A/T gear
position indic.tor and the A/T
gear positaonswitch. lf wircs .re
OK, checktor looseterminal tit in
the PCM connectols. lf n€ces3ary, substitute a known-good
PCMand rocheck.
ATPD (YEL)
a l32Pl
ll
B (25P1
LG1 {BRN/ALKI
ls thereapprox.10V?
To page 14-267
14-266
Check tor 3hort in lhe wire
b€twaen thc A7 terminel and the
A/T g6ar position switch. lf wir.s
are OK, ch.rckto. loose terminal
fit in th6 PCM connectoF. lf nscossary.substhute a known-good
PCM and ..check.
LG2 IBRN/BLK)
Frompage14-266
PCMCONNECTORS
M6asureATP S Voliag€:
1 . S h i f t t o a l l p o s i t i o n so t h e r
than E.
2. Measurethe voltagebetween
the D13and 820 or 822 termi
nals.
D (16P1
B t2sP)
ATP S {LT GRN/RED)
LG1{BRN/BLKI
LG2 (BRN/BLKI
Wire sideof Iemaleterminals
'10
ls thereapprox. V?
Check for short in the wire
between the D13 terminal and
the A/T gear position lwitch or
A/T goar position indicator. It
wir6s are OK, checklor loose l€rminal fit in the PCM connectors.
ll nec*3arv, substitute a known'
good PCMand r6check.
PCMCONNECTORS
MeasureATP L Voltage:
1 . S h i { t t o a l l p o s i t i o n so t h e r
than E.
2. Measurethe voltagebetween
the A22 and 820 or 822 terminals.
ls thereapprox-10V?
Checktor loos€ terminalfit in the
PCM connectors, It nec6s3arY,
substitute a known-good PCM
and rech6ck.
t32Pl
Check lor sho.t in ihe wire
betwgon the A22 terminal and
th. A/T geat position switch or
A/T gear position indicator. It
wires are OK, ch€ckfor 10036terminal fit in the PCM connectors.
lf n6cessery,substitute a known_
good PCMand recheck.
B t25Pl
ElectricalTroubleshooting{'99- 00 Models)
Troubfeshooting
Flowchaft- AIT GearPositionSwitch (Openl
NOTE:Recordallfreezedata beforevou troubleshoot.
. OBD ll Scan Tool indicstE Code
P1706.
. Selt-diagnGi! E indicato. light
blinks six tim€a.
Po$ible Cau3e
. OilconnectedA/T goar position
switch
. Op€n in A/T go.r po.ition switch
wi?o
. Faulty A/T gear polition switch
Test the IVT gear position switch
(seesection23).
PCM@NNECTORS
Measu.eATP R Voltage:
1. Turnthe ignitionswitchON (ll).
2. Shiftto E position.
3. Measurethe voltage between
the D6 and 820 or 822 terminals,
(BRN/BI.XI
Ropair opcn in the wi.. hr.raGn
th6 DOtorminrl lnd the A/t g..r
position awitch.
MeasureATP NP Vohage:
'1. Shiftto
E or N position.
2. Measurethe voltage between
the A9 and 820 ot 822 letminals,
I tO (16P1
B {25P)
LG2IBRN/BLKI
wire side of fomale terminals
ATP NP ILT GRNI
A t:r2Pt
Il
s tzspt
I-G1(BRN/BLKI
Ropair op6n in th€ wiro b€{woan
the Ag t.rminal and the A/T go..
position .witch.
To page14 269
14-264
LG2 {BRN/BLK)
Frompage14-268
Moasule ATP D voltago:
1. Shiftto El position.
2. Measurethe voltage between
the A7 and 820 or 822 termi
nals.
A {32P}
ll
B l25Pl
LGl IBRN/BLK)
LG2 (BRN/BLKI
Repairopen in the wira betwo6n
the A7 torminal and the A/T ge.r
po3ition switch.
MeasureATP S Vollag6:
'1. Shiftto position.
E
2. Measurethe voltage between
the D13and 820 or B22termi
nals.
LGl IBRN/BLK}
Repairop€n in tho wire between
ihe D13 terminal .nd the A/T
gear position switch,
To page14-270
(cont'd)
14-269
ElectricalTroubleshooting{'99- 00 Models}
TroubleshootingFlowchart- A/T GearPositionSwitch (Openl(cont'dl
Frompage14-8-269
PCMCONNECTORS
B (25P1
MsasuroATP L Voftage:
1. Shiftto E position.
2. Measurethe voltagebetween
the A22 and 820 or 822 terminals,
Wiresideof femaleterminals
Bepair opon in the wiro bgtw€en
lho A22 torminal and the A/T
goar poihion lwitch.
PCMCONNECTOR
B I25PI
Check LG Wiro for .n Open Circuit:
'] Turnthe ignitionswitchOFF.
2. Checklor continuitybetween
the 820 t€rminaland body
ground,and betweenthe 822
terminaland body ground.
1 2
9 't0 l 1
LGT(BFN/ALK}
ll
.15 / 7
I
Br1/l/41it8
l L G 2IBRN/BLKI
o) (o)
Wire sideof femaleterminals
Ropai' op.n in the wir€a botw.€n
the 820 rnd 822 toJminals .nd
body ground, and .opsi. pool
ground(Gl01l.
Check tor loose te.minal frt in th6
PCMconn€ctors, lf n€cessary,substitut€ a knowo-good PCM and
a6check,
14-270
J
TroubleshootingFlowchart - Shift Control Linear Solenoid
NOTE:Recordall freezedata beforeyou troubleshoot
.OBD ll Scan Tool indicatos
Code P1870.
. Solf-diagnosisE indic.lor light
indic.t€s Code 30.
PossiblcCause
. Disconn€ctedsolenoid harnos3
connectol
. Short or oDen in shilt control
linetr solonoidwiro
. Faulty shift control linear sole_
noid
. Op€n in VB SOLwite
. ODen in PG'l and PG2 wires or
poor ground {G10'l)
PCMCONNECTORS
M6a3ureVB SOLvoltage:
1. Turnthe ignitionswitchOFF.
the B 125P)and D
2. Disconnect
( 1 6 P )c o n n e c t o r sf r o m t h e
PCM,
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltage between
the D5 and 820 or 822 termi
nals.
B(25P)
-
Dll6P)
LG1IBRN/BLKI
wire sideot femaleterminals
f,
Repairopen or shod in the wire
between the D5 terminal and the
under-dashtuso/telay box.
B PsPI
PCMCONNECTOR
PG,IIBLK)
Checkthe Ground Circuitl
1. Turnthe ignitionswitchOFF.
2. Checklor continuity between
the terminafs 82 and 822 and
b e t w e e nt e r m i n a l s8 1 0 a n d
820.
LG1 IBRN/BLKI
LG2IBRN/BLK)
Repairopen in the wi.e betwoen
the termin.ls 82, B10, B20,and
822 and G101. Repair Pool
ground(G101).
a
{cont'd)
10 page14-272
14-271
('99- 00 Models)
ElectricalTroubleshooting
TroubleshootingFlowchart- Shift GontrolLinearSolenoid(cont'dl
tuom page14 271
HARNESS8P CONNECTOR
SOI."ENOID
SH LSP
M e a s u r eS h i f t C o n t r o l L i n e a r
Solenoid R6sistanceat the Solenoid Hrrness Connector:
1. Disconnectthe solenoidhar
ness8P connector.
2. Measure the resistance
betweenthe No. 3 and No- 7
terminalsoI the solenoidhar
ness8P connector,
SH LSM
Terminalsideof maleterminals
ls the resistance
3.8- 6.8o?
PCMCONNECTOR
D {16P}
SHLSMIGRN/YELISHLSP{BLU/WHTI
Check Shift Control Lin€ar Solenoid tor a Short Circuit:
Checkfor continuitybetweenthe
body groundand the D3terminal
and D4terminalindividually.
Rep.ir short in th€ wir€ tr€twlren
ihe D3 and D4 torminab .nd the
shift cont.ol line.. solenoid.
Wire side oI temale terminals
SH LSM {GRN/YELI SH LSP IALU/WHT}
Measure Shitt Conirol Lineer
SolenoidResbtance:
1. Connectthe solenoidharness
8P connector.
2. Measure the resistance
betweenthe D3 and D4terminats.
ls the resistance
3.8- 6.8O?
Checktor loose terminal fit in the
PCM connector3,It necessary,
substitute a known-good PCM
and recheck.
14-272
Repeir loose ierminrl or open in
the wire3 between tho D3 and D4
terminals end the shift control
linear solenoid.
TroubleshootingFlowchart- PH-PLControlLinearSolenoid
NOTE: Recordall freezedata before you troubleshoot.
. OBD ll Scan Tool indicates
Codo P1873.
. sslt-disgnosisE indicltor light
indicatesCode 31.
Possiblsc.use
. Oisconn6dod solenoid harness
conn6ctol
. Short or ooen in PH-PLcontrol
linear solenoidwire
. F.ulty PH-PLcont.ol linear solenoid
. ODenin VB SOLwire
. Op€n in PGl and PG2 wires or
poor groundlG101l
PCM CONNECTORS
Mo.surevB SOLVohagg:
1. Turnthe ignitionswitchOFF.
the 8 (25P)and D
2. Disconnect
( 1 6 P ) c o n n e c t o r sf r o m t h e
PCM,
3. Turn tho ignitionswitchON (ll),
4. Measurethe voltage between
the D5 and 820 or 822 terminals,
B (25P1
D {16P}
(BRN/BLX)
Wire sideof femaleterminals
Ropairopen or shod in the wiJe
bstwaon tho D5 terminal and the
under-dalh tuso/relay box.
B (25P|
PCMCONNECTOR
Checkthe Ground Circuh:
1. Turnthe ignitionswitchOFF
2. Checktor continuity between
the terminals82 and 822 and
b e t w e e nt e r m i n a l s8 1 0 a n d
820.
LGT IBRN/BLKI
LG2IBRN/BLK)
Fepair open in tho wiro b€tw€en
tho torminds 82, 810, 820, and
822 and G101. Repair Poor
ground(G1011.
(cont'd)
Fo page 14-274
14-273
('99- 00 Models)
Electrical
Troubleshooting
TroubleshootingFlowchart - PH-PLGontrol Linear Solenoid (cont'd)
Frompagel4-273
SOLENOIDHARNESS8P CONNECTOR
Mea3ure PH-PLControl Linear
Solenoid Rosistanceat lhe Solenoid HarnessConnector:
1. Disconnectthe solenoidharness8P connector.
2 . M e a s ur e t h e r e s i s t a n c e
betweenthe No. 2 and No. 6
terminalsoI the solenoidhar
ness8P connector.
HLCLSP
HLCLSM
Terminal side of male terminals
ls the resistance
3.8- 6.8O?
PCMCONNECTOR
B (25PI
HLCI.SM (PNK/BLK)
CheckPH-PLControl LinearSolenoid lor a Short Circuit:
Checkfor continuitybetweenthe
body groundand the 88 terminal
and 817 terminalindividually.
Rep.i. 3hort in the wiro bsh^,een
lhc 88 and 817 terminals and the
PH-PLcont.ol linear solenoid.
Wiresideof femaleterminals
HLCLSM {PNK/BLKI
Measure PH-PLControl Linear
SolenoidResistance:
1. Connectthe solenoidharness
8P connector,
2. Measure the resistance
betweenthe 88 and 817 terminals.
3
I
l0
20
5
-j-
/ 1 1i 8
A/'.nlisl
i.((
HLCLSP IGRN/WHT}
ls the resistance
3.8-6.8 O?
Checklor loose ierminal fit in the
PCM connectoTa.lf necessary,
substitute a known-good PCM
.nd recheck.
14-2 7 4
Repair loose te.minal or open in
the wires between the 88 rnd
817 te.minlb .nd the PH-PLcontrol linear solenoid.
TroubleshootingFlowchart- Start ClutchControlLinearSolenoid
NOTE:Recordall freezedata beforeyou troubleshoot'
'OBD ll Scan Tool indicates
Code Pl879.
. self-diagnosisE indicstor light
indicatesCode 32.
Po$ible Cause
. Disconnectedsolenoid harness
connedol
. Short or open in sta.t clutch
control linear solenoidwiro
. Faulty3tart clutch conttol lin€ar
solenoid
' Ooen in VB SOLwire
. Open in PGI and PG2 wires or
poor ground{G101)
PCMCONNECTORS
MeasureVB SOLVoltag6:
1. Turnthe ignitionswitchOFF
the B {25P)and D
2. Disconnect
( 1 6 P ) c o n n e c t o r s{ r o m t h e
PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the D5 and 820 or 822 terminals,
o l16P)
B l25P) --
LGl IBRN/BLK)
Wire sideof lemaleterminals
ls there batteryvoltage?
Reprir opon or short in the wire
between the D5 terminal and the
undei-d.sh luse/relaYbox.
B {25PI
PCMCONNECTOR
Checkthe Ground Ciicuit:
'1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
the terminafs 82 and 922 and
b e t w e e nt e r m i n a l s8 1 0 a n d
820.
LGl (BRN/BLKI
ls therecontinuity?
Rep.ir open in the wire betwesn
the terminab 82, 810, 820. tnd
822 and G101. RePair Poor
groundlG101l.
(cont'd)
To page14-276
14-215
Electrical
('gg- 00 Modelsl
Troubleshooting
TroubleshootingFlowchart- start clutch control Linearsolenoid(cont,d)
Frcmpage14.275
Measurs Start Clutch Control
Linear Solenoid R€aistanceat ths
Solenoid Harne€sConnector:
1. Disconnectthe solenoidharness8P connector.
2 , M e a s ur e t h e r e s i s t a n c e
betweenthe No. 4 and No. I
terminalsof the solenoidharness8P connector,
SOLENOIDHARNESS8P CONNECTOR
SC LSP
SC LSM
T6rminalsideof maleterminals
ls the resistance
3.8- 6.80?
Check Start Clutch Control Line.r
Solenoid tor a Short Circuit:
Checkfor continuity between tho
body ground and the 818 terminal and B2Sterminal
individually.
R€p.ir short in th. wire bctw.on
th6 818 and 825 termin.lr rnd
the 3hift cont ol linc.r solonoid.
Measure Start Clutch Control
LinearSolenoidR6ist.nco:
1. Connectthe solenoidharness
8P conn€clor.
2. Measure the resistance
betlveenthe 818 and 825 ter,
mtnats,
ls the resistance
3.8-6.8 O?
Checkto. loose tarminal fit in tho
PCM connactors. It necessary,
substitute a known-good PCM
and recheck.
14-276
Wire side of f6maleterminals
SC LSM
(PNK/BLU)
Raprir looa. t€.minal or opan in
tha wirars lratwe.n the B18 and
825 terminal3 and tha st!rt
clutch control linoar 3olanoid,
TroubleshootingFlowchart- lnhibitorSolenoid
NOTE:Recordall freezedata beforeyou troubleshoot'
.OBD ll Scan Tool indicaies
Codo P'l882.
. Self-diagnosisE indicttor light
indic.tes Code 33.
Po3sibleCause
. Oi3connec'tedsolenoid harn6s
connectoa
. Shorl or open in inhibitor 3olenoid wir€
. Faulty inhibitor solenoid
. ODenin vB SOLwire
. Open in PGl and PG2 wires or
poor ground{G101}
PCM CONNECTORS
Me'sure VB SOLvoltagel
'1. Turnthe ignitionswitchOFF.
the B (25P)and D
2. Disconnect
( 1 6 P )c o n n e c t o r sf r o m t h e
PCM.
3. Turnthe ignitionswitchON (ll)
4. Measu.e the voltage between
the D5 and 820 or B22terminals.
(BRN/BLKI
Wire sideot femaleterminals
ls there bafteryvoltage?
Repair open or short in the wire
between the D5 tolminal and the
undor-dashlu36/relay box.
B {25P}
PCMCONNECTOR
Ch€ckthe Ground Circuit:
1. Turnthe ignitionswitchOFF.
2. Checktor continuitybetween
the terminals82 and 822 and
b e t w e e nt e r m i n a l sB ' 1 0a n d
820.
LGl IBRN/BLKI
LG2(BRN/BLKI
R€pairopen in the wire between
the torminal3 82, 810, B20, and
B 2 2 . n d G 1 0 1 . R e P a i rP o o r
ground{G101).
(cont'd)
To page14-278
14-217
('99- 00 Models)
Troubleshooting
Electrical
TroubleshootingFlowchart - Inhibitor Solenoid (cont'dl
Ftom page 14-277
SOLENOIDHARNESS8P CONNECTOR
Mersure Inhibitor SolenoidR6bt.nce at the Solenoid Harne3s
Conn€ctor:
1. Disconnectthe solenoidhar,
ness8P connector,
2. Measure the resistance
betweenthe No.5 terminalof
the solenoidharness8P connectorand bodyground.
SOL INH
Terminalsideof maleterminals
ls the resistance
11.7- 21.0O?
B t25P)
Check Inhibitor Solonoid fo. .
Short Ci.c!it:
Checkfor continuity between the
D2 and 820 or 822terminals.
ll
D t16P)
LGl IBRN/BLKI
Wire sideoI temaleterminals
R.p.ir 3hort in thc wire botwaan
th€ 02 t.rminal and the inhibhot
solenoid.
Measur6 Inhibitor Solenoid
Re3istance:
1, Connectthe solenoidharness
8P connector.
2, Measure the lesistance
between the D2 and 820 or
822terminals.
B t25Pt
LGl {BRN/ALKI
ls the resistance
11.7- 21.0O?
Checkfol looso torminal fit in the
PCM connectors. lf n€cessaay,
substitute a known-good PCM
and r€check.
14-274
Rcpair loo3. tarminal or opan in
tho wha brtw.€n tho D2 to.minal .nd tho inhibitor lolonoid.
otl6Pt
Troubleshooting Flowchart - Drive Pulley Speed Sensor
NOTE:Recordallfreezedata beforeyou troubleshoot'
.OBD ll Scan Tool indicates
Code Pl885.
. Selt-diagnosbE indicator light
indicatosCode 34
PossibleCau3€
. Disconnected diive PulleY
soeeds6n3orconnectol
. Short or open in drive Pull.Y
sooed sonsor wire
. FaultY drive PulleY spo€d sen'
301
checkthe drive pulleYsPeedsensor installation,and check it for
damage.
ls the drive PulleYspeedsensor installedproperly,and not
damaged?
Rein3tallor roplaceand techeck
DRIVEPULEY SPEED
@NNEfiOR
SENSOR
Measuro Drive PulleY Speed Sen_
sor Ro3istanco at the Sonsol
Connector:
1. Disconnectthe 2P conneclor
from the drive Pulley speed
sensor,
2. Measuredrive Pulley speed
sensor resislanceat the sensor connecror.
Terminalsideof maleterminals
ls the resistance350 - 600 O?
D (16PI
PCMCONNECTOR
CheckDrivo PulleYSP6€dSen3o.
lor . Short Circuit:
1. Disconnectthe D {16P)connectorlrom the PCM.
2. Checklor continuitybetween
body groundand the D11ter
minal and D'l2 terminal indi
vidually.
NDR SG IGRNI
Wire sideo{ Iemaleterminals
Repai. short in the wiles
between the Dll lnd D12 terminals and iho drive Pull.Y speed
(cont'd)
To page14-280
14-279
Electrical
('gg- 00 Models)
Troubleshooting
TroubleshootingFlowchart- DrivepulleySpeedSensor(cont,d)
Frompage14-279
PCMCONNECTOR
D {16P}
MeasureDrivo PulleySpeed Sensor Circuit tor an Open:
1 . C o n n e c tt h e d r i v e p u l l e y
speedsensorconnector,
2 . l v l e a s rue t h e r e s i s t a n c e
betweenthe Dl1 and Dl2 terminals.
Wire sideof temaleterminals
ls the resistance350 - 600 O?
Ch6ckfor loose lerminal tit in the
PCM connectors, ll nece3saay,
substituto a known-good PCM
6nd r€check.
14-280
R6pair loose tgrminal or opan in
the wiros betwo€n tho D1,l .nd
Ol2 tarminrl! .nd th. drivs pulley speed *n3or.
TroubleshootingFlowchart- DrivenPulleySpeedSensor
NOTE: Recordall freezedata betore you troubleshoot'
'OBD lt Sc.n Tool indicates
Code Pl886.
. Self-diagnosbE indicator light
indicrt€. Codo35.
Po3sibleCaus€
' O i s c o n n e c t e dd r i v e n P u l l e Y
speeds6nlor connoctor
. Short or opon in d.iven Pulley
soeedsonsol wirc
. Faulty driven Pulley speed sen_
sor
C h e c kt h e d r i v e n P u l l e ys p e e d
sensorinstallation,and check it
Ior damage.
lsthe drivenpulleYspeedsen'
and not
sor installedProPerly,
damaged?
Boin3tallor ropl.ca and recheck.
DRIVENPULLEYSPEED
CONNECTOR
SENSOR
M..sure Drivon PulloY SPoed
Sonsor Rosblanco at the S6n3or
Conn6ctori
1. Disconnectthe 2P connector
trom the driven PUlleysPeed
sensor,
2. lveasuredriven Pulleyspeed
sensorresistanceat the sen_
sor connector.
Terminalsideol maleterminals
ls the resistance350 - 600 0?
D If6P)
FCM CONNECTOR
NDN IWHTI
Check Dtivon Pulloy SP€ed Sen'
sor for a Short Circuit:
1. Disconnectthe D (16P)connectorfrom the PCM.
2. Check tor continuity between
body groundand the D10ter'
minal and Dl6 terminal individually.
Wire sideof femaleterminals
Raoair shott in tho wi.6s
betwoon th. Dlo end D16 tormi'
nak .nd the ddven Pulley spo€d
(cont'd)
Fo page 14'282
14-2A1
ElectricalTroubleshooting['gg - 00 Models)
TroubleshootingFlowchart- DrivenpulleySpeedSensor(cont,dl
Frompagel4 281
M6asure Driven Pulley Speed
SensorCircuit Ior an Op€n:
1 . C o n n e c t h e d r i v e np u l l e y
speedsensorconnector,
2, Measure the resistance
betweenthe D10and Dl6 terminals.
NON SG IRED/WHTI
Wire sideof femaleterminals
ls the resistance350 - 600 O?
Checktor loose terminal tit in the
PCM connectors, lf necessary,
sub3titute a lnown-good PCM
and rech6ck.
14-282
Rgpair loose terminal or open in
the wires botwosn the Dlo and
016 torminab rnd the drivon Dulley speed3ensoa,
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor
NOTE:Recordall freezedata beforeyou troubleshoot
' OBD ll Scan Tool indicates
Code P1888.
. Self-diagnosisE indicalor light
indicats Code 35.
Po$ible Causo
. OisconnectodsecondarYgear
shaft speedsensorconn66or
' short or open in secondarygear
shaft spe€dsensorwiro
. Faulty secondarY gear 3haft
sPeedsensor
Checkthe secondarYgear shaft
s p e e ds e n s o ri n s t a l l a t i o na, n d
checkit for damage.
gearshaft
ls the secondary
speedsensorinstalled
properly,and not damaged?
Reinatallor replaceand rocheck.
GEARSHAFT
SECONDARY
SPEEOSENSORCONNECTOR
Measure SocondarY Gear Sh.ft
Speed Sen3or Resistanceat the
SensorConnector:
1. Disconnectthe 2P connector
trom the secondarygearshaft
speedsensor.
gearshaft
2. Measuresecondary
speedsensor resistanceat the
sensorconnector.
Terminalsideof maleterminals
350- 6000?
ls the resistance
D I15P)
PCMCONNECTOR
VEL (WHT/REO) VEL SG IALK/WHTI
Check SecondarY Gear Shaft
SpeedSensorlor a Short Circuit:
1. Disconnedthe D (16P)connector from the PCM.
2. Checkfor continuitybetween
body ground and the D1 term i n a l a n d D 7 t e r m i n a li n d i vidually.
Wire side oI female terminals
Repair short in the wiros
b.tween the Dl and D7 termi_
n e 1 3a n d t h € s e c o n d a r Yg e a l
3haft lpeed sonsor.
(cont'd)
To page14-284
14-243
ElectricalTroubleshooting('gg - 00 Modelsl
TroubleshootingFlowchart- SecondaryGearShaftSpeedSensor(cont'd)
Frompage14 283
Moasu.€ Secondary Gaar Shaft
Spo6d Sonsor Circuit tor an
Openi
1. Connectthe secondarygear
shaftsp6edsensorconnector,
2 . M e a s ur e t h e r e s i s t a n c e
betweenthe Dl and D7 termi
nals,
Wi16side of femalet6rminals
ls the resistance350 - 600 O?
Checkfor loosoterminal lit in the
PCM connectors. lf necessary,
substilute a known-good PCM
.nd recheck.
14-284
Repair looao terminal or opon in
the wiraa batuvacn the Dl and D7
t.rminrls snd the second!ry
geer rhatt 3peod 3.nior.
TroubleshootingFlowchart- Shift ControlSystem
NOTE:Recordallfreezedata beforeyou troubleshoot
' OBD ll ScanTool indicatesCodo
P1Ato.
. Self-diagnosisE indicator light
indicatosCode 42.
Possiblecause
Faultvshift control svstem
Checkfor Anoth€r Code:
Checkwhether the E indicator
light indicatesanothercode.
ls the E indicatorlightindi
cateanothercode?
P€rform the Tloubleshooting
Flowchart for the indicated
Code(sl.
CheckStall SpeedRPM:
M e a s u r et h e s t a l l s P e e d R P M
(seepage14-298).
ls the stall speedover 3,500rpm?
ls the stallspeedbelow 2,000rpm?
T e s t - d r i v ea n d C h e c k E n g i n e
Speed:
L Drive the vehicle at 30 mph
150km/h) constantlyfor several mlnutes.
2. Checkthe enginespeed
ls the enginespeedwithinthe
(seePage14'296
specification
and 14'297)?
14-245
ElectricalTroubleshootang
('gg- 00 Models)
TroubleshootingFlowchart- Start ClutchControlSystem
NOTE:Recordallfreezedata beforeyou troubleshoot.
. OBD ll ScanTool indicatesCode
P1891.
. Self-diagnosisE indicator tight
indicatesCode 43.
Possibl€Cause
Faultv start clutch control syslem
Checkfor Another Codel
C h e c kw h e t h e rt h e E i n d i c a t o r
light indicatesanothercode.
ls the E indicatorlight indicateanothercode?
Perform the Troubleshooting
Flowchart tor the indic.ted
Codelsl.
Test Stsn Clutch Operation:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe 8P connector
from the solenoidharnesscon
nector.
3. Start the engine,and shift to
E position.
4 . C h e c kw h e t h e r t h e v e h i c l e
moves.
Repl.c€ the stan clutdt rasemHy.
Check Croeping Sp€6d:
1. Turn the ignition switch OFF.
2 . R e c o n n e c tt h e 8 P c o n n e c t o r t o
the solenoid harness connec
3. St€rt the engine, and shift to
E posation.
4. Check whether the vehicle
creeps, and check the creep
ing speed.
Does the vehicle move and is
t h e c r e e p r n gs p e e d a p p r o x , 3
mph (5 km/h)?
fo page14 287
14-2A6
t a
Frompage14'286
CheckSrall Speed RPM:
Measurethe stallspeedRPM(see
page14-298).
ls the stallspeedover 3,500rPm?
Warm Up Engine and Becheck
F ilure:
1 . W a r m u p t h e e n g i n et o n o r
m a l o p e r a t a n gt e m P e r a t u r e
(theradiatorfan comeson).
2. Checkwhetherthe stan clutch
problemappearsagain.
I a
Doesthe problemappear?
The 3v3tem ia OK at thi! iime.
14-2a7
ElectricalTroubleshooting('99- 00 Models)
TroubleshootingFlowchart- El IndicatorLight DoesNot ComeOn
The D indicator light does not
come on whon ths ignhion switch
is tirst turned ON {lll. llt should
come on tor abouttwo s€conds.)
Checkthe ServiceCheckConnector:
Makesure the specialtool {SCS
S e r v i c eC o n n e c t o rils n o t c o n
nectedto the servicecheckconnector,
l s t h e s p e c i a lt o o l ( S C S
Service Connectorl connected
t o t h e s e r v i c ec h e c k c o n n e c tor?
Disconnectthe sp€cial tool f]om
the seruice chcck connoclor and
aecheck.
Checkthe E Indicalor Light:
Shiftto E posjtion.
Doesthe E indicatorlight
Checktor loose te.minal fit in the
PCM connectors, lf nocessary,
substitute a known-good PCM
and aecheck.
Checkthe Ground Circuit:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e B ( 2 5 P )c o n
nectorfrom the PCM.
3. Checktor continuitybetween
t h e 8 2 0 t e r m i n a la n d b o d y
ground,and betweenthe 822
terminaland body ground.
ls therecontinuity?
PCMCONNECTOR
B I25PI
LGl {BRN/BLK)
Fepair open in th. wiros
b€tw.en the 820 end 822 termin a l s a n d g r o u n d { G 1 0 1 1 !, n d
repair poor ground {G1011.
Wire sideot femaleterminals
Measure Power Supply Circuit
Voltage:
1. Turnthe ignitlonswitchON (ll).
2. Measurethe voltagebetween
terminals Bl and 822 and
b e t w e e nt e r m i n a l s B 9 a n d
820.
ls there batteryvoltage?
To page14-289
14-2AA
Ropairop€n or short in tho wire
b€tween the Bl and/or B!| tarminds and the PGM-FImain .ohy,
and between tho PGM-FImain
relay and the under-hood fuso/
r€lav box.
LGlIARN/BLK)
LG2IBRN/BLKI
Frompage14-289
PCMCONNECTORS
D {16P1
1
MsaaureD IND Volt.ge:
1. Turnthe ignitionswitchOFF.
2. Connecttho B (25Plconnector
to the PCM.
3. Connecta digital multimeter
to the D14and 820 or 822termtnals.
il. Turn the ignition switch ON
(lll, and makesure that voltage
is availablefor two seconds
2
3
r s 1 / 7I
2
nn fT /fl
o lzlzz ,rl/zs
1
5
l 1 12
6
9 10
1311
- -T---=4'+:l
LG2IBRN/BLKI\=/
(BRN/BI.X)
Check for open in the wire
between tha D14 terminal rnd
the gauge a33emblY.lf wiro ia
OK, chock for . frulty indicator
light bulb or a Iaulty gaug.
a3r6mblyprintod circuit board.
|
D4 IND (GRN/BLK}
Wiresideof femaleterminals
r l z3
5
6 i / l / t0 1112
CheckD IND for a Short Circuit:
Checklor continuitYbetweenthe
D14terminaland body ground.
l0
D' INDIGRN/BLKI
o
Rgpair3hort in the wire b.tween
the D14 tcrminal and tho gauge
a*somblY.
Checkfor loose terminsl fh in the
PCM connectors Check tho A/T
goar posilion switch. It neces'
saiy, iubstitute a known_good
PCMrnd rochock.
4-289
('gg- 00 Models)
ElectricalTroubleshooting
TroubleshootingFlowchart- E IndicatorLight On Constantly
The E indicator light is on constantly {not blinkingl whenever
the ignition switch is ON lll|.
FCM CONNCCTOR
D tl6PI
Mersure D IND Voltage:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ct th e D ( 1 6 P )c o n nectorfrom the PCM.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the 014terminaa
l ndbody
ground,
2 3
5
t0
12
tsll /
rc
II D4rND(GRN/BLK)
o
Repairshort to power in tho wire
bstween the Dl4 termin.l snd
the gaug€ r3sembly.
MeasureATP DVoltage:
1. Turnthe ignitionswitchOFF.
2 . C o n n e ctth e D ( 1 6 P ic o n n e c tor to the PCM.
3. Turnthe ignitionswitchON lll).
4. Shiftto any positionotherthan
I
6 1
Wiresideof femaleterminals
rcM CONNECTOR
A I32PI
ATP Dil {YELI
E,
5. lMeasure
the voltagebetween
t h e 4 7 t e r m i n a la n d b o d y
ground.
ls thereapprox.10V?
Test the A/T gear position switch
{seesection23).
Checkfor a shorl lo ground in
the wire between tho A7 terminal and A/T ge.r polition switch.
l, wire is OK, substitute a knowngood PCMand recheck.
14-290
Wire sideof lemaleterminals
Solenoid
LinearSolenoids/lnhibitor
)
Test
1.
Disconnectthe 8P connectorfrom the solenoidharnessconnector.
7.
lf all ot the resistancesare within the standard,a
c l i c k i n gs o u n d s h o u l db e h e a r dw h e n c o n n e c t r n g
the battervterminalsto the solenoidharnessconnectorterminalsbelow:
Shift control linear solsnoid
No.3: BattervPositiveterminal
No. 7: Batterynegativeterminal
PH-PLcontrol linear solenoid
No.2: Battervoositiveterminal
No. 6: Bafterynegativeterminal
Start clutch control linear solenoid
No. 4: BatteryPositiveterminal
No.8: Batterynegativeterminal
lnhibitor solsnoid
No,5: BattervPositiveterminal
Body ground:Batterynegativetermrnal
HARNESS
SOLENOID
CONNECTOR
SOLENOIDHARNESSCONNECTOR
ATF OIPSTICK
Terminalsideof maleterminals
Measurethe resistanceof the shift control linear
solenoidbetweenthe No. 3 and No. 7 terminalsof
the solenoidharnessconnector.
Measurethe resistanceof the PH-PLcontrol linear
solenoidbetweenthe No. 2 and No. 6 terminals
l f n o c l i c k i n gs o u n d i s h e a r d , r e p l a c et h e l o w e r
valvebody assemblY,
NOTE: lf the lower valve body assemblyreplacement is required,see Lower Valve Body Assembly
(page14-302).
Replacement
Measurethe resistanceof the start clutch control
linearsolenoidbetweenthe No 4 and No. 8 terminats,
STANDARD:38-6.8O
M e a s u r et h e r e s i s t a n c eo f t h e i n h i b i t o rs o l e n o i d
betweenthe No. 5 terminaland body ground
2 1 . 0O
S T A N D A R D : 1 1-. 7
R e p l a c et h e l o w e r v a l v e b o d y a s s e m b l y i f a n y
is not within its standard.
solenoidresistance
14-291
DrivePulley/DrivenPulley/Secondary
GearShaft Speed
Sensors
Replacement
CAUTION: While replacingthe speed sensor,be sure not to allow dust and other foreign parliclos to enter into the transmission.
'1.
Disconnect
the connectorsfor the drive pulley,the drivenpulley,and the secondarygear shaftspeedsensor.
2.
Removethe 6 mm bolt from the transmissionhousing,and removethe drive pulley.the driven pulley,and the secondarygearshaftspeedsensors.
3.
Replacethe O-ringsbeforereinstallingthe drive pulley,the driven pulley,and the secondarygear shaft sp€edsensors.
6x1.0mm
12 N.m (1.2kgf.m,8.7 lbf.ft)
DRIVENPULLEYSPEEDSENSOB
6x1.0mm
12 N.m (1.2kgt.m,
8.7 tbf.ft)
14-292
@
Start ClutchControl
T
Start ClutchCalibrationProcedure
Shift into E o|. E position.To store the engine
negativepressurein memory.Iet the engine idle in
E or E positionfor one minute underthe following conditions:
NOTE:When the following parts are replaced,the TCM
must memorizethe feedbacksignalfor the start clutch
control.
. TCM
. Transmissionassembly
. Stan clutchassembly
. Lowervalvebodv assembly
. Engineassemblyor overhaul
. With the brakepedaldepressed,
. with the y'\/cswitch oFF.
. With the combinationlight switchOFF.
. With the heaterfan switchOFF.
. Turn OFFall otherelectricalsystems
'96 Model Only
NOTE: Start step 5 within 60 secondsafter the radiator fan goes off.
CAUTION: Do not uso this procsdure on'97 - (X)mod'97 - 00
els or you will damage the transmission. On
models, the TCM or PCM memorizes ths loodback sig'
nals when you drive the vehicle.
1.
2.
rl ,
E n g a g et h e p a r k i n g b r a k e , a n d b l o c k t h e f r o n t
wheelssecurely.
Connectthe SCS serviceconnectorto the Service
C h e c kC o n n e c t o ra s s h o w n . ( T h e S e r v i c eC h e c k
connector (2P) is located under the dash on the
passenger's
sideof the vehicle.)
Shift into E position,and let the engineidle for two
minutes to store the feedbacksignal in memory
underthe sameconditionsas in step5.
7.
Connectthe HondaPGMTester.Checkthat the TCM
hascompletedthe startclutchcalibration.
NOTE:
. The TCM will not storethe feedbacksignalwhen
the CVT fluid temperatureis below 40"C(104'F)
even if the engine coolanttemperaturereaches
the normaloperatingtemperature.
. Repeatthese proceduresuntil the start clutch
calibrationis completedD i s c o n n e c t h e S C S s e r v i c ec o n n e c t o rf r o m t h e
ServiceCheckConnector.
'97 - 00 Models
The TCM ('97- 98 models)and PCM('99- 00 models)
memorizethe feedbacksignal when you drive the
vehicleas follows:
CONNECTOR
I2PI
CONNECTOR
07PAZ- lDl01(xt
Startthe engine,and warm it up to normal operating temperature(the radiatorfan comeson twice).
After warming up the engine (the radiator fan
comesonl.
. Shift into E position.
. Turn OFFall electricalsystems,
. Drive the vehicle up to the speed 37 mph (60
km/h).
. A f t e r t h e s p e e d r e a c h e s3 7 m p h ( 6 0 k m / h ) ,
releasethe acceleratorfor 5 seconds.
.
for 20
Fullydepressthe brakepedaland accelerator
secondsin the E] position.
14-293
Symptom-to-Component
Chart
HydraulicSystem
SYMPTOM
Engineruns,but vehicledoes not move in any position.
Vehicledoes not move in @, [. p positions.
Checktheseitemson the PBOBABLE
CAUSEList
't,2,3,4,5,6,7,8,9,
1 0 ,2 0 ,3 4 ,3 5 ,3 6 ,3 8 ,4 1
Vehicledoes not move in E position.
1 0 ,1 1 ,1 2 ,2 0 ,4 1
5, 'to,11, 12,17,1A,19,20,39,41
No shift to higherratio,
9 , 1 3 ,1 4 .1 5 ,1 6 , 3 5 , 3 7 , 4 0
Pooracceleration.
9, 13,' t4,'t5,16.20,35,37, 38, 40
Flareson moving.
9,'t0,20,2't,35,36,38,40,42
Excessive
shockwhen depressingand releasing
.^^alA/.r^r
^A.1. I
9, 10, 20, 2'1,35, 36, 3A,42
N o e n g i n eb r a k i n g .
9,20,21,35,36,38
Vehicledoes not accelerate
in lll position.
9, 17, 18,19,20. 35,36,38
Vehiclemovesin E position.
(Shiftcableadjustmentis proper).
1 0 ,2 2 , 2 3
Lateshiftfrom N positionto E position,and from E
positionto E position.
'10,1 1 ,1 2 , 2 24, 1
Lateshift from E positionto E position.and from E
positionto N position.
1 l , ' t 2 , 1 7 ,1 8 , 2 2 4
,1
Enginestopswhen shiftedto E positionfrom E position.
9, 10,20,35,37,34,
42
Enginestopswhen shiftedto E positionfrom I
Noisefrom transmissionin @ position.rl
9, 18,19,20,25,26,35,37,38,42
5, 17, 18,'t9,25,26
Excessive
idle vibration.
2,3,4,21,24
Noisefrom transmissionin @ and @ positions.
2,3,19,24,25,2A
Huntingenginespeed.
16,35,37,38
Vibrationin all position.
8, 2a
Shift leverdoes not operatesmoothly.
11,29,4'l
Transmission
will not shift into lll positionor transmission cannotbe removedfrom E position.
11, 29,30, 31,32,33
Vehicledoes not accelerate
to more than a certainspeed.
9 , 1 0 ,1 4 ,1 5 , ' t 6 , 2 0 , 3 5 , 3 7
Excessive
shockon startingoff.
38,42
Flareson accelerating
at low speed.
20,21,38, 42
Excessive
vibration
in E, E, tr, E positions.
Lowenginespeedin E. E. tr. E positions.
20,21,38,42
20,21,38,42
Stall speed high.
10,20,38
Stallspeedlow.
9, 20,27,37, 38
position.
Judderon startingoff.
20,43
*1: Somegear noiseis normalin the Lll positiondue to planetarygearaction.
14-294
t .
CAUSELIST
PROBABLE
Low CVTfluid level
ATF pump worn. AT gearsworn or damaged.Foreignmaterialin ATF pump.
ATF pump chain/ATFpump sprocketworn or damaged.
Inputshaftworn or damaged.
5
S u ng e a rw o r n o r d a m a g e d .
6
Finaldrivenoearworn or damaqed,
1
drivengearworn or damagedSecondarydrive gear/secondary
8
plateworn or damaged.
Flywheel/drive
housingassemblyworn or damaged.
Intermediate
9
'10
Forwardclutchdefective.
1'r
Shift cablebroken/outof adiustment.
't2
M"nu"t
t"uffi
13
ATFfeed pipe (pulleypressure)worn or damaged.
14
Vchiclcspeedsensordefective.
16
'11
rl,
TCM or PCMdefective.
Reversebrakedetective.
'18
1q
Planetarygearworn or damaged.
20
t't
Start clutchdefective.
ATFfeed pipe (startclutchpressure)worn or damaged
23
brakeclearanceincorrect.
Clutchclearance/reverse
worn or damaged
Reversebrakereturnspring/retainer
24
25
Needlebearingon input shaftworn or damaged.
Thrustneedlebearingon carrierworn or damaged.
Thrustwasheron carrierworn or damaged.
27
Enoine outout low.-----------------------Flvwhcelassemblvdefective.
29
30
Controlleverworn or damaged.
Parkpawl/parkpawl shaftworn or damaged
Detentlever/parkbrakerod assemblyworn or damaged
32
Parkgearworn or damaged.
33
Parkpawl springworn or damaged.
34
filter clogged.
ATFstrainer/ATF
50
Lower valve body assemblydefective.
Lowervalvebodv assemblvdefective(PLregulatorvalvebody assemblydefective)'
Lowervalvebodv assemblydefective(shiftvalvebody assemblydefective).
Lowervalve bodv assemblvdefective(startclutchcontrolvalvebody assemblydefective)'
fl,
39
Lowervalve bodv assemblvdefective{inhibitorsolenoiddefective}
40
Solenoidharnessworn or damaged.
41
Manualvalvebody worn or damaged.
PBfeedbacksystem defective.
43
CVTfluid deteriorated.
14-295
RoadTest
NOTE:Warm up the engineto normaloperatingtemperature(the radiatorfan com6son).
1.
Apply the parkingbrakeand blockthe wheels.Start the engine,then shift to the E positionwhile depressingthe
pedaland releaseit suddenly.The engineshouldnot stall.
brakepedal.Depressthe accelerator
2.
Testin E position
Parkthe vehiclein a slope (approx.16'). apply the parkingbrake,and shift into E position.Releasethe brake;the
vehicleshouldnot move.
3.
Test-drivethe vehicleon a flat road in the positionshown in the table.Checkthat the enginespeedsmeetthe approximatevehiclespeedsshown in the table.
NOTE: Throttle position sensor voltage representsthe throttle opening. To monitor the throttle position sensor voltage,useone of the followingmethods:
A. Connectthe HondaPGMTester,and go to the PGM-FIDataList.
OBDll SCANTOOLor
HONOAPGMTESTER
A
1
For road testing on '96 - 98 models, remove the drive/s side kick panel to exposethe TCM; on '99 - OOmodels,
removethe passenger'sside kick panel to exposethe PCM (see page l,[-236),
Set the digital multimeter to checkthrottle position sensor voltage betweenterminals:
. '96 - 98 modols: TCM 84 {+} and Aa (-) or A17 (-1.
. '99 - 0Omodels: FCM C27 {+l and 820 (-l ot 822 l-1.
DIGITALMULTIMETER
(Commerci.llyrvrilabl.l
KS-AHM-32-003
or oquivalant
BACKPROBE
ADAPTER
'96 - 98 Models:
BRN/BLK
D{16Pt
A {26P1
TPS {BED/BLK}
BRN/BLK
Wire side of female terminals
14-296
Waresideot femaleterminals
o @ position: EnginoSpeed rPm
VehicloSpeed
Throttle Opening
25 mph l/() km/h)
|
37 mph {60km/h)
| 62 mph {100km/h}
Throttlepositionsensorvoltage:0.75V
1,250- 1,650
Throttlepositionsensorvoltage:2'25V
Throttlepositionsensorvoltage;4 5 V
Fullthrottleposition
2,500- 3,100
2,650- 3,250
2,700- 3,300
3,950- 4,550
4,650- 5,250
5,200- 5,800
o $l position:EngineSpeedrPm
VehicleSpoed
Throttle Oponing
Throttlepositionsensorvoltage:0.75V
ThrottleDositionsensorvoltage:2.25V
Throftlepositionsensorvoltage:4.5v
Fullthroftleposition
2s mph(40km/hl
- 2,200
1,800
|
37 mph(60km/hl
2,200- 2,800
| 62 mph{r00km/h}
2,950- 3.550
3,250- 3,850
3,550- 4,150
4,050- 4,650
4,100- 4,700
5,100- 5,700
5,900- 6,500
o E position: Engin€Sp6ed rPm
Vehiclo Spoed
Throttle Oponing
25 mph (40km/hl
|
37mPh{60km/h)
ThrottleDositionsensorvoltage:0.75V
Throttlepositionsensorvoltage;2.25V
3,100- 3,700
3,500- 4,100
3,650- 4,250
4,050- 4,650
Throttlepositionsensorvoltage:4.5V
Fullthrottleposition
4,100- 4,700
5,100- 5.700
J 62 mph 1100km/h}
4,450- 5,050
4,800- 5,400
5,900- 6,500
14-297
Stall Speed
Test
CAUTION:
. To prevent transmission damage,do not test stall sp€€d for mole than 10 secondsat a time.
. Do not shift the lsver whils raising the engine speod.
. Be sure lo remove the pressuregauge before tosting stall speed.
. Stall speed tssts should be used tor diagnostic purposesonly,
1.
Engagethe parkingbrake,and blockthe tront wheels.
2.
Connecta tachometerto the engine,and stan the engine.
3.
Makesurethe A/C switchis OFF.
4.
After the enginehaswarmed up to normaloperatingtemperature(the radiatorfan comeson), shift into E position.
5.
Fullydepressthe brakepedaland accelerator
for 6 to 8 seconds,and note enginespeed,
6.
Allow two minutesfor cooling,then repeatthe test in E, E, and E positions.
Stall SpeedBPM in E poshion:
Specification:2,500rpm
Servic€Limit: 2,350- 2.650rpm
Stall Speed RPM in E, E and E positions:
Specitication:3,000rpm
ServiceLimit: 2,800- 3,100rpm
TROUBLE
Stallrpm high in @. p. [, and @ positions
Stallrpm high in E position
Stallrpm low in E, P, [, and @ positions
14-294
PROBABLECAUSE
Low fluid levelor ATF pump output
CloggedATF strain€r
PH regulatorvalve stuck closed
Slippageof forwardclutch
Faultystartclutch
. Slippageof reversebrake
. Faultystartclutch
Engineoutput low
Faultystan clutch
Stuckshiftvalve
FluidLevel
l .
Checking/Changing
CAUTION: while chscking and changing, be sure not to
allow dust and other toreign particles to ent€l inlo the
transmission.
Changing
1.
Bringthe transmissionup to normaloperatingtemperature(the radiatorfan comeson) by driving the
vehicle.Parkthe vehicleon the level ground, and
turn off the engine.
2.
Bemovethe drain plug,and drainthe CVTfluid.
Checking
NOTE: Checkthe fluid level with the engine at normal
operatingtemperature(theradiatorfan comeson).
' 1 . P a r kt h e v e h i c l eo n t h e l e v e lg r o u n d .T u r n o f t t h e
engrne.
2.
Removethe dipstick(yellow loop) from the transmission,and wipe lt with a cleancloth.
NOTE: Checkthe transmissionfluid 50 to 90 seconds aftershuttingoff the engine.
3.
Insertthe diDstickinto the transmission.
DIPSTICK(YELLOWLOOPI
NOTE| lf a coolerflusheris to be used,see page14352and 14-353.
Reinstallthe drain plug with a new sealingwasher,
t h e n r e f i l l t h e t r a n s m i s s i o nw i t h G e n u i n eH o n d a
CVTFluidto the uppermarkon the dipstick.
Automatic TransmissionFluid CaPacity:
3.9 i (4.r US qt. 3.4 lmp qt) 8t chlnging
6.4 I (6.8 US qt, 5.6 lmp qt) 8t ov€lhaul
RscommendedAutomatic TransmissionFluid:
GenuineHonda CVT FluidUse GenuineHondaCW fluid only. Usingotherflui d s c a n a f f e c t t r a n s m i s s i o no p e r a t i o n a n d m a y
reducetransmissionliJe.
R e m o v et h e d i p s t i c ka n d c h e c kt h e f l u i d l e v e l .
shouldbe betweenthe uDDerand lower mark.
DIPSTICK
5.
6.
lf the level is below the lower mark, add fluid into
t h e f i l l e r h o l e t o b r i n g i t t o t h e u p p e r m a r k .U s e
G e n u i n eH o n d aC W F l u i do n l y .
Insertthe dipstickinto the transmission.
ChangeInterval:
Normal Condition: 30, 000 miles 148,000km)
SevereCondition: 30,000 miles (48,000km), but it
you drive at high sPeedsin high
t90"F (32'C) and abovol temperatures, the ttansmission fluid
should be changed evsrY 15,000
miles 124,000km).
{-]lr
ORAINPLUG
18 x 1.5mm
a9 N.7n(5.0kgl.m, 36 lb{'ftl
SEALINGWASHER
Replace.
14-299
PressureTesting
.
.
While testing, be careful of the rot8ling front wheels.
M8k6 suro lifts, iacks, and satety stands are placed properly lsee section 11.
CAUTION:
. Beforetesting, be sur. the transmb3ion fluid is fillod to the propor lcvel.
. Warm up the engin€ to nolmal operating tsmperature bofore testing
. While t€sting, be 3ure not to allow dust and other loreign particles to onler into the transmi$ion.
1.
Raisethe front of the vehicle,and supportit with safetystands(seesection1).
2.
Setthe parkingbrake.and blockboth rearwheelssecurely.
3.
Allow the front wheels to rotate freely.
4.
Warm up the engine(the radiatorfan comeson),then stop aridconnecta tachometer.
5.
Connectthe specialtool to eachinspectionhole.
TOROUE:18 N.m (1.8 kgt'm, 13 tbtfr)
GAUTION:
. Connectthe oil pressurogauge !!€curoly,bs sur6 not to allow dust and other foroign particlG3to ontar the inspsction hole.
. Whon troubleshooting by tho E indicltor light indic.t6 a problam. you mu3t u3e an oil p.essure gluge that moa,
sures 4,9(X)kPa (a.90MPa,50.0 kS cr*,771psi) or more when molsuring driv. pulley pressureand driven pullcy
pre33ure.
NOTE:
. D.ive pulley pressuremay be above 3,430kPa (3.i8 MPa,35.0 kgf/cmr,498 psi) wh€n there is a transmissionproblem that causesthe TCM or PCMto go into the fail-safemode,
. Use a commerciallyavailableoil pressuregauge that measures4,900kPa {4.90MPa, 5O.Okgf/cmr,711 psi) or
more,and the Ay'TOil PressureHose,2210mm (07MAJ- PY4011A).
A/T OIL PRESSURE
GAUGE
SETW/PANEL
0ta{r6 - oO2Oi|(Xt
A/T LOW PRESSURE
GAUGEW/PANEL
0706 - qt7o:t{ro
FORWARDCLUTCHPRESSURE
INSPECTION
"F")
lMarkedwith
DRIVEPULLEYPRESSURE
INSPECTIONHOI.E
(Markedwith "DR")
A/T PRESSUBE
HOSE
2210mm
07MAJ- PYitollA
la R.quir.d)
A/T PRESSURE
HOSE
ADAPTER
07MAJ- PYar'120
lil R.qulr.d)
REVERSE
BRAKEPRESSURE
INSPECTION
I.IOLE
(
ATF DIPSTICK
INSPECTION
HOLE
(Markedwith "LUB")
14-3 0 0
DRIVENPULLEYPRESSURE
INSPECTION
HOLE
lMarkedwith "DN")
CLUICH PRESSURE
INSPECNONHOLE
(Markedwith "SC")
Startthe engine.
pressuresat 1'500rpm'
1 . Shiftto the respectiveshift leverpositionsin the table,and measurethe following
.
.
.
.
ForwardClutchPressure
ReverseBrakePressure
DrivePulleyPressure
DrivenPulleyPressure
8. Shiftto E posltion,and measurethe lubricationpressureat 3,000rpm'
SHIFTLEVER
PBESSURE POSmON
Forward
Clutch
Reverse
Brake
Drive
Pulley
FLUIDPRESSURE
SYMP{OM
Lubrication
Standard/SsrviceLimit
E
No or low forward clutch
pressure
ForwardClutch
1 . 4- 1 . 7 5M P a
(14.3- 17.8kgtcm' , 203- 253Psi)
ts
No or low
reversebrake
pressure
ReverseBrake
1 . 4- 1 . 7 5M P a
(14.3- '17.8kg7cm' ,203- 253Psi)
N
No or low
drive pulley
pressure
ATF pump, PH regulatorvalve,PL
regulatorvalve,
Shiftvalve
0.2- 0.7 MPa
(2 - 7.1 kgflcm' ,28 - 101Psi)
Drivepulley
pressure
roo
PH regulatorvalve,
PL regulatorvalve,
Shift valve.Shift
controllinear
solenoid
high
Driven
Pulley
PROBABLECAUSE
No or low
drivenpulley
pressure
ATF pump, PH regulatorvalve,Shift
valve,Shift control
linearsolenoid
Drivenpulley
pressuretoo
hi g h
PH regulatorvalve
No or low
lubrication
pressure
ATF pump,
Lubricationvalve
1 . 5- 2 . 3M P a
(15.3- 23.5kg?cm' ,218- 334 Psi)
Above0.2 MPa
(Above 2 kgf/cm'. 30 Psi)
the specialtool afterpressuretestlng
9 . Disconnect
the bolts to the specified
1 0 . Installthe sealing boits in the jnspectionholes with new sealingwashers,and tighten
toroue.
TOROUE:18 N.m {1.8 kgf'm, 13 lbf'ft}
CAUTION: Keepall foreign particles out of the transmission'
14-301
LowerValveBodyAssembly
Replacement
Make sure lifts, iacks, and saf€ty stands
@
are placsd prop€rly {seasection 1).
CAUTION: While removing and installing th6 lower
valve body asssmbly, b€ sule not to allow dust and
other for€ign particlesto entsr inio the transmksion.
1.
2.
Raisethe front of the vehicle,and support it with
safetvstands(seesection1).
Set the parking brake,and block both rear wheels
securetv.
7.
8.
9.
10.
1l.
Removethe ATFcooleroutlet line.
Removethe ATFcoolerline bracketbolt.
Removethe ATF pan (fourteen bolts).
Removethe ATF strainer(two bolts).
Removethe one bolt securingthe solenoidharness
connector,
1 2 . R e m o v et h e l o w e r v a l v e b o d y a s s e m b l y( e i g h t
bolts).
LINEBOLT
SEALING
Replace.
28 N.m (2.9kgtm,21 lbtft)
ATF COOI.-ER
OUTLET
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher
(seepage 1+299).
O.RING
Feplace.
CAUTION: Keop all of other toreign parliclos out of
the transmission.
4.
the 8P connectorfrom the solenoidharDisconnect
ness connector.
Remove the ATF cooler hoses at the ATF cooler
lines.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
coolernoses.
SOLENOIOHARNESS
CONNECTOR
OOWELPIN
O.RING
ATF
Replace.
STNAINER
CAUTION: Keep all of other foroign particlo3out of
tho transmission.
6.
6x1.0mm
12 N.m 11.2kgt m,
E.7 tbt'ft)
OOWELNN
RIGHTFRONT
MOUNT/BRACKET
ATF COOLERLINE
10x 1.25mm
sil N.m 15.5kgf.m,
40 rbr.ft)
ATF COOLERHOSE
14-302
VALVE
BODYASSEMBLY
6x1.0mm
12 N.m 11.2kgf.m,
8.7 rbf.ft)
Removethe right front mounvbracket.
10 x 1.25mm
ila N.m (,1.5kgf.m,33 lbtft)
5x1.0mm
12 N.m 11.2kgt.m,
8.7 tbt.ftl
ATF PAN
ATF PAN GASKET
Replace.
ATF COOLERINLET
UNE BRACKETBOLT
8 x 1,25mm
26 N.m {2.7 kgf.m,
20 tbf.frl
x 1.0mm
12 N.m 11.2kgf.m,E.7lbf.ftl
1 3 . Install the new lower valve bodv in the reverse
ordgrof the removalorocedure.
CAUTION: Koep all ot other fo.oign particles out of
ths transmission.
NOTE:
. Replacethe followingparts:
- O - r i n g so n t h e s o l e n o i dh a r n e s sc o n n e c t o r
and the ATFstrainer
- ATF pan gasket
- Sealingwashers
. l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r
warped,put it backto the originalposition.
1 4 . Perform the start clutch calibrationorocedureon
page14-293.
ATFFilter
l .
Removal/lnstallation
Make sure lifts, lEcks, snd safoty stands
!@
ara pl8ced properly {saesection 1).
CAUTION: While removing and installing the ATF tilier,
be sure not to allow dust or other for6ign particle3 to
enter thg transmission.
1.
Raisethe front of the vehicle,and support it with
safetystands(seesection1).
2.
Set the parking brake,and block both rear wheels
securely.
3.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h e C V T f l u i d .
Reinstallthe drain plug with a new sealingwasher
{seepage 14-299).
CAUTION: Keep all toreign particles out ot the
transmission.
Removethe ATF cooleroutletline.
Removethe ATF coolerline bracketbolt.
Removethe ATF pan (fourteen bolts)
Removethe ATF cooler inlet line from the ATF pan
(threebolts).
10. Removethe ATFfilter,and cleanit.
11. Checkthat the ATFfilter is in good condition.
12. Replacethe ATFfilter if it is clogged.
6.
7.
8.
9.
LINEBOLT
28 N.m {2.9 kgf.m,21 lbt.ft)
ATF COO1TROUTIET
6x1.0mm
12 N m (1.2kgf m,
ATF COOLERINI-ET
LINEERACKETBOLT
8 x 1.25mm
26 N.m (2.7kgt.m,
20rbtftt
Remove the ATF cooler hoses at the ATF cooler
lines.Turn the ends of the ATF cooler hosesup to
preventATF from flowing out, then plug the ATF
coolernoses.
fl,
CAUTION: Keep all foreign particles out of the
transmission.
O.RING
Replace.
ATF FILTER
5.
Removethe rightfront mounvbracket.
10 x 1.25mm
4{ N.m {i1.5kgf.m,33 lbf ft)
ATF
GASKET
Replace.
ATF PAN
ATF COOLERLINE
6x1.0mm
12 N.m (1.2 kgt'm,8.7 lbl'ft)
'13. l n s t a l lt h e A T F f i l t e r i n t h e r e v e r s eo r d e r o f t h e
removalprocedure.
10 x 1.25mm
54 N.m {5.5 kgt'm,
40 rbl.ft)
(|'t
ATF COOLERHOSE
GAUTION: Keep all foreign particles out ot the
transmission,
NOTE:
R e p l a c et h e O - r i n g s ,t h e A T F p a n g a s k e ta n d
sealingwashers.
l f t h e A T F c o o l e r i n l e t l i n e b r a c k e ti s b e n t o r
warped.put it backto the originalposition
14-303
Transmission
Removal
@
. Mako
.
4,
suro lifts. iacks, and satety stands are placod
properly, and hoi3t bracket are attached to lhe correct position on the engine {seesoction 1}.
Apply parking brake and block r€ar wheels so tha
vehicle will not roll off stands and fall on you while
working undor it.
Disconnect
the solenoidharnessconnector,
the drive
pulleyspeedsensorconnector,and the groundcable
terminals.
GROUNDCABLE
GROUNDCAELE
CAUTION:Use tender coversto avoid damaging painted
surfaces.
1.
Disconnectthe battery negative(-) terminal from
the battery,then removethe positive(+)terminal.
Removethe intakeair duct and air cleanerhousing
assembly.
3.
Removethe starter cables and cable holder from
the starter motor.
DRIVEPULI.-EY
SPEEDSENSOR
CONNECTOR
STARTERMOTOR
SOLENOIOHARNESS
CONNECTOR
Removethe clip, then separatethe shift cablefrom
the controllever,
CAUTION: Take care not to bend the shift cable.
S}IIFT CABLE
WASHER
WASHER
STARTERCABLE
CONTROLLEVER
14-304
I
6.
Disconnectthe vehiclespeedsensor(VSS)connector, the driven pulley speed sensorconnector,and
the secondarygearshaftspeedsensorconnector.
GEAR
SECONDARY
SHAFTSPEED
SENSOR
8.
R e m o v et h e d r a i n p l u g , a n d d r a i n t h € C V Tf l u i d
Reinstallthe drain plug with a new sealingwasher.
CAUTION:While installing the drain plug' bo 3ur.
nol io allow du3l 8nd other toreign particles to
enter into th€ trsnsmi$ion.
ORIVENPULLEY
SPEEDSENSOR
CONNECTOR
DRAINPLUG
18 x 1.5rnm
(, N.m (5.0 kgfm, 36 lbf'ft|
7.
SEALINGWASHER
Replaco.
Removethe transmissionhousingmountingbolts.
9.
Removethe splashshield.
14-305
Transmission
Removal(cont'd)
10. Removethe cotte. pins and castlenuts,then separate
the balljointsfrom the lowerarm (seesection1g).
-=V,
SELF-LOCKING
\
NUT
\
CASTLEI{UT COTTER
Replace.
oitupea rOax
Replac6.
'16,
Removethe rightfront mounvbracket,
/\<,\
't1. Remove
the right damper fork bolt, then separate
right damperfork and damper.
't2. Pry the right
and left driveshaftsout of the differen-
ATFCOOLER
HOSE
17. Remove the ATF cooler hoses at the ATF cooler
lines.Turn the ends of the ATF cooler hosesuo to
preventCVT fluid from flowing out, then plug the
ATF coolerhosesand lines,
tial.
tJ.
Pullon the inboardjoint to removethe right and left
driveshafts(seesection16).
1 4 . Tie plasticbagsoverthe driveshaftends.
NOTE: Checkfor any sign of leakageat the hose
joints.
18. Removethe engine stiffenersand the flywheel cover.
NOTE:Coatall precisionfinishedsurfaceswith clean
e n g i n eo i l .
Removethe exhaustpipe A.
q.
SELF.LOCKING
NUT
Replace.
SELF.LOCKING
NUT
Replace.
14- 3 0 6
EXHAUSTPIPEA
ENGINESTIFFENER
1 9 . Removethe eight drive plateboltsone at time while
rotatingthe crankshaftpullev.
Removethe distributor'
2 3 . R e m o v et h e t r a n s m i s s i o nh o u s i n gm o u n t i n gb o l t
and rearenginemountingbolts
Atach a hoistingbracketto the engine,then lift the
e n g i n es l i g h t l y .
REARENGINEMOUNTING
TRANSMISSIONHOUSING
MOUNTINGBOLT
WASI{ER
22. Placea iack under the transmission.and raisethe
transmissionjust enoughto take weight off of the
mountbracket
mounts,thenremovethe transmission
Pull the transmissionaway from the engine until it
clearsthe l4 mm dowel pins, then lower it on the
transmissionjack
MOUNT
TRANSMISSION
TRANSMISSIONMOUNT
14-307
lllustratedIndex
Transmission/Lower
ValveBodyAssembly
14-3 0 8
O ATF DIPSTICK
O o-RINGReplace.
.' SOLENOIDHARNESSCONNECTOR
@ LOWERVALVEBODYASSEMBLY
O DOWELPIN
O LINEBOLT
.i ATTfCOOUR IruIETLINEB8ACKETBOLT
€] lrr cooua truler LINEASSEMBLY
O SEALINGWASHERRePIACE'
G, ATF COOLEROUTLETPIPE
6) o-RINGReplace.
@ ATF FILTER
fO o-RINGReplace.
@ ATF PAN
(3 DOWELPIN
(D O-RINGReplace.
E) ATF STRAINER
@ ATF MAGNET
(9 ATF PAN GASKETRePIACE'
O ATF MAGNET
€t oRAIN PLUG
@ SEALINGwAStlER Replace.
TOROUESPECIFICATIONS
Bolt/Nut No.
Torque Value
Size
8F
12J
18D
12 N.m {1.2kgf m, 8.7 lbf'ft}
26 N.m (2.7kgim,20 lbf'ft)
28 N.m (2.9kgf'm,21lbf'ft)
49 N.m (5.0 kgf'm, 36 lbf'ft)
6x1.0mm
8 x 1 . 2 5m m
1 2x 1 . 2 5m m
1 8x 1 . 5m m
Remarks
Linebolt
Drainplug
14-309
lllustratedIndex
Transmission
Housing/Flywheel
Housing
8G
I
)
H
14-310
C
e)
.'
O
6
O-RINGReplace.
OIL SEALRePlace
HOUSING
FLYWHEEL
flVWneel }|OUSttttGGASKETReplace
DIFFERENTTALASSEMELY
@lrr plsslce uruEASSEMBLY
Replace
O O-RING
PIN
@ DOWEL
€) ATFPUMPASSEMBLY
(ODowELPlN,18x 10mm
Replace.
O O-RING
o DowELPlN,22x 10mm
lrr puup oRve cxltttt
iA SNAPRING
part
f3 fxaUst St|t|l, zz t 28 mm Selective
Gtlrr punpontvespaocxer
O PITOTFLANGE
HUB
ontveSPRoGKET
itonTFpurrap
(O THRUSTWASHERS
@ PITOTPIPEBRACKET
PIPE
O PITOTLUBRICATION
@ PITOTPIPE
t3 OIL SEALReplace.
OaSEt AtitC, SOmm SelectivePart
ASSEMBLY
o3lrr passlce ltnE HoLOER
6) o-RING Replace.
€) STARTCLUTCHATF FEEDPIPE
COO-RINGReplace.
€I FEEOPIPEFLANGE
@ SNAPRING
BRACKET
O' CONNECTOR
@ BALLBEARING
6} SNAPRING
64 COTTERRETAINER
6DCoTTERS,25.5mm selectivePart
6t stlnt cLutcHasseMsLv
ASSEMBLY
@secoruomvontvEGEAR
@ o-RINGSReplace
COVER
6) DIFFERENTIAL
rO ttaUSr SntU, zs t 35 mm Selectivepart
GEARSHAFT
@ SECONDARY
@ PARKPAWLSHAFT
@ PARKPAWLSPRING
.1i PARK PAWL
@ TONGUEDWASHERREPIACE,
@ PARKROOHOLDER
@ BALLBEARING
@ o-RINGReplace.
@ VEHICLESPEEDSENSOR
@ OIL SEALReplace.
TOROUESPECIFICATIONS
12 N.m (1.2kgnm,8.7lbf'ft)
22 N.m (2.2kgf'm.16lbf'ft)
26 N.m (2.7 kgf'm, 20 lbf'ft)
29 N.m {3.0 kgf'm, 22 lbift)
6x1.0mm
8 x 1 . 2 5m m
8 x 1 . 2 5m m
8 x 1 . 2 5m m
ft,
14-311
lllustratedIndex
RightSideCover/lntermediate
Housing
88
I
.Fi.
O ENDCOVER
O ATF FEEDPIPE
O DOWELPIN
@ O-RINGReplace.
G) FEEDPIPEFLANGE
@reeopperurucepuru
O] ROLLER
ASSEMBLY
XOUSING
O IruTENMEDNTE
sxlrr lsseugLv
aocorutnoL
ttoustt'tc
@tnlrusmtsstottt
@ SHIFTCABLEBRACKET
CAP
c) BREATHER
@ oll- SEALReplace.
LEVER
@ CONTROL
Replace.
G LoCKWASHER
sENsoR
(D secololaY ceaR SHAFTSPEED
o) onvel put-uv sPEEDSENSOR
Replace.
@ O-RING
(OSNAPRING
6 rnmrsutsstoru xouslNc oRlvENPULLEY
BEARING
SHAFTROLLER
REPIACE'
GASKET
@ ENDCOVER
Replace
@ o-RING
6omnruulL vnLVe goDYLINEA
64 MANUALVALVEBODYLINEB
Replace.
@ O-RING
SPRING
@ DETENT
O ATFFEEDPIPE
Replace.
@ O-RING
@ MANUALVALVEEODY
PIN
@ DOWEL
goDYSEPARAToR
PLATE
@ r'rllull valve
6DSNAPRING
@troRwlno cturcx ASSEMBLY
@ o-RINGReplace
@ SNAPRING
ASSEMBLY
o3spnlrucaetlrupn/RETURNSPRING
@ nevenseennr eBtottt
Feplace.
@ o-RING
@ SNAPRINGRE'AINER
@ ATFFEEDPIPE
.1,
Replace'
GASKET
HOUSING
6) TRANSMISSION
PIN
@ DOWEL
PIPE
@)ATFFEED
Replace.
@ o-RING
60o-RINGReplace.
SENSOR
SPEED
@)DRIVEPULLEY
HANGER
@ TRANSMISSION
@ SNAPRING
part
@ txaust Sxtfu,zs t 31mm selective
BEARING
SALL
@
6J RINGGEAR
6DSNAPRING
part
Selective
@ aevenseaRlxe rND PLATE
DISC
BRAKE
@ REVERSE
PLATE
BRAKE
@ REVERSE
@ DISCSPRING
WASHER
6} THNUST
eelnNc
@}finusr NeeoLr
WASHER
@ THRUST
ASSEMBLY
@ GARRIER
WASHER
@ THRUST
BEARING
NEEDLE
@ THRUST
@}SUNGEAR
RINGREPIACE'
@ SEALING
BEARING
@ NEEDLE
@ INPUTSHAFT
BEARING
@ NEEDLE
RINGFEPIACE'
@ SEALING
Replace'
RING{RUBBERI
@ SEALING
PIPE
@ ATFFEED
TOROUESPECIFICATIONS
6B
8B
8F
8G
12 N.m (1.2kgf'm,8.7lbf'ft)
14 N.m {1.4kgf'm,10 lbift)
37 N.m (3.8 kgf'm, 27 lbf'ft)
26 N.m (2.7kgf'm,20lbf'ft)
29 N.m (3.0 kgf'm, 22 lbf'ft)
6x1.0mm
6x1.0mm
8 x 1 . 2 5m m
8 x 1 . 2 5m m
8 x 1 . 2 5m m
rl,
14-313
TransmissionHousing/LowerValveBodyAssembty
Removal
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,
and dry with compressedair.
. Blow out all passages.
. When removingthe lowervalvebody,replacethe followingl
- O-rings
- ATF pan gasket
- Sealingwashers
O.RING
Replace.
SOLENOIOHARNESSCONNECTOR
DOWELPIN
6 x'1.0mm BOLT
LOWERVALVEBODYASSEMBLY
6 x 1.0mm BOLT
ATF PAN GASKET
Replace.
ATF STRAINER
ATF COOLERINLET LINE
BRACKETBOLT
8 x 1.25mm
ATF COOI..ERINLET LINE
6 x 1.0mm BOLT
6 x 1.0mm EOLT
14-314
l .
'1. Removethe ATFcoolerinlet iine bracketbolt'
2.
Removethe ATFcooleroutlet line
Removethe ATF pan (fourteenbolts).
Removethe ATFstrainer{two bolts)
5.
Removethe one bolt securingthe solenoidharness
connector,then pushthe connector.
6.
Removethe lowervalvebody (eightbolts)
7.
Cleanthe inletopeningof the ATFstrainerthoroughly
with compressedair, then checkthat it is in good
condition,andthe inletopeningis not clogged'
ATF STRAINER
2
c
c;2
'
ar\
INLETOPENING
the ATFstrainerif it is cloggedor damaged
Replace
NOTE:The ATF strainercan be reusedit it is not
clogged.
14-315
TransmissionHousing/Flywheel
Housing
Removal
NOTE:
. Cleanallpartsthoroughlyin solventor carburetorcleaner,and dry with
compressedair.
. Blow out all passages.
. When removingthe transmissionhousing/flywheel
housing,replacethe following:
- O-rings
- Secondarydrive gear assembly
- Start clutch assemblv
- Flywheelhousinggasket
ATF PASSAGELINE
HOLD€RASSEMBLY
8 x 125 mm BOLT
VWHEELHOUSING
IX)WEL PIN
OIFFERENTIAL
ASSEMBLY
EYWIIEELHOUSINGGASKET
Roolace.
SNAPRING
COTTER
RETAINER
ATF PA$gAGE
UNE ASSEMBLY
COTTERS,
25.5 mm
Selectivepart
O.RING
Rsplaco.
STARTCLUTCH
ASSEMBLY
Replace.
6 x 1,0 mm BOLT
O.RING
Replace.
THRUSTSHIM,
25x35mm
Seloctivepart
ATF PUMP DRIVECHAIN
SNAP RING
THRUSTSHIM,22 r 28 mm
part
Seloctive
SECONDARY
GEARSHAFT
SECONDARY
DRIVE
GEARASSEMBLY
Replace.
PARK
PAWL SHAFT
GRII{GS
Replac€.
6 x 1.0 mm BOIT
ATF PUMP DRIVE
SPROCKET
PfTOTFLANGE
ATF PUMP DRTVE
SPROC|(ETHUB
THRUSTWASHERS
PARKPAWL
SPRING
INPUTSHAFT
InANSMISS|O]{ HOUSTNG
DRIVENPULLEYSHAFT
14-316
)
1 . Removethe ATF passageline holderassembly'
Removethe flywheelhousing(twentybolts)'
Removethe ATF passageline assembly(onebolt)
Removethe ATF pump drive sprocket (three bolts),
then removethe ATF pump drive chaan.
Move the pitot flange toward its cutout, then remove
the pitot flange.
10. Setthe specialtool on the startclutch'and attachthe
oawl of the specialtool to the parkgear securelyas
shown.
CAUTION:
. Do not place tho pawl of the spocial tool on the
start clutch guidc. ll the pawl ot the spocial tool
contacts the 3tart clutch guid€, the start clutch
guido may be damaged.
. Be sure not to allow dust and other foreign particles to enter into the drivon pull6y shaft'
STARTCLUTCH
REMOVER
07TAE- P4V0120
STARTCLUTCH
ASSEMBLY
Replace.
PAWL
PITOTPIPE
Removethe snap ring securingthe ATF pump drlve
sprockethub. then remove the 22 x 28 mm thrust
shim, the ATF pump drive sprockethub and the thrust
wasners,
7.
STARTCLUTCH
REMOVER
07TAE- P4V0120
Removethe differentialassemblY.
Removethe park pawl shaft,the park pawl spring,
and the parkPawl'
9.
1 1 .Removethe start clutch and the secondarydrive
gear assemblyusing the specialtool, then remove
the secondarygearshaft.
STARTCLUTCH
ASSEMBLY
Removethe snap ring securingthe startclutch,then
remove the cotter retainerand the cotters.
J
14-317
End Cover/lntermediate
Housing
Removal
NOTE:
. Cleanallpartsin solventor carburetorcleansr,and drywith compressedair,
. Blow out all passages.
. When removing the end cover/intermediatehousing, replacsthe following parts:
- O-rings
- End cover gasket
- Transmissionhousinggasket
- Sealingrings
- Sealingwashers
8 x 1.25 mm BOLT
6 x 1.0mm BOLT
REVERSEBRAKE
END PLATE
{ u
Dtsc
PLATE
DISCSPRING
SNAP
ENDCOVER
GASXET
Feplac€.
THRUST
2 5 x 3 1m m
Selectivepart
RINGGEAR
THRUSTWASHER
THRUSI NEEDLE
BEARING
8 x 1.25mm BOLT
THRUSTWASHER
CARRIER
ASSEMBLY
sNAP /
R|NG I
INIERMEDIATE
HOUSING
ASSEMSLY
THRUSTWASHER
THRUSTNEEDLE
BEARING
SUN GEAR
INPUTSHAFT
o.BING
Replace.
TRANSMISSTON
HOUSINGGASKET
Replace.
SNAPRING
CLUTCHEND
PLATE
FORWARDCLUTCH
ASSEMBLY
SEALINGRING(RUBBER}
Replace.
DOWELPIN
SNAPRING
HOUSING
SPRINGRETAINER/
RETURNSPRINGS
SNAPRING
RETAINER
14-318
l .
1 . Removethe end cover {three6 mm bolts,eleven8
mm bolts).
2. Removethe manualvalvebody linesA and B
3. Removethe snap ring securingthe ring gear,then
removethe thrustshim and the ring gear'
11. Compressthe returnsprings.then removethe snap
ring
C A U T I O N :l f t h e s p r i n g r e t a i n e r t a b i s o n t h e
rsverse braks piston, tho spting letainer may be
damaged. Be surs the spring letainer tab is not on
the piston.
SPECIALTOOL
4. Removethe snap ring securingthe reversebrake
discsand plates,then removethe reversebrakeend
plate.brakediscs,brakeplates,and discspring'
5. Removethe carrierwith the thrust washersand the
thrust needlebearingfrom the forwardclutch
6. Removethe sun gear and the input shaft as a sub
assemblybY Pullingit
The sun gear is pressfittedtightly into input shaft'
7. Removethe snap ring securingthe forward clutch,
and removethe snapring securingthe forwardclutch
end plate,then removethe forward clutchend plate'
8 . R e i n s t a ltl h e c a r r i e ro n t h e f o r w a r d c l u t c h ,t h e n
securethe carrierwith the snap ring on the forward
clutchend Plate.
SPfiINGFETAIiGR
TAB
12. Removethe specialtool, then remove the spring
springassembly.
retainer/return
1 3 . Removethe sealingbolt securingthe reversebrake
pressureinsPectionhole.
1 4 . Apply air pressureto the inspectionholeto remove
the reversebrakePiston
SPBINGREYAINER/
RETURiI SPRIiIG
ASSEMALY
9. Remove the forward clutch and carrier assembly
together.
REVERSEBNAXE
PISTON
' 1 0 .l n s t a l lt h e s p e c i a lt o o l t o r e m o v e t h e s n a p r i n g
securingthe reversebrakereturnspring retaineras
snown.
o-Rrllcs
Replace.
BBAKE
REVERSE
COMPRESSOR
SPRING
07TAE- PaV0110
FCVERSEBRAKE
PRESSUREINS?ECTK)N
HOtl
SEALING
WASHER
Replace.
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ttl
Removethe snap ring retainerfrom the drive pulley
shaft.
1 6 . Removethe manualvalvebody (fivebolts)'
't7 Removethe rollerand pushthe controlshaftassembly toward the outsideof the transmissionhousing,
housing(fourbolts)'
then removethe intermediate
14-319
ManualValveBody
Disassembly/lnspection/Reassembly
NOTE:
. Cleanall partsthoroughlyin solventor carburetorcleaner,and dry with compressedair. Elow out all passages.
. Coatall partswith CVTFluidduringassembly.
SPRINGSEAT
INHIBITOR
REVERSE
VALVESPRING
REVERSE
INHIBITOR
VALVE
MANUAL VALVE
MANUAL VALVEBODY
Inspectfor wear, scratches
and sconng,
14-320
ForwardClutch
l .
lllustrated Index
CLUTCHORUM
\
\
DISCSPRING
\_
CLUTCHEND PLATE
CLUTCHPISTON
SNAPRING
14-321
ForwardClutch
Disassembly
1.
Removethe snap ring, then removethe clutchend
plate,clutchdiscs,and plates.
3.
Installthe specialtoolsas shown.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
SNAPRING
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PXa0100or
07HAE- P150100
2.
Removethe disc spring.
CLUTCHSPRING
COMPRESSOR
BOLT ASSEMBLY
o7R{E-PG402OO
OISC SPRING
CAUTION: lf €ither ond of the sp€cial tool is sst over
an aroa of the spring retainer which is unsupported
by th€ retum spring, the rotainer may be damaged.
Be sure the spccialtool is adiustedto hava tull contaqt with the sp.ing retainer.
t
CLUTCHDRUM
Do not B€t here.
SPECIALTOOL
SPRINGRETAINES
14-322
4.
Compressthe returnsprlng.
6.
Wrap a shop rag aroundthe clutchdrum, and apply
air pressureto the fluid passageto removethe piston.
Placea fingertip on the otherend while applyingair
pressure.
OSHA-APPROVED
30 psi NOzzLE
Removethe snapring.Thenremovethe specialtools,
and returnspring.
springretainer,
SPBINGRETAIT{€R
14-323
ForwardGlutch
Reassembly
NOTE:
. Clean all parts thoroughly in solvent or carburetor
cleaner,and dry them with compressedair.
. Blow out all passages.
. Lubricateall partswith CW Fluidbeforereassembly.
1.
Inspectthe checkvalve;if it's loose,replacethe piston.
CHECKVALVE
3.
Installthe pistonin the clutchdrum. Apply pressure
and rotateto ensureproperseatang,
NOTE: Lubricatethe piston O-ring with CVT Fluid
beforeinstalling.
CAUTION: Do not pinch thc O-ring by installing the
pistoo with too much torqo.
CLUTCHDRUM
InstallnewO-rings
on theclutchpision.
Install the return spring and spring retainer,and
positionthe snap ring on the retainer.
CLUTCHDRUM
PISTON
14-324
l .
5.
lnstallthesDecialtoolsas shown.
6.
Compressthe returnsPrlng'
7.
Installthe snap ring.
CLUTCHSPRING
COMPRESSOR
ATTACHMENT
07LAE- PX40100
CLUTCI{ SPRING
COMPRESSOR
BOLT ASSEMBLY
oTGAE-PG40200
CLUTCHSPNING
COMPRESSOR
ATTACI{MENT
07LAE- Pxil010oo.
07HAE- P150100
CAUTION: lf either end of the specialtool is set ovel
an area of lhe spring retain€r which is unsupported
by the return spring, tho retainsr may be damaged'
Be sure the speciallool is adiusted to have full contact with the spring tetainer.
SIIAP RING
8.
Removethe specialtools.
Sgt h6r6.
Do not sat hore.
SPECIALTOOL
RETAINER
(cont'd)
14-325
ForwardClutch
Reassembly
{cont'd)
9. Installthe discspring.
12. Installthesnap ring.
NOTE:Installthediscspringin the directionshown.
DISC SPRING
SNAPRING
-\
"arr"" o"u*
1 0 . Soakthe clutchdiscsthoroughlyin CW Fluid for a
minimumof 30 minutes.
1 1 . Starting with a clutch plate. alternatelyinstall the
clutch platesand discs.Installthe clutch end plate
with flat sidetoward the disc.
NOTE:Beforeinstallingthe platesand discs,make
sure the insideof the clutch drum is free of dirt or
other toreign matter.
13. Verify that the snap ring end gap is correct.
CLUTCH
CLUTCHENDPLATE
Installin this dir€ction.
Minimum7.9mm (0.31ini
14-326
14. Measurethe clearancebetweenthe clutchend plate
Zeroth€ dial indicaand toDdiscwith a dial indicator,
tor with the clutch end plate lowered,and lift it up to
the snap ring. The distancethat the clutch end plate
moves is the clearancebetweenthe clutch end plate
andtoDdisc.
15. It the clearanceis out of tolerance,selecta new ciutch
end platefrom the followingtable,thenrecheck.
NOIE: lf ihe thickestclutchend plateis installedbut
the clearanceis still over the standard,replacethe
clutchdiscsand clutchPlates.
in at leastthree places,
NOTE:Take measurements
and usethe averageas the actualclearance.
PTATEI{UMBEN
Clutch End Plate-to-TopDisc Clesranc€:
STANDARD:0.6 - 0.8 mm 10.024- 0.031inl
FORWARDCLUTCHEND PLATE
Plate No.
Part Number
Thickn€ss
1or15
22561- P4V- 003 3 . 5m m ( 0 . 1 3 8i n )
2or16
3or17
in)
22562- P4V -OO3 3 . 6m m ( 0 . 1 4 2
2 2 5 6 3 - P 4 V - 0 0 33 . 7m m ( 0 . 1 4 6i n )
4or18
22564- P4V- 003 3 . 8m m ( 0 . 1 5 0i n )
5or19
2 2 5 6 s - P 4 V - 0 0 33 . 9m m ( 0 . 1 5 4i n )
6ot20
7 ot 21
2 2 5 6 6 - P 4 V - 0 0 34 . 0m m ( 0 . 1 5 7i n )
22567-P4V -003 4 . 1m m ( 0 . 1 6 1i n )
8ot22
2 2 5 6 8 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )
9ot23
2 2 5 6 9 - P 4 V - 0 0 3 4 . 3m m { 0 . 1 6 9i n )
in)
22570-P4V-OO3 4 . 4m m ( 0 . 1 7 3
1 0o r 2 4
'll
or 25
2 2 5 7 1 , P 4 V - 0 0 34 . 5m m ( 0 . 1 7 7i n )
12ot 26
2 2 5 7 2 - P 4 V - O O 34 . 6m m ( 0 . 1 8 1i n )
22573-P4V-OO3 4 . 7m m { 0 . 1 8 5i n )
1 3o t 2 7
1 6 . After replacingthe clutchend plate,makesure thal
the clearanceis within tolerance.
14-327
SecondaryGearShaft
25 x 35 mm ThrustShim Selection
1.
Measurethe distancebetweenthe flywheelhousing
surfaceand the ball bearing as shown, then note
the measurement(Measurement
A).
Calculate25 x 35 mm thrust shim thicknessbv followingformula.
FORMULA;
25 x 35 mm Thrust Shim Thicknoss
= Measurement A - Measurement B + Flywheel
Housing GasketThickness:0.5 mm {0.020in}
FLYWHEEL
HOUSING
>dt?'
Example:
MeasurementA: 32.7 mm (1.287in)
Moasurem.nt B: 30.! mm {1.185in}
O
25 x 35 mm Thrust Shim Thickness
= 32.7mm (1.287in) - 30.1mm (1.185in)
+ 0.5 mm {0.020in)
= 3.1 mm (0.122inl
BALLBEARING
Select 25 x 35 mm Thrust Shim D.
A
MeasuringDistance
Selectthe 25 x 35 mm thrust shim from the following the table.
THRUSTSHIM, 25 x 35 mm
EALL
BALL
BEARING
FLYWHEEL
HOUSTNG
Installthe secondarygear shatt in the transmission
housing.
Measure the distance between the transmission
housing surface and the thrust washer mounting
surfaceof the secondarygear shaft as shown,then
notethe measurement(Measurement
B).
No.
Part Number
Thickne3s
90551- P4V- 000 2 . 8m m ( 0 . 1 1 0i n )
B
9 0 5 5 2 - P 4 V - 0 0 02 . 9m m ( 0 . 1 1 4i n )
c
9 0 5 5 3 - P 4 V - 0 0 03 . 0m m ( 0 . 1 1 8i n )
D
9 0 5 5 4 - P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2 2
in)
E
9 0 5 5 5 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6i n )
9 0 5 5 6 - P 4 V - 0 0 0 3.3 mm (0.130in)
G
9 0 5 5 7 - P 4 V - 0 0 0 3 . 4m m ( 0 . 1 3 4i n )
H
9 0 5 5 8 - P 4 V - 0 0 0 3 . 5m m ( 0 . 1 3 8i n )
9 0 5 5 9 - P 4 V - 0 0 03 . 6m m { 0 . 1 4 2i n )
K
14-328
9 0 5 6 0 - P 4 V - 0 0 0 3 . 7m m ( 0 . 1 4 6i n )
90561- P4V- 000 3.8 mm (0.'150
in)
Differential
l .
Bacl(lashInspection
lllustratedIndex
BOLTS
1 0x 1 . 0m m
98 N.m 110.0kgf.m,
72 tbl.ltl
Left-handthreads
1.
Placethe differentialassemblyon V-blocks,and install
both axles.
2.
Checkthe backlashof both piniongears.
Standard (Newl: 0.05- 0.15 mm 10.002- 0.006in)
PINIONGEARS
FII{AL ORIVENGEAR
BAIT EEANIM;
SET RING. 8() tnm
Soloctivopan
lf the backlashis out of tolerance,replacethe differentialcarrier.
14-329
Differential
BearingReplacement
DifferentialCarrierReplacement
NOTE:Checkthe bearingsfor wear and rough rotation.
lf the bearingsare OK, removalis not necessary.
1.
'1. Removethe ball bearingsusinga
bearingpuller.
Removethe final driven gear from the differential
carner.
NOTE: The final driven gear bolts have left-hand
threads.
BOLTS
1 0x 1 , 0m m
98N'm 110,0
kgf.m,
72 tbl.ttl
Left-hand
threads
BAI-LBEARING
Installthe new ball bearingsusing the special tool
with a pressas shown.
DIFFERENTIAL
CARRIER
Installthe final driven gear with its chamferedside
on the innerborefacingthe differentialcarrier.
ORIVER10 mm l.O.
07746- 0030100
Tightenthe boltsto the specifiedtorque in a crisscross
Paftern.
TOROUE:98 N.m (10.0kgt.m, 72 lbf.ft)
BALLBEARING
14-3 3 0
l .
Clearance
Oil SealInstallation/Side
Oil SealRemoval
1.
Removethe differentialassembly.
2.
Removethe oil sealfrom the transmissionhousing.
1.
lnstall a 2.50 mm (0.098in) thick 80 mm wide set
r i n gi n t h e t r a n s m i s s i ohno u s i n g .
NOTE:Do not installtheoil sealyet.
TRANSMISSION
HOUStl{G
TRANSMISSON
HOUSING
3.
OIL SEAL
R€placa.
Removethe oil sealfrom the flywheelhousing.
lnstallthe differentialassemblyinto the transmrssion housingusingthe specialtoolas shown
DIFFEREI{NAL
ASSEMBLY
(cont'd)
14-331
Differential
Oil SealInstallation/Side
Clearance(cont'dl
3.
Installtheflywheelhousing,and tightenthe bolts.
4.
8 x 1.25 mm
29 N m (3.0kgt m,22 lbf.ttl
Measurethe clea.ancebetweenthe 80 mm set ring
and outer race of the ball bearingin the transmission housing.
STANDARD:
0 - 0.15mm (0 - 0.006in)
ug Ei
DOWELPIN
lf the clearanceis more than the standard,selecta
new set ring from the table,and installit.
SETRING,80 mm
Part Number
904' r4-689-000
90415-689-000
90416-689-000
90417-689-000
90418-689-000
90419-PH8-000
Thickness
2.50mm (0.098in)
2 . 6 0m m ( 0 . 1 0 2
in)
2 . 7 0m m ( 0 . 1 0 6
in)
2 . 8 0m m ( 0 . 1 1 0
in)
2 . 9 0m m ( 0 . 1 1 4
in)
3 . 0 0m m ( 0 . 1 1 8i n )
NOTE:lf the clearancemeasuredin steD4 is standard, it is not necessaryto perform steps 7 and 8.
14-332
6.
Removethe flywheelhousing.
7.
Replacettle 2.50mm (0.098in) set ring, 80 mm with
the one ot the correctthicknessselectedin steD5.
FlywheelHousing
Input Shaft Oil Seal
l .
Replacement
8.
Installthe oil sealin the transmissionhousingusing
the sDecialtools as shown.
1.
Removethe input shaft oil seal from the flywheel
housing.
DRIVER
07749- 0010d)0
OIL SEAL
9.
Installthe oil seal in the flywheelhousingusingthe
soecialtools as shown.
Instalithe oil seal in the flywheelhousingusingthe
soecialtoolsas shown.
FLYWHEEL
DRIVER
ATIACHMENT,58 x 72 rnin
0?947- d'40201
PILOT,
26x30mm
oTJAD- PH80200
lmtalled depth:
2 . 5 - 3 . 5m m
ro"nri':,ilii.rl
t@
14-333
Transmission
HousingBearings
DrivenPulleyShaft BearingReplacement
1.
To removethe driven pulleyshaft b'earingtrom the
t r a n s m i s s i o nh o u s i n g ,e x p a n dt h e s n a p r i n g w i t h
s n a p r i n g p l i e r s ,t h e n p u s h t h e b e a r i n go u t u s i n g
the specialtoolsand a pressas shown.
Expandthe snap ring with snap ring pliers,insert
the new bearing part-way into the housing using
the specialtools and a press as shown. Installthe
bearingwith the groovefacingoutsidethe housing.
NOTE: Do not removethe snap ring unlessit's necessaryto cleanthe groovein the housing.
N O T E :C o a ta l l p a n sw i t h C W F l u i d .
R e l e a s et h e p l i e r s ,t h e n u s i n g t h e s p e c i a lt o o l s ,
push the bearingdown into the housing until the
snap ring snapsin place.
07749- 001(xDo
BEARING
ATTACHMENT,
72x75mm
07746 - OO1
0600
GROOVE
SNAP RING
ATTACHMENT,
72x75mm
07746 - (x'l05U)
After installingthe bearingverifythe following:
o The snap ring is seatedin the bearingand housing grooves.
. The ring end gap is correct.
ENDGAP|0 -9 mm
l0 - 0.35 inl
077i()- 001(xrco
SNAPRING
14-334
FlywheelHousing
Bearing
SecondaryGearShaft Bearing
Replacement
1.
Removethe secondarygear shaft bearingusingthe
specialtools as shown.
Replacement
1.
Removethe secondarygear shaft bearingusingthe
soecialtool as shown.
3/8" - 16 SLIDEHAMMER
lCommorciallyaY.ilabl6l
3/8" - 16 SLIDEHAMMER
{Comm6rciallYavailablel
BEARING
ADJUSTABI.T
- 40mm
PULLER.25
07736- A01000A
SecondaryGear Shaft Bearing
GEAR
SECONDARY
SHAFTBEARING
Installthe new secondarygear shaft bearinguntil it
bottomsin the transmissionhousing.usingthe specialtools as shown.
2.
lnstallthe new secondarygear shaft bearinguntil it
bottoms in the flywheel housing,using the special
tools as shown.
DRIVER
07749- (x)10000
ATTACHMENT.
62xGgmm
07745- 0010500
14-335
RingGearBearing
ControlShaft Assembly
RemovaUlnstallation
Replacement
1.
Remove the ring gear bearing.
1.
Removethe bolt and lockwasher.
CONTROLSHAFT
ASSEMBLY
TRANSMISSION
RING
RINGGEAR
Installthe new ring gear bearinguntil it bottoms in
the ring gear.usingthe specialtoolsas shown,
6r1.0mm
14 N.ft 11.4kg{.m,
10 rbf.ftl
CONTROL
LEVER
LOCKWASHER
Replace.
DRIVER
07?{9 - 001(xxxt
2.
Removethe control lever from the control shaft.
3.
Removethe control shaft assembly.
4.
Installthe controlshaftassemblyin the transmission
housing.
Installthe controlleverto the controlshaft.
Installand tightenthe bolt with a new lockwasher.
14- 3 3 6
Transmission
Reassembly
CAUTION:While reassembling.be sure not to sllow dust and othor foreign particlesto enter into the transmission.
NOTE:
. Coatall partswith CVTFluid.
. Replacethe followingparts:
- O-rings
- S e a l i n gr i n g s
- Sealingwashers
- Gaskets
- Startclutchassemblyand secondarydrivegear
assembly
8 x 1.25mm
37 N.m {3.8kgf.m,27 lbtftl
SNAPRING
6x1.0mm
12 N m 11.2kgf.m,8.7 lbl.ft)
MANUAL VALVE
LINES
REVERSE
BRAKE
END PLATE
ENDCOVEB
DOWEL
PIN
Dtsc
PLATE
ENDCOVERGASKET
DISCSPRING
6x1.0mm
12 N.m 11.2kgtm,8.7 lbtft)
THRUSTSHIM,25x 31 mm
Selectivepart
SNAP
RING
RINGGEAR
THRUSTWASHER
MANUAL
VALVE
BOOY
THRUST
BEARING
eB
8 x 1.25mm
29 N.m 13.0kgl m, 22 lbtftl
H^c
INTERMEDIATE
HOUSINGASSEMBLY
THRUSTWASHER
CARRIERASSEMBLY
THRUSTWASHER
ROLI.IR
THRUSTNEEDLE
BEARING
SUN GEAR
ATF FEEDPIPE
INPUTSHAFT
O-RINGS
TRANSMISSION
HOUSINGGASKET
SNAPRING
FORWARDCLUTCH
SHAFT
ASSEMALY
(RUBEERI
SNAPRING
SPRINGRETAINER/
RETURNSPRING
ASSEMBLY
DOWELPtN
REVERSE
BRAKEPISTON
O.RINGS
TRANSMISSION
HOUSING
SNAPRINGRETAINER
ATF FEEDPIPES
14-338
lnstallthe ATF feed pipe in the transmissionhousing, and installthe three ATF feed pipeswith new
O - r i n g si n t h e t r a n s m i s s i ohno u s i n g ,
Installthe two dowel pins and new transmissionhousing gasketon the transmissionhousing.
Pushthe controlshaft assemblytoward the outside
of the transmissionhousing,then installthe intermediatehousingassembly(four bolts).
lnstall the manual valve body separatorplate and
housing,
the two dowelpins on the intermediate
the
detent
with
body
then installthe rnanualvalve
(five
bolts).
spring
Put the controlshaft assemblyback,then installthe
rollerin the intermediatehousing.
6 . lnstallthe reversebrakepiston in the intermediate
housing.
springassemblyon
7 . Installthe spring retainer/return
brake
Piston.
the reverse
1.
NOTE:Installthereturnspringson the springguides
of the reversebrake piston securely
L
1
tnstallthe specialtool to compressthe returnspring
as shown.
REVERSE
BRAKE
COMPRESSOR
SPRING
07TAE- P4V0110
9 . Compressthe return springs,then installthe snap
ring in the intermediatehousing above the spring
retainer.
1 0 . Verifythat the snap ring end gap is correct'
M i n i m u m 1 5m m 1 0 . 5 i9n )
'-t,,,,.
///,,-
\\',r
i/
'/.
.r'
'1
,
.-J?
//
SNAPR I N G
1 1 . S o a k t h e r e v e r s eb r a k ed i s c s t h o r o u g h l yi n C V T
F l u i df o r m i n i m u m3 0 m i n u t e s .
12. Installthedisc springon the reversebrakepiston'
1 3 . S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
installthe reversebrakeplatesand discs lnstallthe
reversebrakeend plate,and the snap ring'
1 4 . Measurethe clearancebetweenthe reversebrake
end plateand the top discwith a dial indicator'Zero
plate
the dial indicator with a reversebrake end
distance
The
ring
snap
the
to
it
up
lift
and
lowered,
that the reversebrakeand platemoves is the clearance between the reverseend plate, and the top
disc.
in at leastthree places'
NOTE:Take measurements
and usethe averageas the actualclearance'
STANDARD:0.45- 0.75 mm (0.018 0'030 in)
CAUTION:lf the spring retainertab is on the reverse
brakc piston, the spring rstainer may be damaged'
Be sure the spring retainertab is not on the piston'
SPECIALTOOL REVERSEBRAKE
rp
{cont'd)
14-339
Transmission
(cont'dl
Reassembly
lf the clearanceis not within the standard,removethe
reversebrakeend plateand measureits thickness.
1 6 . Select and install a new reversebrake end Dlate.
then recheck.
22. Veritythat the outsidediameterol the snap ring is
correct.
Msximum41.4mm11.63
in)
N O T E : l f t h e t h i c k e s tr e v e r s eb r a k ee n d o l a t e i s
installed,but the clearanceis still over the standard,
replacethe reversebrakediscsand plates.
REVERSEBRAKEEND PLATE
SI{APRIiIG
Plat6 No.
1
Part Number
Thickness
22551 - P4V- 003 3 . 6m m ( 0 . 1 4 2i n )
22552-P4V-003 3 . 8m m ( 0 . 1 5 0
in)
2 2 5 5 3 - P 4 V - 0 0 3 4 . 0m m ( 0 . 1 5 7i n )
4
2 2 5 5 4 - P 4 V - 0 0 3 4 . 2m m ( 0 . 1 6 5i n )
5
2 2 5 5 5 - P 4 V - 0 0 3 4 . 4m m ( 0 . 1 7 3i n )
6
7
2 2 5 5 6 - P 4 V - 0 0 3 4 . 6m m ( 0 . 1 8 1
in)
22557-P4V -OO3 4 . 8m m ( 0 . 1 8 9i n )
8
2 2 5 5 8 - P 4 V - 0 0 3 5.0 mm (0.200in)
1 7 . After replacingthe reversebrake end plate, make
surethat the clearanceis within the standard.
1 8 . R e m o v et h e s n a p r i n g , r e v e r s eb r a k ee n d p l a t e ,
discs,plates.and discspring.
1 9 . I n s t a l lt h e s n a p r i n g r e t a i n e ro n t h e d r i v e p u l l e y
shaft.
20. Wrap the drive pulleyshaftsplineswith tapeto prev e n t d a m a g et o t h e O - r i n g s ,t h e n i n s t a l ln e w O nn g s .
2 1 . Installthe forwardclutchassemblyon the drive pulley shaft,then installthesnap ring.
Install the input shaft and the sun gear as a sub
assemDry.
I n s t a l lt h e t h . u s t n e e d l e b e a r i n ga n d t h e t h r u s t
washeron the sun gear.
CARRIER
ASSEMBLY
IHruST
THFUST I'IEEDI!
EEARIT{G
SITAP
O-RINGS
SI{AP RIM;
BETA EB
25. Installthecarrierassemblyon the forwardclutch.
DRIVEPUI.IEY
SHAFT
14-340
26. Installthe thrust washer,the thrust needlebearing'
and the thrustwasheron the carrierassembly'
THRUSTSHIM,
2 5 x 3 1m m
Selective
Pan
SNAPRING
30. lf the clearanceis out of tolerance,removethe 25 x
31 mm thrust shim and measureits thickness'
3 1 . Selectand install a new 25 x 31 mm thrust shim.
then recheck.
THRUSTSHIM, 25 x 31 mm
RINGGEAR
No.
Part Numb.l
90451- P4V- 000
THRUSTWASHERS
THRUSTNEEDLE
EEARING
Thickne*3
1.05mm (0.041in)
B
9 0 4 5 2 - P 4 V - 0 0 0 1.12mm (0.044in)
c
90453-P4V-000
D
90454- P4V- 000
F
9 0 4 5 5 - P 4 V - 0 0 0 1.33mm (0.052in)
90456-P4V-000 1.40mm (0.055in)
'1.19mm (0.047in)
'l.26mm (0.050in)
904s7-P4V-000 1.47mm (0.058in)
90458-P4V-000
90459-P4V-000
CARRIER
ASSEMBLY
21. lnstallthering gear and the 25 x 31 mm thrustshim,
then installthesnaPrrng.
J
90460-P4V-000 1.68mm (0.066inl
K
9 0 4 6 1 - P 4 V - 0 0 0 1.75mm (0.069in)
90462-P4V-000 1.82mm (0.072in)
M
24. Verifythat the outsidediameterof the snap ring is
correct,
1.54mm (0.06'lin)
'1.61mm (0.063in)
N
o
904a0-P4V-000
in)
1.085mm (0.0427
9 0 4 8 1 - P 4 V - 0 0 0 1.155mm (0.0454in)
901a2-P4V-000 1.225mm (0.0482in)
in)
90483-P4V-000 1.295mm (0.0510
Maximum30.7mm (1.21in)
o
R
T
9 0 4 8 4 - P 4 V - 0 0 0 1.365mm (0.0537in)
904a5-P4V-000 1.435mm (0.0565in)
90486-P4V-000
1.5O5mm (0,0593in)
90487-P4V-000
1.575mm (0.0620in)
90488-P4V-00{) 1.645mm {0.0648in)
in)
90489-P4V-000 1.715mm (0.0675
SNAPRING
29. Measure the clearancebetween the 25 x 31 mm
thrustshim and the snaPrlng.
90490-P4V-000
1.785mm (0.0703in)
STANDARD:O.O5- 0.11 mm (0.0020 0.00'8 in)
32. After replacingthe 25 x 31 mm thrust shim, make
sure that the clearanceis within toleranceand the
snap ring outside diameter is correct'
NOTE:Takemeasurementsin at leastthree places'
and usethe averageas the actualclearance
33. Installthe discspringin the directionshown'
34. S t a r t i n gw i t h a r e v e r s eb r a k e p l a t e , a l t e r n a t e l y
install the reverse brake plates and discs lnstall
selectedreversebrake end plate, then install the
snap nng.
RING
REVERSE
END PLATE
BRAKE
Dtscs
SPRING
,**r#*,".
REVERSE
PI-ATES
'- t
)
RINGGEAR
lnstall in this direction.
(cont'd)
14-341
Transmission
(cont'd)
Reassembly
35. Verifythat the snap ring end gap is correct.
M i n i m u m1 8m m ( 0 . 7 1i n )
39. Installthe park pawl,spring,and shaft on the transmissionhousing,then move the controlleverto anv
gear otherthan E position.
SNAPRING
THBUST
SHIM,
25x35mm
,/\,
."or**ol!/'
SECONDARY
GEARSHAFT
Install the manual valve body lines A and B wkh
new O-ringson the manualvalvebody and the intermediatehousing.
8 x 1.25mm
37 N.m 13.8kgf.m,27 lbf.ftl
END
COVER
COTTER
RETAINER
COTTERS,
25.5mm
pan
Selective
STARTCI.UTCH
ASSEMBLY
6x1.0mm
12 N..n (1.2kgt m,
8.7 rbtft)
SECONDARY
ORIVEGEAF
ASSEMBLY
fl
g
O.RINGS
PARK
PAWL SPRING
PARKPAWL
END
COVERGASKET
DOWELPINS
O-RINGS
,10, Install the secondary gear shaft with setected25 x
35 mm thrust shim (seepage ,14-328).
MANUAL VALVE
BODYLINEA
uaNYuAL
VALVE
37. Install the two dowel pins and new end cover gas_
ket on the intermediatehousing,then install new O_
rings on the ATF feed pipes.
Installthe end cover (three 6 mm bolts, eleven g
mm bolts).
NOTE:Installthe nine 8 mm bolts in the end cover
( t w o 8 m m b o l t s r e m a i n i n t h e e n d c o v e r )t h e n
tightenthe eleven8 mm bolts.
14-342
41. Wrap the driven pulley shaft splines with taDe to
prevent damage to the O-rings, then install new O_
rings.
42, Assembleths secondarydrive goar assembly in the
start clutch assembly,then installthem on the driven
pulley shaft,
43. Pull the handle of the specialtool up, then install
the tip of it into the driven pulley shaft hole, and set
the specialtool on the stan clutch.
CAUTION:Whib in3trling thc st rt ctutch and rh.
3ocondlry driye g.!r a3sombly using lh€ special
tool, bo 3urc nol to sllow du3t or olher foraign par_
ticlos to ontq into tho iransmbsion.
STARTCLUTCH
INSTALLER
07TAE - P4V0r30
I c,rrr,unar".
44. Pushthe handleof the specialtool, then tightenthe
nut to seal the secondarydrive gear assemblyon
the drivenpulleYshaftsecurelY.
STAAT CLUTCHIi'ISTALIIR
07TAE- PaV0130
47. lf the clearanceis not within the standard,remove
the cottersand measuretheirthickness
48. Selectand installnew cotters,then recheck.
COTTERS,25.5 mm
Part Number
No.
Thickness
B
9 0 4 2 9 - P 4 V - 0 0 0 2.9m m ( 0 . 1 1 4i n )
9 0 4 3 0 - P 4 V - 0 0 03.0m m ( 0 . 1 1i8n )
c
9 0 4 3 -1P 4 V - 0 0 0 3 . 1m m ( 0 . 1 2l2n )
D
in)
9 0 4 3 2 - P 4 V - 0 0 0 3 . 2m m ( 0 . 1 2 6
49. After replacingthe 25.5mm cotters,make surethat
the clearanceis the standard
50. lnstallthe cotterretainerand the snaprlng
Verify that the outsidediameterof the snap ring is
correct.
Minimum33.9mm (1.33in)
OF
HA'{DI,-E
SHAFT
Pull the handleof the specialtool up, and remove
the specialtool.
46. lnstallthecotters,then measurethe clearanceDelween
the cottersand the startclutchguide
0 - 0.13mm (0 - 0.005inl
STANDARD:
SNAP RII{G
52. l n s t a l l t h e t h r u s t w a s h e r s .t h e A T F p u m p d r r v e
sprockethub and the 22 x 28 mm thrustshim on the
inDUtshaft,then installthe snap ring.
SNAPRING\
in at leastthree places,
NOTE:Take measurements
and usethe averageas the actualclearance
THFUST SHIM, 22 x 2a mm
Selectivepan
ATF PUMP DRIVE
SPROCKETHUB
THRUSTWASXERS
25.5mm
COTTERS,
GAUGE
INPUTSHAFT
lil
START 1
GAUGC
(il
START CLUTCH
(cont'd)
14-343
Transmission
(cont'd)
Reassembly
53. Verifythat the outsidediameterof the snap ring is
correct.
M a x i m u m2 6 . 3m m ( 1 . 0 4i n )
After replacingthe 22 x 28 mm thrust shim. make
sure that the clearanceis within toleranceand the
snap ring outsidediameteris correcr.
58. Installthe pitot flange using its cutout as shown to
clearthe pitot pipes.
SNAP RING
54. Measurethe clearancebetween the 22 x 28 mm
thrustshim and the snap ring.
STANDARD:0.37- 0.65 mm (0.015- 0.026inl
NOTE:Takemeasurementsin at leastthree places,
and usethe averageas the actualclearance.
59. Install the ATF pump drive sprocket.and put the
ATF pump drive chain on the ATF pump drive and
driven sprockets,then install8nd tighten the bolts
(three bolts).
TF PUMPDRIVECHAIN
55. lf the clearanceis out of tolerance,removethe 22 x
28 mm thrustshim and measureits thickness.
co.
Selectand install a new 22 x 28 mm thrust shim,
then recheck.
6x1.0mm
12 N.m
11.2kg{.m,8.7 lbf.ftl
ATF PUMPORIVE
SPROCKET
PITOTFLANGE
THRUSTSHIM,22 x 28 mm
No.
Part Numb€r
Thicknsss
c
9 0 5 7 3 - P 4 V - 0 0 01 . 1 5m m ( 0 . 0 , {i5n )
D
9 0 5 7 4 - P 4 V - 0 0 0 1.40mm {0.055in)
E
9 0 5 7 5 - P 4 V - 0 0 0 1.65mm (0.065in)
F
9 0 5 7 6 - P 4 V - 0 0 0 1.90mm (0.075in)
ATF PUMP
9 0 5 7 7 - P 4 V - 0 0 0 2 . 1 5m m ( 0 . 0 8 5i n )
9 0 5 7 8 - P 4 V - 0 0 0 2.40mm (0.095in)
14-344
INPUTSXAFT
l .
60. Installthe ditferentialassembly
(oneboltl'
61. InstalltheATF passageline assemblywith new O-rings
housing'
62. Installthethreedowel pinsand new flywheelhousinggasketon the transmission
(twentybolts)'
63. Installthe flywheelhousingand connectorbracket
64. InstalltheATF passageline holderassembly(two bolts)'
6x1.0mm
12 N.m {1.2 ksf'm,
8.7 tbf.ftl
L|NE
ATFPASSAGE
"o.o.'o{
I
I
8 x 1.25mm
29 N.m t3.o kg['m, 22 lbf'ttl
/
g
u
s
g
l l
FLYWHEELHOUSING
d
\n
rm
\A
o-nrnc--.-..ff
ATF PASSAGELINE
ASSEMALY
BRACKET
CONNECTOR
DOWELPIN
6x1.0mm
12 N.m 11.2kgd'm,
8.7tbr.tr)
ASSEMBLY
DIFFERENNAL
O.RING
DOWELPIN
DOWELPIN
FLYWHEELHOUSING
GASKET
TRANSMISSION
ItousrNG
ATF PASSAGE
LINEASSEMBLY
PASSAGELINE
GUIOE
TRANSMISSIONHOUSING
(cont'd)
14-345
Transmission
(cont'dl
Reassembly
65 lnstallthe solenoidharnessconnectorwith a new O-ring(one bolt),then installthe lower valve body assemblywith
threedowel pins (eightbolts).
66. Installthe ATFstrainerwith a new O-ring(two bolts).
67. lf necessary,
assemblethe ATF pan,ATFfilter,and the ATFcoolerinlet line (seepage14_303).
68. Installthe ATF pan with the two dowel pinsand a new ATF pan gasket(fourteenbolts).
69. Installthe ATF coolerinlet line bracketbolt.
70. InstalltheATFcooleroutletlinewith the line bolt and new sealingwashers.
6x1.0mm
12 N.m 11.2kgf.m,
8.7 rbtft)
DOWELPINS
ATF STRAINER
ATF COOLEROUTI.IT LINE
DOWELPINS
ATF PAN,/ATFFILTER/
ATF COOLERINLET
LINEASSEMELY
@
@
C4
6x1.0mm
12Nm11.2kgl.m,
8.? tbf.ft)
CONNECTOE
6x1.0mm
12 N.m {1.2kgf.m,
8.7 tbtftl
LOWERVALVEBODY
ASSEMBLY
6x1.0mm
12 N.m 11.2kgf.m,
8.7 tbt.ft)
ATF COOI.ERINI.IT
LINEBRACKETBOLT
I x 1.25mm
26 N.m (2.7kgt.m,20 lbf.ft)
14-346
Flywheel/DrivePlate
WASHER
Installin this direction.
DRIVEPLATE
o0
/,1
vl
. . /
a9a
.t
FLYWHEEL
wear'
lnspectthe teethof the ring gearfor excessive
1 2x 1 . 0m m
74 N.m (7.5kgf.m, 54lbfft)
Torque in a crisscrossPattern
Transmission
Installation
L
Flushthe ATF cooleras describedon pages14-352
and 14-353.
6.
Placethe transmissionon s jack,and raiseit to the
engineassemblylevel.
Removethe used greasein the flywheel hub caD
and flywheelsplines.
7.
Anach the transmissionon the engine,then install
the transmissionhousing mounting bolt and rear
enginemountingbolts.
Fill the insideof the flywheelhub cap,and coatthe flywheel hub splineswith SuperHighTemp Urea Grease
(P/N08798- 9002)as shown.
TRANSMISSION
HOUSING
MOUNTING BOIT
6,1N.m 16.5kgl.m,
47 tbtttl
REARENGINEMOUNTING
BOLT
Replace.
12 x 1.25mm
59 Nrn {6.0 kgl.m. ,€ lbt ftl
SPLINES
Apply SUPEBHlcH TEMP
UREAGREASE
lPlN 08798- 90O2t
WASHER
SUPERHIGHTEMP
UREAGREASE
(P/N 08798 - !)0021
1.5-2.5 g 10.05-0.t9oz)
I n s t a l la n e w s e a l i n g r i n g ( r u b b e r )o n t h e i n o u t
shaft,and installtwo '14x 20 mm dowel Dinsin the
flywheelhousing.
Installthe flywheelsecurelyon the input shaft,then
installthestartermotor on the flywheelhousing.
lnstallthe transmissionmount bracket.Tightenthe
long bolt loosely,and tighten the nuts and bott on
the mount bracket to the specified torque. Then
tighten the long bolt to the specifiedtorque.
12x 1.25mn
6,r N'm 16.5kgtm,47 tbtftl
l-".--..-,^
4,1Nm
la.5 kgt.m,33 tbt.ft)
G
\
V
TRANSMISSON
MOUNT BRACKET
INPUTSHAFT
STARTER
.4;i "lrj
,i rr,"r.,., a
SEALINGRING
{RUEBER)
MOUI{T
l4 x 20 mm DOWELptN
FLYWHEEL
14-348
12 x 1.25mn
74N.m(7.5tstm,5a tbtftt
l .
9. Installthe remainingtransmissionhousing mounting bolts.
PRIMARYOXYGENSENSOR
(see
1 3 . Tighten the crankshaftpulley bolt, if necessary
section6).
1 4 . Connectthe ATF cooler hosesto the ATF cooler lines
(seepage 14-357).
CAUTION: Whilo connecting the ATF cooltr hGes,
b€ sure not lo allow dust and other loreign particles to entg. into the transmission.
15. Installtherightfront mounvbracket'
10 x 1.25mm
a,r N.m {4.5 kgf'm,33 lbt ftl
RIGHTFRONT
MOUNT/BRACKET
ATF COOLERLINE
HOUSING
TRANSMISSION
MOUNNNG BOLT
6il N.m {6.5 kgf.m,47 lbf'ftl
1 0 . Removethe transmissionjack and the hoist. then
remove the hoist bracketfrom the engine'
1 1 . Attach the flvwheel to the drive plate with eight
boltsand torqueas follows:
Rotatethe crankshaftpulley as necessaryto tighten
rhe bolts to half of the specifiedtorque,then to the
final torque,in a crisscrosspattern.
After tightening the last bolt. check that the
crankshaftrotatesfreelY.
10 x 1.25 mm
54 N.m {5.5 kgt'm,
4{) tbl.ftt
ATF COOI,TRHOSE
16. Installthe exhaust PiPeA.
EXHAUSTPIPEA
12. Installthe flywheelcoverand the enginestiffeners
DRIVE
6xl.0mm
12 N.m
ENGINE
10x 1.25mm
-rE l12 kgf'm' STIFfENEB artN.mla.skgt.m,
8.7 tbf.ftl
33tbtftt
*s$o
8 x 1.25mm
24 N.m
(2.1kgf'm,
17 tbt.ftt
oor*rr-@
DRIVEPI.ATEBOLT
6x1.0x14mm
12 N.m {1.2kgt m.
8.7 lbf,ftl
FLYUTHEEL
ENGINESTIFFENER
8 x 1.25mm
'17
24 N.m (2.4 kgt'm, lbf'ftl
Replace.
8 x 1.25mm
26 N.m
12.7kqfin,
20 rbt'ftl
10 x 1.25mm
r,a N.m {4,5kgf m,
33 tbf.ftl
SELF.LOCKING
Replace.
8 x 1.25mm
22 N.m t2.2 kgl m, 16lbf'ftl
GASKET
Replace.
@
\
NUT
SELF.LOCKING
Replace.
10 x 1.25mm
5/aN.m {5.5kgt m,
irc lbf.ft)
NUT
SELF.LOCKING
Replace.
8 x 1.25mm
16 N.m {1.6kgl'm,
12 tbl.ftt
(cont'dl
14-349
Transmission
Installation(cont'd)
1 7 . InstallI new set ring on the end of eachdriveshaft.
20. Installthe splashshietd.
Installthe right and left driveshafts(seesection16).
CAUTION:While instatlingthe drive3haftsin the
differential,be sure not to allow dust and olher foraign particles to enter into tho transmission.
NOTE:
. Cleanthe areaswherethe driveshaftscontactthe
transmission{differential}thoroughly with solvent or carburetorcleaner,and drv with comDressedair.
. Turn the right and left steeringknucklefully outwa.d, and slide each driveshaftinto the differential until you feel its set ring clip engagethe side
gear.
1 9 . Installthe damperfork,then installthe right and left
ball joints to each lower arm with the castleouts
and new cotter pins.
I
6
I
"a,a
6*
s
a
a
6 x 1 . 0m m
9.8 t{.m 11.0kgt.m,
7.2 tbf.trl
2 1 . Connectthe vehicle speed senso. connector.the
driven pulley speedsensorconnectorand the secondary gear shaft speed sensor connector,
10 x 1.25mm
43 N.m
{4.4 kgf.m,32 lbf.ftl
6x1,0mm
12 N.m {1.2kg{.m,8.7 tbf,ft)
DRIVENPULLEY
SPEEDSENSOR
CONNECTOR
SELF-LOCKING
NUT
Replace.
CASTI.I
12x 1.25mm
'12x 1.25
mm
6l N.m
ksr.m.
{6.s
47tbr.ftrl! _ll
ffiteo
- s.otet'.,
E.
SECONOARY
GEAR
SHAFTSPEED
SENSOBCONNECTOR
14-350
6 x 1.0 m.rl
'12N.m
{1.2 kg{.m,8.7tbf.fo
22. Installthe shift cable end on the control lever,and
installthe shiftcableon the shift cablebracket'
CAUTION: Take care not to bend the shift cable'
23. lnstallthe clip in the directionshown.
SHIFI CABLE
25. Connectthe startermotorcableon the startermotor.
and installthe cableholder.
NOTE:When installingthe stanermotor cable.make
s u r e t h a t t h e c r i m p e ds i d e o f t h e r i n g t e r m i n a li s
facingout (seesection23).
LOCKNUT
29 N m {3.0kg{ m, 22lblftl
STARTERMOTOR
SHIFTCABLE
ERACKET
WASHER
IPLASTIC)
STARTEB
MOUNTINGNUT
B
9 N.m (0.9 kgf m,7 lbf ft)
LEVER
CONTROL
24, Connectthe solenoidharnessconnector.the drive
p u l l e y s p e e d s e n s o rc o n n e c t o r .a n d t h e g r o u n d
cableterminals.
6x1.0mm
12 N.m {1.2kgf.m.
8,7 rbtft)
GROUNDCABLE
6x1.0mm
TERMINAL
12 N.m {1.2kgf'm,
8.7lbtfrl
26. Installall removedconnectorsand clamps'
27. Installthe distributor.
28. Installthe intake air duct and air cleaner housing
assemDly.
29. R e f i l l t h e t r a n s m i s s i o nw i t h t h e r e c o m m e n d e d
GenuineHondaCVTFluid(seepage14-2991
CAUTION:While filling the CvT Fluid,bs surs not io
allow dust and other fotoign particles to entor into
the transmission.
30. Connect the battery positive (+) terminal first, then
GROUND
TERMINAL
DRIVEPULLEY
SPEEDSENSOR
CONNECTOR
SOLENOIDHARNESS
CONNECTOR
the negative(-l terminal to the battery'
3 1 . Checkthe ignitiontiming (seesection23).
Startthe engine.Setthe parkingbrake,and shift the
transmissionthrough all gears three times Check
shiftcableadjustment(seepage 14-355).
Checkthe front wheelalignment(seesection18)
34. L e t t h e e n g i n e r e a c ho p e r a t i n gt e m p e r a t u r e( t h e
radiatorfan comes on) with the transmissionin lXl
or E position,then turn it off and checkfluid level'
Perform the start clutch calibration procedureon
page14-293.
36. Roadtest as describedon pages14-296and 14-297
14-351
Transmission
GoolerFlushing
To prevent iniury to face and eyes,always
@
wear safety glassesor a tace shield when using the
transmissionflusher.
7. With the water and air valvesoff, attachthe water and
air suppliesto the flusher.(Hotwaterif available.)
NOTE:This procedureshouldbe performedbeforereinstallingthe transmission.
'1.
Checkthe tools and hosesfor wear and cracksbefore
using.lf wear or cracksare found, reDlacethe hoses
beforeusing.
Usingthe measuringcup.fill the tankwith 2,1ounces
(approximately2/3 full) of biodegradableflushing
fluid (J35944- 20).Do not substitutewith any other
f l u i d . F o l l o wt h e h a n d l i n gp r o c e d u r eo n t h e f l u i d
contatner.
4.
Securethe flusherfiller cap,and pressurize
the tank
with compressedair to between5S0- 829 kpa (5.68.45kgf/cm' ,80 - 120psi).
8. Turn on the flusherwater valve so water will flow
throughthe coolerfor 10 seconds.
NOTE:The air line shouldbe equippedwith a water
trap to ensurea dry air system,
NOTE:lf water does not flow throughthe cooler,it
is completelyplugged,cannotbe flushed,and must
be replsced.
Hangthe tool underthe vehicle.
Attach the tank's dischargehose to the return line
oi the transmissioncoolerusinga clamp.
Connectthe drain hoseto the inlet line on the transmissioncoolerusinga clamp.
IMPORTANT:
Securelyclampthe oppositeend ofthe drain hoseto a
bucketor floor drain,
9. Depressthe trigger to mix the flushing fluid into the
water flow. Usethe wire clip to hold the trigger down.
'10.
While flushingwith the water and flushingfluid for
two minutes.turn the air valve on for five seconds
every 15- 20 secondsto createa surgingaction.
AIR PRESSURE:
MAX 845 kpa (8.45kgflcmr, 120 psi)
11. Turn the water valve off. Releasethe trigger,then
reversethe hosesto the coolerso you can flush in
the oppositedirection.Repeatsteps8 through 10.
TRANSMISSION
12. Releasethe trigger.and rinsethe coolerwith water
only for one minute.
13, Turn the water valveoff, and turn off the water supply.
'14. Turn
the air valve on to dry the systemout with air
for two full minutesor until no moistureis visible
leavingthe drain hose.
CAUTION: Rosidual mobturo in the qooler or lines
cln damagethe transmission,
t
TRANSMISSION
COOLER
FLUSHER
{Commerciallyavailable)
Kent-MooreJ384O5-A
or oouivalent
14-352
15. Removethe flusherfrom the cooler line.Attachthe
drain hoseto a container.
16. Installthe transmission.and leave the drain hose
attachedto the coolerline.
l .
1 7 . Makesurethe transmissionis in the E] position.
w i t h c v T F l u i d ,a n d r u n t h e
F i l lt h e t r a n s m i s s i o n
enginefor 30 secondsor until approximately0 95 {
( 1 . 0U S q t . , 0 . 8l m p q t . )i s d i s c h a r g e d .
TOOL MAINTENANCE
1.
Emptyand rinseaftereachuse.Fillthe canwith water
and pressurizethe can. Flushthe dischargeline to
ensurethat the unit is clean.
1 8 . Removethe drain hose, and reconnectthe cooler
returnhoseto the transmission(seepage14-355)
2,
lf dischargeliquiddoes not foam,the orificemay be
blocked.
'19. Refillthe transmissionwith CVTFluidto the proper
level(seepage 14-299).
3.
To clean,disconnectthe plumbingfrom the tank at
the largecouPlingnut.
FILLERCAP
FILTER
COUPLING
NUT
I
- 0--D -@q
\
\
i
I
I
\
ORIFICE
O.RING
.l,
Removethe in-linetilterfrom the dischargesideand
cleanif necessary'
The fluid orificeis locatedbehindthe filter. Cleanit
with the pick storedin the bottom of the tank handle. or blow it cleanwith air. Securelyreassemble
all parts.
14-353
Shift Cable
RemovaUlnstallation
Make sure lifts, iacks and safety stands are
@
placedproperly(seeseqtion11,
1.
Removethe front console(seesection20).
2.
Shift to E position,then removethe lock pin from
the adiuster.
Removethe air cleanerhousingassembly.
Removethe clip from the control lever,and loosen
the locknut.
CLIP
SHTFT
CABLE LOCKNUT
29 N.m 13.0kgf m,22 lbf.ft)
\.
*o"ra"
\
SHIFTCABI-E
BRACKET
CONTROLLEVER
Removethe shift cablefrom the control lever,the
shiftcablebracket,and the clamp.
Removethe shift cablebracketbolts and nuts,then
remove the shift cable.Take care not to bend the
shift cablewhen removing/installing
it.
SHIFTCABLEBRACKET
ADJUSTER
{1.2kgI m, 8.7lblft)
14-354
7.
lnstallthe shift cable in the reverseorder of removal.
8.
Checkthe cableadjustment(seepage14-355).
t
Adjustment
Make sure lifts, jacks and safety stands are
!@
placed properly (seesection 1).
l.
Removethe front console(seesection20).
2.
Shift to I posirion,then removethe lock pin from
the adjuster.
3. Checkthat the holein the adiusteris perfectlyaligned
with the holein the shiftcable.Therearetwo holesin
the adjuster.They are positioned90" apartto allow
cableadjustmentin 1/4turn increments.
lf the hole is not perfectlyaligned,loosenthe locknut on the adjusterand adjustas required.
Tightenrhe locknutto 7 N.m (0.7kgim,5 lbf'ft).
Installthe lock pin on the adjuster'lf you feel the
lock pin binding as you reinstallit. the cable is still
out of adjustmentand must be readjusted
SHIFTCAELE
7 . M a k e s u r e t h e l o c k p i n i s s e a t e di n t h e a d i u s t e r
{ 0 . 7 k g f . m ,5 l b f ' l t l
securery.
lMovethe shift leverto eachposition,and verifythat
t h e s h i f t p o s i t i o ni n d i c a t o rf o l l o w st h e a u t o m a t l c
transaxlegear positionswitch.
S t a r t t h e e n g i n e ,a n d c h e c kt h e s h i f t l e v e r i n a l l
positions.lf any gear does not work properly,refer
(seepage 14-294and 14-295).
to troubleshooting
1 0 . Insertthe ignition key into the key cylinderon the
Aff gear positionindicatorpanel,and verifythat the
shift lockleveris released.
l,
14-355
Shift Lever
PUSHKNOB
\
PUSHKNOESPRING
X ,l
\2
\re
./
,/
-6r
SILICONEGREASE
SHIFTINDICATORLAMP.
a,-,/
SHIFTLEVER
KNOB
/
Jl
/
SCREW
tn
rn
I 3 N.n l0.3xgtm, 2 lbf ftl
Applynon-hardening
non-hardening
th'
threadlocksealant.
/ Apply
I
SCREW
3 N.m{0.3kgf'm,2 lbl.ft)
A/T GEARPOSTTONINDICATORPANEL
LEVERCOVER
SHIFTLOCK
sotENolD
BUSHING
-611
SII.'|CONEGREASE
SCREW
3 N.m10.3kgl.m.2lbf.ttl
SHIFTI.TVEBASSEMBLY
L@KP'N
dE("""--
n2
6x1.0mm
9,8 N.m 11.0kgf.m,
7.2 tbtft)
-
V INYLTAPE
I n s t a l lt h e b o o t b a n d a n d o u t b o a r d b o o t , t h e n
remove the vinyl tape. Take care not to damage the
boot,
19. Installthenew set ring,
Installthe stop ring into the driv€shaftgroove.
DRIVESHAFT
Note these items after reassembly:
. Make sure the band and clip does not interfere with
anythingand the band does not move.
a Removeany grease remaining on the surrounding
surfaces.
16-14
4.
lnsert the driveshaft into the outboard joint until the
stop ring is closeon the ioint.
6.
Checkthe alignmentof the paint mark with the outboardjoint end.
DRIVESHAFT
7.
)
J
To completelyseat the outboardjoint, pick up the
driveshaftand joint, and drop them from about 10
cm (4 to 5 inches)onto a hard surface.Do not use a
hammer as excessiveforce may damagethe driveshaft.
Packthe outboardjoint with the joint greaseincludsd
in th€ new ioint boot set.
Gleaso quanlity
U.S.,canada, and Brazil'Ploducod:
115- 135g {4.0- 4.8oz}
Japan-Producod:
DOHCVTECangino:
161X,
Rubborboot: 90 - 100g 13.2- 3.5oz)
TPEboot: 1tl6- 115I {3'7- tl'l oz}
Excapt 1000DOHCVTECengine:
Rubbel boot: 70 - 80 g l.2.5- 2.8 ozl
TPEboot: 95 - 105g {3.4- 3.7 oz}
DRIVESHAFT
J
(cont'd)
16-15
Driveshafts
Reassembly
lcont'd)
8 . Installtheoutboardboot and the boot bands.
. lf the boot is the rubber type. go to step 13.
. lf the boot is the TPEtype, go to step 9.
11. Closethe ear portion of the band with a commerciallyavailableboot band Dincerc.
Fit the boot endsonto the driveshaftand outboard
ioint.
BOOTBAND PINCERS
KENT-MOORE
J,35910
or eouivalent
EAR FOFNON
10, Set the ear clamp band by threadingthe tab into the
holesof the band.
Chsckthe clearancabetween the closed ear oonion
of the band. lf the clesranceis not within the standard, close the ear portion of ths band further.
6.0 mm (0.24in) MAX
3.0 mm 10.t2inl MAX
EARCLAMPBAND
Reolace.
16-16
I
13. Fit the boot ends onto the driveshaftand the
outboardjoint
17. Threadthe free end of the band through the nose
sectionof a commerciallyavaiiableboot band tool
KD-3191or equivalentand into the slot on the winding mandrel.
BOOTBANDTOOL
available)
lCommerciallY
or equivalent
KD-3191
Mark spot.
MANDREL
1 4 . Fit the doubleloop boot bandsonto the boot ends'
Pullup the slackin the band by hand'
1 6 . Mark a positionon the band 10 14 mm {0 4 0 6
in,)from the cliP.
1 8 . Placea wrench on the winding mandrelof the boot
band tool, and tighten the band until the marked
spot on the band meetsthe edgeof the clip'
1q
CLIP
lrz
Lift uo the boot band tool to bend the free end of
the band 90" to the clip Centerpunchthe clip, then
fold overthe remainingtail onto the clip
(cont'd)
16-17
Driveshafts
(cont'dl
Reassembly
Installation
20. Unwind the boot band tool, and cut off the excess
free end of the band to leave a 5 - 10 mm (0.2- 0.4
in.)tail protrudingfrom the clip.
1,
Installthe new set ring onto the driveshaftgroove.
Always use a new set ring whenever the driveshaft
is beinginstalled.
INBOARD
JOiIT
21. Bendthe bandby tappingit down with a hammer.
NOTE:Maks sure the band and the clip does not
interferewith anything, and the band does not
mov6. Removeany greaseremaining in the surroundingsurtaces.
SET RII{G GR(X)VE
2.
Installthe outboardjoint into the knuckte.
AANOEND
KNUCKI.E
OUTBOARDJOINT
16-18
3.
lnsertthe inboardend of the driveshaftinto the dift e r e n t i a lo r i n t e r m e d i a t es h a f t u n t i l t h e s e t r i n g
locksin the groove
NOTE: Cleanthe areaswhere the driveshaftcontact
the transmission(differential)thoroughlywith solvent
or carburetorcleaner,and dry with compressedair'
5. lnstallthe dampertork over the driveshaftand onto
t h e l o w e r a r m . I n s t a l lt h e d a m p e r i n t h e d a m p e r
fork so the aligningtab is alignedwith the slot in
the damPerfork.
FLANGEBOLT
l0 r 1.25mm
rit N.m t4.akgf.m,32 lbf.ft)
AIIGN|NGTAB
JOINT
INBOARD
INBOARDJOINT
Replace.
GROOVE
an
NUT
SELF-LOGKING
12x 1.25mm
6,1N.m16.5kgi.m,a7 lbfftl
Replace.
Loosely install the flange bolts and the new selflockingnut.
1 . Apply oil to the seatingsurfaceof the new spindle
nut.
DIFFERENTIAL
FRONTWHEEL
lnstall the knuckieon the lower arm. then trghten
the castlenut and installa new cotterpin
WHEELNUT 12 x 1.5 mm
108N.m (11.0kgl'm, g) lbl ftl
NOTE: wipe off the grease before tightening the
nut at the ball ioint.
CAUTION:
. Be careful not to damagothe ball ioint boot'
. Torque the castle nut to the lower torque sp€cification, thsn tighten it only far enough to align
the slot with th€ pin hol6. Do not align the nut
by loosening.
J
CASTLENUT
12 x 1.25 mm
i$ - 59 N.m 15.0- 6.0 kgl m,35 - 43 lbf ftl
COTTERPIN
Replace.
On reassemblY,
bendthe cotterpin
SPINDLENUT 22 x 1.5 mm
kgt'm,13illbt'ftl
181N m 118.5
usea driftto
NOTE:Aftortightening,
stakethespindlenutshoulderagainstthe drivoshaft'
8. Installa new spindlenut,then tightenthe nut'
9. Cleanthe mating surfacesot the brakedisc and the
wheel. then install the front wheel with the wheel
nuts.
10. Tighten the flange bolts and the new self-locking
nut with the vehicle'sweighton the damper.
fluid (see
11. Refillthe transmissionwith recommended
section13 or 14).
't2. Checkthe front wheel alignmentand adjust if necessary(seesection18),
16-19
IntermediateShaft
Removal
'1.
Disassembly
Drainthe transmissionoil or fluid {seesection13 or
r4).
NOTE: Be carefulnot to damagethe metal rings on the
intermediate
shaftduringdisassembly.
Removethe left driveshaft(seepage 16-3).
1.
Removethe set ring.
3 . Removethe threedowel bolts.
2.
Removethe intermediateshaft outer seal from the
Deaflngsuppon.
OOWELBOLTS
'10x 1.25mm
3.
Removethe externalcirclip,
2.
Removethe intermediate
shaftfrom the differential.
CAUTION: Hold the intermsdiate shaft horizontal
until it is clear of lhe dilterential to prevent damage
to the differential oil seal.
INTERMEDIATE
SHAFT
16-20
Disassembly
shaft bearingout ot the bearPressthe intermediate
ing support using the specialtools and a pressas
shown.
6.
Pressthe intermediateshaftout of the shaft bearing
usingthe specialtools and a pressas shown.
Removethe internalcircliP
Press
INTERNALCIBCLIP
I
Press
HANOLEDRIVER
0?749- 00'10000
SUPPORTBASE
ATTACHMENT
07JAF- SH20400
RING
SUPPORT
BEARING
or distortion
for damage
Check
I
DRIVERATTACHMENT,
12x47 mm
07746- 0010300
FLOATINGRUBBEB
DAMPER
Checkfor deterioration
and oamage.
BASE
SUPPORT
ATTACHMENT
07JAF_ SH20it00
BEARINGSUPPORT
Checkfor damage
ReassemblY
NOTE:
compressedair' Do not wash the rubber
. clean the disassembtedparts with solvent,and dry them thoroughlywith
partswith solvent.
reassembly'
. Becarefulnot to damagethe metalringson the intermediateshaftduring
BEARINGSUPPORTRING
DOWELBOLTS
1 0x 1 . 2 5m m
39 N.m 14.0kgf.m,29lbIftl
EXTERNALCIRCLIP
Packthe interior
of the outerseal.
2.0-35s10.07-012oz)
SHAFTRING
INTERMEDIATE
I
INTERNALCIRCLIP
A4\
SHAFTBEARING
INTERMEDTATE
Replace,
l J
sErR'NG
Reolace
VU
OUTERSEAL
Replace.
(cont'd)
16-21
lntermediateShaft
(cont'd)
Reassembly
1.
Pressthe intermediateshaft bearinginto the bearing support using the specialtools and a press as
shown.
Seatthe externalcirclip in the groove of the intermediateshaft.
Installthe outer seal into the bearingsupportusing
the specialtools as shown.
Prass
I
NOTE: Installthe seal ftush with the bearingsupport.
Pre$
t
DRIVER
ATTACHMENT,
52x55mm
07746- 0010(X)
Packthe Interior
of the ouler seal.
2.0- 3.5g {0.07-0.12 ozl
HANDr.r
DRTVER
- 0011r(x)0
ORIVERATTACHMENT,
52x55mm
077i16- 0010/O0
OUTENSEAL
Seatthe internalcirclipin the grooveof the bearing
suppon.
Pressthe intermediateshaft into the shaft bearing
usingthe specialtools and a press.
Praa.r
I
@--LJ
INTERMEDIATE
SHAFT
Install the new set ring in the intermediateshaft
groove.
DRIVERATTACHMENT,35mm LD.
16-22
lnstallation
1.
lnsertthe intermediateshaft assemblyinto the differential.
CAUTION:Hold the intermodiateshaft horizontal
to prevent damag€to the difterential oil seal'
shaft
NOTE:Cleanthe areaswherethe intermediate
(differential)
thoroughly
transmission
the
contacts
with solvent or carburetorcleaner,and dry with comair,
Dressed
2.
Installthe three dowel bolts,then tightenthem'
DOWELBOLTS
10x 1.25mm
39 N.m {i1.0kgf'm, 29 lbf'ftl
l z
16-23
l .
Steering
Tools
Speciaf
t
Ir/
....."'.....17-2 Inspection and Adiustment
17-30
SteeringOperation'......."'........'......
Power Assist Check
ManualSteering
17-30
With VehicleParked.."................
ComponentLocations
17-31
....."
SteeringLinkageand Gearbox
.......17-3
lndex ................
...--."""..17-32
Pump Beft
Inspectionand Adiustment
17'33
RackGuide Adiustment .'.......'.......'.
17-4
SteeringOperation"'......"...............
17-33
FluidReplacement.....'..".................
17-5
RackGuideAdiustment...................
" 17-34
Pump PressureCheck .............'....-.
*SteeringWheel
'Steering Wheel
(Seepower steering section)
17-35
.."'........'...
*SteeringColumn
Removal
17-35
.............
(Seepower steering sectionl
lnstallation
17-36
......'.....'.'
Disassembly/Reassembly
SteeringGearbox
*Steering
17-5
.................
Column
Removal
17'37
---....
.......""17-7
Removal/lnstallation....'...........
Disassembly
17'38
17-9
..............
..'.........
lnspection
ReassemblY
17-13 Power Steering Hoses,Lines
.............
lnstallation
17-39
FluidLeakageInspeetion............'....
......"..17-39
Replacement
PowerSteering
Component Locations
"""' 17-15
lndex ".......".....
System DescriPtion
17'16
FluidFlow Diagram........."".............
17-17
"........"'...-SteeringPump ............'...
17-20
SteeringGearbox.".................'...'.'.'
Power Steering PumP
17-40
.'.'..'..'.............
Removal/lnstallation
".........17-41
Disassembly
17'42
.......---'."
fnspection
..'.........17-44
Reassembly
SteeringGearbox
17'47
....'........."'
Removal
Troubleshooting
17'22
..........'17-49
DisassemblY
GenerafTroubleshooting..........--....
-26
17-55
17
'...........
Reassembly
Noiseand Vibration.........................
17-65
.............
.............17-28 lnstallation
FfuidLeaks
Ball Joint Boot Replacement.......'..17-68
lp
Ref. No
I
o
@
@
@
@
fof
@
@
@
@
@
@
@
@
@
@
@
@
Tool Number
- PH70100
07GAF
- SD4010A
07GAG
or
- SD40100
07GAG
- SD4020A
07GAG
or
- S040200
07GAG
*07JGG
- 00r010A
07MAC- 5100200
- SR3O2OA
OTNAD
- SR3090A
07NAG
or
07NAG- SR30900
- 5040110
07RAK
- 5040121
07RAK
or
- 5040t20
07RAK
- 0010004
07406
or
07406 001000r
07725- 0030000
- 0010100
07746
- 0020100
07746
07746- 0030300
- 0010000
07749
- SA50001
07916
07965- SA50500
07974- SA5020A
or
07974- SA50200
07974- SA50800
Description
Oty
I Pag€Reterence
PilotCollar
PistonSealRingGuide
1
1
11-54
17-59
PistonSealRingSizingTool
'I
'17-59
BeltTensionGauge
BallJoint Remover,28 mm
CylinderEndSealBemoverAttachment
PistonSealRingSizingTool
1
'I
1
I
17-32
17-6,47
17-51
| /-ao
P/SJoint Adaptor(Pump)
P/SJoint Adaptor (Hose)
1
1
17-34
17-31
't7-34
P/S PressureGauge
UniversalHolder
Attachment,32x 35 mm
Driver,22 mm l.D.
Attachment,30 mm l.D.
Driver
LocknutWrench, 40 mm
FrontHub DiVAssemblyTool
SleeveSealRingSizingTool
@
BsllJoint BootClip Guide
* lncludedin the BeltTensioncauge Set,07TGGOO10OOA.
I
1
1
I
1
1
I
1
't7-42,16
17-57,58
17-10
17-44
't7-57
17-5,33
17-68
17-57
I
17-57,6A
p
v
o
€_
ts7-
(o)
F=1
dysB
@
aal
@
@
@
@
17-2
o
@
@
@
@
ComponentLocations
t
lndex
ManualSteering
NOTE:
beenfound defectiveor damageddur. lf an intactairbagassemblyhas been removedfrom a scrappedvehicleor has
(see
24)'
section
be
deployed
ing transit.storageor service,it should
o Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel
. After installingthe gearbox,checkthe wheelalignmentandadjustif necessary
precautions,
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,
section124)beforeperformingrepairsor service'
WHEEL
STEERING
Removal/lnstallation,
Page17'35
page17-36
Disassembly/FeassemblY,
DRIVER'SAIRBAGASSEMBLY
seesection24
Removal/lnstallation,
J
STEERINGCOLUMN
Removal/lnstallation,
Page17-37
page17'38
Inspection,
CABLEREEL
seesection24
Removal/lnstallation,
SWITCH
IGNTTION
See section23
t,
STEERINGGEARBOX
RackGuideAdiustment,Page17-5
Removai,page17'5
Disassembly,
Page17_7
page17_9
Reassembly,
page17 13
Installation,
TIE.RODEND BALLJOINT
page17-68
BallJoint BootReplacement,
17-3
Inspectionand Adjustment
SteeringOperation
SteeringWheelRotationalPlay
Placethe front wheels in a straightaheadpositionand
measurethe distancethe steeringwheel can be turned
without movingthe front wheels.
Ste€ring Effort Check
Raisethe front wheelsoff the ground.
Turn the steeringwheelwith a springscaleand checkits
reaorng,
ROTATIONAL
PLAY:0 - 10 mm (0 - 0.4 in)
Standard:15 N (1.5kgf,3.3 lbll maximum
lf the play exceedsthe servicelimit, perform rackguide
adjustment(seepage lT-5).
lf the play is still excessiveafter rack guide adjustment,
inspectthe steeringlinkageand gearbox as descrjbed
Detow.
l f i t r e a d sm o r e . p e r f o r m r a c k g u i d e a d j u s t m e n (t s e e
p a g e1 7 - 5 ) .
a o \---------U
Steering Linkageand Gearbox
TIE.ROOLOCKNUT
Checkfor looselocknut.
BOOT
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t i o n .
STEERING
JOINTS
Checkfor loosejoint
COLUMN
Inspectfor loosecolumn
mountingboltsand nuts.
PINIONSHAFTGROMMET
for damageand deterioration.
END BALLJOINT
I n s p e c tf o r f a u l t y m o v e m e n t
ano oamage.
GEABBOXMOUNTING
Inspectf or deterioration.
GEABBOXASSEMBLY
I n s p e c tf o r l o o s e m o u n t i n g b o l t s .
17-4
BALLJOINT BOOT
Inspectfor damageand deterioration.
See pago 17-68tor replacement.
SteeringGearbox
RackGuideAdjustment
Removal
N O T E : P e r f o r mt h e r a c k g u i d e a d j u s t m e n tw i t h t h e
wheelsin the straightaheadposition.
NOTE:Using solventand a brush,to wash any oil and
dirt off the gearbox.Blow dry with compressedair.
1.
Loosenthe rack guide screw locknutwith the specialtool, then loosenthe rackguidescrew.
1.
Raisethe front of vehicle,and supportit on satety
standsin the properlocations(seesectionI ).
2.
Removethe front wheels.
3.
Removethe steeringwheel(seepage 17-35).
4.
Removethe steeringloint cover
RACKGUIDESCREW
JOINTCOVER
STEERING
WRENCH,
40mm
LOCKNUT
07916- SA5000r
l.r
the
Tightenthe rackguide screwuntil it compresses
springand seatsagainstthe rackguide,then loosen
rt.
Retightenthe rackguide screwto 4 N'm (0.4kgf m,
2.9 lbf.ft),then backit off to specifiedangle.
SpeciliedReturn Angle: 30' max.
4.
Removethe steeringjoint lower bolt, and disconnect the steeringjoint by moving the joint toward
t h ec o l u m n .
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
JOINT
STEERING
Checkfor tight or loose steeringthrough the completeturningtravel.
Rechecksteeringeffort(seepage17-4).
l,z
LOWERBOLT
(cont'd)
17-5
SteeringGearbox
Removal(cont'd)
Removethe cotter pin from the castle nut ('96 - '97
models)or nut ('98- '00 models)and removethe nut.
13. Removethe mountingbracket,
Replace.
7 . Installthe10 mm hex nut on the ball joint.
Be sure that the 10 mm hex nut is flush with the ball
joint pin end, or the threadedsectionof the ball joint
pin mightbe damagedby the balljointremover.
NOTE:Removethe ball joint usingthe specialtool,
Refer to section 18 for how to use tho ball joint
remover.
Separatethe tie-rodball joint and knuckleusingthe
specialtool.
CAUTION: Avoid damaging the ball ioint boot.
Pullthe steeringgearboxall the way down to clear
th€ pinionshaftfrom the bulkhead,then removethe
pinionshaftgrommet,
t5.
Move the steering gearbox to right so the left rack
end clearsthe rearbeam,then tilt the left side down
to remove it from the car.
Removethe left tie-rod end, then slide the rack all
the way to the right.
'10.Separatethe exhaustpipeA
or TWC (seesectiong).
PINIONSHAFTGROMMET
1 1 . Disconnectthe shift linkage(seesection13 or section14).
12. Removethe stiffener plate.
STEENINGGEARBOX
17-6
Disassembly
)
'1.
2.
Placethe gearboxin a vise with a soft jaws, then
c l a m p t h e g e a r b o xa t t h e m o u n t b r a c k e to r g e a r
housing.
Pushthe right end of the rack backinto the cylinder
housing so the smooth surfacethat rides against
the sealwon't be damaged.
CAUTION: Be carcful not to distort the gear housin9 by clamping it too iight in the vise incorrectly.
L o o s e nt h e l o c k n u t ,a n d r e m o v e t h e r a c k g u i d e
screw.
7.
Removethe tie-rodend and locknut.
R e m o v et h e d i s c w a s h e r ,s p r i n g a n d r a c k g u i d e
from the gear housing.
Removethe boot bands and tie-rod clips. Pull the
bogtsawayfrom the ends of the gearbox.
RACKGUIOE
SPRING
DISCWASHER
LOCKNUT
TIE.RODCLIP
/
4.
H o l d t h e s t e e r i n gr a c k w i t h o n e w r e n c h , a n d
unscrewthe rackend with anotherwrench.
CAUTION: Be caleful not to damagc the rack sur'
facs with the wrench.
STEERINGRACKENO
RACKGUIDESCREW
8.
Removethe pinion dust seal and the 35 mm snap
nng.
9.
Holdthe pinionshattwith a visesecurely
Removethe pinion by tapping evenly around the
flangedsectionof the gearboxwith a plastichammet.
CAUTION: Do not tap on tho steering rack.
NOTE| Do not reusethe removedpinion.
9._
ViF=\_
PINIONDUSTSEAL
Replace.
SNAPRING,35mm
STEERINGPINION
Feplace.
l ,
17-7
SteeringGearbox
(cont'dl
Disassembly
10. Slidethe steeringrackout of the cylinderhousing.
CAUTION: Be carelul not to damage the bushing in
the cylinderhousing.
12. Replace
the gearboxmountingcushionif necessary:
.
.
To removethe cushion,usea sharpknifeand make
a cut downthe lengthof the cushion.Becarefulnot
to damagethe painton the outsideof the cylinder
housing.Removethe old cushion.
Apply weatherstripadhesiveto the insideof the
new cushion.Installthe cushiononto the cylinder
housingand positionit 20 - 22 mm (0.79- 0.87in)
from the end of the cylinderhousingas shown.
N O T E :A f t e r i n s t a l l i n gt h e c u s h i o n ,w i p e o f f a n y
e x c e s sa d h e s i v et h a t m a y h a v e d r i p p e d i n t o t h e
i n s i d eo f t h e c y l i n d e hr o u s i n g .
1 1 . R e m o v et h e r a c ke n d b u s h i n g .
GEARBOXMOUNTINGCUSHION
20 - 22 mm 10.79- 0.87 in)
Inspectinnerwall tor wear or damage.
17-8
Reassembly
NOTE:
partswith solvent,and dry them with compressedair. Do not dip the rubberpartsin solvent.
. Cleanthe disassembled
. Alwavsreplacethe non reuseablepartswith new ones beforeassembly
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe steeringgearbox.
PINIONOUSTSEAL
Replace.
-6,1
RACKENOBUSHING
MOUNTINGCUSHIONS
GEARBOX
\
^lr
-6i
t r
r@
V."^pR,NG,3smm
a
/
^$'q0
")*o''o"'"'*
\
DISCWASHER
RACKGUIDE
t J
(cont'd)
17-9
Steering Gearbox
(cont'dl
Reassembly
L
Apply a thin coat of greaseto the insidesurfaceof
t h e r a c ke n d b u s h i n g .
Drivein the steeringpinion in the gear housingwith
the soecialtools.
Greasequantity:1 - 3 S 10.04-0.1ozl
CAUTION:Do not till the slots with greas€;th€y
must remain open to serve as air passages,
ORIVER.
22 mm l.D.
o7716qr20100
I n s t a ltl h e r a c ke n d b u s h i n gb y a l i g n i n gt h e r o u n d
projectionon the bushingwith the hole in the cylind e rh o u s i n g
PINIONDUST
SEAL
Replace.
SNAPRING,35 mm
Vinyltape
STEERING
PINION
I n s t a l lt h e 3 5 m m s n a p r i n g s e c u r e l yi n t h e g e a r
housinggroove.
7 . Apply vinyl tape to the pinion shaft,then coat the
vinyltapewith grease.
Installthe piniondust sealon the gear housinguntil
it seatsproperly,then removethe tape.
Greasethe steeringrackteeth.
4.
I n s t a l lt h e s t e e r i n gr a c k i n t o t h e c y l i n d e rh o u s i n g
carefullyto avoiddamagingthe rackend bushing.
G r e a s et h e s l i d i n gs u r f a c eo f t h e r a c k g u i d e ,a n d
installit on to the gear housing.
1 0 . Installthe spring,discwasherand rackguide screw
on the gear housing.
NOTE:Installthe disc washerwith its convexside
facingin.
Dtscw,
a(-\
\ l 1* l
\,
,/
\
SPRING
LOCKNUT
CYLINDERHOUSING
17-10
RACKGUTDE
RACKGUIOESCREW
11. Adjustthe rackguidescrew(seepage 17-5).
I t
12. l n s t a l lt h e n e w l o c k w a s h e r i n t h e g r o o v e i n t h e
steeringrack.
1 3 . Installthesteeringrackend into the rack
LOCKWASHER
Replace.
16. Apply grease around the outside ot the rack end
housing.
RACKEND 54 N m ts.s kgf'm, 40 lbtft)
=-.
.r=-q!q!!.n
SILICONEGREASE
TAB
RACK END
(l*v
1 4 . Hold the steering rack with a wrench and tighten
the rackend with another.
CAUTION: Be careful not to damage the tack surfac€ with the wrench.
1 5 . After tighteningthe rack ends, stakethe four sections of the lock washer with a roll pin drift and a
mallet.
. Placethe wood blockon the presstable.then set
the lock washer section of the rack end on the
wood blocksecurelY.
. Be sure the tool is alignedwith the flat sections
of the steeringrackend beforepressing
. Stakethe lock washer in the center of the flat
section of the steering rack end.
1 7 . Apply a light coat of silicone grease to the boot
grooveson the rackends.
lnstall the boots in the rack end with the tie-rod
clips.
NOTE: Install the boot band with the rack in the
straight ahead position (right and left tie-rodsare
equalin length).
NOTE| WiPe greaseoff
the threadsectlon
ROLLPIN DnlFTl
(Commorci.lly.Yril.blol
Snap-OnNo. PPRSor oquival.nt
rl,
NOTE: This drift has a flat
tip, to prevent puncturing
of metalwasher.
nlCr/
srEEatruG
WOODENBLOCK
TIE.ROOCLIP
(cont'd)
17-11
SteeringGearbox
Reassembly(cont'd)
'19.
Installthe boot band so that the lockingtabs of the
band(stakepoints)are in the rangeshown below.
{ T a b ss h o u l df a c eu p a n d s l i g h t l yf o r w a r o . ,
2 2 . S l i d et h e r a c kr i g h t a n d l e f t t o b e c e r t a i nt h a t t h e
bootsare not detormedor twisted.
20. Bendboth setsof lockingtabs.
2 1 . Lightlytap on the doubled-overportionsto reduce
t h e i rh e i g h t .
CAUTION:Stakethe band lockingtabs firmly.
Stakepoints
+
Lett Boot Band
(Viewedfrom the left side)
17-12
Right Boot Bend
(Viewedfrom the right side)
Fronr
lnstallation
)
1.
Slidethe rackall the way to the righl
2.
Installthe pinion shaft grommet,and insertthe pin
i o n s h a f tu p t h r o u g ht h e b u l k h e a d .
4.
I n s t a l lt h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateattachingbolts.
N O T E rI n s t a l lt h e b o l t s l o o s e l yf i r s t . t h e n t i g h t e n
them securely.
PLATE
STIFFENER
NOTE|Align the notch in the pinion shaft grommet
w i t h t h e t a b o n t h e g e a rh o u s i n g .
ATTACHINGBOLTS
38 N.m (3.9kgf.m.28lbf.ftl
STEEBINGGEARBOX
J
3.
Installthe mountingbracketswith the two gearbox
m o u n t i n gb o l t so n t h e c u s h i o n .
EOLTS
MOUNTING
GEARBOX
43N.m{4.4kgf.m,32lbf'ftl
5.
6.
Centerthe steeringrackwithin its stroke
Slip the lower end ot the steeringjoint onto the pin
ion shaft(line up the bolt hole with the groove
aroundthe shaft),and tightenthe lower bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
steeringwheeland steeringrackcentered
B e s u r e t h a t t h e l o w e r s t e e r i n gj o i n t b o l t i s
s e c u r e l yi n t h e g r o o v ei n t h e s t e e r i n gg e a r b o x
p i ni o n .
lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringioint.
JOINT
STEERING
{4.0 kgt.m,29 lbf.ftl
NOTE:The arrowon the bracket
pointtowardthe front.
J
JOINT
STEERING
LOWERBOLT
22 N.m
{2.2kgf.m,16lbf'ft}
(cont'd)
I t- t5
SteeringGearbox
Installation(cont'dl
7.
Centerthe cable reel by first rotating it clockwise
until it stops.Then rotate it counterclockwise
(approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel(seepage 17-35).
9. Reconnsctthe ti€-rod ends to the steering knuckles,
thon tightsn th€ castlenut ('96-'97 models)or nut
('98-'00 models)to the specifiedtorque,and install
new cotter pins.
NOTE: Before connecting the tie-rod ends, wipe off
a n y g r e a s ec o n t a m i n a t i o nf r o m t h e b a l l j o i n t
tapered section and threads.
Installthe steeringjoint cov€r with the clampsand
clrps.
CAUTION: Torque lhe ct3tle nut to thr lowsr torque
spocification,th€n tighton it only tar anough to
align the 3lot with tho pin hob. Do not align the
nut by loosening ('96 - '97 modcls onlyl.
STEERING
JOINI COVER
TIE.ROD
'96 - 37 model3:
CAST1TNUT
,O - ilt N'm
{4,0 - 4.8 kgf.m.
29 - 35 tbtftl
COTTERPINS
R6plac6.
On rgassombly,b6nd
cotter prn as shown.
'98 - '00 modol3:
NUT
4a N.m
(4.5kgf.m,
33 lbr.ftl
10. Installthe exhaustpipe A or TWC (seesection9).
l l . Connectthe shift linkage (see section 13 or section
14).
Installthe front wheels.
After installation,perform the following checks.
.
.
Adjust the front toe (seesection 18).
Checkthe steering wheel spoke angle. Adjust by
turning the right and left tie-rods, if necessary.
NOTE:Turn the right and lefttie-rodsequally.
17-14
ComponentLocations
I
lndex
Power Steering:
NOTE:
. li an intactairbagassemblyhas been removedtrom a scrappedvehicleor has beenfound defectiveor damagedduring transit.storageor service,it shouldbe deployed(seesection24).
. Beforeremovingthe gearbox,removethe driver'sairbagassemblyand steeringwheel.
. After installingthe gearbox,checkthewheelalignmentandadjustif necessary.
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions,
section{24}beforeperformingrepairsor service.
WHEEL
STEERING
page17-35
Removal/lnstallation,
page17-36
Disassembly/Feassembly,
DRIVER'SAIRBAGASSEMBLY
seesection24
Removal/lnstallation,
/
STEERINGGEAREOX
page17'33
RackGuideAdiustment,
Removal,page17 47
page17-49
Disassembly,
page17-55
Reassembly,
page17-65
Installation,
VALVEEODYUNIT
Overhaul,page17 52
COLUMN
page17-37
Femoval/lnstallation,
page17-38
Inspection,
CASLEREEL
see section24
Removal/lnstallation,
IGNITIONSWITCH
Seesection23
1,,
POWEFSTEERINGPUMP
page11-32
PumpBeltInspection,
PumpBeltAdiustmenl,page11'32
PumpPressure
Check,page17 34
page17'40
Removal/lnstallation,
page17-41
Disassembly/Reassembly,
TIE.RODEND BALLJOINT
page17-68
BallJointBootReplacement,
17-15
System Description
FluidFlow Diagram
power steering,connectedto the steeringgearbox.The fluid pressureis proThe system is a compactrotary-valve-type
vided by a vane-typepump which is driven by the enginecrankpulley.The amount of fluid and pressureis regulatedby
the flow controlvalvebuilt into the pump.The fluid pressurefrom the pump is deliveredto the valvebody unit aroundthe
pinionof the steeringgearbox.The valveinsidethe valvebody unit controlsthe hydraulicpressureand changesthe direction of the flow. The fluid then flows to the powercylinder.where rackthrust is generated.Fluid returningfrom the power
cylinderflows backto the reservoir,wherethe fluid is "filtered"and suppliedto the pump again.
RESERVOIR
VALVEBOOYUNIT
SUB.VALVE
FLOWCONTROLVALVE
17-16
STEERINGGEARBOX
SteeringPump
)
Construction
The pump is a vane-typeincorporatinga flow controlvalve(with an integratedreliefvalve)and is drivenby a POLY-V-belt
operationsfor every rotafrom the crank pulley.The pump features10 vanes.Eachvane performstwo intake/discharge
discharge.
small
during
pulse
pressure
becomes
extremely
hydraulic
fluid
that
the
tion of the rotor.This means
FLOWCONTROLVALVE
ROTOR
/
VANE
CAM RING
Operation
The belt-drivenpulley rotatesthe rotor through the drive shaft.As the rotor rotates,the hydraulicpressureis appliedto
of the cam ring.
the vanechamberof rhe rotor and the vaneswill rotatewhile beingpushedonto the innercircumference
so the vanes
of
the
shaft,
center
portion
respect
to
the
with
The inner circumferenceof the cam ring has an extended
volume
of the
internal
the
movement.
this
roller
As
a
result
of
rotates.
as
the
rotor
direction
in
the
axial
move downward
vanechamberwill change,resultingin fluid intakeand discharge
J
FLUIDMOVEMENT:
STARTOF FLUIDINTAKE:
FLUIDINTAKE:
The vanes are pushed onto
the inner circumferenceol the
cam ring,
l h e v o l u m eo f t h e v a n ec h a m - T h e s u c k e d - i nf l u i d m o v e s
ber increasesso that fluid is towardthe dischargeport.
suckedin.
FLUIDDISCHARGE:
As the vanes return to the
t h e i r o r i g i n a lP o s i t i o no n t h e
inner side,the volume of the
v a n e c h a m b e rd e c r e a s e s o
t h e f l u i d i s d i s c h a r g e df r o m
the dischargeport.
(cont'd)
a - t
I I-
4 -
| t
SystemDescription
SteeringPump(cont'dl
The flow control valve and sub-valvein the pump performs the following steps @ through @ to control the
flow of fluid, that is to increasethe dischargevolume
when enginespeedis low, and to decreaseit when the
engine speed increases.The assistancethrust of the
s t e e r i n gg e a r b o xc h a n g e si n c o m p l i a n c ew i t h t h e
changein the dischargevolume.
FLOWCURVE
l o
t r r
t r r
l o
3
J
PUMP R.P.M.
o
When the engine starts,fluid dischargedfrom the
dischargeport startsto flow through oil passageA,
the fixed orificeand the variableorificeto the steering gearbox.When the engine speed is extremely
low, the return port is closed by the flow control
To STEERING GEARBOX
Fluid pressuredischargedfrom the dischargeport
is appliedto the top of the sub-valve,and the fluid
pressurethat passedthrough oil passageA is applied
to the bottom of the sub-valve.When this happens,
the pressuredifferencebetweenthe ends of oil passageA, which is causedby the resistanceoil passage
A w h e n t h e f l u i d f l o w s t h r o u g h t h e p a s s a g e .i s
appliedto the sub-valve,However,the pressuredifferenceapplied to the sub-valve.that is the force
that pushes the sub-valve down, is too small to
overcomethe spring force, and the variableorifice is
fully openwhen the enginespeedis extremelylow.
Becausethe fluid volume flowing throughthe fixed
orificeand variableorificeincreases,
a pressuredifterence is createdbetweenthe ends of these orifices, and it increasesin proportionto the engine
speed.As the fluid pressurethat passedthe fixed
orificeand variableorificeis directedto the bottom
of the flow control valve. a pressuredifferenceis
created between the top and bottom of the valve,
w h i c h p u s h e sd o w n t h e f l o w c o n t r o l v a l v e a n d
opens the return port. As a result,pan of the fluid
dischargedfrom the dischargeport feturns to the
pump suction port, keepingthe dischargevolume
constant.
In this condition,the sub-valvedoes not move. and
the variableorificestaysfully open.
SUB.VALVE
!rs+/f/ffih\\
o,,-i^"l^tKzYt)9
1y ul3Yl
FLOW CONTNOLVALVE
To STEEnINGGEARBOX
su8-vALvE
ORIFICE
ToP
FLOWCONTROLVALVE
17-1 8
t
To STEERINGGEARBOX
@ The fluid volumethat flows thoroughoil passageA
and the pressuredjfferenceappliedto the sub-valve
i n c r e a s ei n p r o p o r t i o nt o t h e e n g i n e s p e e d .T h e
sub-valvelowers overcomingthe spring force,and
it stans to closethe variableorificeto regulatethe
dischargevolume,Whenthis happens,the fluid volume flowing to the steeringgearboxdecreasesas
the engine speed increases.At the same time, the
flow controlvalvecontinuesto controlthe fluid volume to the returnPort,
To STEERINGGEAREOx
SUB.VALVE
@ As the enginespeedincreasesfunher, the pressure
differenceat the sub-valveincreasesfurtheras well.
The sub-valvethen closesthe variableorificecomp l e t e l y ,r e g u l a t i n gt h e d i s c h a r g ev o l u m e f u r t h e r .
W h e n t h i s h a p p e n s t, h e f l u i d v o l u m e d i s c h a r g e d
from the pump to the steeringgearboxis regulated
a n d m a i n t a i n e da t a g i v e n l e v e l u n t i l t h e e n g i n e
speedreachesthe high speedrange The flow control valve functions continuesto control the fluid
volumeto the returnPort.
/F
ft>..\
'-€/K\A/A
o'.'to"5lo'#2"n
af
11\D7
FLOWCONTROLVALVE
PressureRelief
P r e s s u r ea t t h e d i s c h a r g es i d e o f t h e f i x e d o r i f i c ei s
directedto the bottom of the flow control valve.When
the pressurebuilds up, the reliefvalve in the flow control valveopensto releasethe pressureat the bottomof
the valve.This allows the flow control valve to be
pushed back by the pressuredifference,and the fluid
volumeto the pump returnport increases.
As explainedabove. the system keepsthe pump disc h a r g ep r e s s u r e( r e l i e fp r e s s u r ef)r o m e x c e e d i n gt h e
given level by controllingthe volume of the fluid to the
pump relurn pon,
1.,
FLOWCONTROLVALVE
DAMPINGORIFICE
{Docreasesexcessiv€
vibration in the valv6.)
RELIEFVALVE {Opan)
17-19
System Description
Steering Gearbox
The rack-and-pinion
type steeringgearboxhas a valvebody unit incorporatedwith the pinionto controlthe steeringfluid
pressure.Steeringfluid from the pump is regulatedby a rotaryvalve in the valve body unit and is sent throughthe cylin,
der line to the power cylinder,where hydraulicpressureis applied.The steeringfluid in the other side of the power cylin,
der returnsthroughthe cylinderline and valvebody unit to the reservoii.
VALVEEODYUNIT
CYLINDERLINE
To RESERVOm
+FromPUMP -;
POWERCYLINDER
Valve Body Unit
Insidethe valve body unit is the valve,which is coaxialwith the pinion shaft,and controlsthe steeringfluid pressure.The
valve housingis connectedwith the fluid line from the pump,the returnline to the reservoir,and the two cylinderlines
from the respectivepower cylinder.The pinion shaft is double- structuredwith the input shaft connectedto the pinion
gear,both of which are interconnected
with the torsionbar.
The pin insertedin the valve and the pinion shaft grooveengage;this allowsthe pinion shaft to rotatetogetherwith the
valve.Becauseof this construction,
the differencein angle in the circumferential
directionbetweenthe input shaftand the
valve becomeslargeraccordingto the torsionalstrengthof the pinionor steeringresistance.
However,maximumtorsion
betweenthe shaftsis regulatedby the engagedsplinesof the shaftsat the pin engagementsectionto hold the torsionbar
within the set value,
This allowsthe steeringsystemto functionas an ordinaryrack-and-pinion
type steeringif the steeringfluid is not pressurizedbecauseof a faulty pump,
VALVE
Difforencein angle botwoon the
input shaft and pinion shsft
PINIONSHAFT
lo
-l
INPUTSHAFT
17-20
a
INPUTSHAFT
Control
Pressure
Low assistat higherspeeds:
W h e n s t e e r i n g r e s i s t a n c e I s I o w , s u c h a s w h e n d r i v i n g a t h i g h s p e e d s , o r w h e n d r i v i n g soIt rthe
a i gfeed
h t a pressure
head,theinpu
power cylinderorifices.Most
nearor in the neutralposition,so there is little or no fiow ro any of the
fromthepumpisbypassedtothereservoir.Becauseofthis,thepressurestaysthesameinbothsidesofthepo
der, resultingin low or no asslst
VALVE
From PUMP
RESERVOIR
RETURNPASSAGE
lTo RESERVOIRI
SECTIONA-A
POWERCYLINDER
STEERINGGEARBOX
Highassistat lower speeds:
low speeds'or when turning the wheel wirh the vehicle
When steering resistanceis high. such as when driving at
stopped,thedifference|nang|ecreatedbetweentheinputshaftandtheVa|veopensthef|uidpassageonon
c|osesthefluidpassageontheotherside,ateachpairoforifices'Thef|uidpressureincreasesinthesideo|th
c y | i n d e r | e d b y t h e | a r g e r f | u i d p a s s a g e ' T h i s i n c r e a s e d p r e s s u r e p u s h e s o n t h e r a c k p i s t o n , athe
| l osteering
wingthe
s t eto
eringwh
tluid
the returnpassageopensallowing
be turnedwith light effort.on the other sideof the powercylinder,
r e t u r n t h r o U g h t h e i n p u t s h a f t t o t h e r e s e r v o i r ' T h e f | u i d p a s s a g e s t o t h e p o w e r c and
y | i npower
d e r a uassist
t o m aincreases
tica||ychang
increases.In other words, the passagesbecomelarger
increasingas the steeringresrstance
(for example'when parkingor makinglow speedturns)' and the paswhen the steeringeffort would normallybe high,
sagesbecomesma||erandpowerassistdecreaseswhenthesteeringeffortwou|dnorma||ybe|ow,(forexamp|e,w
drivingat high speedsor straightahead).
FLUIOPASSAGETO
POWERCYLINDER
/t=\
\a!-4,))
=YjJ
SECTIONA-A
l'
{High fluid Pressure}
Troubleshooting
GeneralTroubleshooting
Checkthe followingbeforeyou begin:
. Hasthe suspensionbeenmodifiedin a way that would affectsteering?
. Are tire sizes,tire varietyand air pressurecorrect?
. lsthe steeringwheeloriginalequipmentor equivalent?
. lsthe powersteeringpump belt properlyadiusted?
. ls steeringfluidreservoirfilledtoproperlevel?
. ls the engineidle speedcorrectand steady?
HardSteering(Checkthe poworassist.se€page17-3o.lfthe torce is over 29 N (3.0kgf,6.6lbo, Procedewith this troubleshootinq.)
Checkthe pump fluid pressure
(soepage17-34).
l/easure steady-state
tluid press!re while idling with the both
valvestully open.
It should be 1.500kPa(15 kgf/cmr,
213psi)or below.
Abnormal
lluid pressure
{fluid pressure
is too high)
C h € c kt h e f e e d s n d r e t u r n c i r c u i t l i n € s a n o n o s e
betw6€n the gearbox and pump for clogging and
d€lormation.
Normallineand hose
Normal
Faultyvalve body unit
Checkthe pump fluid pressure
{seepage 17-34).
M e a s u r ep u m p r e l i e f p r e s s u r e
while idling with the pressurecontrol valveIully closed.
It should be 6,400- 7,400kPa(6575 kgflcm,,920- 1,070psi)
Reliefpressure too low
Checkth€ flow control vslve (see page 17-42).
. Chockthe valvo lor smooth movement in the housing.
. Checkthe reliefvalve for leaks.
Normalrelisfpressure
Go to page 17-23
17-22
Abnormal
Faultypump assembly
Faultyllow control valve
(Replace
the pump es an
assembly)
I
Checkthe force requiredto turn
the wheel(seePage17 30i
Startthe engineand measurethe
force requiredto turn the wheel
of
to the right and left.Difference
t h e l o r c e r e q u i r e dt o t u r n t h e
wheel to the right and to the Ieft
should be 2.9 N 103 kgf, 0.7 lbf)
or below.
Normal
Deformed
Abnormal
Faultycylinderlines
Checkfor bent rack shaft
II
Compairthe steeringto another alike
vehicle.
Checkrackguideadiustment(see
page17-33).
AdiustmentOK
Faultyvalvebody unit
/
1,,
(cont'd)
17 -23
Troubleshooting
GeneralTroubleshooting(cont'd)
Assist(excessively
lightsteering)at
high speed.
Shockor vibrationwhen wheelis
turnedto {ull lock.
Checkthe rack guide for proper
adiustment(seepage17 33).
lf the problem is not correctedby
adiustingthe rack guide, adjust
t h e f r o n t w h e e l a l i g n m e n tl s e e
section181.
Checkthe rack guide for proper
adjustment(seepage17-33).
Rackguideis adjustedproperly.
Checkthe belt for slippageand
a o l u s t a s n e c e s s a r y{ s e e p a g e
11 32).
lfthe problemis not correctedby
adjustingthe rackguide,replace
the gearbox.
Steeringwheelwill not return
smoothly.
A a n d B c y l i n d e rl i n e sa r e n o r mal, checkwheel alignment(see
section18).
W h e e l a l i g n m e n ti s a b n o r m a l ,
adjust as needed.
Wheelalignmentis normal.
Checkthe steeringwheel operation and power assistcheck{see
page lT-30).
It the measurementsare out of
s p e c i f i c a t i o n sa, d j u s t t h e r ac k
guide.
lf the problemis not correctedby
adjustingthe rackguide,replace
the gearbox.
17-2 4
Adjustthe rac*guide(seepage17-3).
Unevenor roughsteering
lf the problemis not correctedbY
adjustingthe rackguide,replace
the gearbox.
Adiustthe belttension.Feplacethe
(seePage1732).
belt,il necessary
ldle speedlow or erratic.
lfthe enginestallswhenthe wheel
is turnedwhile car is stoppedor
moving at low speed,adjustthe
idlespe€d(seesection11)
Air in reservoir,or check Power
steeringIluid level.
Checkpower sleeringfluid level lf
the level is excessivelylow, check
lor leaksin the system.Add lluid
to the specifiedlevel.
lf ltuid level is OK, checkO-rings
a n d s e a l so n b o t h e n d s o f t h e
pump inlet hose,and the P/S
pump housing mating surfaces
and the pumP shaft oil seal for
suction leaks. RePlaceParts as
nocessary.
/
Steeringwheel kicksback
duringwide t!rns.
P u m p b e l t s l i P P i n go n P L r l l e Y
(pumpstopsmomentarilY)
Adjust the belt tension (see Page
belt.
1732)orreplace
Installthe power steeringpressure
gauge,Closethe Pressurecontrcl
valve fully and m6ssurethe PumP
pressure{s€epage17-34}.
Checkif pump press{rreis normal
and the gaugeneedletravel is 500
k P a ( 5 k g l / c m ?7, l P s i ) o r l e s s .
Chockthe flow control valve if the
needletravel exceeds500 kPa (5
kgflcm',71 Psi).l{ the flow control
valve is normal, replacethe PumP
as an assemoly.
ll,
17 -25,
Troubleshooting
Noiseand Vibration
NOTE;Pump noisein first 2 - 3 minutesafterstartingin cold weatheris normal.
Humming
Rattleor chattering
Humming due to pulsationof fluid is normal, particularlvwhen the wheel is
turned with the vehicle stooDed.
lf equipped with automatictransmission, the hum could be the
torque conveateror pump noise.
Confirm by temporarily removing
the pump belt.
High-pressureline touching the
frame.
Repositionthe line.
Loose steeringshaft connector,
tie-rod.or balljoint.
C h e c ka n d t i g h t e n , o r r e p l a c e
paatsas necessary.
Columnshaftwobbling.
Replacethe columnassembly.
Checkthe rack guide tor proper
adjustment(seepage 17,33).
Adiusi,if necess€ry.
Rattlingsoundand feelingwhen turningthe steeringwheelraghtand leftwith the
engineOFFis normal.
Pump noise,though not loud.trom the valvebody unit can be heardwhon turning the steeringwheel rightor left.This is normat.
CAUTION: When imp€sting, do not hold the steering wheet a[ the way to
the right or the left.
17-26
)
Pumpnoase
Gratingnoise
from pump
Cavitationcaused bY air bubbles
in the fluid.
Checkthe tluid level.
l f l o w , f i l l t h e r e s e r v o i rt o t h e
proper level,and checklor leaks.
Tighten or replaceas nocessary.
Checklor a crushed suction hose
or a loose hose clamp allowing
air into the suction side of the
sy$em.
Tighton or roplaceas necossary.
Pumpgearnois€
l z /
Rattleor chattgring
NOTE: Pump noise uP to 2 - 3
m i n u t e sa l t e r s t a r t i n gi n c o l d
weatheris normal
ComparepumP noiseat operating
temperatureto simularvehicle.
loud,
lf pump nois€is abnormallY
remove and inspectthe PUmPfor
w6ar and damage(seePage 1741).
Tightenor replacethe Pulley.
l f s h a t t i s l o o s e , r e P l a c et h e
pump.
t r
17-27
Troubleshooting
FluidLeaks
Checkthe gearboxassemblyfor oil leakscarefully.Oil can leak out of various points.dependingon location
of the
faultyoil seals/seal
rings.Checkthe followingbeforeremovingthe gearboxfrom the frame_
SteeringGearbox
Leakingfrom the oil seal on the
top of the valvehousing.
Replacethe valve oil seal from
the valvehousing.
Leakingfrom cylinder end into
left tie rod boot.
Replacethe valve oil seal trom
the pinionshaft.
Replacethe cylinderend sealon
the gearhousingside.
17-2a
Leakinglrom cylinder end into
right tie-rod boot.
Replacethe cylinderend seal on
the cylinderend side.
Leakinglrom the shaftupperend
sectronor pin engagementsec,
tion ol the pinionshaft.
Replacethe valvebody unit.
Leakingfrom cylinderlineA or B
connections{at tlare nut}.
Tightenthe connector.lf it's still
leakinO,
replacethe Iine,cylinder
or valvehousingunit.
L e a k i n gc a u s e db y a d a m a g e d
cylinde.lineA or B.
ReplacecvljnderlineA or B.
Leakingfrom feed line and return
lineioint fittingon the valvebody
unit (atflarenut).
Tighten the connector. ll it's still
leaking,replacethe line,,ointfit,
ting or valv6housing.
the housingO-rings
Replace
lf the housingstill leaks,rePlace
the pumP.
Reservoiris overfilled
Pull off the hose and drain the
reservoitto the Properlevel.
Air leakin suctionsideofthe sys'
tem (reservoir,inlet hose,tront
pump seal).
Pumpoutletline
(highpressure,
L e a k i n ga t t h e t h r e a d e d f i t t i n g
Tighten the fifting. lI it's still leaking, replacethe O-ringor feed line.
Leakingat the swaggedjoint.
/
PumpinletIine
(low-pressure)
Leakingbecauseol damage,dete_
assemblY.
or imProPer
rioration,
Reolaceor rePairas necessarY.
t J
17-29
Inspectionand Adjustment
SteeringOperation
Placethe front wheels in the straight ahead position,
and measurethe distancethe steering wheel can be
turnedwithout movingthe front wheels.
PowerAssist Gheckwith
VehicleParked
1.
Checkthe power steeringfluid level (see page 1733) and pump belttension(seepage17-32).
ROTATIONALPLAY:0 - 10 mm l0 - 0.39 inl
2.
lf the play exceedsthe servicelimit. perform rack guide
adjustment(seepage 17-33).
lf the play is still excessiveafter rack guide adjustment.
inspectthe steeringlinkage and gearboxas described
on the nel(t pag€.
Startthe engine,allow it to idle.and turn the steering wheel from lock-tolockseveraltimes to warm
up the fluid.
3.
Attach a spring scaleto the steering wheel. With the
engine idling and the vehicleon a clean,dry floor,
pull the scaleas shown and read it as soon as the
tires beginto turn.
ROTATIONALPLAY
D 0
The scaleshould read no more than 29 N (3.0 kgf.
6.6 lbf). lf it reads more, check the gearbox and
pump,
17-30
I
SteeringLinkageand Gearbox
COLUMN
STEERING
Inspectfor loosecolumn
mountingboltsand nuts
TIE-RODEND BALLJOINT
Inspectfor faultymovement
and damage.
BOOT
Inspect
damageand deteriorataon
JOINTS
STEERING
Checkfor loosejoint bolts.
l./
SHAFTGROMMET
I n s p e c tf o r d a m a g e a n d d e t e r i o r a t a o n .
TIE-RODLOCKNUT
for looselocknut
STEERINGGEARBOX
lnspectfor loosemountingbolts.
MOUNTINGCUSHIONS
GEARBOX
Inspectf or deterioration
BALLJOINT BOOT
Inspectfor damageand deteriorataon'
Seepage17-68lorreplacement.
lrz
17-31
Inspectionand Adjustment
PumpBelt
NOTE:When usinga new belt,first adjustthe deflection
or tensionto the valuesfor the new belt, then readjust
the deflectionor tensionto the valuesfor the used belt
afterrunningenginefor five minutes.
Adiustment
Inspection
1.
Loosenthe powersteeringpump mountingbolts.
2.
Adjustthe belttension.
'99 - '00
Attachthe specialtool to the belt and measurethe tension of the belt.
Tension:
'99 -'00
mod€ls:B1642 Engin. Type only
Used Bsh:
390 - 540 N lao - 55 kgt.88 - 120 tbf)
New Belt:
740- 880N {75- 90 kgf, 170- 200tbt}
'96 - '00
models:Other EngineTypes
Used Beh:
340 - 490 N (35 - 50 kgf, 77 - ilO tbfl
New Belt:
640- 780N 165- 80 ksf, 1& - 176tbf)
NOTE:
. lf thereare cracksor any damageevidenton the belt,
reDlaceit with a new one.
. Followthe manufacturer's
instructionsfor the tension
gauge.
BELTTENSION
GAUGE
07JGG_ 001010A
.
mod€ls: 816A2 Engin€Typo only
Turn the adjustingbolt by handto get the properbelt
tension,then retightenthe mountingbolts,
ADJUSNNG
BOLT
PUMP MOUNNNG BOLTS
24 N.m (2.4kgf'm, 17 tbtftl
'96 -'00
.
Inspectthe pump beltfor cracksor any damage.
Replacethe belt with a new one if necessary.
POWERSTEERING
PUMP
modek: Othcr Engins Typos
Pry power steering pump away from the engine with
a wrench to get the proper belt tension, then retighten the mountingbolts.
PUMPMOUNTINGBOLT
24 N.m (2,4kgf.m, 17 lbl.ftl
Measuremontwithout Beh Tension Gauga:
Apply a force of 98 N (10 kgt,22 lbfl and measurethe
deflectionbetweenthe power steering pump and the
crankshaftpulleys.
Dsflectior:
'99 -'00 model3:816A2
Engine Typ€ onty
Used Beh:
7.5 - 11.0mm t0.30- 0.43 inl
New Beh:
5.0 - 7.0 mm (0.20- 0.28 in)
'96 - '00
models:Othor Engine Typos
Used Behi
10.5- 14.0mm (0.ial- 0.59 inl
Now Beh:
7.5- 10.0mm (0.30- 0.39inl
POWERSTEERINGPULUY
PUMPMOUNTING
BOLT
24N.m{2.akgtm, 17tbtftl
Start the engine and turn the steeringwheel from
lock-to-lock
severaltimes,then stop the engineand
recheckthe deflectionof the belt,
CRANKSHAFT
PULLEY
17-32
I
RackGuideAdjustment
FluidReplacement
NOTE:Performrack guide adjustmentwith the wheels
in the straightaheadPosition.
Checkthe reservoirat regularintervals,and add fluid as
necessary.
CAUTION: Always us€ Genuine Honda Power Stearing
Fluid-V or S. Using any other type of power sto€ring
tluid or automatic transmission lluid can cause
increasedwear and poor steering in cold weathor.
SYSTEMCAPACITY:
0.85liter 10.90US' qt,0.75 lmp'qt)
at disassembly
CAPACITY:
RESERVOIR
0.4 liter (0.42US. qt, 0.35 lmP.qt)
1.
Loosenthe rack guide screw locknutwith the
cialtool.
'96 - '97 models:
Loosenthe rackguidescrew
LEVEL LINE
LOWERLEVELLINE
LOCKNUTWRENCH,40 mm
'98 - '00 models:
Removethe rack guide screw and remove the old
sealantoff of the threadedsection.
Apply new sealantall around the threads.Loosely
installtherackguidescrew
1.
2.
Raisethe reservoir,then disconnectthe returnnose.
Connecta hose of suitablediameterto the disconnectedreturn hose,and put the hose end in a suitablecontainer.
CAUTION:Take care not to spill tho fluid on the
body and parts. Wipe off any spill€d fluid at oncs'
Tightenthe rack guide screwto 25 N'm (2.5 kgf'm.
18 lbf.ft),then loosenit.
Retightenthe rackguidescrewto 3 9 N'm (0.4kgim,
2.9 lbf.ft),then back it off to specifiedangle.
SpecifiedReturn Angle: 20" max.
4.
T i g h t e nt h e l o c k n u tw h i l e h o l d i n gt h e r a c k g u i d e
screw.
Checkfor tight or loose steeringthrough the completeturningtravel.
PerformfollowinginsPections:
.
.
l r
Steeringoperation(seepage 17-30).
Powerassistwith vehicleparked.
HOSE
3.
4.
5.
6.
7.
Startthe engine,let it run at idle,and turn the steering wheel from lock-to-lockseveral times When
f l u i d s t o p s r u n n i n go u t o f t h e h o s e ,s h u t o f f t h e
engine,Discardthe fluid.
Reinstallthe returnhoseon the reservoir'
Fillthe reservoirto the upperlevelline.
Startthe engineand run it at fast idle,then turn the
severaltimes to bleedair
steeringtrom lock-to-lock
trom the system.
Recheckthe fluid leveland add some it necessary.
CAUTION: Do not fill the reservoir beYond the
upper l€vel line.
17-33
lnspectionand Adjustment
PumpPressureCheck
C h e c kt h e f l u i d p r e s s u r ea s f o l l o w s t o d e t e r m i n e
whetherthe troubleis in the pump or gearbox.
NOTE: First check the power steering fluid level and
pump belttension.
CAUTION: Disconnectthe high pr$sure hos€ with care
so as not lo spill the power sieering tluid on tha frame
and other parts.
1.
2.
3.
Disconnectthe outlet line from the Dumooutlet fitting, then installtheP/Sjoint adaptor(pump)on the
Dumooutlet.
Connectthe P/Sjoint adaptor (hose)to the power
steering pressuregauge, then connect the outlet
hoseto the adaptor.
Installthe power steeringpressuregaugeto the P/S
joint adaptor(pump)as shown.
ourlErHosE
FnrNo
,t"ll lrilu"ott
Startthe engineand let it idle.
7 . Turn the steeringwheel from lock-to-lockseveral
timesto warm the fluid to operatingtemperature.
Measuresteady-state
fluid pressurewhile idling. If
t h e p u m p i s i n g o o d c o n d i t i o nt,h e g a u g es h o u l d
readlessthan 1500kPa(15kgf/cmr,213 psi).
lf it readshigh, checkthe outlet line or valve body
unit (seeGeneralTroubleshooting
17-22).
9 . C l o s et h e p r e s s u r ec o n t r o l v a l v e ,t h e n c l o s et h e
shut-off valve gradually until the pressuregauge
needleis stable.Readthe oressure.
lmmediatelyopenthe pressurecontrolvalvefully.
GAUTION: Do not keep lhe prossure control valve
clos€d more then 5 soconds or the pump could be
damagod by over-heating.
lf the pump is in good condition,the gaugeshould
read at least 6,400- 7,400kPa (65 - 75 kgflcm,,920 1,070psi).A low readingmeanspump outputis too
low for full assist.Repairor replacethe pump,
P/S JOINT ADAPTOBIHOSEI
07RAK- S0i10l2r
ol
07RAK- 50{{)120
P/S PRESSURE
GAUGE
07406- 001000A
or
07406- 0010001
P/S PBESSURE
GAUGE
07{16 -@1@OA
oi
(Pa.t of tooll
11 N.m
11.1kgt m, 8 lbf.ftl
PRESSURE
CONTROLVALVE
SHUT.OFF
VALVE
PUMPOUTLET
FITTING
6 x 1.0 mm BOLT
lPart of tool)
11 N.m
11.1kgf m, 8 lbtftl
4.
5.
Openthe shut-offvalvefully.
Openthe pressurecontrolvalvefully.
17-34
SI{UT.OFFVALVE
Steering Wheel
Removal
lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a R e v i e wt h e
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor service.
CAUTION: Do not tap on the steering wheel or steering
column shaft when installing the stsering wheel.
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gw h e e l .a l i g n t h e
front wheelsstraightahead.
1.
R e m o v et h e d r i v e r ' s a i r b a g a s s e m b l yf r o m t h e
steeringwheel(seesection24)
2.
Disconnectthe horn connectorand cruise control
switchesconnector.
CRUISE
SWITCHESCONNECTOR
l,/
3.
Removethe steeringwheelnut
N O T E :B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,a l i g n t h e
front wheelsstraightahead.
1.
B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l , c e n t e r t h e
cable reel, Do this by first rotating the cable reel
clockwiseuntil it stops.Then rotateit counterclockwise approximatelytwo turns The arrow mark on
the cablereellabelshouldpointsstraightup.
CAELEREEL
Installthe steeringwheel with the steeringwheel
nut.
NOTE: Be sure the steering wheel shaft engages
the cablereeland cancelingsleeve.
WHEELNUT
STEERING
Replace.
ag N.m {5.0kgt rn, 36lbfft)
Attachthe cruisecontrol switchesconnectorio the
steeringwheelcliP,
Connectthe horn connector.
I n s t a l lt h e d r i v e r ' sa i r b a ga s s e m b l y a, n d c o n f i r m
propersystemoperation(seesection24).
1.,
Removethe steeringwheelby rockingit slightlyfrom
as you pull steadilywith both hands.
side-to-side
C h e c kt h e h o r n a n d c r u i s e c o n t r o l s w i t c h e sf o r
properoperatrons.
17-35
Steering Wheel
Disassembly/Reassembly
STEERING
WHEEL
*@*&*W
@,
17-36
SteeringColumn
I
Removal/lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations,precautions,and proceclures
r e p a i r so r s e r i n t h e S R Ss e c t r o n( 2 4 )b e f o r ep e r t o r m i n g
vice.
N O T E :B e f o r er e m o v i n gt h e s t e e r i n gc o l u m nf o r S R S ,
removethe driver'sairbagassemblyand cablereel lsee
s e c t i o n2 4 ) .
w h e e l( s e ep a g e1 7 3 5 ) .
1 . R e m o v et h e s t e e r i n g
2 . R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
driver'skneebolster(seesection20).
3. Removethe combinationswitchassemblyfrom the
s t e e r i n gc o l u m ns h a { tb y d i s c o n n e c t i nt hg e c o n n e c tors.
the ignitionswitchconnectors.
4. Disconnect
5 . R e m o v et h e s t e e r i n jgo i n tc o v e r .
6 . B e m o v et h e s t e e r i n jgo i n tb o l l s .
7 . D i s c o n n e ct th e s t e e r i n gi o i n t b y m o v i n gt h e j o i n t
toward the column,and removeit from the column
shaft.
8 . R e m o v et h e s t e e r i n gc o l u m n b y r e m o v i n gt h e
attachinn
g u t sa n d b o l t .
UPPER
9. Installationis the reverseof the removalprocedure
NOTE:
. Makesurethe steeringjoint is connectedas follows:
a. Insertthe upper end of the steeringioint onto the
steeringshaft (lineup the bolt hole with the flat on
the shait),and looselyinstallthe upperjoint bolt.
b . S l i p t h e l o w e r e n d o f t h e s t e e r i n gj o i n t o n t o t h e
pinion shaft (line up the bolt hole with the groove
a r o u n dt h e s h a f t ) ,a n d l o o s e l yi n s t a l lt h e l o w e r
joint bolt.
Be sure that the lowei joint bolt is securelyin the
groovein the pinionshaft.
c . P u l l o n t h e s t e e r i n gj o i n t t o m a k e s u r e t h a t t h e
steeringjoint js fully seated.Then tightenthe ioint
bolts.
. 8e sure the wires are not caught or pinchedby any
partswhen installingthe column
. Make sure the wire harnessis routed and fastened
properly.
. Makesurethe connectorsare properlyconnected.
STEERINGCOLUMN
COMBINATIONSWITCH
ASSEMBLY
RETAININGCOLLAB
NOTE:Takecarenot to let the
retainingcollarfall out of
positionduringinstallation.
JOINTBOLTS
STEERING
22 N.m {2.2kgf.m,16lbtft}
FLANGEBOLTS
22Nm12.2kgl'm,
FLANGENUT
13 N.m {1.3kgl.m.9 lbf ft)
16tbt.tr)
UPPERJOINT BOLT
Bolt musl line up
COLUMNCOVER
on shaft.
Groove.
JOINTCOVER
CLIP
J
LOWERJOINT BOLT
8oh must line up wrth
groovearoundon shaft.
17-37
SteeringColumn
Inspection
NOTE:The tilt steeringcolumn type is shown;the conv e n t i o n asl t e e r i n gc o l u m ni s s i m i l a re x c e p tf o r t h e t i l t
mechantsm.
Checkthe steeringcolumn ball bearingand the steering joint bearingsfor play and proper movement.lf
there is noiseor if there is excessiveplay,replacethe
steeringcolumnas an assembly.
Checkthe retainingcollar for damage.lf it is damaged,replacethe retainingcollar.
Checkthe absorbingplates,absorbingplate g u i d e s
and slidingcapsulesfor distonionor breakage.
Replacethe steeringcolumn as an assemblyif they
are distortedor broken.
ABSORBINGPLATEGUIDES
COLUMNBALL
BEARINGS
SLIDING
This part is attachod
to the column bracket
with the plasticinjections.
1 . Move the tilt lever from the loose positionto lock
position 3 to 5 times; then measurethe tilt lever
preloadl0 mm {0.4in) from the end ofthe tilt lever.
Preload: 70 - 90 N (7 - 9 kgf. 15 - 20 lbf)
l f t h e m e a s u r e m e n ti s o u t o f t h e s p e c i f i c a t i o n ,
adjustthe pfeloadusingthe followingprocedures.
TILTLOCKBOLT
Tighten the lock bolt with
a. Loosenthe tilt lever,and set the steeringcolumn
in the neutralposition.
b. Removethe 6 mm lockbolt and removethe stop.
c. Adjustthe preloadby turningthe tilt lock bolt left
or flgnr.
d. Pullup the tilt leverto the uppermostpositionand
install the stop. Checkthe preloadagain. lf the
measurementis still out of specification,repeat
the aboveprocedures"a" through"c" to adjust.
CAUTION:Be caretul not to loosen tho tilt lever
when installingthe stop or tightening the 6 mm
lock bolt.
1 73 a
the tilt leverraised.
10 mm (0.4inl
9.8N.m (1.0kgl.m,7lbf.ft)
Power Steering Hoses,Lines
Fluid LeakageInspection
HOSESand LINES
. I n s p e c th o s e sf o r d a m a g e ,l e a k s ,i n t e r f e r e n c eo r
twisting.
. Inspecttluid linesfor damage,rustingand leakage.
. Inspectfor leaksat hose and line joints and connections.
POWERSTEERING
12 N.m {1.2kgt.m,9lbt.ft}
swtTcH
LINES
VALVEBODYUNIT-to-CYLINDER
'17N.m
12 tbl.ftl
{1.7
LINES
VALVEBODYUNIT-Io-FEED/RETURN
Feedline:14 x '1.5mm llare nut
37 N.m {3.8 kgJ.m,27 lbf'tt)
Return Line Joint 16 x 1.5 mm flare nut
28 N m 12.7kgf.m,20lbtft)
LINES
CYLINDERHOUSING-to.CYLINDER
28 N.m (2.7 kgf.m,20 lbf.ft)
8()07
Checkfor leaks.
G€AR8OX
andVALVEBODYUNIT
for leaksatthematingsurface
Check
andflarenutconnections,
OUTLETHOSE
11 N.m
( 1 . 1k g f . m , 8
tbt
(Double
RingTypei
PUMPASSEMBLY
Checkfor leaksat the pump
seal,inletand outletfiftings.
Replacement
1.,
NOTE:
pipesecurely
. Connecteachhoseto the corresponding
until it contactsthe stop on the line.Installthe clamp
or adiustableclampat the specifieddistancefrom the
hoseend as shown.
. Add the power steeringfluid to the specifiedlevelon
the reservoirand checkfor leaks.
CAUTION: Check all clamps for deterioration or delormation; replacewith the clamps new ones il necessary.
ADJUSTABLEHOSECLAMP:
. P o s i t i o nt h e a d i u s t a b l eh o s e c l a m p s a t t h e p o i n t s
indicated(a)in the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop.
HOSECLAMP:
. Positionthe hoseclampsat the pointsindicated(b) in
the drawingabove.
. Slidethe hoseoverthe line until it contactsthe stop.
2.5- 5.5 mm
{0.01- 0.22in)
2.0 - 4.0 mm
(0.08- 0.16in)
2.5- 5.5mm
(0.01- 0.22in)
17-39
PowerSteeringPump
RemovaUlnstallation
NOTE: Eeforedisconnectingthe hosesfrom the pump,
Dlacea suitablecontainerunderthe vehicle.
Connectthe inlet hose and the outlet line. Tiqhten
the pump fittingssecurely.
Removethe belt by looseningthe pump mounting
b o l t s a n d a d j u s t i n gb o l t ( ' 9 9- ' 0 0 m o d e l s :8 1 6 4 2
EngineTypeonly).
Looselyinstallthe pump in the pump bracketwith
mountingbolts and adjustingbolt ('99-'00 models:
81642EngineTypeonly).
1.
OUTLETLINE
11 N.m {1.1kgf'm,
8
1.
Installthepump belt.
CAUTION:
. Make sure that the power steering belt is proporly positioned on the pulleys.
. Do not get power stoering tluid or grease in the
power steering bsh or pulley faces.Cleanoff any
fluid or greasebefore installrtion.
L
8.
Adjustthe pump belt (seepage 17-32).
Fill the reservoirto the upper level line (see page
PUMPMOUNTING
BOLT
24 N.m(2.4kgl.m,17lbfft)
2.
Coverthe Ay'Ccompressorwith severalshop towels
to protectit from spilledpowersteeringfluid.
3.
Disconnectthe inlet hose and the outlet line from
the pump,and plug them.
NOTE:Takecare not to spill the fluid on the body
or parts,Wipe off any spilledfluid at once.
4.
R e m o v et h e p u m p m o u n t i n gb o l t s a n d a d j u s t i n g
b o l t ( ' 9 9 - ' 0 0 m o d e l s :8 1 6 A 2E n g i n eT y p e o n l y ) ,
then removethe pump.
NOTE:
. Do not turn the steeringwheel with the pump
removeo.
. Wrap the opening of the pump with a piece of
tape to preventforeign material from entering
thepump.
17-40
Disassembly
CAUTION: The power steering components are made of aluminum. Avoid damaging the components during assembly.
NOTE:
. Cteanthe disassembledpartswith a solvent,and dry them with compressedair. Do not dip the rubberparts in a solvent.
. Alwavs replacethe O-ringsand rubbersealswith new ones beforeassembly.
. Apply recommendedpower steeringfluid to the partsindicatedin the assemblyprocedures'
. Do not allow dust,dirt, or otherforeignmaterialsto enterthe power steeringsystem.
. Replacethe pump as an assemblyifthe partsindicatedwith asterisk(*) are worn or damaged'
FLANGEBOLTS
20 N.m {2.0kgf.m,
14 rbf ft)
4.5mm ROLLER
*OUTERSIOEPLATE
5 mm ROLLER
.PUMP NOTOR
}SIDE PLATE
l,/
13 x 1.9mm O-RING
Replace.
SNAPRING
*SUB-VALVE
51 x 2.4 mm O-RING
Replace.
15.2x 2.4mm O-RING
Replace.
PUMPSEAL
Replace.
PUMPSEALSPAC€R
INLETJOINT
.PUMP DRIVESHAFT
BALL BEARING
lnspectionand RePlacement,
seepage17-43
FLANGEBOLTS
11 N m 11.1kgf.m,
8 rbf.ftl
10 mm CIRCLIP
*FLOWCONTROI-VALVE
Inspection
and Overhaul,
se[ pasett.tz
g
4
seatuc/
J
mm O-RING
--{;'rX!;'
$
FI-OWCONTROLVALV€ CAP
49 N.m {5.0 kgt m,
36 rb{.ft)
PULLEYNUT
6il N.m {6.5 kgf.m,
47 tbf.frl
(cont'd)
17-41
PowerSteeringPump
Disassembly(cont'dl
Inspection
' t . Drain
the fluid from the pump.
Flow Control Valve:
2 . Hold the steering pump in a vise with soft jaws,
hold the pulley with the specialtool, and remove
the pulleynut and pulley.
1.
Checkthe tlow control valve for wear. burrs, and
other damage to the edges of the grooves in the
vatve,
FLOW
VALVE
CONTROL
CAUTION: Be careful not to damage the pump
housing with the iaws of the vise and extension bar.
UNIVERSALHOLDER
for
Check
to edges.
damage
Inspectthe bore the flow control valve for scratches
or wear.
Slip the valve back in the pump, and checkthat it
moves in and out smoothly.
Loosenthe flow control valve cap with a hex wrench
and removeit.
4. Removethe O-ring,flow controlvalveand spring.
5. Removethe inletjoint and O-ring.
6. Removethe pump coverand pump coverseal.
7. Removethe outer side plate,pump cam ring, pump
rotor,pump vanes,side plateand O-rings.
lf OK, go on step 4; if not, replacethe pump as an
assembly.The flow control valve is not available
separately.
8. Removethe snap ring, then removethe sub-valve
from the pump housing.
9. Remove the circlip, then remove the pump drive
shaft by tappingthe shaft end with the plastichammer.
10. Removethe pump sealspacerand pump seal.
17-4 2
4.
Attach a hose to the end of the valve as shown.
VALVE
FLOWCONTROL
TIOSE
I
5,
Submergethe valve in a containerof power steering fluid or solvent.and blow in the hose.lf air bubbles leakthrough the valve at lessthan 98 kPa
(1.0kgf/cm' ,14.2psi),repairit as follows.
?
i--
,
Ball Bearing:
1.
Inspectthe ball bearingby rotatingthe outer race
slowly. lf any play or roughnessis felt, replacethe
ball bearing.
AIR PRESSURE
BALLBEARING
POWERSTEERTNG
FLUIDor SOLVENT
Hold the bottom end of the valve with a open end
wrench.
7.
l./
Unscrewthe seat in the top end of the valve. and
removeany shims,the reliefcheckball. reliefvalve
and reliefvalvespring.
Removeand discardthe ball bearingusing a press
as snown.
Installthenew ball bearingusinga pressas shown.
RELIEFVALVE
Ball Boaring Rsplaccmont:
RELIEFCHECKBALL
{W-*"'
Prcrt
SEAT
9 N.m
{0.9kgf'm, 6.5 lbt'ftl
RELIEFVALVE
SPRING
Clampthis end in
a openend wrench,
8.
1.,
FLOWCONTROLVALVE
Clean all the parts in solvent, dry them off, then
reassembleand retest the valve. lf the flow control
valve tests OK, reinstallit in the pump. lf the flow
control valve still leaksair, replacethe pump as an
assembly.The flow control valve is not available
separatelY.
NOTE: 11necessary,relief pressureis adjustedat
the factorv by adding shims under the check ball
seat.lf you found shims in your valve,be sure you
reinstallas many as Youtook out.
lnstallwith the
red shielded side
facing down.
NOTE:Supportthe innerrace
with the tool securely.
17-43
PowerSteeringPump
Reassembly
Coat the pump cover seal and the cover bushing
with the power steeringfluid, then installthe pump
coverseal into the groovein the pump cover.
1 . Align the pin of the sub-valvewith the oil passage
in pump housing.and push down the sub-valve.
Installthesnap ring properly.
OIL PASSAGE
Alignthe pin of
lnstallthe outer side olateover the two rollers.
the oil passage.
ROL1IR
OUTERSIDEPLATE
4.5 mm ROLLER
5 mm ROLLER
PUMP HOUSING
SNAPRING
Installthe new pump seal in the pump housingby
hand,then installthepump sealspacer.
NOTE: Insertthe pump seal with its grooved side
facingin.
Positionthe pump drive shaft in the pump housing,
then drive it in usinga specialtool as shown.
Installthe 40 mm circlip with its radiusedside facing out,
40 mm CIRCLIP
ATTACHMENT,
30 mm
d
BALL BEARING
gf'uMP
PUMPCOVER
7.
Set the pump cam ring over the two rollerswith the
" o " markon the cam ring upward.
PUMPCAM RING
oRrvE
sHAFr
/ffi\
ROI,IIR SET HO'"ES
f.\'vj
H
PUMPSEALSPACER
n,/
/:K
/ZA\.-V
PUMPSEAL
Reptace.
ROLl.ERS
17 -44
BUSHING
I
8 . Assemblepump rotor to the pump cover with the
" " " markson the rotor facingdown.
't2. Coatthe O-ringwith power steeringfluid. and posi
tion it into the pump housing.
Installthe pump cover assemblyin the pump houstng.
9 . Setthe 10vanesin the groovesin the rotor.
NOTE:Be surethat the round ends ot the vanesare
in contactwith the slidingsurfaceof the cam ring.
FI.ANGEEOLTS
20 N.m (2.0 kgf.m,
14 tbf.ft)
PUMPROTOR
PUMPCOVER
ASSEMBLY
0 E
51 x 2.4mm
Replace.
gn
't4. C o a t t h e f l o w c o n t r o l v a l v e w i t h p o w e r s t e e r l n g
fluid.
1 0 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the side plate.
1 1 . Installthe side plateon the cam ring by aligningthe
rollerset holesin the side platewith the rollers.
r
1 6 . C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit on the Jlowcontrolvalvecap.
1 7 . Installthe flow controlvalvecap on the pump housing, and tighten it.
E
SIDE PLATE
15. lnstall the flow control valve and spring on the
pump housing.
15.2x 2,1 mm O-RING
Replace.
ROLIIR SETHOTT
SET HOI.^E
FLOWCONTROL
VALVECAP
49 N.m (5.0 kgj m,
36 tbf.ft)
l ,
ROI.I.ERS
{cont'd)
17-45
PowerSteeringPump
(cont'dl
Reassembly
C o a t t h e O - r i n g w i t h p o w e r s t e e r i n gf l u i d , a n d
installit into the groovesin the inletjoint.
Installthe inletjoint on the pump housing.
'11N.m (1.1kgt.m,
8 |bnft)
UNIVERSALHOLDER
PULLEY
NUT
64N.m{6.5kgf.m,
15.2x 2.4
Replace.
-
EI
I n s t a l lt h e p u l l e y a s s h o w n b e l o w , t h e n l o o s e l y
installthe pulley nut. Hold the steeringpump in a
vise with soft jaws.
CAUTION:Be car€fulnot io damagethe pump housing with the jaws ot the vise.
17-46
21. Holdthe pulleywith the specialtool,and tightenthe
pulleynut.
Checkthat the pump turns smoothlyby turning the
pulleyby hand.
SteeringGearbox
Removal
)
NOTE:Usingsolventand a brush,wash any oil and dirt
off the valve body unit its lines.and the end if the gearair.
box. Blow dry with comPressed
1.
Drainthe power steeringfluid as describedon page
2.
Raisethe front of vehicle, and support it on safety
stands in the proper locations(seesection 11.
3,
Removethe front wheels.
4.
Removethe driver'sairbagassembly,and steering
wheel(seepage17-35)
5.
Bemovethe steeringjoint cover.
7. Removethe cotter pin from the castle nut {'96 -'97
'00 modslsl and removethe nut.
models)or nut ('98-
TIE.RODEND
BALLJOINTREMOVER.
28 mm
07MAC- SLqI2|X)
'98 - '00 mod.b:
NUT
COTTERPINS
Repl6ce.
8 . lnstallthe t0 mm hex nut on the balljoint.
Be surethat the 10 mm hex nut is flushwith the ball
joint pin end, or the threaded section of the ball
joint pin might be damagedby the specialtool.
NOTE:Removethe ball joint usingthe specialtool.
Refer to section 18 for how to use ths ball joint
remover.
6.
Removethe steeringjoint lower bolt, and loosen
the steeringjoint upper bolt. Disconnectthe steering joint by movingthe ioint towardthe column
9 . Seoaratethe tie-rodball joint and knuckleusingthe
specialtool.
CAUnON: Avoid damaging tho ball ioint boot.
1 0 . Removethe left tie-rod end, then slide the rackall the
way to the right.
1 1 . Separatethe exhaust pipe A or TWC (seesection 9).
12. Disconnectthe shift linkage(seesection13 or section
14).
t J
(cont'd)
17-47
SteeringGearbox
Removal{cont'dl
1 3 . Loosenthe 14 mm flare nut and disconnectthe feed
17. Removethe mountingbrackets.
line.
1 4 . Loosenthe adjustablehose clamp and disconnect
the returnhose.
t9.
Loosenthe 16 mm flare nut and removethe return
hosejoint trom the valve body unit.
CAUTION: After disconnecting lhe hos6 and lin6.
plug or seal the hose and line with a pioca ol tapa
or equivalent to prevenl foreign matorials trom
entsring the valve body unit.
N O T E : D o n o t l o o s e nt h e c v l i n d e r l i n e A a n d
betweenthe valve body unit and cylinder.
ADJUSTABLE
HOSE
CLAMP
1 8 . Pull the steeringgearboxall the way down to clear
the pinionshaftfrom the bulkhead.then removethe
pinionshaftgrommet.
Move the steering gesrbox to right so the left rack
end clearsthe rearbeam,then tilt the left side down
to remove it from the vehicle,
1 6 . Removethe stiffenerDlate.
CAUTION: Be careful not io bend or damage the
fagd ling and cylindsr lin99 whgn rgmoving thg
ggarbox,
NOTE: Some stiffener plate attaching bolts are also
used as gearboxmounting bolts.The gearboxwill
tilt to sidewhen theseboltsare removed.
STEERINGGEANEOX
17-48,
Disassembly
)
Holdthe steeringrackwith a wrench('98-'00 models: left end only), and unscrewthe rack end with
anotherwrench.
Steering Rack DisassemblY
NOTE:
the gearbox,wash it off with sol
r Beforedisassemble
vent and a brush.
. Do not dip sealsand O-ringsin solvent.
1.
Removethe steeringgearbox(seepage 17-47]..
2.
Removethe tie-rodend and locknut.
3.
Removeair tube and cliPs.
CAUTION: Be caroful not to damage the rack 3urfaco whh the wrench.
NOTE:'96 -'97 modelsis shown.
LOCKWASHER
STEERINGRACK END
STEERINGRACK
t )
Loosen the locknut, then remove the rack guide
screwand O-ring('96-'97 modelsonly)
Removethe boot bands and tie-rod clips Pull the
bootsawayfrom the endsof the gearbox.
7.
Removethe springand the rackguidefrom the gear
housing.
BOOT
(|-,
TIE.RODCLIP
{cont'd}
17 -49
SteeringGearbox
Disassembly(cont'd)
8. RemovecylinderlinesA and B from the gearbox.
11. Drill a 3 mm (0.12in) diameterhole approximatety
2.5 - 3.0 mm (0.10- 0.12 in) in depth in the staked
point on the cylinder.
cAunoN:
o Do nol allow metal shavings to onter the cylin.
der housing.
. After romoying iha cylinder end, remova any
bur6 at the staksd point.
Dcpthi 2,5 - 3.0 mm {0.10- 0.12in}
CYLINDERLINEg
CYLINOCR
LINEA
Drain the fluid from the cylinderfittings by slowly
moving the steering rack back and forth,
CYUNDER
1 0 . Removethe two flange bolts, then remove the valve
body unit from the gearbox. (See page 17-52for
valve body unit disassembly.)
VALVEBOOYUNIT
FLANGEBOLT
1 2 . H o l d t h e s t e e r i n g g e a r b o x u s i n g a C - c l a m pa s
snown.
'96 - '97
mod.ls:
32 mm SHIMS
'00
98 modok:
WAVE WASHER
13. Loosenand removethe cvlinderend.
17-50
t
14. Assemblea 12 x 1.25mm flangenut onto a 12 x 175
mm grade 10flangebolt as shown.
N O T E :W r a p t h e t l a n g e p o r t i o n o f t h e b o l t w i t h
vinyl tapeto protectthe cylinder.
18, Removethe 12 mm bolt and nut from the steering
rack,
1 9 . R e m o v et h e c y l i n d e re n d s e a l f r o m t h e s t e e r i n g
racK.
HOUSING
CYLINDER
Replace.
|
|
mm FLANGE
12,
BOLT
VINYLTAPG {p/N 90i77 - SLo- 000} 12 mm FLANGENUT
Installthe flange bolt into the end of the steering
r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h e
'll4 turn. Hold the flange bolt, and
flange bolt out
tightenthe flangenut againstthe rackby hand.
1 6 . Installthe bearingseparatoron the gearboxhousing
a5snown.
t5.
12 x 175 mm
Ptess
FLANGEBOLT
t./
BEARINGSEPARATOR
0 - 1112"I
lCommerciallyavailablo)
J__--',----)t'
,-----'"
,-,-'-'
fiN\\
----'
| .Wl'---t
I|
-'4a
^--.'--4
A
ooY----\
*
srerhtncnact
Q)
20. lnserta 24" long,3E" drive extensionand the specialtool into the cylinderfrom the gearboxsrcle.
NOTE: Make sure that the specialtool is securely
positionedon the backupring edges'
CAUTION: Be caroful not damago to inner surfaco
of the cylinder housing with the specisltool'
21. Set the gearboxin a press,then pressout the cYlinder end sealand backupring from the gearbox,
GAUTION:
. Keepthe tool sttaight to avoid damagingthe cylin'
der wall. Checkth€ tool angls, and corr€st it if nec€ssary,whon rsmoving the cylinder snd seal.
. Uss a pross to removs tho cylinder end seal. Do
not try to removo ths seal by striking the tool h
will br€ak the backup ring. and the cylinder snd
s€alwill lemain in tho gearbox.
Pross
STEERINGRACK
CYLINDEREND SEAL
1 7 . Set the gearboxin a pressso the gear housingpoint
upward,then pressthe cylinderend seal and steering rackout of the gearbox
NOTE:Hold the steeringrackto keep it from falling
when pressedclear.
1.,
CAUTION:
. Be carsful not damage to inn6l surfaceot the
cylinder housing with the flange bolt.
. Do not place your lingers under th€ ste€ring
rack.
BACKUPRING
CYLINDEREND SEAL
CYLINDEREND SEAL
REMOVERATTACHMENT
07NAD- SR3020A
(cont'd)
17-51
SteeringGearbox
(cont'dl
Disassembly
22. Carelullypry the pistonseal ring and O-ringoff the
prslonrack.
CAUTION| Be caletul not to damage the inside of
seal ring groove and piston edges when removing
the sealrin9,
Valve Body Unii Disassembly
23. Eeforeremovingthe valvehousing,applyvinyl tape
to splinesof the pinionshaft.
24. Separatethe valve housingfrom the pinion shaft/
valveusinga press.
VALVEHOUSING
Vinylt.pe
PINIONSHAFT
Replace.
Checkthe innerwall of the valve housingwherethe
seal ring slideswith your finger.lf there is a step in
t h e w a l l , t h e v a l v e h o u s i n gi s w o r n . R e p l a c et h e
valvehousing.
NOTE:
T h e r em a y b e t h e s l i d i n gm a r k sf r o m t h e s e a l
r i n g o n t h e w a l l o f t h e v a l v e h o u s i n g .R e p l a c e
the valvehousingonly if the wall is stepped.
When the valve housingis replaced,jnstallnew
shim(s)on the bearingsurfaceof the housingto
adjustthe thickness.
Checkthe inside of valve housing
whether the wall is stepped.
17-52
I
2 6 . C h e c kf o r w e a r . b u r r s a n d o t h e r d a m a g et o t h e
edgesof the groovesin the sleeve'
NOTE:The pinion shaft and sleeveare a precision
m a t c h e ds e t l f e i t h e rt h e p i n i o n s h a f t o r s l e e v e
must be replaced,replaceboth partsas a set'
SLEEVESEALRINGS
Checkfor Peeloff or
damage.
28. Usinga cutteror an equivalenttool, cut and remove
the lour seal ringsfrom the sleeve'
CAUTION: Be careful not to damage the edges of
the slgevs grooves and outer surface whsn lemoving the seal rings.
SLEEVE
29. Using a cutter or an equivalenttool, cut the valve
l./
27. Removethe circliPand Pinion shaft sleevefrom the
pinionshaft.
seal iing and O-ringat the groovethe pinion shaft'
Removethe valvesealring and O-ring'
CAUTION: Be careful not to damage the edges oI
the pinion shaft gloove and outer surface when
removing the valve seal ling and O-ring'
Cutting slot Posrtlon.
1.,
VALVESEALRING
Replace.
(cont'd)
-r
l
rt
t
r -99
.<
SteeringGearbox
Disassembly(cont'd)
30. Bemovethe valveoil sealand backupring {'96-'97
models)or wave washer('98-'00 models)from the
oinionshaft.
NOTE:
. Inspectthe ball bearing by rotating the outer race
slowly. lf there is any excessiveplay, replacethe
pinionshaftand sleeveas an assembly.
. The pinion shaft and sleeve are a precisefit; do
not intermix old and new pinion shaftsand
steeves.
BALLBEARING
'98- '(x) mod.lr:
WAVEWASHER
Replace.
3 1 . Pressthe valve oil seal and roller bearing{'96 -,97
m o d e l s lo r b u s h i n g( ' 9 8 - ' 0 0 m o d e l s lo u t o f t h e
valve housing using a hydraulicpress and special
tool shown below.
NOTE: Do not use a hammer; it will damage the
specialtool.
'96 - '97 modob:
PILOTCOLLAR
07GAF- PH70100
VAI.VE OIL SEAL
Replace.
BOI.I"ERBEARING
Replace.
'96 - '00 mod.b:
PILOTCOLLAR
07GAF- PHtoroo
VALVEOII.SEAL
Replace.
BUSHING
Beplace.
17-54
Reassembly
)
NOTE:
parts in a solpartswrth a solvent,and dry them with compressedair. Do not dip the rubber
. clean the disassembled
vent.
. Alwaysreplacethe O-ringsand rubbersealswith new ones beforeassembly'
in the assemblyprocedures'
. Applythe recommendedpowersteeringfluid to the parts+ndicated
power
steeringsystem.
the
to
enter
materials
foreign
o Do not a||owdust,dirt, or other
necessary'
where
tools
special
a Usethe appropriate
CYLINDERLINE A
FLANGEBOLTS
20 N.m (2.0kgt'm, 14lbf ftl
CYLINDERLINEB
VALVEHOUSING
FLARENUTS
28 N.m (2.7ksf m,20 lbf ftl
VALVEOILSEAL
Replace.
--,
''*^'*-1$*€-/s6-,,mode,3:
*--fitllTllli".",'r'o,.n,ft
EUSHING
Replace
..-------......
SLEEVESEAL RINGS
'P'\--
l./
Replace.
lss-,
"o.
Xll,Y5"l'.--r...- gY------..r.u,
CYLINDEREND SEAL
Replace.
,-f-..-S:
_
--€l€--------=- 'oo ,,iod"t.,
-s-'---------
BACKUP
Replace.
I
,
",a"a,,
SS
Replace.
BEARING
.----
HOUSING
CYLINDER
,
/
GEARHouslNG
_\-j
d
//
AJ
,S-'..l.g
.,_-\ t\
-\--'\-
F
s
ircriip'ii.rt'-
vALvE SEALR'NG
-.-.-r_
wAvEwAsHER
,96 _,9? models:
i"pru"".
-\
O.RING
ReDtace.
\ntonsrnrr
97 models onlY:
S_.<---,tj-
n"prac".
)@OOD m\
CYLINDEREND SEAL
/'\N,."._
nrNG
I
'98- 'oo
models:
-
RACKGUIDE
\
:scREw
I
O.RING
Replace.
.98- '00 models:
CYLINDEREND
69 N.m {?.0kgt'm,51 lbl'ft)
t J
(cont'd)
17-55
SteeringGearbox
(cont'd)
Reassembly
Valve Body Unit Reassembly
1. Apply vinyl tape to the steppedportion of the pinion shaft,and coat the surfaceof the vinyl taoe with
the powersteeringfluid.
2. Installthe backup ring ('96 -'97 models)or wave
washer ('98 -'00 models)with its taperedside as
shown below.
3. Coat the inside surface of the new valve oil seal
with powersteeringfluid.
4. Slidethe valve oil seal over the pinion shaft,being
carefulnot to damagethe sealinglip.
Vinyl t.po
{Steppedponion}
'96 - '97 models:
8. Apply power steering fluid to the surface of the
v a l v e s e a l r i n g t h a t w a s i n s t a l l e do n t h e p i n i o n
shaft.
9. Apply power steeringfluid to the insideof the special tool. Set the largerdiameterend of the special
tool overthe valveseal ring.
10. Move the specialtool up and down severaltimes to
makethe valvesealring fit in the pinionshaft.
11, Removethe soecialtool.
12. Turnthe specialtool over,and set the smallerdiameter end of the specialtool over the valve seal ring.
Move the specialtool up and down severaltimes to
m a k et h e v a l v e s e a l r i n g f i t s n u g l y i n t h e p i n i o n
shaft.
Tap6redposition.
BACKUP
PISTONSEALBING
SIZINGTOOL
07NAG - SR:togoA
Grooveside.
ol
surethe springis
seatodin the oil seal.
07NAG - SR3|X)00
lip
'98 - '00
mod.b:
CAUTION: InstEllihe valve oil seal whh its groov.d
3ide tacing opposite tho boaring.
7.
Apply vinyl tape to the splinesand steppedportion
of the shaft, and coat the surface of the vinyl tape
with the powersteeringfluid.
Fit the new O-ringin the grooveof the pinionshaft.
Then slide the new valve seal ring over the shaft
and the groovein on the pinionshaft.
Removethe vinyl tapefrom the pinionshaft,
VALVESEALRIiIG
Replace.
Do not over-expand.
17-56
(g(m
Usethe larger diameter
end of the special
tool first to make
the valve seal ring
fit in the pinion
shaft.
Makethe valvesealring
fit snuglyin the pinion
shaftusingthe otherend
(smallerdiameterend)of
the specialtool.
I
Apply power steeringfluid to the surfaceof the specialtool. Setthe new sealrings over the specialtool
f r o m t h e s m a l l e r d i a m e t e re n d o f t h e t o o l , a n d
expandthe seal rings. Do two rings at a time from
eachend of the sleeve.
NOTE;
the sealring. Installtheresin
. Do not over-expand
seal rings with care so as not to damagethem'
After installation,be sure to contract the seal
rings usingthe specialtool(sizingtool).
. There are two types of sleeveseal rings: black
and brown. Do not mix the different types of
sleevesealringsas they are not compatible
pin18. Apply power steeringfluid to the surfaceo{ the
pinion
shaft
the
ion shaft.Assemblethe sleeveover
b y a l i g n i n gt h e l o c a t i n gp i n o n t h e i n s i d eo f t h e
sleevewith the cutout in the shaft.Then installthe
new circlipsecurelyin the pinionshaftgroove'
NOTE:
B e c a r e f u l n o t t o d a m a g et h e v a l v e s e a l r i n g
when insertingthe sleeve.
Installthecirclipwith its radiusedsidetowardthe
sleeve.
1 4 . Setthe specialtool in the groovesin the sleeve,and
set eachring in eachgroovesecurely.
NOTE: After installation,compressthe seal rings
with your fingerstemPorarilY
BALLJOINT BOOI CLIPGUIDE
07S7,1-SA50800
SLEEVE
'19. Apply power steeringfluid to the seal ring lip of the
valveoil seal.then installthe sealin the valve housi n g u s i n g a h y d r a u l i cp r e s s a n d s p e c i a lt o o l s a s
shown.
CAUTION: Install the valve oil seal with its grooved
side facing the tool.
15. Apply power steeringfluid to the seal rings on the
sleeve,and to the entire insidesurfaceof the specialtool.
16. lnsertthe sleeveinto the specialtoolslowly'
1 7 . M o v e t h e s l e e v ee a c h d i r e c t i o ns e v e r a lt i m e s t o
makethe sealringssnuglyfit in the sleeve'
Pre3s
DRIVER
07749- 0010000
ATTACHMENT.
32x35mm
0774.6- q)101(x)
I
NOTE: Be surethat the seal ringsare not turned uP.
SITEVESEALRING
SIZINGTOOL
or
0797a- SA5020A
07974- SA50200
fr
J
VALVEOIL SEAL
Replace.
Makesurethe
springis in the
oil seal. (cont'd)
17-57
SteeringGearbox
(cont'd)
Reassembly
20. Pressthe new bearing ('96 - '97 models) or new
bushing ('98 -'00 models)into the valve housing
usinga hydraulicpressand specialtool as shown,
NOTE:Placethe rollerbearing('96-'97 models)on
the valve housingwith the stampedletterfacingup
towardsthe valveside.
DRIVER
Pr033
077itg-001tXlOO
+
ATTACHMENT,
3:Ix35mm
07746- 0010,t(x)
'96 - '97 models:
ROLLERBEARING
Letterstampedtace
upward.
'98 - '00 modob:
?/_vusHrNG
['---v-lt
\4)
21. Apply vinyl tape to the pinion shaft.then coat the
vinyltape with power steeringfluid.
Sealing lip face.
VALVEOIL SEAL
VALVEHOUSING
PINION
SLEEVESEALRINGS
Replace.
8e surethat the
sealnngs are not
turnedup, then
install.
E
22. Insertthe pinionshaft into the valvehousino.
CAUTION: Be careful noi to damage th€ valve seal
rings.
23. Removethe vinyltapefrom the pinionshaft.
17-5A
2 4 . P r e s st h e p i n i o n s h a f t / s l e e v eu s i n g a h y d r a u l i c
pressas shown.
N O T E : C h e c kt h a t t h e p i n i o n s h a f v s l e e v et u r n s
smoothlyby turningthe pinionshaft.
)
Steering RackReassembly
25. Coatthe pistonseal ring guide with power steering
fluid,then slideit onto the rack,big end first'
31. Wrap vinyl tape aroundthe rackteeth and rackend
edges,then coat the surfaceof the tape with the
powersteeringfluid
NOTE: Make sure that the vinyl tape is wrapped
carefullyso that thereis no steppedportion
26. Positionthe new O-ringand new pistonsealrlng on
the specialtool, then slide them down toward the
big end of the tool
NOTE:
. Do not over expand the resin seal rings lnstali
the resin ;eal rings with care so as not to damage them. After installation,be sure to contract
the seal ring usingthe specialtool(sizingtool)
. Replacethe piston'sO-ringand sealring as a set'
27. Pull the O-ringoff into the piston groove,then pull
the pistonsealring off into the pistongrooveon top
ol the O-ring
PISTON
PISTONSEALRING
GUIDE
07GAG- SD4O10Aol
07GAG- SD,ol(xt
Coatthe insidesurfaceof the new cylinderend seal
with power steeringfluid.
Installthe cylinderend seal onto the steeringrack
with its groovedsidetowardthe piston.
CAUTION:When installingthe cylinder end seal,
be caieful not damagethe sealing lip face of tho
seal with the edgss or teeth of th€ ste€ring rack'
CYLINDEREND SEAL
Coatthe piston seal ring and the insideof the specialtoolwith powersteeringfluid.
Carefullyslide the tool onto the rack and over the
pistonsealring.
Move the specialtool back and forth severaltimes
to makethe pistonsealring fit snuglyin the piston'
PISTON
Replace.
E
Make sure the
sPring is in the cylinder
end soal
Removethe vinyl tapefrom the steeringrack
NOTE:Removeany residueoftape adhesive
(cont'dl
17-59
SteeringGearbox
Reassembly{cont'd)
3 5 . I n s t a l lt h e n e w b a c k u pr i n g o n t h e s t e e r i n gr a c k ,
then placethe cylinderend sealto piston.
BACKUPRING
37. Installthe flange bolt into the end of the steerino
r a c k u n t i l i t b o t t o m s i n t h e h o l e ,t h e n b a c kt h l
f l a n g e b o l t o u t 1 / 4t u r n . H o l d t h e f l a n g eb o l t a n d
tightenthe flangenut againstthe rackby hand.
38. Installthe cylinderend seal into the bottom of the
c y l i n d e rb y p r e s s i n go n t h e b o l t w i t h a p r e s sa s
shown.
CAUTION: Do not push on the boh with excessive
force as it may damage tho cylinder end seal.
Preas
12 x 175mm FLANGEBOLT
{P/N 90177- SLo - 000}
36. Greasethe steeringrackteeth,then Insenthe steer-
12 mm FLANGENUT
ing .ack into the gear housing.
CAUTION: Be careful not to damage to inner surface of the cylindsr housing with the rack edges.
?q
R e m o v et h e f l a n g e b o l t . a n d c e n t e rt h e s t e e r i n g
rack.
W r a p v i n y l t a p e a r o u n dt h e r a c k e n d e d g e s .a n d
coatthe surfaceof the tape with the power steering
fluid.
NOTE: Make sure that the vinyl tape rs wrapped
carefully so that there is no stepped portion.
17-60
)
4 1 . Coatthe insidesurfaceof the new cylinderend seal
with power steeringfluid.
Installthe cylinderend seal onto the steeringrack
with its groovedsidetowardthe piston'
Pushin the cylinderend sealwith your finger'
CAUTION:When installing the cylinder end sesl'
be carelul not damage the sealing face ot the seal
with the threads and burrs at the staked position oI
the cylinder housing.
tr
ENDSEAL
CYLINDES
Replace.
Makesurethe sPring
end seal
is in the cylincler
CYLINDEREND
SEAL
Removethe vinyl tapefrom the steeringrack'
NOTE:Removeany residueoftape adhesive
Holdthe steeringgearboxusinga C-clampas shown'
C-CLAMP:
GEARBOX
46. C o a t t h e i n s i d es u r f a c eo f t h e c y l i n d e re n d w i t h
power steeringfluid,then installthecylinderend by
screwingit into the cylinderhousang.
4 7 . Removethe C-clampfrom the steeringgearbox'
After tighteningthe cylinderend' stakethe point of
-'00
t h e c y l i n d e rh o u s i n gs h o w n b e l o w F o r ' 9 8
modelsgo to step51.
NOTE: Stakethe cylinder in the position opposite
from where the stake was removed during disassemoly.
Stake point. Depth: 1 0 mm (0.04in)
Be carefulnot to damage
the bushingwhen inserting
the cylinderend.
-'97 model only)'
49. Selectthe 32 mm shim(s)('96
N O T E :O n l y r e i n s t a ltl h e o r i g i n a l3 2 m m s h i m ( s )
when the steeringgearboxis reassembledwithout
replacingthe pinionshatt,valve housing,and gear
box housingwith new ones.
l f t h e p i n i o n s h a f t , v a l v e h o u s i n g ,a n d g e a r b o x
housingare replaced,selectthe new shim{s)as follows.
Shim selection:
a. Set the four 32 mm shims on the bearingsurfaceof
t h e g e a r b o xh o u s i n g .T o t a l t h i c k n e s so f t h e f o u r
shimsshouldequalno more than 0 70 mm'
010 mm'
Shim set: four 32 mm shims (Thickness:
0.15mm, 0.20mm, 0.25mm respectivelyl
CAUTION: Th€ four 32 mm shims do not have
thickness identification marks Measure the thickness of each shim using a micrometsr, and mark
the shim lor identification.
l-,
(cont'd)
17-61
SteeringGearbox
(cont'd)
Reassembly
b.
I n s t a l lt h e v a l v e b o d y u n i t o n t h e g e a r b o x ,a n d
tighten the flange bolts to the specifiedtorque.
VALVEBODYUNTT
FLANGEBOLT
20 N.m {2.0ksl.m, 14lbI.ftl
Example:
Measurementis 0.28mm (0.011in):
0.70- O.28= 0.42mm (0.028- 0.011= O.Ot7inl
The selectedshims should be 0.28 mm lO.OtOin) and
0.15mm {0.006in} in thickness.
lf the r€quired shim thicknessis 0.10 mm or less, no
shims are necessarv.
50. Sot the selected32 mm shims (,96 - ,97 models
only) on the bearingsurfaceofthe gearbox housing.
FLANGE
BOLT
20N.m12.0ksf.m,1l lbtftl
VALVEBODYUNIT
O-RING
Replace.
Measurethe clearancebetween the gearbox and
valvebody unit usinga feelergaugeas shown.
-A-l
NOTE:Measurethe clearanceat the point midway
betweenthe two mounting bolts.
'96 - 37 modsl3
only:
32 mm SHIMS
{S.loctod numb.r of
3him!l
NEEDLEBEARING
-R1
5 1 . Coat ths new O-ring with grease,and carefully fit it
on the valvehousing.
Apply greaseto the needlebearingin the gearbox
housing.
D e t e r m i n et h e r e q u i r e dt h i c k n e s so f t h e 3 2 m m
shims by subtractingthe clearanceobtainedin the
step "c" from the total thicknessof the four shims.
( T o t a lt h i c k n e s so f t h e 4 s h i m s )- ( C l e a r a n c e=)
Requiredthicknessof the shims
EA
NOTE:Selectthe shims so that the total thickness
is closeto. but lessthan,the requiredthickness,
54. Tighten the flange bolts to the specifiedtorque.
17-62
Installthe valve body unit on the gearboxhousing
by engagingthe g€ars.
NOTE: Note the valve body unit installationposition (directionof line connection).
)
55. InstallthecylinderlinesA and B.
NOTE:
. C l e a nt h e j o i n t s o f t h e c y l i n d e rl i n e s A a n d B
thoroughly. The joints must be free of foreign
materlal.
. Installthe cylinderlinesA and B by tightingthe
flare nuts by hand first, then tighten the flare
nutsto the specifiedtorque.
17 N.m {1.7 kgt'm, 12 lbl.ft)
6 0 , l n s t a l lt h e n e w l o c k w a s h e ri n t h e g r o o v e i n t h e
steeringrack.
61. Screweachrackends into the rack'
-'00 mod62. Holdthe steeringrackwith a wrench('98
ends'
rack
els:left end onlY),and tightenthe
CAUTION: Bo cateful nol to damage ihe rack surface with the wranch.
'96 -'97 model is shown.
NOTE:
LOCKWASHER
RACKEND
STEERING
54N'm t5 5 kgtm' 40lbl'ft)
28 N.m (2.7 kgf m,20 lbf ftl
CYLINDERLINE8
STEERINGRACK
CYLINDERLINEA
56. Greasethe sliding surface of the rack guide, and
installit onto the gear housing
'97 models:
5 7 . 36 Apply a thin coat of greaseto the new O-ring,and
installit on the rackguidescrew.
38 - '00 models:
Remove the old sealant off of the threaded section,
then apply new sealantall aroundthe threads
58. Installthe spring, rack guide screw and locknuton
the gear housing.
Adjustthe rackguide screw(seepage17-33)'
NOTE:After adjusting,checkthat the rack moves
smoothlyby slidingthe rackright and left'
-Gl
'1
r
After tighteningthe rack ends, stakethe four sections of lockwasherwith a drift and a mallet.
Placethe wood block on the presstable. then set
the lock washer section of the rack end on the
wood block securelY.
Be sure the tool is alignedwith the flst sections
of the steeringrackend belorepressing.
Stake the lock washer in the center ot the flat
section of the steering rack end.
l:.
1
O.BING
Replace.
NOTE:Thisdrift hasa flat,
to preventpuncturing
l /
WOODENBLOCK
LOCKNUTS
{cont'd}
17-63
SteeringGearbox
(cont'dl
Reassembly
64. Apply greaseto the circumferenceof the rack end
housing.
67. Adjust the air hose fitting positionof the boots bv
turningit as shown below.
LEFTBOOT
(Viewedfrom the
left side)
RIGHTBOOT
{Viewedfrom the
right side)
RACKEND GROOVE
=^.
#-q!:s!!H
SILICONEGREASE
AIR HOSEFITTING
A p p l y a l i g h t c o a t o f s i l i c o n eg r e a s et o t h e b o o t
grooveson the rackends.
66. lnstall the boots in the rack end with the tie-rod
clips.
NOTE:Installthe boots with the rack in the straight
ahead position (right and left tie-rodsare equal in
length).
Install new boot bands on the boot, and bend both
sets of locking tabs.
CAUTION: Stlke ths band locking tabs firmly.
RACK END
NOTE: Wipe the greaseoff
the threadsection.
Lightlytap on the doubled-overportionsto reduce
their height.
Slide the rack right and left to be certainthat the
boots are not deformed or twisted.
TIE.RODCLIP
17-64
lnstallation
7 1 . C o n n e c tt h e a i r t u b e b e t w e e nt h e r i g h t a n d l e f t
boot.
lnstallthe clipson the cylinderlines'then clampthe
air tube with the cliPs.
CAUTION: Be carelul not to bend or damage the feed
line and cylinder lines when installing the gearbox'
1,
Beforeinstallingthe gearbox,slide the rack all the
way to right.
2.
Installthe mounting cushion on the steeringgearDOX.
CYLINDERLINE A
Installthe pinionshaftgrommet,then insertthe pinion shaft up throughthe bulkhead.
NOTE:Align the notch in the pinion shaft grommet
with the tab on the valvehousing.
CLIP
l./
I n s t a l lt h e m o u n t i n g b r a c k e to v e r t h e m o u n t t n g
cushion,then installtwogearboxmountingbolts'
MOUNTINGBRACKET
cusHroN
l-,
NOTE:Installthe bracket
with the arrow Pornllng
towardthe front.
39 N.m
(4.0kgj m, 29 lbtftl
(cont'd)
17-65
SteeringGearbox
(cont'dl
Installation
5.
I n s t a l l t h e s t i f f e n e rp l a t e w i t h t h e t w o g e a r b o x
mountingboltsand stiffenerplateaftachingbolts.
CAUTION: Be sure the air tube is not caught or
pinched by stiffener plate,
N O T E :I n s t a l lt h e b o l t s l o o s e l yf i r s t , t h e n t i g h t e n
them securely.
9 . Centerthe steeringrackwithin its stroke.
1 0 . Slip the lower end of the steeringjoint onto the pinion shaft (lineup the bolt holewith the groove
aroundthe shaft),and tightenthe upper and lower
steeringjoint bolt.
NOTE:
. Connectthe steeringshaft and pinion with the
cablereeland steeringrackcentered.
. Be surethat the lower steeringjoint bolt is securely
in the groovein the steeringgearboxpinion.
. lf the steeringwheel and rack are not centered,
r e p o s i t i o nt h e s e r r a t i o n sa t l o w e r e n d o f t h e
steeringjoint.
STEERING
JOINT
UPPERBOLT
22 N.m (2.2kgf.m,
16 tbt.ftl
ATTACHINGAOLTS
38 N.m 13.9kgf.m, 28 lbf.ftl
MOUNTINGBOLTS
(} N.m (4.a kgt m, 32 lbf.ftl
6.
Installthe returnhosejoint by tighteningthe l6 mm
f l a r en u t .
7.
Connectthe relurn hose securely,and tighten the
a d j u s t a b l eh o s e c l a m p f r o m t h e e n g i n ec o m p a r t ment.
8.
C o n n e ctth e f e e d l i n e a n d t i g h t e nt h e 1 4 m m f l a r e
nut.
NOTE:Makesure that there is no interference
betweenthe fluid lines,the rear beam or any other
parts.
ADJUSTABLEHOSE
CLAMP
(seepage17-39)
16 mm FLARENUT
28 N.m {2.9 ksl.m. 20 lbf.ft)
RETURN
1a mm FLARENUT
37 N.m (3.8kg{.m,27 lbt.ftl
17-66
PINIONSHAFT
Groove,
STEERINGJOINT
LOWERBOLT
22 N.m (2.2kgt.m,16lbtttl
1 1 .Centerthe cable reel by first rotating it clockwise
u n t i l i t s t o p s .T h e n r o t a t ei t c o u n t e r c l o c k w i s e
(approximatelytwo turns) until the arrow mark on
the label points straight up. Reinstallthe steering
wheel (seepage17 35).
)
12, Installthe steeringjoint coverwith the clampsand a
clrp.
1 4 . Installthe exhaustpipeA or TWC (seesection9).
1 5 . Connectthe shift linkage(seesection13 or section
14).
1 6 . lnstallthe front wheels
1 7 . Fill the systemwith power steeringfluid, and bleed
air from the system(seepage17-331
1?
the tie-rodendsto the steeringknuckles,
Reconnect
tightenthe castlenut ('96-'97 models)or nut ('98
'OOmodels)to the specifiedtorque,and installnew
cotter plns.
performthe followingchecks
1 8 . After installation,
. S t a r t t h e e n g i n e ,a l l o w i t t o i d l e , a n d t u r n t h e
steeringwheel from lock-tolockseveraltimes to
warm up the fluid. Checkthe gearboxfor leaks
(seepage17-39).
. Adjustthe front toe (seesection18).
. Checkthe steeringwheel spokeangle.Adjust by
turningthe right and lefttie-rods,if necessary.
NOTE:Turn the right and lefttie-rodsequallv
NOTE: Before connectingthe tie-rod ends, wipe off
from the ball joint tapered
any greasecontamination
sectionandthreads.
t r
CAUTION: Torquo the castle nut to the lower torque
sp€cification, then tighten it only tar enough to align
the slot with the pin hole. Do not align the nut by
loosening{,96-'97 modelsonly).
NE-RODEND
'96 -'97 models:
CASTLENUT
40 - a8 N'm
(4.0- 4.8 kgf'm,
29 - 35 lbf.ftl
\
COTTERPINS
Replace.
On reassembly,bend
the cotterPin6s shown.
'98 -'00 mod€ls:
NUT
&l N.m
{a.5kgf'm,33lbl'ftl
(l-,
17-67
Balljoint Boot Replacement
'96 - '97 models:
'98 - '00
models:
1.
CAUTION:Do not contaminatothe boot installation section with grease.
Removethe boot set ring and the boot.
CAUTION:Do not contaminatethe boot installa.
tion section with grsase.
2.
Packthe interiorof the boot and lip with grease.
3.
Wipe the greaseoff the sliding surfaceof the ball
pin,then packthe lower areawith freshgrease.
CAUTION:
. Keep greaseoff the boot installation seciion and
the tapered s€ction ot the ball pin.
. Do not allow dust, dirt, or oth6r foreign materials to 6nt8r the boot.
LIP
EALLPIN TAPERED
SECTION
Wipe off the grease.
-6lr
SECTION
Wipe off the grease.
4.
BOOTINSTALLATION
SECTION
Wipeoff the grease
1.
Removethe boot from the tie-rodend, and wiDethe
old greaseoff the ball pin.
2.
Packthe lower area ofthe ball pin with fresh grease.
3.
Packthe interiorof the new boot and liD with fresh
grease.
CAUTION:
. Keop groasc ott tho boot installalion sestion and
th. iapored s.ction if th€ ball pin.
. Do not allow dust. dirt, or other foreign materials
to entor tho boot.
LtP .6r
J_/
ru
BOOT INSTALLA
SECTION
Wipe off the gr€ase,
Installthe boot in the grooveof the boot installation
sectionsecurely,then bleedthe air from the boot.
Installthe new boot usingthe specialtool as shown
below.
ADJUSTINGBOLT
Adjustthe depth
by turningthe bolt.
NOTE: The boot must not be a gap atthe boot instal
lation sections.
FRONTHUB
DIS/ASSEMBLYTOOL
07965 - SA5o500
SETRING
Adjust the specialtool with the adjustingbolt until
the end of the tool aligns with the groove on the
boot. Slidethe set ring over the tool and into posiUOn.
CAUTION: After installing the boot, qhsck the ball
pin tapered section for grease contamination and
wipe it it necGsary.
17-68
CAUTION: Aftor installing the boot, chock the batl
pin tapgred section tor grgase cortamination. and
wipe it it n€ces3ary.
Suspension
)
l r
18-2
.............
SpecialTools
ComponentLocations
......f8-3
lndex ,,..............
Alignment
Wheel
.......18-4
Caster..............
..................
l8-4
Camber
Front Toe Inspection/
........18-5
Adiustment
RearToe lnspection/
........18-5
Adiustment
18-6
TurningAngleInspection................
Wheel/HubInspection
l8-7
BearingEnd P|ay..............................
.......18-7
WheelRunout
Front Suspension
SuspensionArms Replacement
('96- 99 modelsl..........................
18-8
SuspensionArms Replacement
('992D Si and Si-Rmodels) ........18-9
18-10
Knuckle/HubReplacement.............
Lower Ball Joint Replacement.......18-16
..........
18-17
BallJoint Boot Replacement
Front Damper
18-17
.................
Removal
18-18
..................
Disassembly/1nspection
...........
18-19
Reassembly
18-19
.............
lnstallation
RearSuspension
SuspensionArms Replacement
('96- 99 models)....................,.....
18-21
SuspensionArms Replacement
('992D Si and Si-Rmodels) ........1A-22
Hub BearingUnit Replacement......18-23
UpperArm Eushing
.....18-25
Replacement
RearDamper
.................
18-26
Removal
.....1A-27
.............
Disassembly/|nspection
...........
18-28
Reassembly
18-29
.............
lnstallation
SpecialTools
Ref. No.
Tool Numbor
o
07GAF- SE00200
07GAF- SE00401
07GAG- SD40700
07JAF- SH201l0
07JAF- SH20120
07JAF- SH20200
07MAC- S100200
07746- 0010500
07749- 0010000
07947- 6340201
07965- SB00100
07965- 5800200
07965- SD90100
07974- SA50700
€)
@
\9
o
@
aa\
@
o
@
@
@
o
Description
Hub AssemblyGuideAttachment
Hub DivAssemblyBase
BallJoint BootClip Guide
Hub Dis/Assembly
Pilot,38 mm
Hub Dis/Assembly
Shaft,22.4x25.4 mm
BallJoint RemoverBase
BallJoint Remover,2Smm
Attachment,62 x 68 mm
Driver
Driver Attachment
EallJoint Remover/lnstaller
BallJoint InstallerBase
SupportBase
BallJoint BootClip Guide
@
@.@
@
o
1a-2
@
Oty
PageReteronc€
,|
td- tc
1 8 -1 4
18-17
1 8 -1 4
1 8 -1 4
18-16
1 8 - 1 21, 3
18-14
1 8 -1 4
1 8 -1 5
1 8 -1 6
1 8 -1 6
18-15
1 8 - 1 61, 7
1
1
1
1
1
1
1
1
1
1
1
I
1
@
ComponentLocations
lndex
)
W h e e l A l i g n m e n t ,p a g e l 8 4
Front Suspension:
FBONTDAMPER
. Removal,page18-17
. Disassembly/lnspection,
page18-18
. Reassembly,
page18'19
. Installation,
page18-19
UPPERARM
' Replscement,
page18-8
KNUCKLE/HUB
. Replacement,
page18'10
. WheelBearingReplacement,
page18-14
. LowerEallJointReplacement,
page18-16
BAR
STABILIZER
' Replacement,
page18-8
LOWERARM
. Replacement,
Page18-8
Rear Suspsnsion:
REARDAMPEB
. Removai.page18-26
. Disassembly/lnspection,
page 18-27
. Feassembly,
page lS-28
. Installation,
page18-29
UPPERARM
' Replacement,
page18 20
LOWERARM
. Replacement,page 18-20
l-,
ARM
. Feplacement,
page18 20
TRAILINGARM
' Replacement,
page18-20
18-3
WheelAlignment
Caster
Camber
N O T E :F o r p r o p e ri n s p e c t i o n / a d j u s t m eonf t h e w h e e l
alignmentcheckand adjustthe following beforechecki n gt h e a l i g n m e n t .
lnspection
.
.
.
.
Checkthat the suspensionis not modified.
Checkthe tire sizeand tire pressure.
Checkthe runoutof the wheelsand tires.
Checkthe suspensionball ioints.{Hold a wheel with
your hands and move it up and down and right and
leftto checkfor wobbling.)
N O T E :U s e c o m m e r c i a l l y - a v a i l a b
l em p u t e r i z efdo u r
co
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's
instructions.
1 . C h e c kt h e c a m b e ra n g l e .
Camberangle:
Front: 0'00' j 1"
Rear:-1"11"
2.
Inspection
N O T E :U s e c o m m e r c ilal y - a v a i l a b lceo m p u t e r i z efdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t { c a s t e rc. a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equiDmentmanufacturer's
instructions.
1 . Checkthe casterangle.
Casterangle: 1',10'I 1'
2.
lf out of specification,checkfor bent or damaged
suspensron
components.
18-4
lf out ol specification,checkfor bent or damaged
suspensron
components.
,f,
Front Toe Inspection/Adiustment
RearToe Inspection/Adiustment
N O T E :U s e c o m m e r c i a l l y - a v a i l a bc loem p u t e r i z efdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n g a n g l e ) .F o l l o w
instructions.
the equipmentmanufacturer's
co
l em p u t e r j z e Ido u r
N O T E :U s e c o m m e r c i a l l y - a v a i l a b
w h e e l a l i g n m e n te q u j p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
instructions.
the equipmentmanufacturer's
1.
Checkthe tire pressure.
1.
NOTE:
slth
a M e a s u r ed i f f e r e n c ei n t o e m e a s u r e m e n tw
the wheelspointedstraightahead.
. if the parkingbrakeis engaged,you may get an
incorrectreadang,
Centersteeringwheel spokes.
?
C h e c kt h e t o e w i t h t h e w h e e l s p o i n t e d s t r a i g h t
ah e a d .
Fronttoe: lN 1 1 2 mm llN l/16 r 1/16 inl
4.
-
lf adjustmentis required,go on to step 4.
-
lf no adjustmentis required,remove alignment
equrpmenr.
Loosenthe tie-rod locknuts,and turn both tie-rods
in the same directionuntil the front wheels are in
straightaheadposition.
Reartoe-in:2 11mm ttltollllS int
2.
4,1N.m {4.5 kgf.m,33 lb{.ft)
6.
lf adjustmentis required,go to step2.
-
lf no adjustmentis required,remove alignment
equipment.
Beforeadjustment,note the locationsof adiusting
boltson the right and left compensatorarms
ADJUSTINGBOLT
10 x 1.25mm
64 N.m 16.5ksf m, 47 lbtft)
In
Turn both tie-rodsequally until the toe readangon
the turningradiusgaugeis correct.
4.
After adjusting,tightenthe tie-rodlocknuts.
.
NOTE:Repositionthe tie-rodboot if it is twistedor
displaced.
-
Loosenthe adjustingbolts, and slide the compen
satorarm in or out. as shown,to adjustthe toe
TIE.ROD
LOCKNUT
'14x 1.5mm
t J
R e l e a spea r k i n gb r a k e .
ARM
CoMPENSAToR
Tightenthe adiustingbolts
Example:
A f t e r t h e r e a r t o e i n s p e c t i o n t, h e w h e e l i s 2 m m
(0.08in) out of the specification.
- M o v e t h e a r m s o t h e a d j u s f i n gb o l t m o v e s 2 m m
(0.08in) inwardtrom the positionrecordedbeforethe
adjustment.
- The distancethe adjustingbolt is moved should be
equalto the amountout-of-specification.
18-5
WheelAlignment
TurningAngle Inspection
N O T E rU s e c o m m e r c i a l l y - a v a i l a b
co
l em p u t e r i z e fdo u r
w h e e l a l i g n m e n te q u i p m e n t o m e a s u r ew h e e l a l i g n m e n t ( c a s t e rc, a m b e r ,t o e , a n d t u r n i n ga n g l e ) .F o l l o w
the equipmentmanufacturer's
instructions.
'1. Turn
t h e w h e e l r i g h t a n d l e f t w h i l e a p p l y i n gt h e
b r a k e ,a n d m e a s u r et h e t u r n i n g a n g l e o f b o t h
wneets.
Turningangle:
lnward wheel: 39'50'
Outwald wheel (referencel:33'10'
2.
l f t h e t u r n i n g a n g l e is not within the specifications,
c h e c k f o r b e n t o r d am a g e d s u s p e n s i o nc o m p o nents,
18-6
Wheel/HubInspection
WheelRunout
BearingEnd Play
\
1.
Raisethe vehicleoff the ground,and suppon it wjth
safetystandsin the properlocations(seesection1).
1.
Raisethe vehicleoff the ground,and supportit with
safetystandsin the properlocations(seesectionI I
2.
Removethe wheels,then reinstallthewheel nuts
2.
Checkfor bent or deformedwheels.
3.
Attachthe dial gaugeas shown.
3.
Attachthe dial gaugeas shown.
4.
the bearingend play by movingthe disc in
N4easure
or outward.
4.
Measurethe wheel runoutby turningthe wheel.
Front/R€ar:
Standard:0 - 0.05mm l0 - 0.002inl
Front and RearWheel Axisl Runout:
Standard:
0 - 1.0 mm (0 - 0.0,1inl
Steel Whoel:
Aluminum Wheel: 0 - 0.7 mm (o - 0.03 in)
ServicaLimit:
2.0 mm (0.08inl
t./
Measureend playat
hub flange.
Bear:
Front and RearWheel Radill Runout:
Standard:
0 - 1.0 mm (0 - 0.04 in)
Steol Wheel:
AluminumWheol:0 - 0.7 mm (0 - 0.03in)
ServiceLimit:
1.5mm {0.06in}
M e a s u r e e n d P l a Ya t c e n t e r o f
the hub cap.
l J
lf the bearingend play measurementis more than
the standard,replacethe wheelbearing.
lf the wheel runout is more than the servicelimit,
replacethe wheel.
1A-7
FrontSuspension
('96- 99 models)
SuspensionArms Replacement
CAUTION:
. Replacethe selt-lockingnuts after removal.
. The vehicle should be on the ground betore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners.
. The right and left damper forks are not interchangeable.
The left damper fork is markedwith "AL" while the right
"AR'
damperfork is markedwith
. The right and left upperarmsare not interchangeable.
The left upperarm is markedwith "SO1-L"while the right upper
arm is markedwith "SOl-R".
. Beforetighteningthe upperand lower mountingnuts on the stabilizerlink,adjustthe locationof the link with the suspensionundervehicleload.
. When installingthe radiusarm washers,the "FR" markfacesthe front ofthe vehicle.
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary
(seepage18-4).
FLANGEBOLTS
1 0x 1 . 2 5m m
54 N.m 15.5kgl.m,
40 tbf.ftl
STAEILIZER
END
RUBBER
BUSHING
Checkfor deterioration
and damage,
BALLJOINT BOOT
- ---\--
. C h e c kf o r d e t e r i o r a t i o n a n d d a m a g e .
. S e e p a g e 1 8 - 1 6f o r b o o t r e p l a c e m e n t .
-\
STABILIZER
BAR
Checkfor bendingand damage.
FLANGEBOLT
1 4x 1 . 5m m
103N.m{10.5kg{.m,.
76lb{.ft)
\
FLANGEBOLT-
/)l
t,t,,"-iV
,/4,
v:\
;iffillr-"ilHitffi*::,"*"
c
LOWERARM
Checkfor
Jl
TT
da
and damaoe,
o.'-----------
1 4x 1 . 5m m
Replace.
83 N.m {8.5kgf.m, 61 lbf.ftl
1 { x 1 . 5m m
89 N.m {9.1 kgt m. 66 lbtft)
-6;
SILICONEGREASE
RUBBERBUSHING
DAMPERFORK
Checkfor damage.
FLANGEBOLT
10x 1.25mm
€ N.m {4.6 kgt m.
32 tbf.ft)
SELF-LOCKING
NUT I x 1.25
22 N.m (2.2kg{.m, 16lbf.ftl
Replace.
SELF-LOCKING
NUT
12x 1.25mm
Replace.
6it N m {6.5 kgf.m, 47 lbf.ftl
RUEBERBUSHING
. Checkfor deterioration
and damage.
.6t",.,"o".c"Ke
STAAIL|zER
ENDRUBBER
EUSHINGS
Notethe direction
of the bushings.
18-8
SuspensionArms Replacement('992D Si and Si-Rmodels)
I
CAUTION:
. Replacethe selt-lockingnuts after removal.
. The vehicle should be on the ground belore any bolts or nuts connectedto rubber mounts or bushings are tightened.
NOTE:
. Wipe off any dirt, oil or greaseon the threadsbeforetighteningthe fasteners
"AL" while the right
The left damper fork is markedwith
. The right and ieft damper forks are not interchangeable.
"AR"
damperfork is markedwith
"SOl-L" while the right upper
The left upperarm is markedwith
. The right and left upperarms are not interchangeable.
"SO1-R".
arm is markedwith
. Beforetighteningthe upper and lower mountingnuts on the stabilizerlink,adiustthe locationof the link with the susp e n s i o nu n d e rv e h i c l el o a d .
"FR" markfacesthe front of the vehicle.
. When installingthe radiusarm washers,the
(seepage18-4).
. After installingthe suspensionarm, checkthe front wheelalignment,and adjustif necessary
FLANGEBOLTS
10 x 1.25mm
sit N.m 15.5kgf.m,
40 tbtftl
UPPERARM
' Checkthe balljointbootfor
deterioration
anddamage.
. Checkthe bushingfor deterioration
anooamage,
. C h e c kt h e b a l l i o i n t f o . f a u l t y
BUSHING
STABILIZER
movement and clamage.
Alignthe stabilizermark
with the end of stabilizerbushing
FLANGEBOLT
1 4x 1 . 5m m
103N.m (10.5kgf.m,
l./
76tbr.ftl
BAR
STABILIZER
Checkfor bendingand damage.
FLANGEBOLT8 x 1.25mm
22 N.m (2.2 kgf.m, 16lbf.ft)
LINK
STABILIZER
. Checkthe balliointbootfor
deteriorationand damage.
. Checktheballiointtor faulty
LOWERARM
movementanddamage.
Checkfor
damage.
-.6r
NUT
SELF-LOCKING
1 4x 1 . 5m m
Replace.
83 N.m 18.5kgf m, 61 lbf.ft)
FLANGEBOLT
1 4x 1 . 5m m
89 N.m 19.1kgf.m,66 lbf.ft)
hSHrtlrT.[*"u
srr-,co",
Checkfor deterioration
6g619g
ano oamage.
NUT
SELF.LOCKING
10 x 1.25mm 29 N m 13.0kgf m, 22 lbf ftl
Replace.
Holdthe ballioint pin usinga hex wrench,
nut.
the self'locking
and taghten
FLANGEBOLT
10x '1.25mm
43 N.m {4.4kgf.m,
32 tbtft)
FLANGENUT l0 x 1.25mm
29 N.m 13.0kgI m,2.2 lbf ft)
Beforetighteningthe {langenut,
positionthe balljoint Pin
in the middleof its rangeof travel,
undervehicleload
with the suspension
DAMP€RFORK
Checklor damage.
DAMPERFORK
RU88ERBUSHING
Checkfor deterioration
and damage.
RANGE
4@lsrlrcoNE
NUT
SELF.LOCKING
12 x 1.25mm
Replace.
64 N m 16.5kgl.m, 47 lblft)
GREASE
J
18-9
FrontSuspension
Knuckle/Hub
Replacement
CAUTION:
. Replacotho salf-lockingnuts after romoval.
. The vehiclo should be on tho ground bsfore any bohs or nuls connectedto rubber mounb or bushings are tightened.
. Torqu€ th€ castle nut to the lowor torque specification,ihen tighton it only far enough to align th€ slot whh the pin
hole. Do not align the nut by loosening.
NOTE:
. Use only genuineHondawheel weightsfor aluminumwheels.Non-genuinewheel weights may corrodeand damage
the aluminumwheels.
. On the aluminumwheels,removethe centercap from the insideof the wheelafter removingthe wheel,
. Beforeinstallingthe brakedisc,cleanthe matingsurfacesof the front hub and brakedisc,
. Beforeinstallingthe wheel,cleanthe matingsurfacesof the brakediscand wheel.
o Wipe off the greasebeforetighteningthe nut at the ball joint.
CALIPERMOUNTINGBOLT
1 2x 1 . 2 5m m
108N.m {11.0kgl.m,80lbf.ft)
CASTLENUT
10 r 1.25mm
39 - ia7N.m (4.0- 4.8 kgf.m,29 - 35 lbf,ftl
COTTERPIN
Replace.
WHEELBEARING
Replace.
page18-14
Replacement,
CIRCLIP
LOWERBALLJOINT
Inspectfor faulty
movementand wear.
Replacement,
page18-16
SETRING
BALLJOINT BOOT
Checkfor deterioration
and damage.
CASTLE
NUT
12x 1.25mm
49- 59N.ml5.O- 6.0kg{.m.36- /(} lbf,ftl
SCREW
5x0.8mm
5 N.m {0.5 ksl.m, 4 lbf.ftl
FRONTHUB
Checkfor damageand
cracks.
Replacement,
page18-10
SPINDI.T]{UT
22 r 1.5 mm
lEl N.m {18.5kgf.rn,13{ lbl.ttl
Replace.
NOTE:
. Beforeinstellingthe spindle nut. apply
6n9ineoilto th6 seatingsurfaceofthe nut.
. Atter tightening, uso a drift to stakethe
spindle nut should6ragainstthe driveshaft.
BRAKEDISC
Checkfor wear and
rust.
page18-11
Replacement,
lnspection,
section19.
WHEELNUT
12 x 1.5mm
'108N.m
1r1.0kgf.m, 8lt lbf.ft)
6 mm BRAKEDISCRETAININGSCREW
9.8 N.m 11.0kgf.m, 7 lbtft)
18-10
)
1.
7. Removethe 6 mm brakedisc retainingscrews.
Loosenthe wheel nuts slightlY.
Raisethe front of the vehicle,and support it with safety standsin the properlocations(seesection1).
3 . Removethe wheel nutsand wheel.
6 mm BRAKEOISC
RETAININGSCREWS
9.8 N.m t1.0 kgf.m, 7 lbf'ft)
WHEEL NUT
'108N.m
{11 kgf m, 80 lbl.ft)
I x 1.25mm BOLTS
8 . Screwtwo 8 x 1.25mm bolts into the discto push it
awayfrom the hub,
18'lN.m 118.5kgf m, 134lblfti
Replace.
NOTEIBeforeinstallingthe spandlenut, apply
engineoil to the seatingsurfaceof the nut After
tightening,use a drift to stakethe spindlenut
shoulderagainslthe driveshaft
l )
Raisethe locking tab on the spindle nut, then remove
the nut.
Remove the brake hose mounting bolts.
BRAKEHOSEMOUNTINGBOLT
I x 1.25mm
12 N.m (1,2kgtm,8,7 lbf'ftl
NOTE: Turn each bolt two turns at a tameto prevent
cockingthe disc excessivelY.
Removethe brakediscfrom the knuckle.
1 0 .Checkthe front hub for damageand cracks.
1 1 . R e m o v et h e w h e e l s e n s o rf r o m t h e k n u c k l e( f o r
vehicleswith ABS).
NOTE:Do not disconnectthe wheel sensorconnector.
N.m
{'1.0kgf m,
7 tbf.ft)
CALIPERMOUNTINGBOLTS
12 x 1.25mm
108 N.m {'11.0kgtm, 80 lbt.ft)
6.
Removethe caliper mounting bolts and hang the
caliperassembiyto one side
CAUTTON:To prevent accidentaldamage to the
caliper assemblyor brake hoso' use a short piece of
wire to hang the caliPertlom lhe undelcarriage.
WHEEL
MOUNTING
BOLTS
9.8 N.m
11.0kgf,m, 7 lbf'ft)
(cont'd)
FrontSuspension
(cont'dl
Knuckle/HubReplacement
NOTE: Use the specialtool to separatethe ball joints
from the suspensionor steeringarm,
CAUTION: 86 careful not lo damagethe ballioint boot.
17. Oncethe specialtool is in place,turn ths adjusting
bolt as necessaryto make the jaws parallel.Then
hand-tighten the pressure bolt, and recheckthe
jaws to makesurethey are still parallel.
12. Cleanany din or greaseoff the balljoint.
13. Removethe cotter pin from the steeringarm, and
removethe nut.
14. Apply greaseto the specialtool on the areasshown,
This will ease installationof the tool and prevsnt
damageto the pressurebolt threads.
AI\IUSTING BOLT
PRESSURE
AOLT
NOTE: After making the adiustment to the adiusting bolt, be sure the head of the adjusting bolt is in
this position to the allow the jaw to pivot.
1 5 . Installa 10 mm hex nut onto the ball joint. Be sure
that the hex nut is flushwith the balljoint pin end to
prevent damage to the threaded end of the ball
joint.
1 6 . Install the special tool as shown. Insert the jaws
carefully,makingsure you do not damagethe ball
joint boot. Adiust the iaw spacing by turning th6
pressurebolt.
NOTE: lf necessary,apply penetratingtype lubricantto loosenthe balljoint.
COTTER.PIN
Replace.
On reassembly,
bend the cofter pin
CASTI.TNUT
10 x 1,25mm
39 - 47 N.m
14.0- 4.8 kgf.m, CASTLENUT
29 - 3s tbl.ftt
10 r 1.2smn--]*-
corrcn nn
Replace-
18-12
.\
1 8 . With a wrsnch, tighten the pressurebolt until the
ball joint shaft pops loose from the steering arm.
we.r cye plotection. Thc brtt ioint
E@
cln brcrk loose suddenly and sclt'tol dirt or other
d.brb inio youl .ye..
10
Rsmov€the tool, then remove th€ nut from the end
of the ball ioint and pull the ball joint out of the
stoering/suspensionarm. Insp€ctthe ball joint boot
and replaceit if damaged.
)
20, Removethe cotter pin from the lower arm ball joint
castlenut. and removethe nut.
Removethe cotterpin from the upper ball joint castle nut, and removethe nut.
COTTER.PIN
Replace.
On reassembly,
bend the cotter Pan
NUT
CASTLE
12x 1.25mm
49- 59 N.m(5.0- 6.0kgl m,36-,13lbf'ft|
'12x 1.25mm
39 - 47 N.m
14.0- 4.8 kgf m,
29 - 35 tbf.ft)
12mm HEXNUT
07MAC- SL00200
lnstallthe 12 mm hex nut onto the balljoint
Be sure that the hex nut is flush with the ball joint
pin end, or the threadedsectionof the ball joint pin
mlght be damagedby the balljoint remover'
l r
25. Usethe specialtool as shown on page l8-12to separatethe balljoint and knuckle.
NOTE: lf necessary,apply penetratingtype lubri
cantto loosenthe ball joint.
BALLJOINT REMOVER,28 mm
07MAC- SL00200
21. lnstalla 12 mm hex nut onto the ball joint. Be sure
that the hex nut is flush with the ball joint pin end'
or the threadedsectionof the ball joint pin might be
damagedby the balljoint remover.
26. Putl the knuckteoutward and remove the driveshaft
outboardjoint from the knuckleby tapping the driveshaft end with a plastichammer,then removethe
knuckle.
KNUCKLE
Checkfor damage.
22. Usethe specialtool as shown on page l8-12to separatethe ballioint and lowerarm.
NOTE; lf necessary,apply penetratingtype lubricantto loosenthe ball joint.
l J
18-13
FrontSuspension
(cont'dl
Knuckle/Hub
Replacement
NOTE: Replacethe bearingwith a new one after removal.
29. Pressthe wheel bearingout ofthe knuckleusingthe
specialtools and a Dressas shown,
27. Separatethe hub from the knuckleusingthe special
tools and a hydraulicpress.
CAUTION:
o Take cale not to distort the splash guard.
. Hold onto the hub to keep it from falling whon
pr$sed clear,
. To prevenl damage to the tool. mak€ sure the
threads are fully engagedbelore pressing.
Press
HUBDIS/ASSEMBLY
PILOT,38
mm
BEARTNG
t
- SH20110
07JAF
SEPARATOR
-
DRIVER
07749- (X)l0000
KNUCKLE
Pross
t
ATTACHMENT,
62x68mm
07746- 0010500
O- 1112in.
(Commercially
available)
HUB DIS/ASSEMBLYBASE
07GAF- SEoo4Ol
WHEEL
BEARING
Replace.
Pressthe wheel bearing inner race from the hub
using the specialtools, a bearingseparator,and a
press as shown.
HUB DIS,/ASSSMBLY
PILOT,38 mm
07JAF- SH20110
KNUCKLE
HUB DIS/ASSEMALY
SHAFT.22.{x 25.4mm
07JAF- SH20120
FRONT
I{U8
28. Removethe circlip and the splash guard from the
knuckle.
Checktor bendingand damage.
HUB DIS/ASSEMBLY
SHAFT,22.4
x 25.4mm
07JAF- SH20120
18-14
I
N O T E :W a s h t h e k n u c k l ea n d h u b t h o r o u g h l yi n
highflash point solventbeforereassembly.
31. Pressa new wheel bearing into the knuckleusing
the specialtoolsand a pressas shown
34. lnstallthe hub on the knuckleusingthe specialtools
shown and a hydraulicpressas shown.
CAUTION:Take care not to distort tho splashgusrd'
N O T E :P l a c et h e w h e e l b e a r i n go n t o t h e k n u c k l e
with the pack seal (metalcolor) toward the inside
Be careful not to damage the sleeve of the pack
seal.
Press
HANOI.E
07749- 001
HUB/ASSEMBLY
GUIDEATTACHMENT
07GAF-SEflt2d)
KNUCKLE
DOUBLELIPSEAL
COLOR)
{BLACK
DRIVER
ATTACHMENT
58x72mm
07947- 6340201
FRONTHUB
SUPPORTBASE
07966- StXx)100
SPLASHGUARD
KNUCKLE
BASE
SUPPORT
07965- SD90100
32. Installthecirclipsecurelyin the knucklegroove'
33. Installthesplashguard,and tightenthe screws.
scREws
5 N.m(0.5kgdm, 4lbt'ft)
tnstall the knuckle in the reverse order of removal'
and pay particularattentionto the followingitems:
.
.
.
.
.
.
.
l-,
.
Be careful not to damage the ball joint boots
when installingthe knuckle.
Torque all mounting hardwareto the specified
torque valugs.
Torquethe castlsnuts to the low€r torque speclfications,then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
lnstall new cotter pins into the castlenuts after
torquing.
Avoid twistin0 the sensorwires when installing
the wheelssnsor.
Beforeinstallingthe brakedisc,cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matingsurfaceofthe brakediscand the insideof the wheel
Checkthe front wheel alignment,and adjustit if
(seepage18-4).
necessary
18-15
FrontSuspension
Lower BallJoint Replacement
L
Removethe knuckle(seepage18-11).
Installthe ball joint boot and set ring usingthe specialtool (seepage18-16).
8.
Removethe boot by pryingthe set ring off.
C h e c kt h e b o o t f o r d e t e r i o r a t i o na n d d a m a g e .
replaceif necessary.
ADJUSTINGBOLT
Adjustrhe depthby
turningthe bolt.
Installthe specialtools onto the ball joint and tighten the casflenut.
P o s i t i o nt h e s p e c i a lt o o l s o v e r t h e b a l l j o i n t a s
shown. then set the assemblyin a vise. Pressthe
ball joint out of the knuckle,
BALLJOINTREMOVER/INSTALLER
07965- SB00r00
CASTLENUT
l
f
BALLJOINTREMOVER
BASE
07JAF- SH20200
Placethe balljoint in positionby hand.
7.
Installthe specialtools over the ball joint as shown,
then pressthe ball joint in.
BALLJOINT INSTALLEBBASE
07965- 5800200
Installthe knucklein the reverseorder of removal,
and pay particularattentionto the followingitems:
.
.
.
.
.
.
.
BALLJOINT HOUSINGSURFACE
18-16
.
Be careful not to damage the ball joint boots
when installingthe knuckle,
Torque all mounting hardwareto the specified
torquevalues.
Torquethe castlenuts to the lower torque specifications.then tighten them only far enough to
align the slot with the pin hole. Do not align the
castlenut by loosening.
Installnew cotter pins into the castlenuts after
torquang.
Avoid twisting the sensorwires when installing
the wheelsensor.
Beforeinstallingthe brakedisc.cleanthe mating
surfacesof the front hub and the inside of the
brakedisc.
Beforeinstallingthe wheel,cleanthe matingsurfaceof the brakediscand the insideof the wheel.
Checkthe front wheel alignment,and adjustit if
necessary{seepage18-4).
FrontDamper
!
BallJoint BootRePlacement
1.
Removal
Removethe set ring and the boot.
l.
Removethe front wheels(seepage18-11).
CAUTION:Do not contaminatethe boot installation section with grease.
2,
R e m o v et h e d a m p e r p i n c h b o l t t r o m t h e t o p o f
damperfork.
Packthe interiorof the boot and lip with grease
DAMPERFORK
EALLPIN TAPEREDSECTION
OAMPER
FORK
BOLT
EOOTINSTALLATIONSECTION BOOTINSTALLATIONSECTION
Wipe off the grease.
Wipeoff the grease.
3.
Wipe the greaseoff the sliding surfaceof the ball
pin and packwith freshgrease.
CAUTION:
. Keep greaseoff the boot installation section and
the tapeled section of the ball pin.
. Do not allow dust, dirt, or other toreign materials to enterthe boot.
l J
4.
Installthe boot into the grooveof the boot installation sectionsecurely,then bleedthe atr.
5.
Installthe upper and lower ball joint boot set rings
usingthe specialtools as follows:
OAMPER
PINCH
AOLT
1 0x 1 . 2 5m m
NUT
SELF-LOCKING
1 2x 1 . 2 5m m
Replace.
Removethe damper fork bolt and self-lockingnut
from the bottom of the damper fork, then remove
damperfork.
Removethe damperby removingthe two nuts
DAMPER
L o w e r b a l l j o i n t : A d i u s t t h e s p e c i a lt o o l w i t h t h e
adjustingbolt until the end of the tool alignswith
the groove on the boot. Slide the set ring over the
tool and into Position.
BALLJOINT
BOOTCLIP
GUIDE
AOJUSTINGBOLT
Adjust the depth by
turningthe bolt.
UPPEREALL
JOINT EOOT:
07GAG- SD40700
LOWERBALL
JOINT BOOT:
07974- SA50700
l t
CAUTION: After installing the boot, check the ball
pin tapsrod section fol grease contamination and
wipe it if necessary.
18-17
Front Damper
Disassembly/lnspection
Disassembly
'1.
Compressthe damper spring with the spring compressor accordingto the manufacturer,sinstructions,then removethe self-lockinonut.
Replace.
DAMPER
MOUNTING
WASHER
CAUTION: Do not compress the spring more than
n€cessaryto remove the nut.
10 mm SELFLOCKINGNUT
Replace.
BASE
DAMPER
MOUNTING
BUBBER
Checkfor deterioration
and damage.
STRUTSPRING
COMPRESSOR:
(Commerci.llyavailabl.l
BRANICKO T/N MST.s8I}A, T/N 7200,
or eouivalent
Releasethe pressurefrom thg spring compressor,
then disassemble
the damperas shown in the next
column.
Inspostion
1. Reassemble
all parts,exceptthe spring.
2. Pushon th€ damperassemblyas shown.
DAMP€R SPf,ING
Checktor weakenedcompression
and damage.
SPBINGMOUNTINGRUBBER
Checkfor deterioration
and damage,
BUMP STOP
Checkfor
damage.
DUSTCOVER
PLATE
OUSTCOVER
Checkfor bendingand damage.
Checkfor smooth operationthrough a full stroke,
both compressionand extension,
N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l v .l f i t
does not (no compressionor no extension),the gas
is leaking,and the dampershouldbe replaced.
Checkfor oil leaks,abnormalnoises,or bindingduring these tests.
18-18
DAMPERUNIT
and
BUMPSTOPPLATE
\
Reassembly
lnstallation
't. Installthe damperunit on a springcompressor.
1.
2.
Assemblethe damper in reverseorder of removal
exceptthe damper mountingwasherand self lockingnut.
NOTE:Align the bottom of the damper spring and
springlower seatas shown.
Looselyinstallthe damperonto the frame with the
aligning tab facing inside.then loosely install the
two flangenuts.
NUTS
FLANGE
10x 1,25mm
49 N.m(5.0kgt'm,36 lbf'ftl
DAMPERASSEMBLY
STRUTSPRINGCOMPRESSOR:
lcommercially availablel
T/N MST.58OA,T/N 7200,
BRANICK@
or 6quival€nt
l r
SPBINGLOWERSEAT
3.
P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e
damperunit as shown.
4.
Compressthe damPersPring.
Installthe dampermountingrubber,dampermounting washer,and a new 10 mm self-lockingnut.
Hold the dampershaft.and tightenthe 10 mm selflockingnut.
NUT
SELF-LOCKING
10x 1.25mm
29 N.m 13.0kgf m, 22 lbf ft)
Replace.
DAMPER
MOUNTINGWASHER
(l-t
{cont'd)
18-19
Front Damper
Installation(cont'd)
2. Installthe damperfork over the driveshaftand onto
t h e l o w e r a r m . I n s t a l lt h e f r o n t d a m p e r i n t o t h e
damperfork so the aligningtab is alignedwith the
slot in the damperfork.
ALIGNINGTAB
DAMPER
PINCH
EOLT
10 x 1.25mm
43 N.m 14.4kgf.m,32 lbtftl
12x 1.25mm
64 N.m 16.5kgl.m, 47 lbtftl
Replace.
Looselyinstallthe damperpinch bolt into the top of
the damperfork.
Looselyinstallthe damperfork bolt and a new selflockingnut into the bottomof the damperfork.
Raisethe knucklewith a floor jack until the vehicle
just lifts off the safety stand.
The ftoor ilck must be sscuroty posi@E
lionsd or personal iniury may r€€uh.
Tightenthe damperpinchbolt.
7 . Tightenthe damperfork bolt and self-locking
nut.
8 . Tightenthe flangenuts on top of the damper.
9 . Installthe brake hose mounts with the brakehose
mountingbolts.
1 0 . Installthe front wheel.
1a-20
RearSuspension
I
SuspensionArms Replacement('96- 99 modelsl
bafore hoisting' Wh€n
tffi
Whsn ths suspensionarms ar6 to be removed. place additionsl weight in the trunk
gravity may change causing ths cat to tip tor'
substantial weight is removed ftom th6 teal of ths vehicl6, the center of
ward.
CAUTION:
. Replacethe selt-lockingnuts after removal.
.Thgvehic|eshouldb€onthggroundboforeanybohsornutsconnectodtorubbelmountso]bughingsaretighton.
NOTE:
. Makesurethe toe adjustingboltson the compensatorarm are installedin the samedirection'
,.t UP LK,,or "t UP LS'.is stampedon the |eft upperarm and ,,t UP R" or "t UP RH G.,or
. ,,t UP 1,, or ,,t UP LH G,. or
"t UP RK" or "t UP RS" on the right upperarm'
"t UP" stampedsidefacesforward'
. The rightand left "ornp"n""to, uitt rre symmetricallnstallsothe
.Afterinsta||ingthesuspens|onarm,checktherearwhee|alignment,andadjustifnecessary(seepagelS-4).
FLANGEBOLT
10 x 1.25mm
54 N.m
(5.5kgf'm, 40 lbf'ftl
ADJUSTINGBOLT
(FLANGEBOLTI
10x 1.25mm
UPPERARM INNER
BUSHING
Checkfor deterioration
and oamage.
47 tbf.ftl
DAMPERMOUNTINGBOLT
(FLANGEBOLT}
10 x 1.25mm
54Nm
(5.5kgd.m,iro lbf'ft)
t J
l0 mm FLANGEBOLT
N.mt4.0kstm, 29lblftl
UPPERARM
Checkfor bendang
damage-
FLANGEBOL
10 x 1.25mm
ARM
COMPENSATOR
Checkfor bending
ano oamage,
TRAILINGARM
FI.ANGEBOLT
10 x 1,25mm
54 N.m
(5,5ksrf.m,4{}lbf'ft}
I 54 N.m
(5.5ksrm, aolbf'ftl
\
ARM
COMPENSATOR
INNERBUSHING
SILICONE
.GREASE
.@]
Checktor deteriorataon
and damage.
FLANGEBOLT
10 x 1.25mm
64 N.m {6.5 kgt'm,
47 lbf.ft)
FLANGEAOLT
12 x 1.25mm
64 N.m {6.5 kgf m,
47 tbf.ftt
LOWERARM
Checkfor cracks
ano damage.
LOWENARM BUSHING
SILICONE
.,..i@l
GREASE
Checkfor deterioration
and oamage,
1A-21
RearSuspension
SuspensionArms Replacement
('gg2D Si and Si-Rmodels)
CAUTION:
. Roplacethe self-lockingnut after removal.
' The vehicle should be on the gtound before any bohs or nuls connectedto rubber
mounts or bushing are tightened.
NOTE:
' Makesurethe toe adjustingbortson the compensatorarm are insta|edin the same
direction.
. "t UP L" or "t UP LH G" or "t Up LK" or "l Up LS,,is stampedon the left upperarm and ,,t
Up R,,or "t Up RH G,,
" i U PR K " " t
o r U P R S " o n t h e r i g h tu p p e ra r m .
. T h e r i g h ta n d l e f tc o m p e n s a t oarr m a r es y m m e t i c aIrn. s t a lsl o t h e " u p r " m a r k p o i n t s t o t h e f r o n t .
. After installingthe suspensionarm, checkthe wheelatignmentand adiustif necessary,
FLANGEBOLT
'10x 1.25mm
54Nm155kgl.m,
8 rhm BOLTS
22 N.m {2.2 kgf.m, 16 tbtfrl
,rc lbf.ftl
STABILIZER
BUSHTNG
STAEILIZER
BAR
Checkfor bendingor damage.
FLANGEBOLT
10 x 1.25mm
64 N m {5.5 kgf.m,47 lbtftl
UPPERARM BUSHING
Checkfor deterioration
and
Alignthe stabitizer
mark
with the end ot the stabilizerbushing.
FLANGEBOLT
'10x 1.25mm
54 N.m 15.5kgt.m, a0 lbtftl
FLANGEBOLT
10x 1.25mm
54 N.m 15.5*gf.m,
stLrcoNE
UPPERARM BUSHING
iO lbf.ftl
EOLTS
TRAILINGARM
Checkfor bendingand
10x 1.25mm
39 N m ll kgf.m, 29 lbf.ft)
UPPERARM
Checkfor b€ndingor damage.
#@l
stLtcoNE
COMPENSA
TORARM BUSHING
FLANGENUT
r '1.25mm
29 N.m {3.0 ksl.m,22 lbtft}
Beloretightening the flange nut,
positionthe balljoint pin
in the middleol its rangeof
travel,with the suspension
under
vehicleload.
COMPENSATOR
ARM BUSHING
Checkfor deterioration
and damage.
FLANGEBOLT
l0 x 1.25mm
6l N.m 16.5kg{.m,a7 lbt.ftl
LOWERARM
Checkfor damage-
FLANGEBOLTS
10 x 1,25mm
64 N.m {6.5kgf.m, 47 lbf.ftl
LOWERARM BUSHING
-Gr
SELF.LOCKNGNUT
10 x 1.25 mm 29 N.m (3.0 ksl.m, 22 tbtfrl
Replace.
Hold the ball ioinl pin using a hex w.enct.
and tighten the selfjocking nut.
STABILIZEBLINK
stltcoNE
LOWERARM BUSHING
. Checkfor deteriorationand damaoe.
' Seepage18 25 for bushingreplaciement.
' C h e c kf o r b e n d i n g a n d d a m a g e .
. C h e c kt h e b u s h i n g f o r d e t e r i o r a t i o na n o
oamage.
18-22
FLANGEBOLT
10 x 1.25rnm
54 N.m {5.5 kgt m, iro lbf.ft)
I
HubBearingUnit RePlacement
NOTE:
weightsmay corrodeand damage
o Use only genuineHondawheel weightsfor aluminumwheels Non-genuinewheel
t h e a l u m i n u mw h e e l s .
. o n t h e a | u m i n u m w h e e | s , r e m o v e t h e c e n t e r c a p f r o m t h e i n s i d e o f t h e W h e e | a f t e r r e m o v i n g t h e w h e e |(or
'
brake
hub and the brakedisc
. Beforeinsta||ingthe brakedisc (or brakedrum),c|eanthe mating surfacesof the rear
orum,.
andwheel'
. Beforeinstallingthe wheel,cleanthe matingsurfacesofthe brakedisc(or brakedrum)
* 1 :Forvehicleswith drum brakes.
*2'.'99 2D Si and Si-Bmodels
12 6 mm FLANGEBOLT
9.8 N.m {1.0kgf m, 7 lbf'ft|
SPINDLEWASTIER
TRAILINGARM
Checkfor cracking
and oamage,
SPINDLENUT
22 x 1.5mm
181N,m (18.5kgt'm.134lbfft)
Replace.
NOTE:
' Beforeinstallingthe spindlenut,apply
engineoil to the seatingsurfaceof the
nut,
' Aftertightening,usea drift Punch
to lockthe spindlenut shoulderinto
the spindle.
*2 SPLASHGUARO
Checkfor cracking
and damage.
HUBCAP
Beplace.
12 BRAKEDISC
Checkfor wear and
rust,
'2 6 mm BRAKEDISCRETAININGSCREW
9.8 N'm 11.0kgt m, 7 lbf'ft|
\
l r
)
*1 BACKINGPLATE
/\
*1 BRAKESHOE
r1 FLANGEBOLT
10 x 1.25mm
6,0N.m (6.5ksl.m,47 lbl'ftl
'1 BRAKEORUM
REAB
HUB UNIT BEARING
Checkfor cracking
and damage.
l-t
NUT
WHEEL
1 2x 1 . 5m m
kgt'm.80lbt'ft)
108N.m{11.0
(cont'd)
1A-23
RearSuspension
Hub BearingUnit Replacement(cont'dl
NOTE:Disctype {'992D Si and Si-Rmodets)
8 . Release
the parkingbrakelever.
1.
Loosenthe wheel nuts slightly.
2.
Raisethe rear of vehicle,and supportit with safety
standsin the properlocations{seesection1).
9 . R e m o v et h e b r a k e d r u m , h u b u n i t b e a r i n g ,a n d
spindlewasherlfor vehicleswith drum brakes).
3.
Removethe wheel nuts and rearwheel.
4.
Pullthe parkingbrakeleverup.
5.
R e m o v et h e h u b c a p .
6.
R a i s et h e l o c k i n gt a b o n t h e s p i n d l en u t , t h e n
removethe nut.
SPINDLE
NUT
22x 1.5mrn
lFor vehictes
\
\with drumbrakes;/
181N.m (18.5kgf'm,134lbf.fi)
Replace.
NOT€:
. Eeforeinstallingthe spindlenut,
applyengineoil to the seating
surfaceof the nut.
. Aftertightening,usea drift to
stakethe spindlenut shoulder
againstthe spindle.
BRAKEDRUM
SPINDI-E
WASHER
10. Removethe 6 mm flangeboltsand calipershield.
WHEELNUT
12x 1.5mm
108N.m
I I 1 kgt m, 80 lbf.ftl
CALIPER
SHIELO
C h e c kf o r b e n d i n g a n d d a m a g e .
6 mm FLANGEBOLTS
9.8 N.m {1.0kgf.m, 7 lbf,ft)
HUBCAP
ReplaceNOTE:Takecarenot to damagethe hub untt
on disassembly.
7 . Remove the 6 mm brake disc retaining screws.
6 mm BRAKEDISC
RETAININGSCBEWS
9.8 N.m 11.0kgl.m, 7 lbf.frl
1A -2 4
T
UpperArm BushingRePlacement
1 1 . Removethe two brakehose mountingbolts
1)
R e m o v et h e c a l i p e rb . a c k e tm o u n t i n gb o l t s ,a n d
hangthe caliPerto one side
1.
R e m o v et h e u p p e r a r m b u s h i n g a n d u p p e r a r m
j n n e rb u s h i n ga s s h o w n
ARMINNERBUSHING
UPPER
CAUTION:To prevent accidentaldamage to the
caliper or brake hose, use a short piece of wile to
hang the caliperfrom the undercarriage.
BOLTS
BRAKE
HOSEMOUNTING
22 N'm{2.2kgf'm,16lbt"ft}
ARMBUSHING
UPPER
t t
I
ARM
REARUPPER
Scribea line on the upperarm innerbushingso that
it is in linewith the bolt mountingsurface
Markto pointson the upper arm so that they are In
line and make a right anglewith the arm as shown
in the drawing.
l r
CALIPER
10x 1.25mm
38N'm (3.9kgf'm,28lbf'ftl
Screwtwo 8 x 1.25mm bolts into the discto push it
awayfrom the hub.
NOTE:Turn each bolt two turns at a time to prevent cockingthe discexcessively.
BOLTMOUNTING
SURFACE
Drivein the upperarm innerbushingwith the marks
aligned.
1 4 . Removethe brakedisc.
1 5 . Removethe hub unit bearingfrom the spindle
5.
Drivethe upperarm bushingintothe upperarm
NOTE: Drive in the upper arm bushingand upper
a r m i n n e r b u s h i n g u n t i l t h e i r l e a d i n ge d g e s a r e
flush with the uPPerarm
UPPER
ARM
SPINOLEWAS}IER
l t
16. lnstallin the reverseorderof removal.
1A-25
RearDamper
Removal
1.
Bemovethe rearwheels(seepage1g-22).
2.
Removethe speakercoverand speaker(Hatchback).
Sedanand Coupe:Removethe trunk side panel(see
section20).
3.
Removethe two flange nuts.
FLANGENUTS
10x 1.25mm
4.
Removethe flangebolt from the damper.
FLANGEBOLT
'10x 1.25mm
FLANGE
BOLT
10x 1,25mm
Removethe flangebolt that connectsthe lower arm
to the trailingarm.
18-26
6.
Lowerthe rearsuspension,
and removethe damper.
I
Disassembly/lnsPection
Disassembly
1.
Compressthe damper spring with the spring comp r e s s o ra c c o r d i n gt o t h e m a n u f a c t u r e r ' isn s t r u c tions,then removethe self-lockingnut.
lnspection
1.
all parts,exceptthe sprlng.
Reassemble
2.
Pushon the damPeras shown.
GAUTION: Do not compress the spring more than
necessaryto remove the sell-lockingnut.
WOODENBLOCK
l r
STNUTSPRINGCOMPRESSOR:
lComm6rcially.vailablel
ERANICKoT/N MST-580A,T/N 7200,or equivalent
Release the pressure from the spring compressor.
then disassemblethe damper as shown on page 18-
Checkfor smooth operationthrough a full stroke,
both compressionand extension.
N O T E :T h e d a m p e r s h o u l d m o v e s m o o t h l y l f i t
does not (no compressionor no extension),the gas
is leaking,and the dampershouldbe replaced.
CheckJor oil leaks,abnormal noises,and binding
duringthesetests.
(|-r
{cont'd)
18-27
RearDamper
(cont'dl
Disassembly/lnspection
SELF-LOCK|NG
NUT
10x 1.25mm
- el
v
29 N.m{3.0kst'm,22 lbf.ftl
Replace.
DAMPEB
MOUNTING
WASHER
DAMPER
MOUNTING
8U8BER
Checktor
deterioration
ano oamage.
DAMPER
COLLAR
Reassembly
1.
Installthe damperunit onto a springcompressor.
NOTE:Followthemanufacturer's
instructions.
Assemblethe rear damper in the reverseorder of
disassemblyexceptthe damper mounting washer
and self-lockingnut.
NOTE:Align the bottom of the damper spring and
springlower seatas shown.
DAMPER
MOUNTINGBASE
OAMPERMOUNTING
BUBBES
Checkfor
deterioration
ano oamage.
DAMPERSPRING
Checklor weakness,
compression,
and damage.
SPRINGMOUNTING
RUBBER
Checkfor deterioration
ano oamage.
P o s i t i o nt h e d a m p e r m o u n t i n g b a s e o n t o t h e
damoerunit as shown.
SIRUTSPRING
COMPRESSOR:
(Commerciattyavaitabtel
DAMpERMOUNTTNG
BRANICKO
T/N MST-580A,T/N 7200.
or cquivalont
BUMP STOP
Checkfor weakness
and damage,
OUSTCOVERPLATE
DUSTCOVER
Checklor bending
Compressthe damperspring with the spring compressor.
Installthe damper mounting washer, and loosely
installa new self-locking
nut.
DUSTCOVERBOOT
Checkfor deterioration
and damage.
Holdthe dampershaftwith a hex wrench,and tighten the self-locking
nut.
SELF-LOCKING
NUT
10 x 1,25mm
29 N m 13.0kgt.m, 22 lbtftl
Replace.
OAMPERUNIT
18-2A
:
DAMPER
MOUNTING
WASHER
RearDamper
I
lnstallation
' 1 . L o w e r t h e r e a r s u s p e n s i o n a, n d p o s i t i o n t h e
damperwith the springstop pointedtoward the left
SPRINGSTOP
2.
Looselyinstallthetwo flangenuts
FLANGENUTS
10x 1.25mm
49 N.m (5 kgf.m, 36 lbt'ft)
Tightenthesenuts in
step7.
l r
3.
Looselyinstallthe flangebolts.
FLANGEBOLT
10 x 1.25mm
54 N.m {5.5 kgf m, 40 lbt'ft1
FLANGEBOLT
10 x 1.25mm
54 N.m {5.5 kgf.m,
/r0 lb{.ft|
Raisethe rear suspensionwith a floor jack until the
vehicle just lifts off the safety stand.
Tne floor iacx must be securelYPosi!@@
tionod or peFonal iniury may rssull
Tightenthe flangebolts.
Tightenthe two flangenuts on top of the damperto
the specifiedtorque.
7.
Checkthe rearwheel alignmentand adjustif necessary (seepage18-4).
1A-29
t
Brakes
..."...19-1
Brakes
Conventional
Anti-lockBrakeSystem(ABS)."......"..19-43
It-,
l t
t
Brake
Conventional
.............19'2
SpeciafTools
ComponentLocations
......19-3
lndex ................
Inspectionand Adiustment
BrakeSystem RubberParts
19-4
and BrakeBooster...........,.,.............
19-5
............
BrakePedal
........
19-6
ParkingBrake
.................
19-7
Bleeding
Front BrakePads
Inspectionand Replacement..........19-8
Front ErakeDisc
19-12
DiscRunoutInspection...................
DiscThicknessand Parallelism
..........
19-12
Inspection
Front BrakeCaliper
19'13
..........
Disassembly
...........
19-16
Reassembly
MasterCylinder/BrakeBooster
19-21
.......................
Removal/lnstallation
PushrodClearanceAdiustment ......19-22
19-23
BrakeBoosterInspection................
l-l
RearBrakePads
Inspectionand Replacement,,........19-24
RearBrakeDisc
19-26
DiscRunoutlnspection...................
DiscThicknessand Parallelism
..........19-26
Inspection
RearBrakeCaliper
...........19-27
Disassembly
........."
19-31
Reassembly
RearDrum Brake
19-35
..............................
Index/lnspection
19-36
....,.,.......
Inspection
19-37
BrakeShoe Disassembly..............."
19-37
...............'..
BrakeShoeReassembly
BrakeHoses/Lines
Inspection/TorqueSpecifications..... 19-39
19-40
...........................
HoseReplacement
ParkingBrakeCable
lnspectionand Replacement........,.19-41
SpecialTools
Ref. No.
o
I
Tool Numbo]
- SG00100
07HAE
07JAG- SD40100
- SA50001
07914
o
19-2
Descriplion
BrakeSpringCompressor
PushrodAdjustmentGauge
SnapRingPliers
@
Oty
I
PageReference
19-28,
33
19-22
ComponentLocations
I
lndex
ERAKE
PEDAL
Inspectron
and
page195
Adjustment,
HOSES
LINES
BRAKE
page19-39
ications,
Inspection/Torque
specif
page19-40
HoseReplacement,
BOOSTER
MASTERCYLINDER/BRAKE
page19 21
Removal/lnstallation,
Adjustment,page19_22
PushrodClearance
BrakeBoosterInspection,page 19-23
l J
PARKINGBRAKECASLE
inspectionand Replacement,
p a g e1 9 4 1
BBAKE
Adiustment,page19-6
FRONTBRAKES
NOTE: There are two types offront brakecalipers:
"5410"
The calipertypescan be identitiedby the
or "2056"stampedon the caliperbody.Checkthe
type ot the brakecaliperbetore servicing.
FrontBrakePads
5410Type:page19-8
2056Typerpage19 10
FrontBrakeDisc,page19-12
FrontBrakeCaliper
5410Type:page19-13
2056Type:page19-14
REARORUMBRAKES
page19-36
Inspection,
page19'37
BrakeShoeBeplacement,
REARDISCBRAKES
RearBrakePads,page19 24
RearBrakeDisc,page19 26
RearBrakeCaliper,page19'27
l J
19-3
Inspectionand Adjustment
BrakeSystemRubberPartsand BrakeBooster
@ Brake Boostet
Checkbrakeoperationby applyingthe brakes.
lf the brakesdo not work properly,checkthe brake
booster,Replacethe brakeboosteras an assembly
if it does not work properlyor if there are signs of
leakage.
€) Piston Cup and PressureCup Inspeqtion
.
Checkbrakeoperationby applyingthe brakes.
Visuallycheckfor damageor signs of fluid leakage.
R e p l a c et h e m a s t e rc y l i n d e ra s a n a s s e m b l yi f
the pedal does not work properly or if there is
damageor signsof fluid leakage.
.
C h e c kf o r a d i f f e r e n c ei n b r a k e p e d a l s t r o k e
b e t w e e nq u i c k a n d s l o w b r a k e a p p l i c a t i o n s .
Replacethe master cylinder if there is a differencein oedalstroke.
Brake Hoses
Visuallycheckfor damageor signsof fluid leakage.
Replacethe brakehose with a new one if it is dama g e do r l e a k i n g .
@ CaliperPiston Seal and Piston Boots
Checkbrakeope.ationby applyingthe brakes.
Visuallycheckfor damageor signsof fluid leakage.
lf the pedal does not operateproperly,the brakes
drag. or there is damageor signs of fluid leakage,
disassembleand inspectthe brakecaliper.Replace
the boots and seals with new ones wheneverthe
brakecaliDeris disassembled.
@ Wheol Cylindor Piston Cup and Dust Cover
19-4
Checkbrakeoperationby applyingthe brakes.
Visuallycheckfor damageor signsof fluid leakage.
lf the pedal does not operate properly,the brakes
drag, or there is damageor signs of fluid leakage,
disassembleand inspectthe wheel cylinder.lf necessary,replacethe wheelcylinderas an assembly.
BrakePedal
)
PedalHeight
1. Disconnectthe brakeswitch connector,loosenthe
brakeswitch locknut,and backoff the brakeswitch
until it is no longertouchingthe brakepedal,
2.
4.
At the carpetcutout,measurethe pedalheightfrom
the right sidecenterof the pedalpad.
Screw in the brake switch until its plunger is fully
depressed(threadedend touching the pad on the
pedal arm). Then back off the switch 1/4 turn to
m a k e 0 . 3 m m ( 0 . 0 1i n ) o f c l e a r a n c eb e t w e e nt h e
threadedend and pad. Tighten the locknutfirmly.
Connectthe brakeswitchconnector.
CAUTION: Make sure that the brake lights go off
when the pedal is released.
PUSHROD
LOCKNUT
)
LOCKNUT
*
5.
I t
POINTICUTOUTI
Standard PedalHeight (with carpet removed):
156.5mm 16.16inl
M/T:
A/T, CVT:161mm (5 5/16 in)
3.
Loosenthe pushrodlocknut,and screwthe pushrod
in or out with pliersuntil the standardpedal height
from the floor is reached.After adjustment,tighten
the locknutfirmly.
0.3mm
(0.01in)
Checkthe brakepedalfree play as describedbelow.
PedalFreePlsy
1. With the engine off, inspectthe play on the pedal
pad by pushingthe pedalby hand.
FreePlay:1 - 5 mm (1/16- 3/16 inl
2.
adjust
lf the pedal free play is out of specitication,
the brakeswitch.
CAUTION: lf the pedal free play is insufficient, it
may result in brake drag.
N O T E : D o n o t a d i u s tt h e p e d a l h e i g h tw i t h t h e
Dushroddepressed.
BRAKEPEDALPAO
PUSHROOLOCKNUT
15 N.m
(1.5kgf.m. 11 lbI.ft)
19-5
Inspectionand Adjustment
ParkingBrake
Removethe rearconsole(seesection20).
Inspection
1. Pullthe parkingbrakeleverwith 196N {20kgf.44 lbf)
force to fully apply the parkingbrake.The parking
brake lever should be locked within the sDecified
numberof clicks.
Pullthe parkingbrakeleverup one click,
Tightenthe adjustingnut until the rearwheelsdrag
slightlywhen turned.
Lever Lockedclicks: 6 - I
Pulledup w i t h 19 6 N 1 2 0k g f , 4 4 l b f )
\
ADJUSTING
NUT
2.
Adjustthe parkingbrakeif the leverclicksare out of
specification.
Beleasethe parkingbrakeleverfully, and checkthat
the rear wheelsdo not drag when turned.Readjust
if necessarv.
Adiusiment
NOTE:After servicingthe rear brakepadsor calipers,or
the rear brakeshoe, loosenthe parkingbrakeadjusting
nut, startthe engine,and depressthe brakepedalseveral times to set the self-adjusting
brakebeforeadjusting
the parkingbrake.
1.
Raisethe rear wheels off the ground, and support
the vehicleon safetystands.
Elock the front wheels bofore iacking
l@
uDthe rear ot the v6hicle.
2.
On vehicleswith rear disc brakes,make sure the
parkingbrakearm on the rearbrakecalipercontacts
the brakecalioerDin.
19-6
7.
Make sure that the parkingbrakesare fully applied
when the parkingbrakeleveris pulledup fully.
8.
Reinstallthe rearconsole.
I
Bleeding
CAUTION:
. Always use GenuineHondaDOT3 BrakeFluid.Using 8
n o n - H o n d ab r a k € f l u i d c a n c a u s e c o r r o s i o n a n d
docrea3ethe life of the system.
. Make surs ||o dirt or other foteign matter is allowed
to contaminate the brake fluid,
. Do not spill brake lluid on the vehicle, it may damago
the paint; if brake lluid doos contac{ the paint, wash
it ofl imm€diately with water.
FRONTT
NOTE:The reservoiron the mastercylindermust be at
the MAX (upper)level mark at the start of the bleeding
p r o c e d u r e a n d c h e c k e da f t e r b l e e d i n g e a c h b r a k e
caliper.Add fluid as required.
1.
Makesure the brakefluid levelin the reservoiris at
the MAX lupper)levelline.
MAX {UPPER)LEVEL
REARlDrum Brakel:
CYLINDER
Havesomeoneslowly pump the brakepedslseveral
times,then applysteadyPressure.
Loosenthe brakebleedscrewto allow air to escape
f r o m t h e s y s t e m .T h e n t i g h t e n t h e b l e e d s c r e w
securely.
Repeatthe procedurefor eachwheelin the sequence
shown below until air bubblesno longerappearin
the fluid.
REAR(DiscBrake):
Refillthe mastercylinderreservoirto the MAX (upper)levelline.
ELEEDINGSEOUENCE:
1,,
O Front Right
(D Bo.r Right
O Front Left
O Rear Left
AIEEDSCREW
9 N.m (0.9ksf m, 6.5 lbf'ft)
19-7
Front BrakePads
Inspectionand Replacement
NOTE:Therearetwo typesof front brakecalipers:
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e " 5 4 1 0 " o r
"2056" stamped on the caliper body as shown below.
Checkthe type of the brakecaliperbeforeservicing.
4.
Removethe pad shim. pad retainers,and pads.
NOTE:When the caliperis equippedwith an outer
pad shim, replacethe shim togetherwith the pads
5i110Type:
NOTE:For 2056type disassemblyprocedures.
see page
19-'10.
Never use an air hose or dry brush lo clean brake
assgmblios.
Use an OSHA approved vacuum cleaner to avoid
breathing brake dust.
1 . Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands.Remove
the front wheels.
2 . Removethe brakehosebracketfrom the knuckle.
Removethe caliper bolt, and pivot the caliper up
out of the wav.
5.
U s i n g v e r n i e rc a l i p e r s m
, e a s u r et h e t h i c k n e s so f
each brakepad lining.The measurementdoes not
includethe pad backingplatethickness.
Brake PadThickno$:
Standard:9.5 - 10.5mm 10.37- 0.41 in)
SerYicoLimit 1.6 mm {0.06in}
CALIPERBOLT
NOTE:Checkthe hosesand pin boots for damage
and deterioration.
19-8
lf the brake pad thicknessis less than the service
limit, replacethe front Dadsas a set.
)
7. Cleanthe caliperthoroughly;removeany rust,and
checkfor groovesand cracks.
8. Checkthe brakediscfor damageand cracks.
9. lnstallthe pad retainers,
'12. Pushin the pistonso that the caliperwill fitoverthe
pads, Make sure that the piston boot is in position
to prevent damaging it when pivoting the caliper
down.
CALIPERBOLT
N m (3.3kgf m,2a lbf.ft)
10. Apply greaseto the points indicatedby the arrows
in the followingillustration:
NOTE:Use the pad greaseincludedin the pad set
or Molykote Nl77grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
I t
o
.
.
.
.
Pistonend and innerDadcontactsurface
Padand calioerbracketcontactsurface
Outerpad and caliperbody contactsurface
Outer pad shim and outer pad contact surface
Outerpad shim and caliperbody contactsurface
1 3 . Pivotthe caliperdown into position,then installthe
caliperbolt and tightenit.
CAUTION: Be caretul not damage the pin boot
when pivoting the caliper dowr.
1 4 . lnstallthe brakehosebracketon the knuckle
NOTE: Inspectthe brake hose for interferenceor
twisting.
WEARINDICATOB
1 5 . Depressthe brakepedalseveraltimes to makesure
the brakeswork. then test-drive.
INNER PAD
OUTERPAD
11. Installthe brakepadsand pad shim correctly.
.
.
l.t
Whon reusing the pads, always reinstall the
brake pads in their original positions to prevont
loss of braking efticiency.
Contaminated brake discs or pads teduce stopping ability. Keep greaseoft the discs and pads'
NOTE: lnstall the Dad with the wear indicator on
the inside.
N O T E :E n g a g e m e n o
t f t h e b r a k e m a y r e q u i r ea
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplicat i o n s o f t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
Dedalstroke.
1 6 . After installation.checkfor leaksat hose and line
jointsor connections,
and retightenif necessary.
(cont'd)
19-9
Front BrakePads
(cont'dl
Inspectionand Replacement
2056Type:
5.
@
. Never use an air hose or dry brush to
clgan brake
assemblies.
Use an OsHA-approvedvacuum cleanor lo avoid
breathing broke dust.
.
1.
2.
3.
U s i n g v e r n i e rc a l i p e r s m
. e a s u r et h e t h i c k n e s so f
each brake pad lining.The measurementdoes not
includethe pad backingplatethickness.
Brake PadThicknsss:
Standard;
8.5 - 9.5 mm 10.33- 0.37 in)
ServicaLimh: 1.6 mm {0.06in}
Loosenthe front wheel nuts slightly.then raisethe
vehicle, and support it on safety stands. Remove
the front wheels.
Removethe brakehosebracketfrom the knuckle.
Removethe caliperbolt B, and pivot the caliperup
out of the wav,
lf the brake pad thicknessis less than the service
limit, replacethe front pads as a set,
EOLTB
NOTE:Checkthe hosesand pin boots for damage
and deterioration.
Removethe pad shim, pad retainers,and pads.
NOTE:When replacingthe pads, replac€the shim
togetherwith the padsas a set,
OUTER
PADSHIM
C h e c kf o r w e a r .
INNER PAD
PAORETAINERS
Checkfor weaknessand
damage,
OUTERPAD
19-10
7.
Cleanthe caliperthoroughly;removeany rust. and
checkfor grooves and cracks.
8.
Checkthe brakediscfor damageand cracks,
9.
Installthe pad retainers.
)
lO. Apply greaseto the points indicatedby the arrows
in the followingillustration:
12. Pushin the pistonso that the caliperwill fit over the
pads.Make sure that the piston boot is in position
t o p r e v e n td a m a g i n gi t w h e n p i v o t i n gt h e c a l i p e r
NOTE:Use the pad greaseincludedin the pad set
or Molykote M77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
.
o
.
.
.
Pistonend and innerpad contactsurface
Padand caliperbracketcontactsurface
Outerpad and caliperbody contactsurface
Outerpad shim and outer pad contactsurface
Outerpad shim and caliperbody contactsurface
PISTON
CALIPERBOLTB
26 N.m {2.7kgt m,
20 rbl.ftl
WEARINDICATOR
OUTERPAD
OUIER
PADSHIM
1 3 . P i v o tt h e c a l i p e rd o w n i n t o p o s i t i o n ,t h e n i n s t a l l
caliperbolt B and tightenit.
1 4 . lnstallthebrakehosebracketon the knuckle.
NOTE:Inspectthe brakehose for interferenceand
twisting.
Depressthe brakepedalseveraltimes to makesure
the brakeswork,then test-drive
I 1. Installthe brakepadsand pad shim correctly
@
o When reusing the pads, always reinstall the
.
brake pads in their original positions to plevent
loss of braking etticiencY.
Contaminated brake discs ol pads reduce stopping ability. Keep greaseoft the discs and pads.
t f t h e b r a k e m a y r e q u i r ea
N O T E :E n g a g e m e no
greater pedal stroke immediately after the brake
pads have been replacedas a set. Severalapplicat i o n s o t t h e b r a k e p e d a l w i l l r e s t o r et h e n o r m a l
pedal stroke.
1 6 . After installation,checkfor leaksat hose and line
jointsand connections,
and retightenif necessary.
N O T E :I n s t a l lt h e p a d w i t h t h e w e a r i n d i c a t o ro n
the inside.
1 9 - 11
Front BrakeDisc
DiscRunoutInspection
L
2.
Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands. Remove
the front wheels.
DiscThickness
and Parallelism
Inspection
1 . Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands.Remove
the front wheels.
Removethe brakepads(seepage19,8).
Removethe brakepads(seepage 19-8).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoroughlyand removeall rust.
Use wheel nuts and suitableplain washersto hold
the disc securelyagainstthe hub,then mount a dial
i n d i c a t o ra s s h o w n , a n d m e a s u r et h e r u n o u t a t
10 mm (0.4in) from the outeredgeof the disc.
U s i n g a m i c r o m e t e r ,m e a s u r ed i s c t h i c k n e s sa t
eight points, approximately45" apart and 10 mm
(0.4in) in from the outeredgeof the disc.
Brake Disc Runout:
ServiceLimit: 0.10 mm (0.004inl
WHEELNUT ANO
PLAINWASHER
'108N.m
(11 kg{.m,80 lbf.ft)
BrakeDbc Thickn6s:
Standlrd: 20.9- 21.8 mm (0.82- 0.86 in)
Max. RefinishingLimit: 19.0mm 10.75inl
NOTE:Replacethe brakedisc if the smallestmeasurementis lessthan the max. refinishinqlimit.
Brake Disc Parallelism:0.015mm (0.fit06 in) max.
lf the disc is beyond the servicelimit, refinishthe
brake disc with an on-car brake lathe, The KwikLathe produced by Kwik-way Manufacturing Co.
and the "Front BrakeDisc Lathe" offeredby Snapon ToolsCo.are approvedfor this operation.
Max. RefinishLimit: 19.0mm (0.75in)
NOTE:A new disc shouldbe refinishedif its runout
is greaterthan 0.10mm (0.004in)
NOTE:This is the maximum allowabledifference
betweenthe thicknessmeasurements.
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brake disc with an on-car brake lathe.
The Kwik-Latheproduced by Kwik-WayManufacturing Co. and the "Front BrakeDisc Lathe"offered
by Snap-onTools Co. are approvedfor this operation.
NOTE:Seesection18for brakedisc reDlacement.
19-12
Front BrakeCaliper
Disassembly
NOTE:Therearetwo typesof front brakecalipers:
"5410"or
T h e c a l i p e rt y p e s c a n b e i d e n t i f i e db y t h e
"2056" stamped on the caliper body as shown below.
Checkthe type of the brakecaliperbeforeservicing.
R e m o v et h e c a l i p e rp i n s a n d p i n b o o t s f r o m t h e
calioerbracket,
PINB
CALTPER
BRACKET
CAL|PER
3.
5410Type:
see page
NOTE:For 2056type disassemblyprocedures,
19-14.
CALIPERPIN A
4,
@
o Never use an air hose ot dry brush to clean brakg
.
I t
assemblies.
Use an OSHA approved vacuum clganer to avoid
breathing brake dust.
CAUTION:
. Do not spill brake lluid on the vehicls; it may damage
the paint; if brake fluid does conlact the paint, wash
it off immedistely with waier.
. To prevenl spills, covet the hose ioin$ with rags or
shop towels.
. Clean all parts in brake fluid and air dry; blow out all
passageswith compressedair.
L
lf necessary.apply compressedair to the caliper
fluid inlet to get the piston out. Placea shop rag or
wooden blockas shownto cushionthe pistonwhen
it is expelled.Uselow pressureair in shortspurts.
@
. Do not place your iingers in tront ol the piston.
.
Do not use high air pressure; use 8n OSHA
approved 30 PSInozzls,
Removethe banjo bolt, and disconnectthe brake
hosefrom the caliDer.
CALIPER
BANJO EOLT
Removethe pistonfrom the caliper,and checkthe
pistonfor scoring.
Removethe boot clip,pistonboot and pistonseal.
CAUTION:Take care not to damage the cylindcr
PISTONSEAL
Replace.
SEALING
Replace.
BOLTS
Removethe caliperbolts,then remove the caliper
from the bracket.
l J
BOOTCLIP
Replace.
\
,
,t. (
\)
CALIPERBODY
Checkfor scoring
PISTONBOOT
Replace.
(cont'd)
19-13
Front Brake Caliper
Disassembly(cont'dl
2056Type:
4.
@Nevor u3e an air hos€ or dry brush to clgan brake
R e m o v et h e p i n b o o t , s l e e v eB a n d s l e e v eb o o t
from the caliperbody.
CALIPER
EODY
Check for scoring
on cytinder wa .
assomblios.
Use an OSHA approved vacuum cl6aner to avoid
braathing braks duet.
CAUTION:
. Do not spill brakefluid on ths vchicle; it may damage
the paint; if brako fluid does contact the p.int. wash
it olt immediately with wato..
. To prevsnt spills, cover the ho3o ioints whh rag3 or
shop towels.
. Cl€an all parts in brake fluid and air dry; blow out 8ll
passagsswith compr63€d air.
1.
Removethe banjo bolt, and disconnectthe brake
hosefrom the caliper.
SEALINGWASHERS
SLEEV€B
Checkfor damage.
lf necessary,apply compressedair to the csliper
fluid inlet to get the pistonout. Placea shop rag or
woodenblockas shownto cushionthe oistonwhen
it is expelled.Use low pressureair in shortspurts,
a Do not placo your lingers in ftont ol tho pkton.
a Do noi usa high air prsssure; uso an OSHA
approved 30 PSInozzle.
WOODENALOCK
Removecaliper bolt B, pivot the caliper up out of
the way,then removethe caliperfrom the bracket.
Removethe guide pin boot from sleeveA on the
caliDerbracket.
C h e c kf o r d a m a g e .
GUIDEPIN BOOT
Replace.
GALIPERBRACKET
Checktor cracks.
19-1 4
Removethe pistonfrom the caliper,and checkthe
pistonfor scoring.
7.
Removethe boot clip, pistonboot and pistonseal.
CAUTION;Take care not to damage the cylinder
bore.
goor cLtP
Replace.
SEAL
NSTON BOOT
Replace.
I
l.t
19 - 1 5
Front BrakeGaliper
Reassembly
5410Type:
NOTE:For 2056type reassemblyprocedures,
see page19-18.
o
.
.
.
Never use an air hose or dry brush to clean brako assemblies.
Use an OSHA approved vacuum cleanerto avoid breathing brake dust.
Contaminatedbrake discs or pads reducestopping abilhy.
when reusing the pads, always reinstall the brake pads in their original positions to pr€vent loss of braking €fficiency.
CAUTION:
. Do not spill brake fluid on the vehicle;it may damagethe paint; if brake fluid do€s contaci the psint, wash it oft imme"
diately with water.
. Cleanall parts in brake fluid and air dry; blow out all passag€swhh comp.€ssedair.
. Betorereassembling,checkthat all parts are free ol dust and othor toreign particlos.
. Replaceparts wilh new ones whenever specifiedto do so.
. Make sure no dirt or other toreign matt€r is allowed to contaminate the brake fluid.
. Always use Genuine Honda DOT 3 Brake Fluid. Using a non.Honda brake tluid can cause corrosion and decressethe
life of th€ system.
NOTE:
. Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid.
. Replaceall rubberpartswith new oneswheneverdisassembled.
z_.
.=-.q8! .9!,H:
Use recommendedrubber greasein the caliper seal set.
-.61'
use recommendedsealgreasein the catipersealset.
BRAKEPADS
CALIPERBRACKEIMOUNTINGBOLT
108N.m {11.0kgt m,80lbf.ft)
PIN BOOTS
"k..6
Replace.
tilfliltn
prr'r
e-....,-q\,
t w t\J fl iJI Il car-rpen
-
WEAB
WEAB
INDICATOR
rNDrcAroR
l n s r a l li n n e r p a d w i t h
irs weat indicatot !pwatd/,.
lAV
@{
\
*
*/
W
q
1
CALIPERBRACKET
OUTERPADSHIM
-o
CAI-IPER
PIN A -
-'''---&@
PAD RETAINERS
PISTONSEAL
PISTONBOOT
Replace.
Replace.
-6r
/
BLEEDSCREW
S N.m (0.9kgt.m, 6.5 tbf.ftl
CALIPERBODY
19-16
I
6
v o/
eoorcr-re
neptace.
'1.
Cleanthe piston and caliperbore with brakefluid,
and inspectfor wear and damage.
C o a tt h e n e w p i s t o n s e a l w i t h t h e r e c o m m e n d e d
rubbergreasein the caliperseal set.and installthe
sealin the cylindergroove.
Apply the recommendedseal greasein the caliper
sealset to the sealinglips and insideof a new piston boot,and securelyinstallit in the caliperwith the
new bootclip.
CAUTION: Be careful nol to damage the caliper
cylinderwall.
Apply the recommendedseal greasein the caliper
seal set to the sliding surfaceof the pins and the
lnsideof the new pin boots.
lnstallthe pin boots into the groovesin the caliper
bracketproperly.
CALIPERERACKET
CALIPER
-6l
CALIPEBPIN B
-6.l
PIN BOOTS
Replace.
PISTONSEAL
Replace.
--^.
,:=-qE!!!-H
RUBBER GREASE
-6l
CALIPERPIN
I J
PISYONBOOT
Replace.
j@i
SILICONEGREASE
7. Insertpin A and pin B into the caliperbracket.
8. Install the pin boots into the grooves in the pans
propeny.
9. Installthe brakepads in their originalpositions(see
page 19-9).
10. Pushin the pistonso that the caliperwill fit overthe
pads,and installthe caliPer.
11. Tightenthe caliperbolts.
12. Connectthe brakehoseto the caliperwith new sealing washers,and tightenthe banjobolt.
BANJO EOLT
34 N.m (3.5kg{ m, 25 lbflt}
SEALINGWASHERS
Replace.
L u b r i c a t et h e c a l i p e ra n d p i s t o nw i t h b r a k ef l u i d ,
then installthe pistonin the cylinderwith the dished
end facingin.
CALIPERBOLT
32 N.m 13.3kgt.rn,24lblft)
'13. Fill the brakereservoitand bleedthe brakesystem
{seepage19-7).
1 4 . Performthe following checks:
. Checkfor leaksat hose and line joints and connections.and retightenif necessary.
. Checkfor brakehosesfor interferenceand twisting.
(cont'd)
19-17
Front BrakeCaliper
Reassembly(cont'd)
I
2056Type:
. Never use an air hose or dry b.ush to clean brake assemblies.
. Uso an OSHA approved vacuum cleansrto avoid breathing brake dust.
. Contaminatedbrake discs or pads reducestopping ability.
t when reusing the pads, always r6instsll the brake pads in their original positioos to prevent
loss ol braking efficiency.
CAUTION:
' Do not spill brake tluid or th€ vehicle; it m8y damage the paint; if brake fluid does
contact the paint, wash it off immediately with water.
. Cleanall parts in brake tluid and air dry; blow out all passageswith compr63ed air.
. Beforo reassembling,checkthat all parts are fr€e of dust and other foreign particles,
. Replaceparts with new ones wheneveaspecifiedto do so.
. Make sure no dirt or other foreign matter is allowad to contaminato the brake fluid,
' Always use Genuine Honda DOT 3 Brake Fluid. Using a non-Hondabrake fluid can
caus€ corrosior and decreasethe
life ol the system.
NOTE:
. Coatthe piston,pistonseal,and caliperborewith cleanbrakefluid.
. Replaceallrubberpartswith new oneswheneverdisassembled.
.'=5@:
-6l
Use recommendedrubbergreasein the calipersealset,
' Use recommendedsealgreaseIn the calipersealset.
@6--i#i['i,?li"..;:l]l?Y]li"'"'
BRAKEPAOS
-/ffr
r""'"rr
r"""ip"autr,
WEAR,INDICAToR.
,ffi
\
CALIPERBRACKET
OUTERIPAD
i t s w e a r n d c a t o r u ' w\a r d
\
e"6ft
'ADRETATNERS
pr
MffiA
GUIDE
PIN
BOOT
\\ ) {I
I II )
I I
\I\d/ tt\' id
6
% '---r..'.*
caL,PER
u -es
**=*t
".-,."oo*'J.l,
ru,oonW
U
BLEED
SCREW
9 N.m(0.9kgf.m,6.5lbf.ft)
\
o@
-"-41
q.-
SLEEVE8
t\
r{.i'""Jg*'
a,t/
CALIPERBOLTB
2 6 N m { 2 . 7 k g f . m20
, tbf.ftl
c'f3!@
PISTONEOOT
Replace. CALIPERBODY
PIN BOOT
Replace.
19-18
SLEEVE
A
.&l
BOOTCLIP
Replace.
1.
Cleanthe piston and caliperbore with brakefluid,
and inspectfor wear and damage.
4.
Lubricatethe caliper and piston with brake fluid,
t h e n i n s t a l lt h e p i s t o n i n t h e c y l i n d e rw i t h t h e
dishedend facingin.
Coat a new Distonsealwith the recommendedrubber greasein the calipersealset,and installtheseal
in the cylindergroove.
Apply the recommendedseal greasein the caliper
seal set to the sealinglips and insideol a new piston boot, and securelyinstallit in the caliperwith a
new boot clip.
CAUTION: Be carelul not to damage ths calipor
cylinder wall.
Apply the recommendedseal greasein the caliper
seal set to the sliding surfaceoJ sleeveB and the
insideof the new pin and sleeveboots.
lnstallthe new sleeveand pin boots 8nd sleeveB
on the caliDer.
I J
NOTE: Makesure to installthe boots into the grooves
in the caliperand sleeveB properly.
BOOT
SI.EEVE
Replace.
Replace.
-6,
SILICONEGREASE
-1!!4!!n
RUBEERGREASE
=_.
SLEEVEB
Y
P IN BOOT
Replace.
t./
(cont'd)
19-19
Front BrakeCaliper
(cont'dl
Reassembly
7 . Apply the recommendedseal greasein the caliper
seal set to the sliding surfaceof sleeveA and the
insideof a new guide pin boot.
I n s t a l lt h e g u i d e p i n b o o t i n t o t h e g r o o v e i n t h e
sleeveA.
1 1 .Connectthe brakehoseto the caliperwith new sealing washers,and tightenthe banjobolt.
Tightenthe caliperbolt B.
BANJOBOLT
Make sure that the brake pad retainersand brake
padsare in their originalpositions(seepage 19-10).
26 N.m (2.7 kgl.m, 20 lbtftl
1 3 . Fill the brake reservoir and bleed the brake svstem
(seepage 19-7).
Installthe caliperonto sleeveA, and pivot it down
into position.
NOTE:Installthe guide pin boot into the groove in
the caliperproperly.
BRACKET
SLEEVEA
19-20
1 4 . Performthe following checks.
. Checkfor leaksat hose and line ioints and connectaons,and retighten if necessary.
. Checkfor brake hoses for interferenceand twistIng.
MasterCylinder/BrakeBooster
I
RemovaUlnstallation
CAUTION:
. Be care{ulnol to bend or damagethe brake lineswhen
rsmovingthe mastsr cYlinder.
. Do not soill brakefluid on the vehicle; it may damage
the paint; if brake fluid does contact the paint, wssh
it off immediatelYwith water'
. To prevent spill3, cover the hose ioints with rags or
shop towels.
the brakefluid levelswitchconnectors'
1 . Disconnect
the
2 . Remove reservoircap from the mastercylinder'
3 , The brakefluid may be suckedout through the top
of the mastercylinderreservoirwith a syrlnge.
the brakelinesfrom the mastercylinder'
Disconnect
5 . R e m o v et h e m a s t e rc y l i n d e rm o u n t i n g n u t s a n d
washers.
6. Removethe mastercylinderfrom the brakebooster'
7. Disconnectthe vacuum hose trom the brakebooster'
8. Removethe cotterpin and clevispin from the clevis'
CAUTION: Do not disconnect the clevb by removing it from the operating rod of the brako booster' lf
the clevis is loosened, adiust the pushrod length
before installingth€ brake booster (seepage 19-221'
9. Removethe four boostermountlngnuts
10. Pull the brake booster forward until the clevis is
clearof the bulkhead.
1 1 . R e m o v et h e b r a k eb o o s t e rf r o m t h e e n g i n ec o m panmenr.
'12. Installthe brakeboosterand mastercylinderin the
reverseorderof removal.
CAUTION:
. When connecting the brake lines. make sure
that there is no inte erence between the brake
lines and oth6r Parts.
r Be careful not to bend or damage the brake lines
when installing the master cylinder.
N O T E : l f r e p l a c i n gt h e m a s t e rc y l i n d e ro r b r a k e
b o o s t e r ,c h e c ka n d a d i u s tt h e p u s h r o dc l e a r a n c e
be{oreinstallingthe mastercylinder(seepage 19-221'
, n d b l e e dt h e
F i l l t h e m a s t e rc y l i n d e rr e s e r v o i r a
(see
19-7).
brake svstem
Page
1 4 . After installation.checkthe brakepedal height and
brake pedaltree play (see page l9-5) and adjust if
necessary.
BOOSTER
BRAKE
(WithABS:7" + 8" tandembrakebooster)
\l/
-6.4
CLEVISPIN
BRAKEFLUIOLEVEL
SWITCHCONNECTORS
MASTERCYLINDER
COTTERPIN
Replace.
VACUUM HOSE
To RearWheelCylinders
t'N't'ttrnt'-''
To FrontCaliper
(WithoutABS)
$
To FrontCaliper
lWithoutABSi
15 N.m {1.5kgl m,
11 tbtft)
CONTROLVALVE
PBOPORTIONING
l r
1 5 N . m { 1 . 5 k g i f . m ,1 1 l b t f t }
(With ABS: To modulator unit)
19-21
MasterCylinder/BrakeBooster
Pushrod GlearanceAdjustment
NOTEr
. T h e m a s t e rc y l i n d e r p u s h r o d - t o - p i s t o cn l e a r a n c e
must be checkedand adjustmentsmade, if neces_
sary,beforeinstallingthe mastercylinder.
. ABS type is shown, conventionalbraketype is similar.
1.
Setthe specialtool on the mastercylinde.body;push
in the centershaft until the top of it contactsthe end
ofthe secondarypistonby turningthe adjustingnut.
N O T E :l f t h e c l e a r a n c eb e t w e e nt h e g a u g e b o d y
and adjustingnut is 0.4 mm (0.02in), the pushrodto-pistonclearanceis 0 mm. However,if the clear_
ance betweenthe gauge body and adjustingnut is
0 mm, the pushrod-to-piston
clearanceis 0.4 mm
(0.02in) or more.Therefore,it must be adjustedand
rechecked.
6. lf clearanceis incorrect,loosenthe star locknut,and
turn the adjusterin or out to adjust.
NOTE;
. Adjustthe clearancewhile the specifiedvacuum
is appliedto the booster.
. Holdthe cleviswhile adjusting.
7 . Tightenthe star locknutsecurely.
Removethe specialtool.
0 - 0.4mm (0- 0.02in)
STARLOCKNUT
22 N.m
{2.2kg,f.m,16lbtft)
Withoutdisturbingthe centershaft'sDosition,install
the specialtoolupsidedown on the booster.
Installthe mastercylinder nuts, and tighten to the
specifiedtorque.
Connectthe boosterin-linewith a vacuumgaugeO_
101 kPa (0 - 760 mmHg, 30 in.Hg)to the booster,s
e n g i n e v a c u u m s u p p l y , a n d m a i n t a i na n e n g i n e
speedthat will deliver66 kpa (500mmHg,20 in.Hg)
vacuum.
With a feelergauge.measurethe clearanceDetween
the gaugebody and the adjustingnut as shown.
Clearance:0 - 0.4 mm {0 - 0.02 in)
PUSHROD
ADJUSTMENTGAUGE
ADJUSTER
07JAG- SD('1(x)
9. Adjust the pushrodlength as shown if the booster
rs removed.
11610.5
mm
{{.571 0.02in)
VACUUM GAUGE
(Comm€rciallyavaileblel
0 - 101kPa
{0 - 760 mm Hg, 30 in.Hg)
AOJUSTINGNUT
FEELER
GAUGE
PUSHROD
LOCKNUT
15 N.m 11.5kgf.m,11 tbtftl
1 0 . Install the master cylinder {see page l9-21).
19-22
BrakeBoosterInsPection
FunctionalTest
1. With the engine stopped,depressthe brake pedal
severaltimes to depletethe vacuumreservoir,then
depressthe pedalhard and hold it for 15 seconds lf
t h e p e d a l s i n k s ' e i t h e r t h e m a s t e rc Y l i n d e ri s
bypassinginternally,or the brake system (master
c y l i n d e r .l i n e s .m o d u l a t o r ,p r o p o r t i o n i n gc o n t r o l
valve,or caliPer)is ieaking.
2. Start the engine with the pedal depressed lf the
pedalsinksslightly,the vacuumboosteris operating
n o r m a l l y .l f t h e p e d a l h e i g h t d o e s n o t v a r y , t h e
boosteror checkvalve is faultY.
3. With the engine running.depressthe brake pedal
l i g h t l y .A p p l y j u s t e n o u g hp r e s s u r et o h o l d b a c k
a u t o m a t i ct r a n s m i s s i o nc r e e p .l f t h e b r a k ep e d a l
s i n k sm o r e t h a n 2 5 m m ( 1 . 0i n . ) i n t h r e e m i n u t e s ,
t h e m a s t e rc v l i n d e ri s f a u l t y . A s l i g h t c h a n g ei n
pedal height when the A'lCcompressorcycleson
a n d o f f i f n o r m a l . ( T h e A / C c o m p r e s s o rl o a d
changesthe vacuumavailableto the booster')
Booster CheckValve Test
1. Disconnectthe brake boostervacuum hose at the
booster.
2. Stan the engineand let it idle.Thereshouldbe vacuum. lf no vacuum is available,the checkvalve is
not working properly. Replacethe brake booster
vacuumhoseand checkvalve,and retest.
BRAKEBOOSTER
VACUUMHOSE
( C h e c kv a l v e
built-in)
LeakTest
1 . D e p r e s st h e b r a k ep e d a lw i t h t h e e n g i n er u n n i n g .
then stop the engine.lf the pedal height does not
vary while depressedfor 30 seconds,the vacuum
b o o s t e r i s O K . l f t h e p e d a l r i s e s .t h e b o o s t e ri s
faulty.
2, With the engine stopped,depressthe brake pedal
s e v e r a lt i m e s u s i n g n o r m a l p r e s s u r e W h e n t h e
Dedalis first depressed,it should be low On conthe pedalheightshouldgradsecutiveapplications,
uallv rise. lf the pedal positiondoes not vary, checK
the boostercheckvalve.
l./
19-23
Rear Brake Pads
Inspection
and Replacement
Never use an air hose or dry brush to clean brake
assemblies.
Use an OsHA-apptoved vacuum cl€aner to avoid
breathing brake dust,
'L
4.
Removethe outerpad shim,pads,and pad retainers.
PAORETAINERS
Blockthe front wheels,loosenthe rear wneet nuts
s l i g h t l y ,s u p p o r tt h e r e a r o f t h e v e h i c l eo n s a f e t y
stands,then removethe rearwheels.
Releasethe parkingbrake,and removethe calioer
s hi e l d .
OUTERPAO
SHIM
Checkfor
REARBRAKE
PADS
Check
for wear.
CALIPER
SHIELD
Removethe brakehose clamp bolt from the trailing
arm first, then remove the two caliper mounting
boltsand the caliperfrom the bracket.
CAUTION:
. Thoroughly clean the outside of the caliDerto
prevent dust and dirt trom entering inside.
. Support the calipor with a pieco of wire so that
it does not hang fuom the brake hose.
U s i n g v e r n i e rc a l i p e r s m
, e a s u r et h e t h i c k n e s so f
each brakepad lining.The measurementdoes not
anclude
the pad backingplatethickness.
BrakePad Thickness:
Standard:
7.0 - 8.0 mm {0.28- 0.31 in}
ServiceLimit: 1.5 mm {0.06in}
NOTErCheckthe hosesand pin boots for damage
or deterioration.
PARKING
BRAKE
CABLE ^.. ._-_ ---.
BACKINGPI-ATE
lf the pad thicknessis less than the service limit,
replacethe padsand shimstogetheras a set.
19-24
I
7 . Cleanthe caliperthoroughly;removeany rust, and
checkfor groovesand cracks.
Checkthe brakediscfor damageand cracks.
l v l a k es u r e t h a t t h e p a d r e t a i n e r sa r e i n s t a l l e di n
their correctpositions.
12. Rotatethe caliperpistonclockwiseinto the cylinder'
then align the cutout in the piston with the tab on
the innerpad by turningthe pistonback
CAUTION: Lubricate ths boot with rubber grease
to avoid twisting the piston boot. lf the piston boot
is twisted, back it out so it sits properly.
CALIP€RMOUNTING
BOLTS
23 N,m {2.3kg{.m, 17 lbt'ft)
CUTOUT
BRAKECALIPER
PAD RETAINERS
Apply greaseto the pointsindicatedby the arrow in
the followingdrawing:
NOTE:Use the pad greaseincludedin the pad set
or lMolykoteM77 grease,and apply a thin coat of
greaseevenlyto the designatedpoints.
. Pistonend and inner pad contactsurface
. Padand caliperbracketcontactsurface
. Outerpad shim and outer pad contactsurface
. Outerpad shim and caliperbody contactsurface
1 3 . Installthe brakehoseclampon the trailingarm.
1 4 . Installand tightenthe calipermountingbolts.
1 5 . Installthe calipershield.
1 6 . After installation.checkfor leaksat hose and line
jointsand connections,
and retightenif necessary.
1 1 . l n s t a l lt h e b r a k ep a d s a n d o u t e r p a d s h i m o n t h e
caliper bracket.Installthe inner pad with its wear
indicatorfacingdownward.
@
iwhen
t./
.
reusing the pads, always reinstall the
brake pads in iheil original posiiions lo prevont
loss ol braking efficiency
Contaminaled brake discs or pads reduce stopping ability. Keepgreaseoff the discs and pads.
1 7 . Depressthe brakepedalseveraltimes to makesure
the brakeswork,then test-drive
of the brakemay requrregreater
NOTE:Engagement
pedaltravel immediatelyafter the brakepads have
of
been replacedas a set. Severallight applications
pedal
travel.
pedal
the
normal
will
restore
the brake
Greaterthan normal pedaltravel may damagethe
mastercylinder.
19-25
RearBrakeDisc
DiscRunoutInspection
1 . Loosenthe front wheel nuts slightly,then raisethe
vehicle, and suppon it on safety stands. Remove
the front wheels.
DiscThickness
and Parallelism
Inspection
1.
Loosenthe front wheel nuts slightly,then raisethe
vehicle,and support it on safety stands. Remove
the front wh6els.
2.
Removethe brakepads(seepagej9-24).
3.
U s i n g a m i c r o m e t e r .m e a s u r ed i s c t h i c k n e s sa t
erght points, approximately45" apart and 1o mm
{0.4 in) in from the outer edge of the disc. Replace
the brakedisc if the smallestmeasurementis less
than the max. refinishinglimit.
Removethe brakepads(seepage 19-24).
I n s p e c t h e d i s c s u r f a c ef o r d a m a g ea n d c r a c k s .
Cleanthe discthoaoughly,and removea rust.
Use wheel nuts and suitableplain washersto hold
the disc securelyagainstthe hub. then mount a dial
i n d i c a t o ra s s h o w n . a n d m e a s u r et h e r u n o u t a t
10 mm (0.4in) from the outeredgeof the disc.
Brake Disc Runout:
ServiceLimit:0.10mm {0.00,tin)
BrakeDisc Thickness:
Standard:8.9 - 9.1 mm (0.350- 0.358in)
Max. RsfinishingLimit: 8.0 mm {0.31in}
5.
Brake Disc Parallelirm:0.015mm
(0.0006inl msx.
lf the disc is beyond the servicelimit, refinishthe
brakedisc,
NOTE;This is the maximum allowabledifference
betweenthe thicknessmeasurements.
Max. RetinishingLimit: 8.0 mm {0.31in)
4.
NOTE:A new disc shouldbe refinishedif its runout
is greaterthan 0.10mm (0.004in).
lf the disc is beyondthe servicelimit for Darallelism.
refinishthe brakedisc.
NOTE;Seesection18for brakedisc replacement.
19-26
Rear BrakeCaliper
Disassembly
@
f l',leveruse an air hose or dry brush to clean brake
5,
R e m o v et h e p i n s a n d p i n b o o t s f r o m t h e c a l i p e r
bracket.
assemblies.
Use an OsHA-approvedvacuum cleaner to avoid
breathing brake dust.
. Contaminated brake discs or pads reduce stopping
ability.
.
CAUTION:
. Do not spill brake tluid on the cal; h may damagethe
paint; if brake fluid does contact the paint, wash ii
ofl immediatelYwith water.
. To prevent spills, cover the hose ioints whh rags or
shop tow€ls.
. Clean all parts in brake fluid and air dry; blow out all
passagsswith complessedair.
1.
Removethe calipershield(seepage 19-24).
2.
R e m o v et h e l o c k p i n a n d c l e v i sp i n . R e m o v et h e
cableclip,and disconnectthe cablefrom the arm
CABLECLIP
PIN A
6.
Removethe pad springfrom the caliperbody
Removethe banjobolt and two sealingwashers
Removethe two calipermountingbolts and caliper
body from the bracket.
CALIPERMOUNTNG AOLTS
CALIPERBRACKET
Checkfor cracks
SEALING
WASHERS
Replace.
BANJO
BOLT
(cont'd)
19-27
RearBrakeGaliper
Disassembly(cont'd)
7.
Removethe piston by rotatingthe piston counterc l o c k w i s ew i t h t h e t o o l , a n d r e m o v et h e p i s t o n
boot.
CAUTION: Avoid damaging the piston.
PISTONBOOT
Replace.
Removethe pistonseal.
CAUTION: Take care not to damage the cylinder
bore.
CALIPERBODY
Check for scoring on
9. Installthe specialtool betweenthe caliperbodv and
spnng cover.
CAUTION: Be caretul not to damags the inside of
the caliper cylinder during caliper disassembty.
BRAKESPRING
COMPRESSOR
07HAE- SG00100
LOCKNUTS
Positionthe locknutsas shown.then turn the shaft
untilthe platejust contactsthe caliperbody.
N O T E : D o n o t c o m p r e s st h e s p r i n g u n d e r t h e
springcover.
1 1 . Turn the shaft clockwise1/4-'ll2 tu.n to comoress
adjustingspringB in the caliperbody.
CAUTION: To preyant damage to the inner compononts. do not turn the shaft mor€ than 1/2 turn.
SHAFT
LOCKNUTS
PISTONSEAL
Replace.
ADJUSTII{G
SPRING8
19-28
\
Lowerthe locknutsfully,and tightenthem securely.
15. Removethe adjustingbolt.
NOTE:Keepthe locknutsin this positionuntil you
r e i n s t a l l t hcei r c l i p .
1 3 . Removethe circlipwith snapring pliers.
SNAPRING
PLIERS
07914- SA50001
't4. Hold the platewith your fingers,and turn the shaft
Removethe specialtool from the
counterclockwise.
calioer.
LOCKNUTS
Removethe springcover,adjustingspringB, spacer,
bearingA, and cup from the adjustingbolt.
'17. Removethe sleevepiston,and removethe pin from
the cam in the caliperbody.
SLEEVEPISTON
Checklor wear and
damage,
i
I
I
6-50-a
w l
\
I
O-RIITG
Repl6ce.
l./
(cont'd)
19-29
RearBrakeGaliper
(cont'dl
Disassembly
18. Removethe returnspring.
RETURN
SPRING
PARKINGLEVER/
CAM ASSEMBLY
Checklor damage.
1 9 . Removethe parkinglever and cam as an assemblv
from the caliperbody.
CAUTION: Do not loosen the parking nut with the
cam inslalled in the caliper body, lf the leyer and
shaft must be separated, hold the lever in a vise,
and loosenthe parking nut,
Removethe cam boot.
19-30
I
Reassembly
"n ",, hos6 or drv brush to ctoan brake assemblies.
HP*
o Use an OSHA-approvedvacuum cleanel to avoid brealhing brake dust'
. Contaminatedbrake discs or pads reducestopping sbility.
. When reusing the pads, in3tall thom in thoil original positions to prevent loss of braking efficiency'
CAUTION:
. Do not soill brake fluid on the vehicle; lt may damagelhe paint; if brake fluid does contacl the paint' wash it oft immediately with water.
. Cl€anall Darts in brake fluid and air dry; blow out all passagsswith comPressedair'
. Belore rsas3embling,checkthat all parts ars free ot du3t and othor tor€ign particles'
. Replaceparts with new ones whenever spscifiodto do so.
o Make sur€ no dirt or othor foreign matter is allowed to contaminate the brake tluid'
. Always use Genuine Honda DOT 3 Brake fluid. Using a non-Hondabrake fluid can Gtuse corrosion and decreasethe
lif€ of ths system.
NOTE:
. Coatpiston,pistonseal,and caliperborewith cleanbrakefluid
. Replaceall rubberpartswith new oneswheneverdisassembled.
Userecommendedsiliconeand pin greasesin the calipersealset.
o .-'{@]:
. -ffi,Use
rubbergreasein thecalipersealset.
recommended
-"'9
sPRTNG
RETuRN
iiilji:ll;;
__X.,,..".^
8 mm FLANGEBOLT
23 N.m (2.3kgt'm, 17lbf ftl
BLEEDSCREW
9 N.m (0.9kgtm,6.5lbf'ft|
@
BEARINGA
PAOSPNING
=^.
\
F
PISTONBOOT
-61
@@-t-.
CUP
r---
Replace.
.ffi
PINBOOTS
Replace.
OUTERPAD SHIM
BRAKEPAOS
I
"l-r,r.,"or"'*o" orr"
23N.m{2.3kgtm,17lbf.ftl
l /
PISTONSEAL
Replace.
@.,
\@
CALIPERBMCKET \
----.-,o,
MOUNTINGEOLTS
q%
54 N.m (5.5 kgf.m,40lbl.ft)
CALIPEB
BRACKET
PISTON
(cont'd)
19-31
RearBrakeCaliper
(cont'dl
Reassembly
L
Packall cavitiesof the needlebearingwith the rec,
ommendedrubbergreasein the calipersealset,
5.
I n s t a l l t h ep i n i n t h e c a m .
O.RING
Replace.
Coat a new cam boot with recommendedrubber
grease in the caliper seal set, and install it in the
caliperbody.
PARKINGNUT
28 N.m (2.8 kgt m,
20rbr.trt
SLEEVE
PISTON
SPRII{G
WASHEN
Installa new O-ringon the sleevepisron.
z.
.-_e!!!9!.{
RUBBER
GREASE
7.
Installthe sleevepistonso that the hole in the bottom of the pistonis alignedwith the pin in the cam,
and the two pins on the pistonare alignedwith the
holesin the calioer.
Coat a new cup with recommendedrubber grease
in the caliperseal set, and installit with its groove
facingthe bearingA side of the adjustingbolt.
€8.--:BTif
@'-.-3nfi""'i"
Apply recommendedrubber greasein the caliper
seal set to the pin contactingarea of the cam, and
installthe cam and lever assemblyinto the caliper
bodv.
@--seacrn
eeenrne
a
$
fi,*,*^"
lnstallthe returnspring.
CAUTION:
. When the cam and lever wgre separatod.b€ surg
to assemble them bofore installing the cam in
the caliper body, Install the lev€r and spring
washer. apply locking agent to the threads, and
tighten the parking nut while holding the l.vor
whh a vise,
. Avoid damaging the cam boot since it must bs
installed before thg cam.
. When installing the cam, do nol allow the cam
boot lips lo turn outside in.
GF-
=^.
#-g!!!!!Jl
RUBBER
GREASE
o
19-32
CUP
Replace.
Fit the bearingA, spacer.adjustingspring B, and
springcover on the adjustingbolt, and installthem
in the caliDercvlinder.
1 0 . l n s t a l lt h e s p e c i a tl o o l o n t o t h e s p r i n gc o v e r ,a n d
turn the shaft untilthe locknutcontactsthe plate.
13. Coat a new piston sealwith recommendedsilicone
greasein the calipersealset,and installit in the cali-
per.
PISTONSEAL
Replace.
-6l
PISTONBOOT
Replace.
RUBBER
GREASE
1 4 . Apply recommendedrubber greasein the caliper
seal set to the sealinglips and insideof a new piston boot,and installit in the caliper.
Coatthe outsideof the pistonwith brakefluid, and
i n s t a l li t o n t o t h e a d j u s t i n gb o l t w h i l e r o t a t i n gi t
clockwisewith the tool.
1 1 . Checkthat the flaredend of the springcoveris below
the circlipgroove.
CAUTION: Avoid damaging the piston and piston
boot.
12. Installthe circlip into the groove.then removethe
specialtool.
NOTE:Checkthat the circlipis seatedin the groove
properly.
PISTON
CIRCLIP
SPRINGCOVER
t.t
(cont'd)
19-33
RearBrakeCaliper
(cont'dl
Reassembly
'16. Installthepad
springonto the caliper.
21. Installthe brakepad retainersand brakepads (see
page19-25).
22. Align the cutout in the piston with the tab on the
innerpad (seepage 19-25).
Installthe caliperonto the caliperbracket.and tighten the calipermountingbolts.
PAD SPRING
CALIPERMOUNTINGBOLTS
23 N.m {2.3 kg{.m. 17 lbf.ft)
1 1 . Apply the recommendedpin groasein the caliper
sealset to the slidingsurfaceof the pins and inside
of the new pin boots.
Installthe pin boots into the groovesin the caliper
bracketproperly.
PINBOOTS
Replsce.
BANJO BOLT
34 N.m
13.5kg{.m.
25 rbtft)
WASHERS
Replace.
24. Connectthe brakehoseto the caliperwith new seal,
ing washers,and tightenthe banjo bolt,
Insertths cable through the arm, and connectthe
cabls to the lever with the clevis pin and lock pin.
Installthe cableclip securely.
CLEVISPIN
-t
(Bl.ck Colorl
//t
LOCKPIN
Roplace.
PIN
Repl6ce.
PIN GREASE
19. Insertpin A and pin B into the caliperbracket.
20. Installthe pin boots into the grooves in the p rn s
propefly.
19-34
26. Installthe caliDershield.
27. Fill the brakereservoir,and bleedthe brakesvstem
(seepage19-71.
28. Operatethe brake pedal severaltimes, then adjust
the parkingbrake(seepage 19-6).
performthe followingchecks:
29. After installation,
. Checkfor leaksat hose and line joints and connections,and retightenif necessary.
. Checkthe parkingbrakeleverfor operation,and
adjust it if necessary.
. Checkfor brakehosefor interference
or twistinq.
RearDrum Brake
Index/lnspection
Never use an air hose or dly brush to clean brake assemblies,
Use an OSHA approved vacuum cleanarto avoid breathing brake dust,
a Contaminatedbrake linings or drums reducestopping ability.
a Block the tront wheels before iacking up ths r€ar of lhe vehicle.
'1.
Blockthe front wheels,loosenthe rear wheel nuts slightly,supportthe rear of the vehicleon safety stands,then
removethe rearwheels.
2.
Release
the parkingbrake,and removethe rearbrakedrum.
WHEELCYLINDER
Inspectfor leakage.
lf necessary,
replaceas an assembly.
I N m 10.9kgtm, 6.5 lbf.ftl
PARKINGBRAKELEVER
Markedleftand right.
u-cLrP
WAVE
WASHER
Replace.
I
UPPERRETURNSPRING
Checkfor weakness
ano oamage,
@
J
PIVOTPIN
/ €f-l
.^ *'t")
TENSIONPIN
10 mm BOLT
6,1Nm 15.5kgf m,
47 tbf.ft)
BACKINGPLATE
Markedlelt andright-
II
ctEv'sB
/
ADJUSTERBOI-T
|
d " /
/
, Installsecurelyon
tensionpin.
IU
(t
Checkratchetteeth
for wear and damage.
LOWERRETURN
SPRING
Checkfor weakness
and oamage.
BRAKESHOE
Inspection,
seepage19-36
lf brakeshoes are to be
r e u s e d ,m a r k a n d r e a s s e m b l e
in same position.
,.ro,".r r.*,"n
/
/
SELF.ADJUSTER
LEVEB
SELF-ADJUSTER
SPRING
Checkfor weakness
ano oamage.
BRAKEDRUM
Inspection,
seepage'1936
t
19-35
RearDrum Brake
Inspection
1 . Checkthe wheelcylinderfor leakage.
6.
Checkthe brakeliningsfor cracking,glazing,wear,
and contamination.
Measure the inside diameter oJ the brake drum
usingthe insideverniercalipers.
Drum Inside Diameter:
Standard:
199.9- 200.0mm {7.870- 7.874in)
Servic€Limit: 201.0mm (7.913inl
Measurethe brakeliningthickness.
Brake Lining Thickness:
Standard:
4.0 mm {0.157in}
ServiceLimit: 2.0 mm 10.08in)
INSIDEVERNIERCALIPERS
WHEELCYLINDER
BRAKEORUM
LININGS
NOTE; Measurementdoes not include brakeshoe
thickness.
4.
lf the brakelining thicknessis lessthan the service
limit, replacethe brakeshoesas a set.
Checkthe bearingsin the hub unit for smooth operation. lf defective,refer to section 18
19-36
7.
l f t h e i n s i d ed i a m e t e ro f t h e b r a k ed r u m i s m o r e
than the servicelimit, replacethe brakedrum.
8.
C h e c kt h e b r a k ed r u m f o r s c o r i n g ,g r o o v e s ,a n d
cracks.
t
BrakeShoeDisassembly
1.
R e m o v et h e t e n s i o np i n s b y p u s h i n gt h e r e t a i n e r
springsand turningthem.
TENSIONPINS
6.
Removethe wave washer,parkingbrakelever,and
pivot pin from the brakeshoe by removingthe Uclrp.
PARKINGERAKE
I-EVER
WAVEWASHER
/
@@
I
I
U-CLIP
Replace.
RETAINER
SPRINGS
Lower the brake shoe assembly,and remove the
lower returnspring.
NOTEi Be carefulnot to damagethe dust cover on
the wheelcylinder.
t
1 . Apply brakecylindergrease(P/Nr08733- B020E)or
equivalentrubber greaseto the sliding surfaceof
the pivot pin,and insertthe pin into the brakeshoe.
3.
Removethe brakeshoeassembly.
4.
the parkingbrakecablefrom the parking
Disconnect
brakelever.
Installthe parkingbrakelever and wave washeron
the pivot pin and securethem with the U-clip,
lever,
Removethe upper returnspring,self-adjuster
a n d s e l f - a d j u s t esrp r i n g ,a n d s e p a r a t et h e b r a k e
snoe5.
NOTE: Pinchthe U-clip securelyto preventthe pivot
pin from comingout of the brakeshoe.
ADJUSTEBBOLT
Checkratchetteethfor
wearano oamage.
UPPERRETURNSPRING
Checkfor weakness
a n oo a m a g e .
N
r
ll
//
t
BrakeShoeReassembly
,6;::"'
LEVER
,'/
(cont'd)
19-37
RearDrum Brake
BrakeShoeReassembly
{cont'dl
C o n n e c tt h e p a r k i n g b r a k ec a b l e t o t h e p a r k i n g
brakelever.
5. Cleanthe threadedportionsof clevisesA and B.
Coat the threads of the cleviseswith grease.To
shoften the clevises, tun the adjuster bolt.
Apply greaseon eachslidingsurface.
contaminated brake linings reduce
!@
stopping ability. Keep greaseor oil off the blake linings. Wipe any excessgreaseoff the parts,
.
Apply brakecylindergrease{P/N:08733- 8020E)
o r e q u i v a l e nrt u b b e rg r e a s et o t h e s l i d i n gs u r facesas shown.
6. Hook the self-adjusterspring to the self-adjuster
leverfirst,then to the brakeshoe
7. Installthe clevisesand upper return spring. noting
the installationdirection.
NOTE:Be carefulnot to damagethe wheel cylinder
dustcovers,
8. Installthe lower returnspring.
+a
Slidingsurlace
9. Installthe tensionpins and retainingsprings.
SpRtNG
uppERRETURT{
CLEVISB
CLEVISA
Apply Molykote44MAto the brakeshoeendsand
oppositeedgesofthe shoesas shown.
_' o
+O
Opposite edge of the shoe
Brake shoe ends
LOWERRETURNSPRING
't0. Installthebrakedrum.
1 1 . lf the wheel cylinderhas been removed,bleed the
brakesystem(seepage 19-7),and checkfor leaksat
brakeline connections,
and retightenif necessary.
12. Depressthe brake pedal severaltimes to set the
self-adjusting
brake.
1 3 . Adjustthe parkingbrake(seepage19-6).
19-38
Brake Hoses/Lines
L
J
Specifications
Inspection/Torque
and twisting.
leaks,interference,
t. Inspectthe brakehosesfor damage,deterioration,
2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines.
and retightenif necessary'
3. Checkfor ieaksat hoseand line iointsand connections,
4. Checkthe mastercylinderand ABS modulatorunit for damageand leakage
CAUTION: Replacetho brake hose clip whenev€r the brake hose is serviced.
l-lNE
ABS MODULATORUNIT-Io-BRAKE
19 N.m (1.9 kgf.m, 14lbl.ftl
CONTROLVALVE.
PROPOBTIONING
io-BRAKELINE
11 tbf.ftl
l5 N.m (1.5
MASTERCYLINDER-Io-BMKELINE
15 N.m (1.5ksrf.m,11 lbf'ft)
J
REARDISGBRAKE:
BRAKEHOSE-to4ALlPER
{BANJOBOLT}
34 N.m (3.5kgtm,25 lbf ftl
BLEEOSCREW
9 N'm (0.9kgf.m, 6.5 lM.ftl
CYLINDER
BRAKELINE-to-WHEEL
15 N.m (1.5kgl.m, 11 lbf.ftl
BLEEDSCREW
7 N.m {0.7kst m, 5 lbf,ttl
HOSE
BRAKELINE-io-aRAKE
15 N.m {1.5
11 tbtft)
HOSE
BRAKELINE-Io-BRAKE
15 N.m (1.5kgt.m, 11 lbf'ft)
(BANJOBOLT}
3,1N.m 13.5kgf.m, 25 lbf.ft)
J
19-39
BrakeHoses/Lines
HoseReplacement
CAUTION:
. Bgfore reagsembling,chgck that all parts are free of
dust and othor foroign particles.
. Repl8ceparts with new ones whenever specified to
do so,
. Do not spill brake fluid on th6 vehicle; it may damage
tho paint; if brake fluid does contact the paint, wash
it off immediately with water.
6. Installthe brakehose bracketand brakehose onto
the knucklefirst.then connectthe brakehoseto the
caliperwith the banjobolt and new sealingwashers.
BRAKEHOSE
1 . Replacethe brakehose if the hose is twisted,cracked,
or if it leaks.
Disconnect
the brakehosefrom the brakeline using
a 10 mm flarenut wrench.
FLARENUT
WRENCH
lCommercially
available)
6 mm HOSEBRACKET
BOLTS
9.8 N.m
{1.0kgf m, 7 lbtfr}
BRAKELINE
BANJOBOI.T
34N.m
{3.5kgf.m,25lbt.ftl
7 . I n s t a l lt h e b r a k eh o s e o n t o t h e u o o e r b r a k eh o s e
bracketwith a new brakehoseclip
15 N.m
(1.s ks{.m, 11 lbl.ftl
BRAKEHOSE
Removeand discardthe brake hose cliD from the
brakehose.
8 . Connectthe brakelineto the brakehose.
After installingthe brakehose,bleedthe brakesystem (seepage 19-7).
Removethe banjo bolt, and disconnectthe brake
hosefrom the caliper.
1 0 . Performthe followingchecks:
.
Removethe brakehose bracketfrom the knuckle.
.
Checkthe brakehoseand line joint for leaks,and
tightenif necessary.
Checkthe brakehosesfor interference
and twistIn g .
19-4 0
ParkingBrakeCable
and Replacement
Inspection
L
CAUTION: The parking blake cables must not be bent or distorted. This will lead to stiff operation and premature cable
failure.
PARKINGBRAKECABLE
Checkfor faultymovement.
PARKINGBRAKELEVER
Checkfor smooth
operation.
DISCBRAKETYPE:
CLEVISPIN
EOUALIZER
\ i
,
PARKINGBRAKESWITCH
Disc BrakeType:
the parkingbrakecablefrom the leveron the
Disconnect
caliperby removingthe lockpin and clevispin, and remove
the cablefrom the arm by removingthe clip
Drum BrakeType:
Removethe parkingbrakecablefrom the backingplate
usinga 12 mm offsetwrenchas shown.
PARKINGERAKECABLE
BACKINGPLATE
CLEVISPIN
/
{tt
12 mm
OFFSETWRENCH
(Commercially
available)
19-41
L
-
Anti-lockBrakeSystem(ABSI
SpecialTools
.............
19-44
ComponentLocations.........................
19-45
Anti-lockBrakeSystem (ABS)
t
t /
Wheel Sensor
........19-64
Solenoid
.................
19-60
ABS PumpMotor .............................
19-68
Main Relay
.............
19-71
lgnition Voltage
.... 19-73
CentralProcessingUnit {CPU}........19-74
Modulator Unit
Removal/lnstallation.......................
19-75
ABS Control Unit
Replacement
.........19-76
Pulsers/WheelSensors
Inspection
..............
19-76
Wheel SensorReplacement............
19-77
Features/Construction...................,
19-46
Operation
...............
19-47
Circuit Diagram
.........19-50
ABS Control Unit Terminal
Arrangement
.........19-52
TroubleshootingPrecautions.............
19-54
DiagnosticTroubleCode (DTCI
DiagnosticTroubleGode(DTCI
Indication
...........
19-56
DTCErasure
...........
19-57
Symptom-to SystemChart .............
19-58
Troubleshooting
ABS IndicatorLight DoesNot
ComeOn
............
19-60
ABS IndicatorLight DoesNot
Go Off ............................................
19-62
SpecialTools
Ret.No.
(!)
19-44
I
I
Tool Number
07PM- 0010100
I
I
Description
SCSService
Connector
I
O,V I pageReference
t
I 19_s6
ComponentLocations
t a
SERVICECHECKCONNECTOR
{2PI
MOOULATORUNIT
ABS CONTROLUNIT
BIGHT.REAR
WHEEL
SENSORCONNECTOR
RIGHT-REAR
WHEELSENSOR
LEFT.R€AR
WHEEL
SENSOR
CONNECTOR
UNDER.DASHFUSE/RELAY8OX
LEFT.FRONT
WHEELSENSOR
J
FUSE/RELAY
BOX
UNDER.HOOD
lcl lilo Al FUSE
E
o
ABS INDICATORLIGHT
UNOEF.DASI{FUSE/RELAYBOX
METEBI7.5 AI FUSE
t
HORN/STOPI15 A) FUSE
ABS FUSE/RELAYBOX
UNDER.HOOO
ABS +B (20 A) FUSE
PUMP MOTOR{'O A} FUSE
0 00000
n
u
0 00000
0
BR DEFRLY 17,5A) FUSE
MTRCHECK(7.5AI FUSE
PUMPMOTORBELAY
19-45
Anti-lockBrakeSystem(ABSI
Features/Construction
When the brakepedalis depressedduring driving,the wheelscan lock beforethe vehiclecomesto a stop, In such a case,
the maneuverability
of the vehicleis reducedif the front wheelsare locked,and the stabilityof the vehicleis reducedif the
rearwheelsare locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto
ensurethe grip forceof the tires.and it therebyensuresthe maneuverbility
and stabilityof the vehicle.
Judgingthe vehiclespeed.the ABS calculatesthe slip rateof the wheelsbasedon the vehiclespeedand the wheel speed,
then it controlsthe brakefluid pressureto attainthe targetslip rate.
Grip Force of Tire and Road Surlace
Slip Rate
COEFFICIENT
OF
FRICTION
BRAKING
STARTPOINT
TARGETSLIPRATE
ROTATIONAL
DIRECTION
RADIAL
DIRECTION
OF THE
ROTATIONAL
OIRECTION
SLIPRATE
19-46
A: Distancewithout slio
8: Slippsd distance
C: Actuel distance
VEIIICLESPEED- WHEELSPEEO
sr-rrmre=f=
VEHICLESPEED
t
-
Operation
ABS Control Unit
Main Control
The ABS control unit detectsthe wheel speedbasedon the wheel sensorsignalit received,then it calculatesthe vehicle
speed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring decelerationbasedon the
rateof deceleration.
The ABS control unit calculatesthe slip rate of each wheel. and it transmitsthe control signal to the modulator unit
solenoidvalvewhen the slip rateis high.
The pressurereductioncontrolis a three-modesystem,that is pressurereduction,pressureretainingand pressureintensifying modes.
t
Self-diagnosisFunqtion
The ABS controlunit is equippedwith a main CPUand a sub CPU,and the CPUScheckeachother'
The CPUscheckthe circuitof the svstem.
"systemdown mode" or the "controlinhibitionmode"
Whenthe CPUSdetectfailure,they shiftto the
SOLENOID
VALVE
LIGHT
ABS INDICATOR
MAIN
RELAY
SYSTEIV
DOWN
ON
No
operation
Drive
inhibition
CONTROL
INHIBITION
ON
No
operalron
Drive
inhibition
MODE
CPU
Operation*r
Operation
Restartcondition
lgnition
switch
OFF + ON
Automatic
DTC
Memory
Memory
*1: ExceptCPUfailure
can be classifieldinto thesefour categories:
The self-diagnosis
Initial
diagnosis
O:
@: ExceptABS control
@: DuringABS control
@: Duringwarning
On-board DiagnosisFunstion
The ABS controlunit is connectedto the data link connector{16P).
The ABS systemcan be diagnosedwith the HondaPGMTester.
/
(cont'd)
19-47
Anti-lockBrakeSystem{ABS)
Operation(cont'dl
ABS Modulator
The ABS modulatorconsistsof the inlet solenoidvalve, outlet solenoidvalve, reservoir,pump, pump motor and
the
dampingchamber.
The modulatorreducesthe caliperfluid pressuredirectly,and it is also referredto as a circulatingtype becausethe brake
fluid
circulatesthrough the caliper,reservoirand the mastercylinder.
The hydrauliccontrolhasthree modes:pressurereducing,pressureretaining,and pressureintensifying.
The hydrauliccircuitis the independent
four channeltype, one channelfor eachwheel.
PUMPMOTOR
RF
LR
rN: INLETVALVE
Pressureintensifyingmode:Inletvalveopen,outletvalveclosed
{ N O R M A L t YO p E N I
OUT: OUTIET VALVE {NORMALIY CTOSED)
Mastercylinderfluid is pumpedout to the caliDer.
Pressureretainingmode: Inletvalveclosed,outletvalveclosed
Caliperfluid is retainedby the inletvalveand outletvalve.
Pressurereducingmode: Inletvalveclosed,outletvalveoDen
Caliperfluid flows throughthe outletvalveto the reservoir.
Motor operationmode:
When startingthe pressurereducingmode,the pump motor is ON.
WhenstoppingABS operation,the pump motor is OFF.
The reservoirfluid is pumpedout by the pump,throughthe dampingchamber,to the master
cvlinder.
19-48
L
Wheel Soeed and Modulator Contlo
EELSPEED
OUTLET
VALVE
ON
OFF
t
INLET
VALVE
ON
OFF
t\,40ToR
ON
OFF
pressure
when the wheelspeeddropssharplybelowthe vehiclespeed,the inletvalveclosesto retainthe caliperfluid
pressure.
The pump
fluid
caliper
reduce
the
to
momentarily
opens
valve
the
outlet
further,
speed
drops
When the wheel
motor startsat this time.
As the wheelspeedis restored,the inletvalveopensmomentarilyto increasethe caliperfluid pressure.
WheelSensoJ
type
The wheelsensorsare the magneticcontactless
frequencychanges
As the gear pulserteeth rotatepastthe wheel sensor'smagneticcoil,AC currentis generatedThe AC
and
therebydetects
frequency
signal
wheel
sensor
the
unit
detects
with the wheel speed.The ABS control
in accordance
the wheelspeed.
Thereare four wheelsensors,one for eachwheel
The gear pulserhas50 teeth.
GEARPULSEB
at HIGHSPEED
WHEELSENSOB
gl
/
at LOWSPEED
=
o
19-49
GircuitDiagram
AA DEFBLYI7.5AI
-
E8l{'Ytr
LEFT.FSONT
SOLENOIO
_@f_u,
n4@f-n,
UNDER.HOOO
A8S FUSE,/FELAY
BOX
3P CONNECTOR(O number)
|
UNDER-OASH
FUSSRELAY
8OX
(O numbe,
ZoPCONNECTOR
2 3
2 3 l
UNDER.HOODAAS FUSE/RELAYBOX
2P CONNECTOR(! number)
|
5 6
t3 / i 1 5 /
t0 tl
MOOULATORUNIT IOP CONNECTOR
7 8 I
t8
20
UNDER.OASHFUSE,/RELAY
BOX
1 8 PC O N N E C T O R( E n u m b € r )
2 3
- l
9
ll
5 6
2 13)t4 /
1617
GAUGEASSEMELY5P CONNECTOR
---t-t 1 t / 1 3) / l 5 l
Wiresideot temaleterminals
19-50
zrJrF!_
l l l 2 3 l l
14TiEltl
c@4
PIMP MOTOR2P CONNECTOR
(Ll number)
fFl
GTN
t
ABS CONIROLUN]T
ECM/ PCMISCS'
V
+B
Y
WHTNED
,,,+-{l-,
[,b.,,,,,
B6li!
-F- ?,,]
8U(
JG,Ol, Ga02
SENSOR
LEFT.
RIGHT,
\EWIK
l
LEFT
-o&"^1'
;___.|-1
**1.
,I
coierou cot,croz
ABS CONTROLUNIT26P CONNECTOR
1O numb€r)
1 2 3 4
14t5 1 6 1 7
6
/
8
1 9 , / 21
I
CHECK
SERVICE
(2P}
CONNECTOR
l 0 . / t t 1 2 r3
lrl2f
23
UNIT22PCONNECTOR
ABSCONTROL
1! numb€r)
OATALINK
CONNECTORO 6P)
WHEELSENSOR
2PCONNECTOB
FRONT
/.[Ttl\
REAR
tc-T-l z
I
r[B'
l
12 13
/
Wire side of female terminals
Terminalsideof
maleterminals
19-51
ABS ControlUnit TerminalArrangement
ABSCONTROL
UNIT26PCONNECTOR
Wire sideof temaleterminals
Terminal
numo0r
Wire Terminalsign
color Terminalnamo
Voltage
Conditions
(lgnitionSwitch ON flt))
Dgscription
teminals
PCOM
(Primary
common)
Power sourcefor the solenoid
valve and pump motor.
scoM
Powersourcefor the solenoid
6
GRY
8
GRN
sensorsignal.
RLO
Detectsleft-rearwheelsensor
(Rear-left
0) s r g n a l .
FRO
D€tectsright-frontwheel
(Front-right0) sgnsorsrgnal,
STOP
hects brakeswitchsignal.
(Stop)
(Prevents
unnecess€ry
ABSoperation)
2.GND
12
14
15
r6
17
19
FLO
BRN^/vHT (Front-left
0)
YEL
RLOUT
(Rearjeftoutlet)
RR]N
REDMHT (Rear-right
inlet)
B1
(Battery1)
82
WHT/GRN (Baftery
2)
GND2
BLK
{Ground2)
RR1
GRN/'/EL (Rear-right
1)
R
L
l
LT BLU (Rea.-left
1)
53mVor aboveon
4-17
(AC
digitaltester
Whenthe wheelis
nce)
turned at 1 turn/second. range){Fefera
6-19
150mvp-por above
on oscilloscope
a-21
Stops
Brakepedaldepressed.
9-GND
Brakepedalreleased.
Whenthe wheelis
turnedat 1 turn/
secono.
12.GND
Powersourcefor the solenoid
vatveandpumpmotor.
Powersourcefor the solenoid
varveanopumpmotor.
Ground for the ABS control
unit.
Detects right-rear wheel
sensorsignal.
13-GND
19-52
GND3
(Ground
3)
AC:3^6V
Approx.3 V
Batteryvoltage
15.GND
16-GND
17-4
19-6
21-8
Below0.3V
53 mV or above
on digitaltester
Whenthe wheelis turned (ACrange)
at 1 turn/second.
(Referance)
150
mVp-por above
on oscilloscope
23-10
Stops
Approx.2.5V
'6
25.GND
Ground for the ABS cgntrol
unit.
OFF
14.GND
ON
RL-IN
(Rear-lett
inletl
-9
53mVor aboveon
(AC
digitaltester
range)(Referance)
150mVFporabove
on oscilloscope
Approx.2.5V
OV
OFF
theSCSservice]
lconnect
connector I
i
ut
BLK
ON
Approx.2.5V
Batteryvoltage
OV
ON
9!ops
Drivesleft-rear
outletsolenoid
Drivesright-rearinlet solenoid
valve.
Approx.3 V
Batt€ryvoltage
10-23
Detectsleft-rearwheelsensor
sagnal.
FRl
Detectsright-frontwheel
GRN/BLK(Front-right
1) sensorsignal.
FL1
Detectsleft-frontwheelsensor
(Front-left1) s i g n a l .
Drivesleft-r€ar
inletsolenoid
RED
OV
OFF
theSCS
service\
lConnect
conneclor l
\
3-GND
Detectsleft-frontwheelsensor
signal.
10
ON
ON
AC:3-6 V
BLK/WHT (Secondary
common)
tG2
Detectsignitionswitch2
ELVBLU (lgnition
2)
!9nal. (systemactivatesignal)
RRO
Detects right-rear wheel
BLU/YEL (Rear-right
0)
=
1-GND
Output voltago
26.GND
-9
ON
OV
OFF
AC:3-6 V
OFF
theSCS
service]
lconnect
connector l
\
Approx.3 V
Below0.3V
\
e
UNIT22PCONNECTOR
ABSCONTROL
Wiresideof femaleterminals
Volt.ge
Terminal
numbel
Wiro
coror
Terminalsign
De3cription
lTqrminalnamsl
FR-IN
terminils
Drivesright-frontinlet
solenoidvalve.
ON
I-GND
RED/BLU {Front-right
inlet)
riJ
Detectsservicechecksignal
troublecode
{Diagnostic
(Servicecheck indication)
signal)
scs
BRN
t
(Warning
ramp)
7
BLU/RED
8
BLU/YEL
10
YEUBLK
11
FLIN
RED/BLK
inlet)
{Front-l€ft
l4
FL.OUT
{Front-left
outlet)
ConditionE
(lgnition Switch ON (ll)l
DrivesABSindicatorlight(The
indicatorlightgo€soff when
ABScontrolunitoutputsbattery volta9e),
Not used.
Drivesleft-frontoutlet
solenoidvalve.
MCK
srgnal.
lMotorcheck)
22
BLK
RR-OUT
(Rear-right
outletl
GND2
(Ground2)
AC:3-6 V
OV
Appro)(.5 V
Approx,2 V
Indicatorlight ON
Batteryvoltage
lightOFF
Indicator
10-GNO
Approx.3 V
ON
OV
OFF
A C : 3 - 6V
ON
11-GND
PMR
YELRED (Pumpmotor
reray,
BLU
OFF
7-GND
OFF
the
lconnect SCSservicq
connector I
\
12-GNO
Pump
1 7 . G N D motor
reray
ON
19-GND
Batteryvoltage
OFF
OV
ON
OV
OFF
AC:3-6 V
Pump ON
motor
relay OFF
OFF
servicq
theSCS
lconnect
connedor )
\
ON
21-GND
uJ
22-GND
ON
OFF
sewicq
ponnect
theSCS
connedor l
\
Drivesright-rearoutlel
solenoidvalve.
Ground for the ABS control
untt.
Approx.3 V
Approx. 5 V
14.GND
Drivespumpmotorrelay.
19
OV
OFF
theSCSservicq
/Connect
connector I
\
Drives left-front inlet solenoid
Drivesright-frontoutlet
FR.OUT
YEUBLU (Front-right solenoidvalve.
outlet)
with Honda
Communicates
DLC
PGMTester.
(Datalink
LT BLU
connector)
BRNA/EL
ON
SCSserviceconnector
connected.
4-GND
SCSserviceconnector
disconneded.
Detects pump motor drive
17
-9
Output voltago
Approx.3 V
OV
AC:3-6 V
Approx.3 V
Below0.3v
19-53
TroubleshootingPrecautions
ABS Indicator Light
I
The ABS indicatorlight comeson when the ABS controlunit detectsa problemin the system.However,even
though
the system is normal,the ABs indicatorlight can come on, too, under the following conditions.To determine
the
actualcauseof the problem,questionthe customeraboutthe problem,takingthe followingconditionsinto consideration.
. Signaldisturbance
. Wheelsoin
. Only drivewheelsrotate
. Batteryvoltage fluctuates
2. When a problemis detectedand the ABS indicatorlight comes on, the indicatorlight can stay on untatthe ignition
switchis turnedoff, or it can automatically
go off, dependingon the mode.
. Lightstaysonuntil the ignitionswitchisturned off;Whenthe systemis inthesvstemdown mode.
o Lightautomaticallygoesoff:
Whenthe systemis in the controlinhibitionmode.
(refer to symptom-to-systemchart)
3 The ABS indicator light stays on when the system is reactivatedwithout erasing the DTC,but it goes off after starting
the car.
when the wheel sensorsystem is faulty and the ABS indicatorlight comeson, the algorithm of the system automatically
turns off the ABS indicatorlight after the wheel speedsignal returnsto the normal speed.while, when the DTCis erased,
the CPUis resetand the ABS indicatorlight goes off when the systemcheck€dout normal by the initial diagnosis.
Therefore,test-drivethe car after servicingthe wheel sensor system, and be sure that the ABS indicator light does not
come on.
4. When the ABS control unit outputs battery voltage to the gauge assembty,the ABS indicator light goes off.
DiagnosticTrouble Code (DTC)
1. The diagnostictroublecode (DTC)is memorizedwhen a problemis detectedand the ABS indicatorlight does not go
off, or when the ABS indicatorlight comeson.
The DTCis not memorizedwhen the ABs indicatorrightcomeson unressthe cpU is activated.
2. The memory can hold any number of DTCs.However,when the same DTc is detectedtwice or more, the later one is
writtenover the old one.
Therefore.when the same problem is detectedrepeatedly,it is recordedas one DTC.
3. The DTCSare indicatedin the orderof ascendingnumber,not in the orderthev occur.
4. The DTCSare memorizedin the EEpROM{non-volatilememorv}.
Therefore,the memorizedDTCScannot be canceledby disconnectingthe battery. perform the specifiedoroceduresto
erase.
Solf-diagnosis
1. The self-diagnosis
can be classifieldintothesefour categories:
' Initialdiagnosis; Performedright afterthe enginestarts and untiltheABs indicatorlight goes
off.
o ExceptABS control: Performedwhen the ABS is not functioning,
. DuringABS control:Performedwhen the ABS is functioning.
. Duringwarning:
Performedwhen the ABS indicatorlight is ON.
2 The system performs the following controls when a problem is detectedby the self-diagnosis:
. ABS indicatorlight ON
. Memory of DTC
. Modechangeto the "systemdown mode,,or the "controlinhibitionmode,,.
ABS INDICATOR
LIGHT
MAIN
RELAY
SYSTEM
DOWN
ON
No
operal|on
Drive
inhibition
Operation+r
CONTROL
INHIBITION
ON
No
operat|on
Orive
inhibition
Operation
MODE
SOLENOID
VALVE
CPU
Restartcondition
lgnition
switch
OFF- ON
Automatic
DTC
Memory
Memory
*1: ExceptCPUfailure
19-54
t
J
Kickback
1. The motor operateswhen the ABS is functioning,and the fluid in the reservoiris forcedout to the mastercylinder
causingkickbackat the brakepedal.
2.
TheABScontrolunit operatesthe solenoidvalvewhen the brakepedalis releasedafterthe initialdiagnosisYoumay
hearthe faint solenoidvalveoperationsoundat this time. but it is normal.
Pump Motor
1. The pump motor operateswhen the ABS is functioning
2.
You may hearthe faint operationsound
The ABS control unit checksthe pump motor operationduring acceleration.
at this time. but it is normal.
Brake Fluid Replacament/AirBlsading
and air bleedingproceduresare the same as for conventionalbrakes
1. Brakefluid replacement
Troubleshooting
pre1. The troubleshootingflowchartsexplainthe procedureson the assumptionthat the causeof the problemis still
sentand the ABS indicatorlight is still on.
followingthe flowchartwhen the ABS indicatorlight does not come on can resultin incorNotethat troubleshooting
judgment.
rect
2.
\
t
Ouestionthe customerabout the conditionswhen the problemoccurred,and try to reproducethe same conditions
for troubleshooting.
self,diagnosisis made at varioustimes such as the initialdiagnosis,exceptABS control.during ABS control,during
acceleraiion,during the specifiedvehiclespeed,etc. Therefore,the symptom cannot be checkedunlessthe check
conditionsmatchwith the problemconditions
3.
When the ABS indicatorlight does not come on duringthe test drive,but the troubleshootingis performedbasedon
the DTC,checkfor the looseconnectors.poor contactof the terminals,etc,beforetroubleshooting.
4.
erasethe DTCand test-drivethe car.Be surethat the ABS indicatorlight does not come on.
Aftertroubleshooting,
5.
The connectorillustrationsshow the femaleconnectorswith a singleoutlineand the male connectorswith a double
ouflrne.
6.
The connectorterminalcavitiescontainingfemaleterminalsare alwaysnumberedby lookingat the connectorfrom
the wire side.and the cavitiescontainingmale terminalsare alwaysnumberedby lookingat the connectorfrom the
terminalside.
r'
19-55
DiagnosticTrouble Code (DTCI
DiagnosticTroubleCode{DTC)Indication
NOTE:This operationcan also be carriedout with the HondapGM
Tesrer.
l
connectthe scs serviceconnectorto the servicecheckconnectorinside
the passenger,s
side kickpanel.
2.
Turn the ignitionswitchON (||).but do not startthe engine.
NOTE:Do not depressthe brakepedalwhen turningthe ignitionswitch.
3
Recordthe brinkingfrequencyof the ABS indicatorright.The brinkingfrequency
indicatesthe DTc.
4,
Turn the ignitionswitchOFF,and removethe SCSserviceconnector.
NorE: The MslfunctionIndicatorLamp (MlL)will stay on after the engine
is startedif the scs serviceconnectoris
connected.
5.
Erasethe DTC.
Condhionsfor DTCindication
. The vehicleis stoDDed.
. The SCSserviceconnector is connectedbefore the ignition switch
is turned ON fll).
. The brakepedalis released.
. Th€ SCSservice connectorremains connectedduring this procedure
The DTGindication stops 8nd the ABs conltol unit executesthe softwaro
tunqtion if at least one of the following conditions b satisfied:
o The vehicleis not stoDoed.
' The ABS control unit receivesthe normat signal (which is for
the ABS controt unit) from a Honda pGM Tester.
. The SCSserviceconnector is disconnectedduring this procedu.e,
u.s.A.
@
CANADA
@
SERVICECHECK
CONNECTOR
{2PI
SCSSERVICECONNECTOR
07PAZ- 0010100
ABS INDICATORLIGHT
DTC: 3 3
A8S INDICAIORLIGHT
swirch
Snilion
' when the ignitionswitchis turnedoN (ll),the ABs indicator
light comeson to checkthe bulb. Do not count it as a DTc.
o The ABS controlunit can memorizeany numberof DTCs.
. The new DTCis not memorizedwhen the ABS controlunit has
alreadymemorizedthe same
. l f t h e D T C i s n o t m e m o r i z e d , t h e A B S i n d i c a t o r l i g h t s t a y s O N a f t e r i t g o e s o f f f o r 3 . 6 s e cDTC,
onds.
19-56
L
J
DTGErasure
side kickpanel.
1 . Connectthe SCSserviceconnectorto the servicecheckconnectorinsidethe passenger's
2.
Depressthe brakepedal.
indicatorlight
Turn the ignition switch oN (ll) while holdingthe brakepedal,but do not start the engine.The ABS
goes off after two seconds.
4.
Afterthe indicatorlight goes off, releasethe brakepedal The indicatorlightcomeson afterfour seconds
5.
goes off again after four secAfter the indicatorlight comeson, depressthe brakepedal again.The indicatorlight
pedal
is
still
depressed.
The
brake
onds.
6.
Afterthe jndicatorlight goesoff, releasethe brakepedalagain'
7.
Afterfour seconds,the indicatorlight blinkstwice for 0 3 secondand the DTCis erased
8.
Confirmthe DTCindication,and checkthat the DTCwas erased
the brakepedal
NOTE:Always maintainthese steps.lf you disconnectthe scs serviceconnectorand/orfail to operate
not
be
erased
DTC
will
the
indication,
light
accordingto the indicator
\
t
Conditions for DTCerasure
o The vehicleis stopped.
. The SCSserviceconnectoris connectedbeforethe ignitionswitchis turnedON {ll)
. The brakepedalis depressedbeforethe ignitionswitchis turnedON (ll)'
. The SCSserviceconnectorremainsconnectedduringthis procedure
following conditions is
The DTC erasurestops and ABS control unit executesthe software lunction it at least one ot the
satisfied:
o The vehicleis not stopped.
duringthis servace'
. The SCSserviceconnectoris disconnected
.TheABscontro|unitreceivesthenormaIsigna|(whichisfortheAEscontro|unit)fromaHondaPGMTester'
. The brakepedalis not operatedaccordingto the indicatorlight indication
. The DTCerasureis finished
0.3sec
LIGHT
ABSINDICATOR
OFF
DEPRESS
BRAKEPEDAL
RELEASE
lqnitionswitch
oN (I)
J
19-57
DiagnosticTrouble Code (DTCI
Symptom-to-System
Chart
DTC
DETECTIONTIMING
o
H1=
DIAGNOSIS/
SYMPTOM
i.'s
EV9
z\ 9 = r = t
8 € E6 < _ 6
>=
PNOBABLECAUSE
6tz
,
.
'
.
.
ABS indicator iighr does
not com€ on when ignirion
swrt.h is lu.ned on (ll)
NO
DTC
ON
A B S i n d i c a t o rl i g h td o e s
nol90 oft 6frer engine is
t1
13
oN.
Wheel sensor (op€n/short
o
O
o
Open in the pow€. source circ!ir ror the ABS -.ndicato;lisht
Elown ABS indicalo.lighr butb
Open in rhe ABS indicaror tight drive cncuit.
Shori ro pow€r in theWALpcircuit
F a u l t y A B Sc o n t r c t ! n i t
Open in the lG2 circuit
Opon in the +B circuir
Op€n andlor short ro body ground jn the WALP circuit
Faultv AAS coni.ol unn
upen, snofiro bodyground and/or shodro power in rhe wh€61
o
ll
Faulty ABS co.lrctunit
BL
12
Shortto wh6sls€n6or(O)circuir
in t'e.h;;Go-nso, trtcircuti
Faultywhsels€nsorinsra|ation
oN.
o
(chipp€d pulser gea/noise)
a
o
FaultyABScont.olunir
I8
31
32
Op.ni shonto bodygroundand/o.shorrtopowsrin rhe
F8-OUT
FL.IN
Solenoid (open/shon ro
3'l
a
ON
op€n in lh6 coM circuit
o
FT.OUT
a
FaultyABSconlrclunit
RF.IN
88 OUT
8t rN
RLOUT
31
38
ON
o
op€n in tho motor pow€..ourco circlia
O p € ni n i h € m o r o . c N O c i r c u i t
o
Faulty ABS conrrol unit
52
ON
o
Open in rh€ COM, PMR 6nd/o. MCKcircuir
Op€n.n.Vor blown lus€ in the under hood AgS rusdretry box
o
Faufty pump moto. rotay
faulv ABS conlrolunit
53
ON
54
ON
ON
.
.
.
,
o
lgnition voltage (low vott-
o
o
c
o
o
o
Sho.tto bodygrou.d in the pMR circuit
Shon to powsr in tha puhp moror pow6rsource circu
r.urty pump motor.etay
FalltyABS contolunit
Open, rhorr ro bodygrcund and/or blown fus€ in the B1 or 82
Shonto body ground.n.Vor short to powor in rhe COM circuit
Faulty modul.tor unn
Faulty ABS controt unit
o
.
.
.
.
Connection ot the24 V bariorv tor enqins starr
Faurtycharoins system
Op€n in th6lG2 circuit
Fa!lly ABS contrcl unil
E{€rml facior{sl en bs rhe ouse{sl ot |he probtem
F.ulty ABS conrrot unit
81
ON
CPU
o
o
o
o
r: It DTcs 1 1 18
{wheel sensor codes) wore del*ted the lasr time the v6h cls wEs d riv€n, rhe a8s indicator tight
wi stay on u ntit lh6 ignition swirch is rurn6d oN
connorunit contnms rhat rhe wheet sensoB . rc OK,
19-58
t), and the
L
e
MANAGEI\,4ENT
CONDITIONFOR DETECTION
DUNING
ABS CONTFOL
EXCEPT
ABSCONTAOL
FEFER
TO
PAGE
19-60
19-62
The ABS indicator lighl cones on when vehicle is stopp€d and wheel sensor a given vohaqe does nol
1 96 4
The ABS indicaror comes on under th€lollowing conditions
t h e e l r e a c h e sa
. W h e n m o r e t h a n o n e o t w h e e l sa r e a s t a n d s t i l a n dt h e l e l o c i r v o t t h e f a s t e s w
' fohen th. velocityof the faslesl wheel reachesor exceds a given sped, and it there ar€ somewh@ls
whose velocityis slowe.lhan a cenain percenlageoi lh€ fast6t wheelsped for 3 given period
. when rhere are lemporary open or short ctcuits ol rhe wheel sonsor' chipp€d pulser gear, orsrgnal
orslJrbaaLe
The main relay repeatsON/OFFswitching atalltimes
. W h e n t h e m a i n r e l a y i s O N , a s h o r t t $ t p u l s e i s s e n t l o e a c h v a l v e l f t h e r e s s o m e d i s ' r e p an c v ,l h e
A B S i n d i c a l o rl i g h t c o m e so n .
. When rhe main relay is OFF,a shonl€sl pulse is s€nlto each valve lfth6 solenoid drive voltage rs
out ol a qiven range, the ABS ndicalor lighl comes on
\
.t
'The pump nolot s activaled orc€ o' Mrce sfier every gn't'on sw'lch ON (ll) operarion whrle lte -^
v c h i c l ea c L e l e r a l e sl r e n t h e m o l o r o t i v e v o ' t a S e r s r h e c l e d W h e n l h e v o l l a 9 6r s a b n o r m a r , l r eA b s
indicaror llghl comes on.
. Afte. ABS ;onl rol com pletion, the moror isswitched ofi 6nd the main CPU checksthe molor dnve
voltase. when rhe vortase is abnormsl, the ABS indicato49!!!99!:l!:_D!rino an active motor lesl or AAS control,lhe main CPU checksihe supplv voltage to the motor'
whe;lhe vohage s abnofmal, the ABS indicator lightcomes on
lirhe moror drvevoltage indicates molot operalion when the main cPU does notswilch the motor
oN, rhe ABs indicaro. comes on
. Wh"" " ".1"".1d ""1r. f"llure is detecred,the CPU checksth€ voltage ofthe main rel6v output lllhe
vohaqe is lowerthan 6 given vohage, theABS indicator light comes on
. The ;ain r€lay repeatsON/OFFswitching ar a!ltimss when the main rel.v is ofi, a shorl l6st pulse
is sent ro €ach valve. The CPU mon tors the reJer€ncevohage ll the vohage is out ot a g iven range'
the ABS indic.tor lightcomes on
wt'",, rt'e lgnitlon rottag" is ower or higherthan a given voltage,lhe CPU inhibils ABSlonlroland
swirches oli the ma in relaY,6nd the ABS indicaror light com€s on When the ig n ilion vohage recove's
t o n o r m a lf 6 n g 6 ,A B S i n h i b i t i o ni s c a n c e l e d .
1 96 4
19-66
19-68
19,68
19-64
1 97 1
19.73
CpU anO suU CeU ch€ck each other undercertain condnions. Whon rhe CPUSdstectthe fol'
rimln
lowing discrepanaies,rhe ABS indicator light comss on
. whe; rh€re is discGpancv n lhacarculated wheelspeed velocirv thar continuosJor more than a given
.i^/hen rhere is discrcoancvin the ehase informalion lhat continuesfor morerhan a given period
' When rhere is discrepancYin thecalculared conlfol pa.amerer'
. When thewatch dog conrrolp!lsetailslof a given penod
. W h e nt h 6 c h e c k o t t h €R O Mt a i 1 s .
. when there is disrepancy inrhe data roading.nd wriung prcledurc ot RAM
19 7'l
t r
19-59
Troubleshooting
ABS IndicatorLight DoesNot ComeOn
The A8S indicator light does not come on when ignition switch is turned ON ll.
Tho ABS indicator light does not
come on wh€n ignition switch is
tu.ned ON {lll.
check the METEB(7.5A) fuse in
the under-dash
fuse/relay
box.
NOTE:All indicatortightsexceptthe charg,
ing systemlight will not come on when the
METER17.5A) ft se is btown.
NO
Beplacethe tu3e and recheck.
YES
NOTE:
Reinstallthe
fuseif it is OK.
Checkfor an open in th6 lcl circuii:
1, Disconnect
the gaugeassem
bly 5Pconnector.
2. Turn the ignitjonswitch ON l).
3. Measurethe voltage between
the gauge assembly5P conn e c t o rt e r m i n a lN o . 5 a n d
body ground.
ls there bafteryvoltage?
GAUGEASSEMBI"Y5P CONNECTOR
Wiresideof femaleterminals
. Ropair opan in tho wiro
botwe€n thc METER t7.5 At
tuso and gauge .$cmbly.
. Roplacc th. und.r-dash tus./
r.l.y box. lop.r cirouit in3ido
the box.l
C h e c kt h e A B S i n d i c a t o rl i g h t
bulb in the gaugeassembly.
ls the bulb OK?
Ch€cktor a short to power in the
WALPcircuit:
Measurethe voltage betweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. I and bodyground.
ls there batteryvoltage?
lTo page19-61)
19-60
Replir short to power in tho wiiG
b.tweon the gruge rs3embly
.nd ABS control unh.
t
J
{Frompage19.60)
Checkthe geuge a$embly:
1. Turn the ignitionswitchOFF.
2. Connectthe gauge assembly
5Pconnector.
3. Connectthe terminalNo. 3 to
b o d y g r o u n dw i t h a i u m p e r
GAUGEASSEMBLY5P CONNECTOR
,c? "
|
l1t/'.lt/t5
JUMPER
I GNDIBLK}
wrRE I
4. Turnthe ignitionswitchON (ll).
Doesthe ABS indicator
lightcomeon?
-L
Replaceth€ ABS indicato. light
drive circuit in the gauge ai3omblY.
.Repair open in the wire
beiween the gauge assemblY
and body ground.
. Repair poor ground {G401,
G402t.
t
19-61
Troubleshooting
ABS IndicatorLight DoesNot Go Off
The ABS indicator light does not go off after the engine is started.
-
With enginerunning,ABS
indicator light is ON.
With tho SCS sewice connecto. connected l3oe page 19-561,
no DTCis indicated,
ChecktheRRDEFRLY{7.5A)tuse
in the under-dashfuse/relaybox.
Raphco tha furo and rochack.
YES
NOTE:Feinstattthe
luse it it is OK.
Checkthe ABS +B (20 A) fuse in
the under hood tuse/relaybox.
R6pl.ce tho tu3c lnd r.ch.ck.
YES
NOTE:Reinsta the fuse if it is OK.
ABS CONTROLUNIT 26PCONNECTOR
IG2IELK/BLUI
Chockfor an open in the lG2 cirGUrt:
1. Turnthe ignitionswitchON (lt).
2. Measurethe voltage between
the ABS controlunh 26Pconn e c t o rt e r m i n a lN o . 3 a n d
body ground.
Wire sideof femaleterminals
Bopair opcn in tha wir. botw.cn
th. RR DEFRLY 17.5Al tus. .nd
ABS control unit.
Checktor an opon in thG Bl end
82 circuit:
M e a s u r et h e v o l t a g e b e t w e e n
bodygroundand terminalsNo. 14
and No. 15individually.
ls there banery voltage?
1Topage19-63)
19-62
ABS CONTBOLUN]T 26PCONNECTOR
8T IWHT/GRNI
Rrpair opsn in tha wiro t atwa,an
the ABS +B (20 Al fu.r .nd ABS
control unh.
Wiresideof temaleterminals
t
v
lFrompage19-621
ABS CONTROLUNIT 22PCONNECTOR
Ch6ck lor . short to body ground
in ihe WALPGircuit:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pand gaugeassembly
5P connectors.
3. Checkfor continuitybetween
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
body ground.
WALP{BLU/REDI
Wire sideol femaleterminals
Ropair short to body g.ound in
tho wire betweon the ABS con_
trol unit and gaugeaasembly.
ABS CONTROLUNIT 22PCONNECTOR
WALP {BLU/REDI
Checkthe AgS cortrol unit:
1. Connectthe ABS control unit
22Pconnector.
2. Turnlhe ignitionswitchON (ll).
3. Measurethe voltagebetween
the ABS controlunit 22Pcon'
n e c t o rt e r m i n a lN o , 7 a n d
body ground.
rt
ls there bafteryvoltage?
Wire sideol femaleterminals
Check tor rn open in lho GND2
circuit:
1. Connectthe ABS controlunit
26PconnectorterminalNo. 16
to body groundwith a iumper
2. Measurethe voltagebetween
the ABS controlunit 22Pconn e c t o rt e r m i n a lN o . 7 a n d
body ground.
ls there batteryvoltage?
ABS CONTROLUNIT 26PCONNECTOR
wire sideol femaleterminals
' Repairop€n in the wit€ between
the ABS control unit and body
ground.
. Rep.ir poor ground lG40'1,
G1(}2t.
Checktor loo3€ ABS control unit
connector!. lf necesaary,substi_
tute a known-qood ABS control
unit and r€check,
Check lor an open in the WALP
circuit:
Measurethe voltagebetweenthe
g a u g e a s s e m b l y5 P c o n n e c t o r
terminalNo. 1 and body ground.
GAUGEASSEMBLY5P CONNECTOR
.D
ls therebatteryvoltage?
J
Ropai. opon in the wiro botween
the ABS control unit end gauge
assemblv.
Y
Wire sideof femaleterminals
Replacethe ABS indicrtor light
driv6 ci.cuit in the gtuge assembly.
19-63
Troubleshooting
WheelSensor
DiagnosticTrouble Gode {DTC)ll-18: Wheol S€n3ol Diagnosis
NoTE: The ABS indicatorlight comeson when only the drive wheelsare turning,signaldisturbanceis
detected,etc.Therefore,
test-drivethe car at a speedof 12 mph (20 krn/h)or more after turning the ignition:witch from OFF
to ON fll), and if the ABS
indicatorlight does not come on, the svstemis OK.
A8S CONTROLUNIT 26PCONNECTOR
-
-
With the ignition switch ON
{ll), ABS indicator tighr doe.
noi go off,
Aftsr driving, ABS indicatot
light comeson.
With the SCS so.vice connactor conn€c,ted{soepege 19-561,
DTCs11-18a.e indicrted.
Chocklhe wheol sensorci.cuit:
1 . D i s c o n n e ctth e A B S c o n t r o l
unit 26Pconnector.
2. lleasure the resistance
betweenthe appropriatewheel
sensor(0)and (1)circuittermi,
ls the resistance
OK?
/Frontr750 1050o/20"C,68.F\
68"F/
\Rear: 850- 1150O/20.C,
RRO
IBLU/YELI
Appropriate
Terminal
(0)srDE 11)SrD€
r 1, 12 (Right-front) No.8: FRo N o . 2 1 :F R I
13, 14 (Left-front)
No.10:FLo N o . 2 3 :F L 1
15, 16 {Right-rear) No.{: RRo N o . 1 7 :R R l
17,18(Left-rear) No.6: RLo No.19:RLI
0Tc
. Reprir op€n in the l0l or {0 circuit wiro, or shon to thc {01circuit wi.o in thc {11circuit wirc
bctween ths ABS control unit
and approprietowheel a6nsor.
. R.pl.ce th€ epp.opri.te wheal
3€nloa.
Checktoru short to body ground
in the wheel senso. circuit:
Checkfor continuity betweenthe
ABS control unit 26P connector
appropriatewheel sensor(0) cir
cuit terminaliand body ground.
. Rapair short to body ground in
th6 (0) or lll cilcuit wi..
bctwa.n th6 ABS control unit
and appropdaie whoel lonsor.
. Rep|'c6 tho appropriatc whcel
sanlor.
Chock tor a sho.t to powe. in tho
wheel3en3or circuit:
1. Reconnect
the ABScontrolunit
26Pconnector,
2. Startthe engine.
3. Measurethe voltage between
the ABS controlunit 26Pconnectorappropriate
wheelsens o r ( 0 ) c i r c u i tt e r m i n a l a n d
body ground.
ls there4 V or more?
NO
Ropair rhon to powo. in the l0l
or lll circuit wire batw.en th€
ABS cont.ol unit and .pplopriata
whccl !€naoa,
NOTE:
. Normalvoltage:Approx.2V
' 0 V: Replace
the ABScontrotunit.
. 4 V or more indicatesa short to power.
fio page 19-65)
19-64
RR1IGRN/YELI
RLl (LT BLU}
FL1IGRN/ORN}
FRl (GRN/BLKI
Wire sideol femaleterminals
t
(Frompage19-64)
Checktor chippedpulsergear.
Replacethe drivesh.tt or hub
unil. (Chippedpulser g€ar)
\
e
DTC 11, 13, 15. 17: Roplacethe
ABS control unil.
OfC 12, 11.16,18:The ABS control unit may have detected signaldisturbance.
l r
19-65
Troubleshooting
Solenoid
DiagnosticTrouble Code {DTC}31-38: Solenoid Diagnosis
-
-
ABS CONTROLUNIT 22PCONNECTOR
FL.OUT(YEL/ALK)
With the ignition switch ON
(lll, ABS indicator light does
nol go oft. or ABS indic.to.
light comes on while ABS i3
functioning.
With the SCS servicoconnector connected ls€. pag€ 19-561,
DTCa31-38 are indicstod.
DTC
3 1 :F R J N
32:FR-OUT
33i FL'IN
Checkfor a short lo powor in tho
sol6noid circuitl
1 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pand 26Pconnectors.
2. Start the engine.
3. Measurethe voltage between
the ABScontrolunitconnector
a p p r o p r i a t es o l e n o i dc i r c u i t
terminal*and bodyground.
ls there batteryvoltage?
34:FLOUT
3s:RRIN
36:RR-OUT
37: RLIN
38:RL-OUT
Appropriate Appropriate
Connector
Terminal
22P
No.1
22P
No.12
22P
No. 11
22P
No.10
26P
No.13
22P
No. 21
26P
No.25
26P
No.12
Wiresideof femaleterminals
ABS CONTROLUNIT 26PCONNECTOR
RL.OUTIYEL}
Ropri. short to powor in thc
appropriate solanoid ci.cuit wiro
botw6.n ths ABS cont.ol unit
and modulrtor unit.
Checkfor a short to body ground
in the 3olenoidcircuit:
Checktor continuity betweenthe
appropriate
solenoidcircuitterminal*and bodyground.
Wiresideof femaleterminals
. Repairshort to body ground in
lhe .ppropriato solonoid circuit
wire betwoan th6 ABS control
unit and modllato. unit.
. Replacothe modul.tor unit.
31:FR-lN
Appropriate
Terminal
No.2:SCOM
32:FR-OUT
No. 2: SCOM
33i FLIN
No.1:rcOM
34:FL-OUT
No. l: PCOM
DTC
Checkth€ ABS control unit:
'1. Turnthe ignitionswitch
OFF.
2. Connectthe ABS control unit
22Pand 26Pconnectors.
3. Connectthe SCS service con4. Turnthe ignitionswitchON {ll}.
5. Measurethe voltage between
the ABS control unit 26P connectorappropriateCONIcircuit
terminal++
and bodyground.
ls thereapprox.3 V?
YES
(Topage19-671
19-66
35: RR{N
No.1:PCOM
36:RR-OUT
37rRL'lN
38:RL-OUT
No.1:rcOM
No.2:SCOM
No. 2: SCOM
Checkfor loos€ ABS control unh
connectora. It naceslrry, aub3titutc . known-good ABS control
unit tnd recheck.
RL.OUT(YEL}
t
e
(Frompage19 66)
ABS CONTROLUNIT 22PCONNECTOR
DTC
36:RR-OUT
No.2l
3 7 :B L - l N
26P
No.25
38:8I-OUT
26P
No. 12
33: FL IN
34:FL-OUT
35: BR-lN
ls thereapprox.3V?
\
J
Terminal
22P
22P
22P
22P
26P
22P
31:FB-lN
32:FR'OUT
Checktor an op€n in th€ solenoid
circuit:
Measurethe voltage betweenthe
ABS control unit connectorappropriatesolenoidcircuitterminal*
and bodyground.
FL.OUT{YEL/BLK}
Conn€clor
No. 1
No. 12
No.1l
No. 10
No. 13
' Repsir opon in the appropriate
COM circuit wiro botwoon the
ABS control unit and modulatol
unit.
' Repair open in ihe appropriate
sol€noid ci.cuit wiro between
tho ABS control unit and modulator unit.
. Roplacothe modulator unil.
Wiresideof femaleterminals
ABS CONTROLUNIT 25PCONNECTOR
BL.OUT(YELI
Checkloi loGe ABS control unit
connoctors. It necessarv,substitute a known-good ABS control
unit and recheck.
Wire sideof femaleterminals
19-67
Troubleshooting
ABS PumpMotor
DiagnosticTrouble Codo {DTC}51-53r ABS pump Motor Diagnosis
-
With the ignition switch ON
(ll), ABS indicator lighr doos
not go otf.
With tho SCS s€rvico connee
tor conn€cted lsee page 19661,
OTCa51-53 aro indicated.
Checkthe MTRCHECK(7.5A) fuse.
NO
Repl.ce the fuse .nd recheck.
YES
NOTE:Reinstall
the fuse if it is OK
N O T E : S h o r t t h e P M R t e r m i n a tt o b o d y
groundfor a moment,and recheckthe fuse.
lf the fuse is blown,checkfor a shortto body
groundin the MCKcircuit.
AAS CONTNOLUNIT 22PCONNECTOR
7
12
11
A
t0 t l
19
2 l 22
PMRIYEL/RED}
I JUMPER
I WIRE
Wiresideof femaleterminals
NO
Replacotho tuse and rocheck.
YES
NOTE:Reinstall
thefuseif it is OK.
N O T E :S h o r t t h e P M F t e r m i n a lt o b o o y
groundfor a moment,and recheckthe fuse.
lf the fuse is blown,checkfor a shortto body
ground in the wire between the under-hood
ABSluse/relaV
box and pumDmotor.
Rcphce th€ pump motor rol6y.
Check the pump motor power
sourcecircuit:
Turnthe ignitionswitchON (ll).
Doesthe pump motoroperate?
Ch€ck for a short to !'ows. in tho
pumP motor power 3ource ciacrrit:
Removeth6 purnpmotor relay,
Doesthe pump motoroperate?
Checktor loGe ABS control unit
connoctors. lf nocessary,substitute a known-good ABS control
unit and roch€ck,
(To page19-69)
19-68
Bopairsho.t to powsr in the wir€
botwoen the under-hood A8S
tuse/.elay box and ABS pump
motor.
t
t
(Frompage19-68)
UNDER.HOOD
ABS
FUSE/RELAY8()X
JUMPERWIRE
Checkthe pump motor circuit:
1. Removethe pump motor relay.
2. Turnthe ignitionswitchON (ll).
3. Connectthe pump motor relay
connector+8 and MOTORter
minalswith a iumperwire tor
a momenr,
Doesthe pump motor operate?
Ch€ckfor an open in the pump
moior +B circuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe pump motor
2P connector,
3. Turnthe ignitionswitchON (ll).
4. Connectthe pump motorrelay
connector+B and MOTORterminalswith a jumperwire.
5. Measurethe voltage between
the pump motor 2P connector
terminal No. l and body
ground.
TERMINAL
TERMINAL
PUMPMOTOR2P CONNECTOR
MOTOR+8 lWHTl,$
rv)
Y
Wiresideot femaleterminals
ls therebatteryvoltage?
\
Check the pump motor opgration:
Connectthe battery{+}terminalto
the pump motor 2P connectorterminalNo. 1.andthe (-)terminalto
the terminalNo. 2 for a moment.
lt
Doesthe pump motoroperate?
Chockfor a short to body ground
in the PMRcircuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe ABS control
unit 22Pconnector.
3. Checkfor continuitybetween
t e r m i n a lN o . 1 9 a n d b o d y
grouno,
Repail opon in ths wirg botwgen
tho pump motor and bodv ground,
or poor ground (G,!09).
Ropair 3hort to body g?ound in
tha wire between the underhood ABS fuse/rclay box and
ABS cortrol unit.
Repaiaopen in the wire botween
tho under-hoodABS fuse/relay
box and pump motor.
MOTOR+B {RED}
MOTORGND (BLK)
ReDlacolho modulator unit.
(Feultypump motor)
ABS CONTROLUNIT 22PCONNECTOR
WiresideoI femaleterminals
(cont'dl
(Topage19-70)
19-69
Troubleshooting
ABS PumpMotor (cont'dl
(Frompage19-69)
Check tor an opon in the PCOM
circuit:
1. Turnthe ignitionswitchOFF.
2 . R e c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
3. Connectthe SCSserviceconnector,
4. Turnthe ignitionswitchON (ll).
5. Measurethe voltage between
t h e p u m p m o t o r r e l a yc o n
n e c t o r P C O I , tI e r m i n a l a n d
body ground.
ls thereapprox.3 V?
--l
Repair opon in tha wiro bEtwoon
th. und€r-hood ABS fu3./rclsy
box and ABS control unit.
n
ABS CONTROLUNIT 22PCONNECTOR
Chockfor rn op6n in tho PMRcircuit:
Measurethe voltage beNveenthe
ABS control unit 22P connector
terminalNo. 19and body ground.
ls thereapprox.3 V?
Ropair opon in tho wira b€twoon
tho undor-hood ABS fu.e/rel.y
box and ABS control unit.
Chock for an opon in ths MCK
circuh:
1. Turnthe ignitionswitchOFF.
2- Disconnectthe SCS service
connector.
3. Turn the ignitionswitchON lll).
4. Measurethe voltage between
the ABS controlunit 22Pconn e c t o rt e r m i n a l N o . 1 7 a n d
body ground while connecting the pump motor relay
connector+8 and MOTORter'
minal with a jumper wire for
moment.
Repeirop.n in th. wire batween
tho undor-hood ABS fu.o/rol.V
box rnd ABS control unh.
Ch6cklor loose ABS contlol unit
connoctors. lf ngc63ary, sub3titute d known-good ABS control
unit and recheck.
19-70
wire sideoI temaleterminals
t
f
MainRelay
DiagnosticTrouble Code {DTC}54: Msin Relay Diagnosis
-
-
With the ignition switch ON
{ll), ABS indic.tor light does
not go off.
With the SCS 3ervicaconnoctor connected (s€epag€ 19-561,
DTC54 is indicated.
checktheABS+B (20Alfuse.
Replaceth6 fuso and rechock.
ABS CONTROLUNIT 26PCONNECTOR
YES
NOTER
: einstall
thefuseif it is OK.
Ch€ck for an op€n in the 81, 82
circuit:
M e a s u r et h e v o l t a g e b e t w e e n
body ground and the ABS control
'14
terminalNo.
unit26Pconnector
andNo. 15individually.
B1
{WHT/GRNI
Wire sideof femaleterminals
Repairopen in the wire betweon
the ABS control unit and underhood ABS tuse/relav box.
\
e
Checkfor a short lo body ground
in the PMRcircuit:
1- Turnthe ignitionswitchOFF.
2. Removethe pump motor relay.
3 . D i s c o n n e ctth e A B S c o n t r o l
unit 22Pconnector.
4. Checkfor continuitybetween
t e r m i n a lN o . 1 9 a n d b o d y
grouno.
ls therecontinuity?
Checktor a short to body ground
in the PCOM,SCOMcircuit:
1 . D i s c o n n e ctth e A B S c o n t r o l
unit 26Pconnector.
2. Checkfor continuitybetween
bodygroundandthe ABScont r o l u n i t 2 6 Pt e r m i n a l sN o . 1
andNo.2 individually.
ls therecontinuity?
l r
ABS CONTROLUNIT 22PCONNECTOR
Repairshort to body ground in
the wire betweenthe undorhood ABS fuse/relay box and
ABS control unit.
Wiresideof femaleterminals
PCOM
scoM
IGRN/WHT} {BLK/WHTI
. Bepai. short to body ground in
tho PCOMcircuit wire betwoen
the ABS control unit and underhood ABS fu3e/.olaybox.
. Repair3hort to body ground in
the PCOMor SCOMcircuit wire
between the ABS control unit
and moduletor unit.
. R c p l a c et h 6 m o d u l a t o r u n i t .
(Short circuit insidotho unit)
{ T op a g e1 97 2 )
(cont'd)
19-71
Troubleshooting
MainRelay(cont'd)
(Frompage19'71)
PCOM
(GRN/WHTI
Checktor a short to powor in the
PCOM,SCOMcircuit:
1. Turn the ignition switch ON
(BLK/WHT}
r).
2. Measurethe voltage between
body groundand ABS control
unit 26P connectorterminals
N o . l a n dN o . 2 i n d i v i d u a l l y .
Replacethe ABS control unit.
. Repair 3hoit to power in ihe
rcOM circuil wire bgtween the
ABS control unit end unde.hood ABS fuse/relay box.
. Repair sho to powor in tha
PCOM oJ SCOM circuit wiro
betwoen the ABS control unit
and modulator unit.
' Repl.co the modul.tor unit.
lshort to Dowcr iGido the unit)
V o l t ag e
19-72
scoM
lgnitionVoltage
DiagnosticTrouble Code (DTC)61: lgnhion Voltage Diagno3is
-
With tha engin€ running, ABS
indicator lighl is ON.
With the SCS s€rviceconnecto. conn€ctod ls€€ page 19-561,
DTC61 is indicated.
Problemv€rification:
1. Erasethe DTC.
2. Startthe engine.
3. Make sure that the ABS ind;
catorlight comeson and DTC
61 is indicated.
ls DTC61 indicated?
The system b OK .t this time.
A8S CONTROLUNIT 26PCONNECTOR
Checkthe lG2 cilcuii:
Measurethe voltagebetweenthe
ABS control unit 26P connector
terminalNo.3 and body ground.
]
ls there18V or above?
IG2IBLK/BLU}
Wiresideof lemaleterminals
lf the vohage is 0 V, checklor an
opon in the lG2 circuit.
It there is 12 - 17 V. substitute a
known-goodABS colrtrolunit and
Jecheck.
I t
19-73
Troubleshooting
CentralProcessingUnit (CPUI
DiagnosticTroublo Code IDTC)81: CPU Disgnosis
-
-
With the ignition switch ON
{lll. ABS indicator light does
not go oft.
With tho SCS servi@ connector conn€cted lsee page 19{6},
DTC81 is indicated.
P.oblemvedfication:
1. Erasethe DTC.
2. Test-drive
the vehicle.
3. Make sure that the ABS indi,
catorlight comeson and DTC
81 is indicated.
ls DTC81 indicated?
The system k OK rt this time.
19-74
R€pllc6 th. ABS control unh.
Modulator Unit
\
i
RemovaUlnstallation
l
CAUTION:
. Do not spill brake tluid on the car; it may damage the paint; it brako lluid does contact the paint, wash it off immediately with wator.
a Take care not to damage or delorm the brake lin€s during removal and installation.
. To prevent the brake tluid from tlowing, plug and cover the hose €nds and ioints with a shop tow6l or equivalent
mat€rial.
N O T E |T i g h t e n t h e f l a rneu t s t o 1 5 N . m( 1 . 5k g n m .l 1 l b f . f t ) .
Removal
'1. Disconnect
the modulatorunit 10Pand Dumpmotor 2P connectors.
2.
Disconnect
the brakelines,then removethe modulatorunit.
Installaiion
1.
Installthe modulatorunit.then connectthe brakelines.
2.
Connectthe modulatorunit 10Pand oumDmotor 2P connectors.
3.
Bleedthe brakesystem.
4.
Startthe engine,and checkthat the ABS indicatorlight goesoff.
Fom
right-1461
J
PUMP MOTOR
2P CONNECTOR
-R
/2e'
t'
TOR UNIT
t t
19-75
ABS Control Unit
Pulsers/Wheel
Sensors
Replacement
Inspection
1.
Removethe right side kickpanel.
1 . Checkthe front and rear pulserfor chippedor damaged teeth.
2.
Disconnect
the ABS controlunit connecrors.
3.
Removethe ABS controlunit,
Measurethe air gap betweenthe wheel sensorand
pulserall the way aroundwhile rotatingthe pulser.
4.
lnstallthe ABS control unit in the reverseorder of
removal,
Slandard: 0.4 - 1.0 mm (0.02- 0.04 in,
N O T E ; l f t h e g a p e x c e e d s1 . 0 m m ( 0 . 0 4i n ) , t h e
p r o b a b i l i t yi s a d i s t o r t e ds u s p e n s i o na r m w h i c h
shouldbe replaced.
Dbc brake typo
0.{ - 1.0mm
(0.02- 0.04 in)
CONNECTORS
19-76
Drum brake typ6
t
l}
WheelSensorReplacement
NOTE:
. Becarefulwhen installingthesensorsto avoidtwistingthe wires.
. The torquevalueof the boltsis 9.8 N.m (1.0kgf.m,7 lbf.ft).
Front
\
WHEEL
SENSOR
FRONT
J
Rear
1.
2.
3,
Removethe hub bearingunit (seesection18).
Removethe four backingplatebolts.
to disconnectthe
Pullthe backingplateawayfrom the trailingarm, then removethe wheelsensor.lt is not necessary
brakeline.
NOTE:This illustrationis drum braketype.The torquevalueof the disktype is same as drum type.
REARWHEELSENSOR
I t
19-77
l}
Body ('96 modell
\
I t
e
Doors
FrontDoorIndex(4D)
...20-2
RearDoorIndex{4Dl
.....20-8
DoorfndexlzDl3Dl
.......20-14
Emblems
fnstallation
20-118
Exterior
20-93
ComponentLocationIndex...............
*FrameRepairChart ..........
20-120
* Interior
20-58
ComponentLocationIndex...............
Mirrors
MirrorRep|acement
..................
.........
20-24
Mirror Holder/GoverReplacement... 20-25
..........
20-25
RearviewMirrorReolacement
Moonroof
.....................20-50
lndex..........
and Latch/
OpenerCable/Opener
Wiperand Washer
...,.20-107
ComponentLocationIndex..........
Seatsand Seat Belts
.....20-73
GomponentLocationIndex..........
....20-119
Sub-frame
Windshield,RearWindow and OuarterGlass
Index..........
.....................20-26
Body {'97 modell
Body ('98 modell
Body ('99 modell
Body ('00 model)
20-123
20-131
20-135
20-141
Doors
FrontDoor lndex
,ID:
WEATHERSTRIP
I
\ t
I
r^r f\
\ )
t \ '
ffitr6-
i'
\ - !
fud
-@a,
\tEf
POWERWINDOW
swtTcH
Adjustment,page
20-23
DOOR
PROTECTOR
OOORPOCKET
J$--"**^
20-2
l}
GLASS
Replacement,
page20 6
Adiustment,
page 20-20
GLASSRUN
CHANNEL
t
.
t
\
' \
\
CENTERLOWER
CHANNEL
e
LOCKROD
PROTECTOR
STRIKER
Adjustment,
page20-23
\
CYLINDER
PBOTECTOR
\
/ h )
cYLTNoER
ROD
Y
<
,/
,/
LATCH
Replacement,
20-6
I t
^o
?'2'
'
ll
\ ttt[
#-l|r&
/
REGULATOR
Replacement,
page20-6
ourERHANoLE
\necuLaron
HANOLE
page20-5
Replacement,
LOCK
CYLINOER
RETAINER
CLIP
INNENHANDLEROD
- )
LATCH
PROIECTOR
POWERDOOR
LOCKSwlTCH
(driver'sonly)
//
s
*Nqd'
/
-"-/
INNER
HANDLE
20-3
Doors
DoorPanelReplacement
NOTE;Takecarenot to scratchthe door paneland other
pans.
1.
Remove:
. Innerhandle(seepage20-3)
. Mirror mount coverpanel(seepage20-24)
2.
lf applicable,
removethe regulatorhandleby pulling
the clip out with a wire hook.
HANOLE
4.
Releasethe clips that hold the door panel.Remove
the door panelby pullingit upward.
NOTE:Removethe door panelwith as littlebending
as possibleto avoidcreasingor breakingit.
95 mm {3.74in.)
12mm
.L
TRIM PAD
(0.47
in.) f
REMOVER
(Commercially
availablel
Snap-on
r_
#A'177,o.
lmm
equivalenl
(0.04in.l
rr-l
45 mm
(1.77in.l
>i Clip loc.tions, 5
3.
l u - i
Removethe door grip coverand speakercover,then
removethe screws.
POWER
WTNOOW
>: Screwlocations,
5
swtTct{
J$- I
:fe i
cL,P /\
REMovERil
_ _t/
I
I
Dasconnect
the
;peakerconnector,
5.
20-4
lnstallation is the reverse of the removal procedure.
\
:
OuterHandleReplacement
4.
NOTE:Raisethe glassfully.
'1. Remove:
. Door panel
. Plasticcover(seepage2o-21
2.
Pull out the outer handle.Pry the outer handle rod
out of its joint usingdiagonalcutters
NOTE:
note location@ of the outer
a To easereassembly,
joint
it.
beforedisconnecting
rod
on
the
handle
. Takecarenot to bendthe outer handlerod.
o Use a shop towel to protectthe opening in the
ooor.
Pullout the retainercliP.
CYLINDERPROTECTOR
OUTERHANDLE
ROD
i4'
BUSHING
Replace.
DIAGONAL
CUTTERS
,w.
\
LOCKCYLINDEB
RETAINER
CLIP
C
3.
Removethe bolts,then removethe cylinderprotector, lockcylinderand outer handle.
>: Boltlocaiions,2
6x1.omm
I
i.eN.. tr.orgf.-,
7.2rbr.fi)
I
,2
CYLINDER
SHOP
TOWEL
5.
lnstallationis the reverseof the removalprocedure
NOTE:Makesurethe door locksand opensproperly.
LOCKCYLINDER
ROD
CYLINDER
20-5
Doors
Latch Replacement
Glass/Regulator
Replacement
NOTE:Baisethe glassfully.
' 1 . Removel
o Door panel(seepage20-4)
. Plasticcover (see page 20-2l,
1.
Remove:
. Door panel(seepage20-4)
. Plasticcover(seepage20-2)
. Outerhandle(seepage20-5)
Removethe bolt, then move the center lower channel
forwa rd.
Disconnectthe connector,and detachthe harness
clip from the door. Bemovethe latch through the
hole in the door.
NOTE:Takecare not to bend the inner handlerod,
outer handlerod, cylinderrod and lockrod.
Carefullymove the glassuntil you can seethe bolts,
t h e n r e m o v e t h e m . C a r e f u l l yp u l l t h e g l a s s o u t
throughthe window slot.
NOTE:Takecarenot to drop the glassinsidethe door.
>i Boltloc.tions,2
fi s'r.o-.
i
kstm,l
Clb9.8 N.m11.0
_-l't!!t
,/
>: Screwlocations,
3
GLASS
LOCKROO
REGULATOR
6 x 't.0mm
8 N.m(0.8kgtm,
6 tbf.ftl
4.
Installationis the reverseof the removalprocedure.
NOTE:
. Make sure the inner handle rod and connector
are connectedproperly.
. Makesurethe door locksand opensproperly.
20-6
\
L
3.
Disconnectthe connector,and detachthe harness
clip, then removethe regulatorthrough the hole in
the door,
4.
Greaseall the slidingsurfacesof the regulatorwhere
snown.
>: Bolt locations
B>,3
a>,4
6x1.0mm
8 N.m {0.8kgl m,
ttt*,
)
REGULATOR
REGULATOR
MOTOR
lnstallationis the reverseof the removalprocedure.
I
NOTE:Rollthe glassup and down to seeif it moves
freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjusrthe positionof
(seepage20-20).
the glassas necessary
t
ar Nul locations,3
6x1.0mm
8 N.m 10.8kgf m,
6 rbt.ftl
Loosen.
REGULATOR
{Manualtype)
20-7
Doors
RearDoor Index
,[D:
OUTER
WEATHERSTRIP
INNER
WEATHERSTRIP
PLASTIC
COVER
DOOR
Adjustment,
page 20-23
t\
\\
INNERMOLDING
POWER
WTNDOW
\asw[cH
\
\
\ € \
\ ; \
€ -*r'
:-?
(=__:\
*e€
\
/
/
/
/
DOOn
GRIP
COVER
20-8
\
\
\
DooR
GRIP
fu4 ffir",
M
R*
/
HINGE
-
o(x)R
PROTECTOR
\
L
CHANNEL\
REAR
\
\fl
N\
\,\
\ \r\
\ iI\l l
ld 1l
6P
c"AN"..:
REo"
coLLAR
\
lll
| 1l
J I
)\3€)\IJ
:&
fr\
\tr \
lll
6/
\
REGULATOR
HANOLE
lJ
'All
l'A\
OUTERHANDLE
Replacement,
Page20-11
W-*d
a)" u\
t
POWERWINDOW
MOTOR
STRIKER
Adjustment,
page 20'23
I
I
%
grc
*)u*ro*
LOCKROD
PROTECTOR
Replacement,
page 20-12
criss lLl
sroeeen
lll
pase20,tt
Repracement,
\
l5[1tf
CHANNEL
LATCH
PROTECTOR
POWEROOOR
LOCKACTUATOE
t
20-9
Doors
Door PanelReplacement
NOTE:Takecarenot to scratchthe door paneland other
parts.
3.
1. Remove:
. Innerhandle(seepage20-9)
. Regulatorhandle(seepage20-4)
2.
Releasethe clips that hold the door panel.Remove
t h e d o o r p a n e lb y p u l l i n gi t u p w a r d .
NOTE:Removethe door panel with as little bendangas possibleto avoidcreasingor breakingit.
Removethe door grip cover,then removethe screws.
,L
12mm
(0.47in.) T-
TRIM PAD
REMOVER
(Commercially
available)
Snap-on
#4177,or
lmm l---4
(o.o1in.l1 fequival€nt
>: Screwlocation3.2
rt{,nu"
-l
45mm '
11.77in.l
> r C l i pl o c a t i o n sT,
4l N l
rRrMPAD---_Jl
REMOVER
4.
20-10
.I+
F/
i
]
Installationis the reverseof the removalDrocedure.
t
Outer HandleReplacement
NOTE:Raisethe glassfullY.
1.
Remove:
. D o o rp a n e l
. Plasticcover(seepage20-8)
2.
Removethe screws.
4.
Pull out the outer handle.Pry the outer handlerod
out of its joint usingdiagonalcutters.
NOTE:
. To easereassembly,note locationO of the outer
it.
handlerod on the joint beforedisconnecting
. Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.
3
>: Screwlocations,
6x1.0mm
6 N.m {0.6kgf m,
4 tbf.ftl
BUSHING
Replace.
o
:"'*,w,
DIAGONAL
\
\
a
OUTER
HANDLE
ROD
3.
Move the latchdown, and removethe bolts.
>: Bolt locations,2
6x1.0mm
9.8 N,m
)
kst.n,7.2lbiftl //
11.O
SHOPTOWEL
5.
lnstallationis the reverseof the removalprocedure
surethe door locksand opensproperly.
NOTE:N4ake
20-11
Doors
Latch Replacement
Glass/RegulatorReplacement
NOTE:Raisethe glassfutty.
L
Remove:
. Door panel{seepage20-10)
. Plasticcover (seepage20,8)
2.
Carefullymove the glassuntil you can seethe bolts,
then removethem.
1.
2.
Remove:
. Door panel(seepage20-10)
. Plasticcover(seepage20-8)
. Outerhandle(seepage2O-1,l
Removethe lockcrankand clip.
>: Screwlocation,I
NOTE:Takecarenotto dropthe glassinsidethe door.
>: Cliplocation,I
qn@l #
_
__)
>: Eoltlocations,
2
|
p
@
.-
_-__)
o'r.o-,n
I
9.8N.m{t.okof.m.
I
:'zulnt
/
LOCK
ROO
LATCH
Removethe rearchannelcollar.
NOTE:Takecare not to bendthe lock rod and inner
handlerod.
3.
C a r e f u l l yl o w e r t h e g l a s s .R e m o v et h e b o l t s a n d
screwfrom the rearchannel,then removethe glass
from the rearchannel.
NOTE:Takecarenotto dropthe glassinsidethe door.
>: Bolt.screwlocations
A, 1
,
c, 1
I
q)h:iT(--n,,".i m
6x1.0mm
8 N.m (0.8 kgt m,
6 tbtttl
- - illt)
Disconnect
the
connector.
Removethe latchthroughthe hole in lne door.
5.
lnstallationis the reverseof the removatproceoure.
NOTE:Makesurethe door locksand opensproperly.
20-12
B, 1
,,<\
'/
-
)
6x1.0mm
8 N.m to.8 ksf.m, 6 tbt.ftt
IDF-IIID
I
-__,/
.)
t}
4.
Carefullyremovethe glassfrom the window slot.
c
\
7.
NOTE:
a lf necessary,remove the power window motor
from the regulator.
. Beforeremovingthe powerwindow motor,scrloe
a lineacrossthe sectorgearand regulator.
REAR
CHANNEL
COLLAR
5.
CLIP
Grease all the sliding surfaces of the regulator where
shown.
SECTORGEAR
REGULATOR
Removethe outer molding,then removethe quarIer grass.
OUARTER
\
POWERWINDOW
MOTOR
>: Bolt locations,3
POWER
wTNDOW
MOTOR
6.
Disconnectthe connector,and detachthe harness
clip, then removethe regulatorthrough the hole in
the door.
-... er
l'
A
nicuuron
8.
lnstallationis the reverseof the removalprocedure.
>: Bolt locataons
A>,2
\ t
6x1.0mm
[l o t't.-to.arsl -.
fr- - - . e- -ttt- .ttt
-,/
]
L
j
)
I
B> , 2
6 x 'l.0 mm
I N.m {0.8 ksl'm,
6 tbf.ft)
)
NOTE:Rollthe glassup and down to see if it moves
freelywithout binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glassis closed.Adjust the positionof
the glassas necessary(seepage20-20).
20-13
Doors
Door Index
2DI3D:
GLASSGUIDE
CLIP
sAsH
I
€
*
/
.u\\
\
\
Y
OU?ER
WEATHERSIRIP
\
I
et'
PLASTIC
COVER
ii\
<]<--
-it v
@
$=-!xtruce
\rre
,",
INNERHANDLE
(sqjR5f"'
S
\
\
h-P
eowenooon
rocKswrrcH
dD
\b
\
BRACKET
INNEFHANOLE
TRIM
{without power
door locks)
h
W/
;ril;"i-"-\
J E
powen____-.-@.*\L'l
swrrcH
t
-Qa,
(l+,
- p
Q*-BsfL-,"
9
wtNDow
\
DOOR
Adjustment,
page 20-23
dl
ARMREST
POCKET
ARMREST
POCKET
lwith power
\s-l
@."
TRIM
(withpowerdoorlocks)
20-14
MTRROR
MOUNT
COVERPANEL
dnJ.*-{
r-1*{
SPEAKER
,P
SPEAKERCOVER
?
GLASS
Replacement,
page20-19
Adjustment,
page 20-20
GLASSRUN
CHANNEL
3ill,'^lri"*'"tt--.-.qq
\,
\I\
\\II REGULATOR
pagezo rs
\\\\ neptacement,
\\'l\
\
trq\\\\ v.
6
tr
POWER
MOTOR
CYLINDER
PROTECTOR
LATCH
Replacement,
page20-18
STRIKER
Adjustment,
page20-23
\
RETAINEB
LOCK
CLIP
CYLINDER
fitn
\a
\.vqE
BOD PROTECTOR
INNERHANDLEROD
LATCH
PROTECTOR
20-15
Doors
Door PanelReplacement
N O T E :T a k e c a r e n o t t o s c r a t c ht h e d o o r p a n e l a n d
other parts.
'1.
2.
5.
Remove:
. I n n e rh a n d l et r i m ( s e ep a g e2 0 - 1 4 )
. Mirror mount cover panel(seepage20-24)
Releasethe clips that hold the door panel.Remove
the door panel by pulling it upward.Disconnectthe
speakerconnector.
NOTE:Removethe door panelwith as littlebending
as possibleto avoidcreasingor breakingit.
l f a p p l i c a b l e r, e m o v et h e r e g u l a t o rh a n d l e b y
p u l l i n gt h e c l i po u t w i t h a w i r e h o o k .
.L
REGULATOR
HANDLE
12
fim
TRIM PAD
(0.47 in.) TREMOVER
(Commercially
available)
Snap-on
#A'177,or
1mm
equivalent
{0.04in.)
WIREHOOK
11.77in.l
>: Clip locations,
l^
3.
J[
=l$
ll,\*
R e m o v et h e a r m r e s tp o c k e t ,t h e n d i s c o n n e ctth e
powerwindow switchconnector.
,,)
atrREMoVER
tl
-)
DOORPANEL
ARMREST
POCKET
4.
Removethe speakercover,then removelhe screws.
>: Screwlocations,
3
I
| 6b:a,'
L"_
O)
6.
COVER
20-16
CONNECTOR
lnstallation is the reverse of the removat oroceoure.
b
Outer Handle Replacement
4.
NOTE:Raisethe glassfully.
1.
2.
Remove:
. Door panel
. Plasticcover(seepage20-14)
Pull out the outer handle.Pry the outer handlerod
out of its joint usingdiagonalcutters.
NOTE:
. To easereassembly,
note location@ ot the outer
it.
handlerod on the joint beforedisconnecting
. Takecarenot to bendthe outer handlerod.
. Use a shop towel to protectthe opening in the
door.
Pullout the retainerclip.
CYLINOER
PROTECTOR
EUSHING
Replace.
LOCKCYLINDER
DIAGONAL
CUTTERS
,pr,
\
RETAINER
CLIP
\
e
3.
Removethe bolts,then removethe cylinderprotector, lockcylinderand outer handle.
>: Boltlocations,2
6x1.omm
]
9.8N.m {1.0kgf.m,
1.2tbl,ttl
)
_,
_-_-,/
CYLINDER
PROTECTOR
SHOP
TOWEL
5.
Installationis the reverseof the removalprocedure.
NOTE:Makesurethe door locksand opensproperly.
LOCKCYLINOER
CYLINOER
ROD
20-17
Doors
Latch Replacement
NOTE:Raisethe glassfully.
3.
Removethe boltsand movethe centerlowerchannel.
1.
Remove:
. Door panel(seepage20-16)
. Plasticcover(seepage20-14)
. Outerhandle{seepage20-17}
NOTE:Takecare not to bend the inner handle rod
and lock rods.
2.
Removethe rod protector.
>: Screw locations
A>,3
8>,3
6x1.0mm
ffu
LATCH
_"
l
6 N.m{0.6kef.m,
11111
)
q )
CENTERLOWEB
CHANNEI
CBANK
HOLDER
PROTECTOR
Disconnect
the connector,
6x1.0mm
8 N.m 10.8kgt.m,
6 tbtft)
Remove the inner handle, then remove the latch
throughthe hole in the door.
5.
lnstallationis the reverseof the removalprocedure.
NOTE:Makesurethe door locksand opensproperly.
20-18
L
Glass/RegulatorReplacement
1.
Remove:
. Door panel(seepage20-'16)
. Plasticcover(seepage20-14)
2.
Carefullymove the glassuntil you can seethe bolts,
then loosenthem. Slidethe guide rearward,remove
t h e g l a s s t r o m t h e g u i d e , a n d c a r e f u l l yp u l l t h e
glassout throughthe window slot.
3.
Disconnectthe connector,and detach the harness
clip, then removethe regulatorthrough the hole in
the door.
NOTE:Scribea line aroundthe rearrollerguidebolt
to showthe originaladjustment.
>: Boltlocations
NOTE:Takecarenot to dropthe glassinsidethe door.
a >,4
6xL0mm
8 N.m (0.8 kgt m, i
'-1
>: Bolt localions,2
6x1.0mm
E
l*
\3
B> , 2
9.8N.m{1.0kgtm,I
7.2tbrfil
I
Loosen
,/
ROLLER
t
)
6x1.omm
I N.m {0.8 kgt.m,
6lbrft
Loosen.
,/
I
I
]
REGULATOR
J
BOLTS
GUIDE
(cont'd)
20-19
Doors
(cont'dl
Glass/Regulator
Replacement
Greaseall the slidingsurfacesof the regulatorwhere
shown.
NOTE:
. lf necessary,remove the power window motor
from the regulator.
. Beforeremovingthe powerwindow motor,scribe
a line acrossthe sectorgearand regulator.
GlassAdjustment
NOTE:
. Placethe vehicleon a firm, levelsurfacewhen adjusting the glass.
. Checkthe weatherstrips
and glassrun channelfor damage or deterioration,and replacethem if necessary.
1.
Remove:
. Door panel(seepages20-4,10, 16)
. Plasticcover(seepages20-2,8,14)
2.
Adjustthe glass.
SECTORGEAR
REGULATOR
4D:
a.
Raisethe glassfully.
b.
Loosenthe glass mounting bolts (front door)
and regulatormountingbolts.
Push the glass rearward (front door glass)or
iorward (reardoor glass).
d.
Tighten the glass mounting bolts (front door)
and regulatormountingbolts.
A >: Gl.3s mountingbolt
locations.
B >: Regulrtor mouting
bolt loc.tions.
Front:
5.
Installationis the reverseof the removalorocedure.
NOTE:Rollthe glassup and down to seeif it moves
freely without binding.Also make sure that there is
no clearancebetweenthe glassand glassrun channel when the glass is closed.Adjustthe positionof
the glassas necessary.
20-20
REGULATOR
b
Rear:
GLASS
+"
+
REGULATOR
e.
\
J
Loosenthe front channelmountingbolts (front
d o o r ) o r r e a r c h a n n e lm o u n t i n g b o l t l r e a r
ooor,,
f.
Lowerthe glass.
g.
P u s h t h e f r o n t o r r e a r c h a n n e l sa g a i n s tt h e
glass,then tightenthe mountingbolts.
2DI3D:
Raisethe glassas far up as possible,and hold
it againstthe glassrun channel.
b.
>: Frontandrear
L o o s e nt h e r o l l e rg u i d e b o l t s ,a n d a d j u s tt h e
glassso it is parallelwith the glassrun channel.
GLASSRUN
CHANNEL
channel mounting
bolt locations
Front:
ROLLER
GUIDEBOLTS
\
(cont'd)
20-21
Doors
GlassAdjustment {cont'd)
c.
Tightenthe rollerguide bolts.
d.
Loosenthe front channelbolts.
e.
Lowerthe glass.
f.
Pushthe front channelagainstthe glass,then
tightenthe mountingbolts.
6.
Checkfor water leaks.
Spray water over the roof and on the sealingarea
as shown.
NOTE:
. Adjustthe water pressureas shown.
. Do not squeezethe tip of the hose.
GLASS
0.5 m {1.6ft)
HOSE
HOSE
U
- \ ,
300 mm {11.8in)
MOUNTING
BOLT
3.
Checkthat the glassmovessmoothly.
4.
Raisethe glassfully and checkfor gaps.
5.
Checkthe glassoperation.
1.
NOTE:Checkthat the glass contactsthe glass run
channelevenly.
Attachthe plasticcover,then installthe door panel
(seepages20 4, 10, 16).
Installthe regulatorhandleso it pointsforwardand
up at a 45 degreeanglewith the glassclosed.
WEATHERSTRIP
Forward -
20-22
b
PositionAdjustment
StrikerAdjustment
NOTE: Placethe vehicleon a firm, level surfacewhen
adjustingthe doors.
lvlakesurethe door latchessecurelywithout slamming.
lf it needsadjustment:
After installingthe door, checkfor a flush fit with the
body,then checkfor equalgaps betweenthe front, rear,
a n d b o t t o m d o o r e d g e sa n d t h e b o d y . T h e d o o r a n d
body edgesshouldalso be parallel.Adjust at the hinges
as shown,
NOTE;The strikernuts are fixed, but the strikercan be
adjustedslightlyup or down,and in or out.
'L
Loosenthe screws,then insert a shop towel between
the body and striker.
CAUTION:Placea shop towel on the iack to prevent
damage to the door when looseningthe door and hinge
mounting bohs for adiustment.
BOLTS
DOOR
MOUNTING
8 x 1.25mm
28 N.m{2.9kgf.m.21lbt'ft}
boltsslightly
Loosen
thedoormounting
to movethedoorlN or OUTuntil
it'sflushwiththebody.lf necessary,
voucaninstallashimbehindone
hingeto makethedooredges
Inserta shoptowel
betweenthe body and
PLASTIC
P A R A L L E Lw i t h t h e b o d y .
HINGEMOUNTINGBOLTS
I x 1.25mm
28 N.m (2.9kgf.m,21lbtft)
Removethe innerfender,
loosenthe hingemounting
bolts,and move the door
BACKWARD
or FORWARD,
UP or DOWNas necessary
to equalizethe gaps.
Lowerthe glass.
J
sc8Ews
8 x 1.25mm
18 N.m (1.8kgf.m,
13 tbtftl
ifF t
2.
Lightlytightenthe screws.
3.
Wrap the strikerwith a shop towel, then adjustthe
strikerby tappingit with a plastichammer.
CAUTION: Do not tap the striker too hard.
The door and body edges should be parallel-
4.
Loosenthe screws.and removethe shoptowel.
5.
Lightlytightenthe screws.
H o l d t h e o u t e r h a n d l eo u t , a n d p u s h t h e d o o r
againstthe body to be surethe strikerallowsa flush
fit. lf the door latchesproperly,tighten the screwsand
recheck.
\
NOTE:Checkfor water leaks.
20-23
Mirrors
Mirror Replacement
NOTE:Take care not to scratchthe mirror. mirror base
coverand door.
l
L o w e r t h e d o o rg l a s s .
2.
Carelullypry out the mirror mount cover panel by
nano.
3.
Removethe mirror mountingnuts while supporting
the mirror.
a: Nutlocations,3
Power mirro.:
€)CONNECTOR
(Nrirrorside)
MIRROR
(Doorharness
side)
CONNECTOR
MIRROR
MOUNT
COVEB
PANEL
Manual mirror:
Installationis the reverseof the removalprocedure.
Removethe cap, screw and knob,then removethe
mirror mount cover panel.
NOTE:Make sure the connectoris connectedproperly.
MIRRORMOUNT
KNOB
20-24
|}
Mirror Holder/CoverReplacement
RearviewMirror Replacement
CAUTION: Put on gloves to protecl your hands.
1.
Removethe rubberdamper.
2.
Pry the cover off using the end of a flat tip screwdrivef.
L
C a r e f u l l yp r y o u t t h e m i r r o r h o l d e rw i t h a f l a t t i p
screwdriveras shown.
PIVOT
CAUTION: When prying with a flat-tip screwdriver,
wrap it with a shop towel to prgvant damage.
-6r
JOINT PIN
-G{
3.
Removethe screws,then removethe rearviewmirror,
4.
Installationis the reverseof the removalprocedure.
SCREW
5x0.8mm
il N.m lo.a kgf.m,
3 lbf.ftl
SHOPTOWEL
J
Installationis the reverseof the removalprocedure.
NOTE:Apply greaseto the locationsindicatedby
the arrows.
>: Sc.ewlocations
A> ,3
ry
s>,2
I
6)drD
)
To remove the screws,
pull the sealaway.
SHOPTOWEL
I
20-25
Windshield,RearWindow and OuarterGlass
Index
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
Windshieldl2Dl3D/4D):
RUBBER
UPPER
DAM
FASTENER,
2
(Sell-adhesive
type,glassside)
FASTENER,
2
body side)
lClip-type,
WINDSHIELD
Removal,page20 28
page20-29
Installation,
RearWindow (2Dl4Dl:
FASTENER,
4
(Self-adhesive-type,
glassside)
FASTENER,4
lSelf adhesive-type,
body sidel
/
/
* , /
M
SPACER,
w
/>
@
20-26
b
RearWindow l3Dl:
FASTENER,4
(Self-adhesive-type,
glassside)
SPACER,
|
I
,o"r.".". o
bod'side)
{ff*'*'YPe
DAM,2
RUBBER
tI
=
@
I
SEALA, 1
SEALB,2
e
OuarterGlass:
3D:
2D:
OUARTERGLASS
Removal,page20-40
page20 4l
Installation,
OUARTER
GLASSTRIM
FASTENER
(Self-adhesave
type,
body side)
$(
\
\
\)f\
\il]
n,
FASTENER
(Self-adhesive-type,
glassside)
LOWERCLIP
lSelf adhesive'type)
LOWERRUBBER
DAM
LOWERCLIP
(Selfadhesive-type)
J
20-27
Windshield
Removal
CAUTION:
. Put on gloves to plotest your h8nds.
. Use seat covers to avoid damaging any surfaces.
1.
4.
To removethe windshield,first removethe:
. Rearviewmirror (seepage20-25)
. Sunvisorsand holders(seepage20-64)
. Frontpillartrim (seepages20-59,60, 61)
! Windshieldwiper arms and cowl cover (seepage
20-1131
Apply protectivetape along the edge of the dash
b o a r da n d b o d y a s s h o w n .U s i n ga n a w l , m a k e a
h o l e t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ef r o m
i n s i d et h e c a r . P u s ht h e p i a n ow i r e t h r o u g ht h e
hole,and wrap eachend arounda pieceof woodPROTECTIVE
'1"
|
PIANOWIRE
UPPER
RUBBER
DAM
WINDSHIELO
Peel off the molding, and removethe glass brackers.
AOHESIVE
NOTE:When molding removal is difficult,cut the
moldingwith a knife.
MOLDING
WINDSHIELO
RUBBER
DAM
W i t h a h e l p e ro n t h e o u t s i d e ,p u l l t h e p i a n o w i r e
backand forth in a sawingmotion,and carefullycut
t h r o u g ht h e r u b b e rd a m a n d a d h e s i v ea r o u n dt h e
entirewindshield.
CAUTION: Hold the piano wile as closeto ihe windshield as possible to prevent damage to the body
and dashboard.
3.
Pull down the front of the headliner(see page 2064).
CAUTION: Take care not to bend the headlinet
excsssively.
WINDSHIELD
6.
20-24
Carefullyremovethe windshield.
t
Installation
'1.
G l u e t h e r u b b e rd a m a n d f a s t e n e r st o t h e i n s i d e
faceof the windshieldas shown.
Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
surfacearoundthe entirewindshieldopeningflange.
NOTE:Be carefulnot to touch the windshieldwhere
adhesivewill be applied.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
. Removethe rubberdams and tastenersfrom the
body.
. Maskoff surroundingsurfacesbeforepainting.
2.
>: Faslener localions, 2
FASTENER
ALTGNMENT,
\ -o
MARK
Cleanthe body bondingsurfacewith a spongedampenedin alcohol.
NOTE: After cleaning,keep oil, grease and water
from gettingon the surface.
ALIGNMENT
MABK
3 . lf the old windshieldis to be reinstalled,use a putty
knife to scrapeoff all traces of old adhesive,then
c l e a nt h e w i n d s h i e l ds u r f a c ew i t h a l c o h o lw h e r e
new adhesiveis to be applied.
13.5mm
(0.53in.)
NOTE:Make sure the bonding surfaceis kept free
of water,oil and grease.
t
C
LOWERRUBBER
DAM
CAUTION:Avoid setting the windshield on its edges;
small chips may later deyelopinto cracks.
NOTE:
. Cleanthe shadowedarea.
o Cleanarea@ as shown.
WINOSHI€LD
5.
lnside
Align and glue the molding to the edge of the windshield.
NOTE: Be caretul not to touch the windshield where
&
a4)
WINDSHIELD
MOLOING
WINDSHIELO
100mm
{3.94in.l
)
J
WINDSHIELD
Apply primer(3M N'200,or equivalent)
to edSe (cont'd)
of the windshield.
20-29
Windshield
Installation (cont'd)
Installtheglassbracketsand fastenersas shown.
NOTE:The numbersafterthe part namesshow the
quantitiesof the oartsused.
9. With a sponge, apply a light coat of glass primer
around the edge of the windshieldas shown. then
lightlywipe it off with gauzeor cheesecloth.
>: Fastonerlocations,2
FASTENER^
I
I
t/////,
'/////l
NOTE:
. Do not apply body primerto the windshield.and
do not get body and glassprimerspongesmixed
up.
. Nevertouch the primed surfaceswith your hands.
lf you do. the adhesivemay not bondto the windshieldproperly,causinga leakafterthe windshield
is installed.
. Keepwater. dust, and abrasrvemateraalsaway
from the primedsurface.
Applyglassprimer
I Apply glass p.imer here.
to the molding.
GLASSBRACKETS,
2
MOLDING
7.
Set the windshieldon the glassbrackets,then center it in the opening.Make alignmentmarksacross
the windshieldand body with a greasepencilat the
four pointsshown.
NOTE:Be carefulnot to touch the windshieldwhere
adhesivewill be aDolied.
WINDSHIELD
10. With a sponge.apply a light coat of body primerto
the original adhesiveremainingaround the windshield openingflange. Let the body primer dry for
at least10 minutes.
NOTE:
. Do not apply glassprimer to the body, and be careful not to mix up glassand body primer sponges.
. Nevertouch the primed surfaceswith your hands.
. Maskoff the dashboardbeforepaintingthe flange.
7////l
/////l
I Apply body p mer hcre.
6mm
/
SCREW
8.
Removethe windshield.
2 0-3 0
16mm
(0.6:|in.)
5mm
(0.2 in.l
16 mm
{0,63in.}
3
1 1 . Thoroughlymix the adhesiveand hardenertogether
on a glassor metal plate with a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mixing.
. Followthe instructionsthat come with the adhestve.
1 4 . U s e s u c t i o nc u p s t o h o l d t h e w i n d s h i e l do v e r t h e
opening,align it with the alignmentmarksmade in
step7, and set it down on the adhesiveL
. ightly
push on the windshielduntil its edge is fully seated
on the adhesiveall the way around.
NOTE:Do not openor closethe doorsuntiladhesive
ri vI Y
A L T G N M E N TM A R K
Beforefilling a cartridge.cut the end of the nozzle
as shown.
Cut nozzleend
10 mm 10.39
in.)
7 mm (0.27in.l
tu
13. Packadhesiveinto the cartridgewithout air pockets
to ensurecontinuousdelivery.Putthe cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the windshieldas shown.
NOTE:Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer.
12mm (0.47in.)
l_Z oo*.t,ut
Make a slightly thicker
bead at each corner.
8 mm 10.31in.l
5mm
(0.2in )
='+
MOLDING
A\uloto^o
-.\\
.
UPPER
RUBBER
DAM
FASTENER
/
w
WINDSHIELD
LOWEB
RUBBER
DAM
LOWER
RUBBER
DAM
lmm
10.04in.l
)
WINDSHIELD
1 5 . Scrape or wipe the excessadhesiveoff with a putty
knifeor towel.
NOTE: To removeadhesivefrom a paintedsurfaceor
the windshield,wipe with a soft shop towel dampened
with alcohol.
1 6 . Let the adhesivedry for at leastone hour, then spray
water over the windshieldand checkfor leaks.Mark
the leakingareas,let the windshielddry, then seal
with sealant.
NOTE:
. Let the car stand for at leastfour hours after windlf the car hasto be usedwithin
shieldinstallation.
the firstfour hours,it must be drivenslowly.
. Keepthe windshielddry for the first hour after
installation.
. Checkthat the ends of the side molding are set
underthe cowl cover.
't7. Reinstallall remainingremovedparts.
NOTE:
. Installthe rearviewmirror rubber damper after
the adhesivehasdriedthoroughl',.
. Advisethe customernot to do the followingthings
for two to three days:
- Slam the doors with all the windows rolled
up.
- T w i s t t h e b o d y e x c e s s i v e l y( s u c h a s w h e n
going in and out of drivewaysat an angle or
drivingover rough,unevenroads).
20-31
RearWindow
Removal
2DllDl
4.
CAUTION:
. Put on gloves to protect your hands.
. Uso ssat coversto avoid damaging any surlaces,
. Do not damage thg roar window dofogggr grid linss,
window antenna grid lines, and tsrminalg.
1.
2,
3.
Apply protectivetape along the edge of the body as
shown. Using an awl, makea hole through the
adhesivefrom insidethe car. Pushthe piano wire
through the hole,and wrap eachend around a
pieceof wood.
PIANOWIRE
ADHESIVE
To removethe rearwindow,first removethe:
. T r u n kl i d
. Rearseatcushion(seepages20-79,81)
. Rearseat side bolsters{4D,see page 20-79)
. Rearseat-back(2D,seepage20-81)
. Rearshelf{seepages20-59,61}
. Rearpillartrim {4D,see page20-59)
. Sidetrim panel(2D,seepage20-61)
. Ouartertrim panel(2D,see page20-61)
. Rear roof trim (see page 20-65)
REARWINDOW
PROTECTIVE
TAPE
TAPE
REARWNDOW
Disconnectthe rear window defogger connector
from eachside.
PIANOWIRE
Peeloff the molding.
PROTECTIVE
TAPE
NOTE:When molding removal is difficult,cut the
moldingwith a knile.
ADHESIVE
MOLDING
With a helper on the outside, pull the piano wire
backand forth in a sawingmotion,and carefullycut
through the adhesivearound the entire rear window.
F"*t,
ID_HESI.VE
---, ,/,/
CAUTION: Hold the piano wiro as close to the rear
window as possiblsto prcyent damageto the body.
REARWINDOW
S
MOLDING
6.
20-32
Carefullvremovethe rearwindow.
I
lnstallation
1 . Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g
flange.
4.
N O T E : B e c a r e f u ln o t t o t o u c h t h e r e a r w i n d o w
whereadhesivewill be applied.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding
o Maskoff surroundingsurfacesbeforepainting.
. R e m o v e t h e f a s t e n e r sa n d s p a c e r sf r o m t h e
oooy.
2.
Apply the double-facedadhesivetape (NITTO501,
or equivalent)to the edge of the rear window, then
installthe moldingaroundthe edge of the rearwindow as shown.
ALIGNMENTMARK
ADHESIVE
TAPE
I in.)
867mm 134.
5mm
{0.2in.}
C l e a nt h e b o d y b o n d i n g s u r f a c ew i t h a s p o n g e
dampenedin alcohol.
ADHESIVE
TAPE
Thickness:
0.16mm (0.006in.l
NOTE: After cleaning,keep oil. greaseand water
from gettingon the surface.
MOLDING
ALIGNMENT
MARK
GLASS
usea putty
lf the old rearwindow is to be reinstalled,
knifeto scrapeoff all tracesof old adhesiveand the
rubberdam,then cleanthe rearwindow surfacewith
alcoholwherenew adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free
of water,oil and grease.
)
MOLDING
wtNoow
CAUTION:Avoid setting the rear window on its
edges;small chips may later develop into cracks.
NOTE:Cleanthe shadowedarea.
5.
Glue the fastenersand spacersto the insidefaceof
the rearwindow as shown.
N O T E ; B e c a r e f u ln o t t o t o u c h t h e f e a r w i n d o w
where adhesivewill be applied.
>:Fa3l€ner, spacer
locations
A >, 4
FASTENER
MOLOING
(:r:^#T
ry
ALIGNMENT
!\raRKs
a>,2
Outside
I
REARWINDOW
)
REARWINOOW
SPACER
liGrtrrrrertrr
\..!44llc-'''
-
-
(cont'd)
20-33
RearWindow
Installation (cont'dl
6.
Gluethe fastenersto the body as shown.
Fastenerlocations,4
9 . W i t h a s p o n g e ,a p p l y a l i g h t c o a t o { g l a s sp r i m e r
aroundthe edgeoI the rearwindow as shown,then
lightlywipe it off with gauzeor cheesecloth.
FASTENER
NOTE:
. D o n o l a p p l y b o d y p r i m e rt o t h e r e a rw i n d o w .
and do not get body and glass primer sponges
mixed up.
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
w i n d o w p r o p e r l y c, a u s i n ga l e a ka t t e rt h e . e a r
window is installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
'/fur1
: lppty gtassprimerhere.
\ - . * l
-E4,7-7
,.-)
,
/
l
4 Y l
F-LNGENY:,//
MOI-DING
7.
Set the rear window, then centerit in the opening.
Make alignmentmarksacrossthe rear window and
body with a greasepencllat the four points shown.
ALIGNMENTMARK
FASTENER
REARWINDOW
10. With a sponge,apply a light coat of body primer to
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n d t h e r e a r
window openingflange.Letthe body primerdry for
at least10 minutes.
NOTE:
. Do not applyglassprimerto the body.and be care,
ful not to mix up glassand bodyprimersponges.
. Nevertouchthe primedsurfaceswith your hands.
-\
-.._s
/fu/
: Applyboay primerhere.
1 6m m
(0.(I, in.l
16 mm
(0.63in.l
l
6mm r
{O.24in.}
8.
Remove the rear window.
20-34
7mm
{0.28in.}
' 1 1 . Thoroughlymix the adhesiveand hardenertogether
on a glassor metalplatewilh a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mixing.
. Followthe instructionsthat came with the adhesive.
14. Use suctioncups to hold the rear window over the
t a r k sm a d ei n
o p e n i n ga, l i g ni t w i t h t h e a l i g n m e nm
a
d
h
esiveL
. ightly
o
n
t
h
e
s
e
t
i
t
d
o
w
n
step7, and
p u s h o n t h e r e a rw i n d o w u n t i l i t s e d g e sa r e { u l l y
seatedon the adhesiveall the way around.
NOTE:Do not openor closethe doorsuntilthe adhesiveis dry.
1 2 . Beforefilling a cartridge,cut the end of the nozzle
SUCTION
CUPS
a ss h o w n .
ALIGNMENT
MARK
1 0m m { 0 . 3 9i n . )
7 mm (0.27in.l
J
1 3 . Packadhesiveinto the cartridgewithout air pockets
to ensurecontinousdelivery.Put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a do l a d h e s i v ea r o u n d
the edge of the rearwindow as shown.
NOTE|Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer.
Makea slightlythicker
beadat eachcorner.
12 mm 10.,Uin.)
[/
GLASS
oo*r.,u.
Scrapeor wipe the excessadhesiveoff with a putty
knifeor towel.
NOTE:To removeadhesivefrom a paintedsurface
or the rear window, use a soft shop towel dampenedwith alcohol.
1 6 . L e t t h e a d h e s i v ed r y f o r a t l e a s to n e h o u r , t h e n
s p r a y w a t e r o v e r t h e r e a r w i n d o w a n d c h e c kf o r
leaks.Mark the leakingareas,let the rear window
dry,then sealwith sealant.
8 mm (0.31in.)
MOLDING
FASTENER
NOTE:Let the car standfor at leastfour hoursafter
rear window installation.lf the car has to be used
within the Iirst tour hours,it must be drivenslowly
1-7. Reinstallall remainingremovedparts
SPACER
MOLDING
NOTE:Advisethe customernot to do the following
thingsfor two to threedays:
.
.
Slamthe doorswith all the windows rolledup.
Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g
over rough.unevenroads).
FASTENER
)
REARWINDOW
20-35
RearWindow
Removal
3D:
Upper portioni
CAUTION:
. Put on gloves to ptotect your hands.
. Us€ seat cove6 to avoid damaging any surfaces.
. Do not damage the rear window defogger grid lines.
. Take carg nol scratchthe terr window molding.
'1.
2.
To removethe rearwindow,firsr removethe:
. Rearcentershelf(seepage20-60)
. H a t c hu p p e r t r i m , h a t c ht r i m p a n e la n d h a t c h
sidetrim (seepage20-63)
. Rearwindow wiper arm (seepage2O-115)
. Hatchspoiler(seepage20 101)
TAPE
Side portion:
D i s c o n n e ctth e r e a r w i n d o w d e f o g g e rc o n n e c t o r
from eachside.
GLASS
Apply protectivetape to the inner edge of the tail_
gate.
From insidethe hatch,usea knifeto cut throughthe
rearwindow adhesiveall the way around.
NOTE:
. lf the rear window is to be reinstalled,take care
not to damagethe molding.
. lf the molding is damaged,replacethe rear win_
dow and moldingas an assembly.
Lower portion;
HATCH
ffi#
ADHESIVE
Carefullyremovethe rearwindow.
NOTE;Checkthe moldingfor damage,and replace
the rearwindow if necessary.
REARWINOOW
20-36
t
lnstallation
'1.
Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r f a c ea r o u n d t h e e n t i r e r e a r w i n d o w o p e n i n g
flange.
NOTE:
. Do not scrapedown to the paintedsurfaceol the
body; damaged paint will interferewith proper
bonding.
a Removethe rubberdams,spacersand fasteners
from the hatch.
. M a s k o f f s u r r o u n d i n gs u r f a c e sb e f o r ea p p l y i n g
primer.
2.
C l e a nt h e h a t c h b o n d i n g s u r f a c ew i t h a s p o n g e
d a m p e n e di n a l c o h o l .
N O T E :A f t e r c l e a n i n g ,k e e p o i l , g r e a s eo r w a t e r
from gettingon the surface.
3.
O
l f t h e o l d r e a r w i n d o w i s t o b e r e i n s t a l l e du, s e a
putty knife to scrapeoff all tracesof old adhesive,
t h e n c l e a nt h e r e a r w i n d o w s u r f a c ew i t h a l c o h o l
where new adhesiveis to be applied.
4.
Glue the rubberdams to the insideface of the rear
window, as shown, to containthe adhesiveduring
and gluethe fasteners,spacerand seals
installation,
as shown.
NOTE:
. Gluethe rubberdams usingthe printeddots as a
g ui d e .
. Be careful not to touch the rear window where
adhesivewill be aPPlied
>r Fastener,
spacorandseal
locations
A>,4
B > ,1
SPACER
FASTENER
/
"-*^1
w
A L.IGNMENT
IIARKS __,/
C>,2
S E AA
L
l
s i
'W
o.\6fif,", j
]
ryt48rq
__ ,,/
D> '2
'EAL B
- \ l
NOTE;Makesurethe bondingsurfaceis keptfree of
water,oil and grease.
19Pry/
CAUTION:Avoid setting the rear window on its
edges;the moldingcan be permanentlydeformed.
NOTE:Cleanthe shadowedarea
REARWINDOW
FASTENER
PRINTEDDOTS
REARWINDOW
MOLOING
)
(cont'd)
20-37
RearWindow
Installation(cont'd)
Installthe fastenersto the hatchas snown.
>: Fastener
locations,
4
8.
W i t h a s p o n g e .a p p l y a l i g h t c o a t o f g l a s sp r i m e r
a r o u n dt h e e d g e o f t h e r e a r w i n d o w ,t h e n l i g h t l y
wipe it off with gauzeor cheesecloth.
NOTE:
. Do nol apply body primer to the rear window,
and do not get body and glass primer sponges
maxedup.
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
w i n d o w p r o p e r l y c, a u s i n ga l e a k a f t e rt h e r e a r
window is installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
V/////f , apety st,." o.imer here.
Inside
----
tUt
| @NJ-l
rll \
,zN \
GLASS
I
- -t-
RUBBER1 5m m
DAM
{0.59in.l MOLDING
I 15mm
L 10.59in.l
t
\
SPACER
GLASS
REARWINOOW
Set the rearwindow uprighton the hatch,then center it in the opening.Make alignmentmarks across
the rear window and body with a greasepencil at
the four pointsshown.
NOTE: Be carefulnot to touch the rearwindow where
adhesive
will be applied.
FASTENER
7.
Remove the rear window.
20-38
3
9. With a sponge,apply a light coat of body primerto
t h e o r i g i n a la d h e s i v er e m a i n i n ga r o u n dt h e r e a r
window openingflange.Let the body primerdry for
at least10 minutes.
12. Packadhesiveinto the cartridgewithout air pockets
to ensurecontinuosdelivery.Put the cartridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the rearwindow as shown.
NOTE:
. Do not applyglassprimerto the body,and be careful not to mix up glassand bodyprimersponges.
. Nevertouchthe primedsurfaceswith your hands.
NOTE:Apply the adhesivewithin 30 minutesafter
applyingthe glassprimer.
////////
' acoV boay primerhere.
ffi;fr'L/:ADHEs' vE
8mm
{ 0 . 3 1i n . l
GLASS
t
1 0 . Thoroughlymix the adhesiveand hardenertogether
on a glassor metalplatewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mlxlng.
. Follow the instructionsthat came with the adhesive.
1 1 . Beforefilling a cartridge,cut the end oJ the nozzle
MOLDING
as shown.
---$ ,R1
GLASS
Cut nozzle
f\+,,","
in.t
to.oa
10 mm {0.39in.)
ffi-f
MoLD|NG/
I
-.17
\
7 mm (0.27in.)
(cont'd)
20-39
RearWindow
OuarterGlass
Installation {cont'd)
Removal
13. Use suctioncups to hold the rear window over the
opening.align it with the alignmentmarks made in
slep 6. and set it down on the adhesive.Lightlypush
on the rea. window until its edges are fully seated
on the adhesiveallthe way around.
3D:
NOTE:Do not openor closethe doorsuntilthe adhe_
sive is drv.
sucTtoN
CUPS
CAUTION:
a Pul on gloves to protect your hands.
. Use seat covers to avoid damaging any surfaces,
1. To removethe quarterglass,first removethe:
. Rearseat-backand rear seat cushion (see page
20_80)
. Rear center shelf and rear side shelf lsee page
20_60)
. R e a rt r i m p a n e la n d s i d e t r i m p a n e l ( s e ep a g e
20_60)
. Upper anchorbolts from the front and rear seat
belts{seepages20-86.89)
. Ouartertrim panel(seepage20-60)
2,
From insidethe car, use a knifeto cut through the
quarterglassadhesiveall the way around.
NOTE:
. lf the clip on the rearedge is broken,the quarter
glasscan be reinstalled
usingbutyltape(seepage
20-421.
. Apply protectivetape alongthe edgeof the entire
quarterglassopeningflange.
1 4 . Scrapeor wipe the excessadhesiveoff with a putty
knifeor towel.
NOTE:To removeadhesivefrom a paintedsurface
or the rear window. use a soft shop towel dampenedwith alcohol.
1 5 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r . t h e n
spray water over the rear window and check for
leaks,Mark the leakingareas,let the rear window
dry, then sealwith sealant.
NOTE: Letthe car standfor at leastfour hoursafter
rear window installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following
thingsfor two to threedays:
. Slamthe doorswith all the windows rolledup.
. Tr,vistthe body excessivelylsuch as when going
in and out of drivewaysat an angle or driving
over rough,unevenroads).
20-40
OUARTER
GLASS
lnstallation
1 . Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r t a c ea r o u n d t h e e n t i r eq u a r t e rg l a s s o p e n i n g
flange.
Uppcr portion:
AOHESIVE
TAPE
Lower oortion:
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
r Removethe rubberdams from the body.
. lf any of the clips are broken,removethem from
the body.
. Mask off surroundingsurfacesbefore applying
pnmer.
Cleanthe body bondingsurfacewith a spongedampenedin alcohol.
PROTECTIVE
TAPE
ADHESIVE
NOTE: Afier cleaning,keep oil, greaseand water
from gettingon the surface.
lf the quarterglass is to be reinstalled,use a putty
knife to scrapeoff all traces of old adhesive.then
cleanthe quaner glass surfacewith alcoholwhere
adhesiveis to be apPlied.
NOTE:Make sure the bonding surfaceis kept free
of water,oil and grease.
l
Pillar portion:
CAUTION: Avoid setting the quarter glass on its
edges;small chips may later devglop into cracks.
NOTE:Cleanrhe shadowedarea.
CLIP
3.
Carefullyremovethe quarterglass
N O T E :C h e c kt h e q u a r t e rg l a s st r i m a n d c l i p s f o r
damage,and replacethem if necessary'
)
(cont'd)
20-41
QuarterGlass
Installation (cont'd)
4.
Gluethe upperand lower rubberdams to the inside
Iace of the quaner glass,as shown, to containthe
adhesivd
e u r i n gi n s t a l l a t i o n .
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
whereadhesivewill be applied.
>: Alignment
mark
locations
GLASS
UPPER
RUBBER
DAM
6.
lf the old quarterglassis to be reinstalled(and the
c l i p o n t h e r e a r e d g e i s b r o k e no f f ) , a p p l y a l i g h t
coat of primer (3I/ C-100,or equivalent),
then apply
butyl tape to the quarterglass,as shown. and seal
the body holewith pieceof urethanetape.
NOTE:
. Be carefulnot to touch the quaner glasswhere
adhesivewill be applied,
. Do not peelthe separatoroffthe butyltape.
//////// '.8u'Jt tape tocarionst3M8628,or
equivetenrl
'
Thickness:3.2
mm lo.t3in.l
Width:6.4mm {0.25in.)
UPPER
RUEBER
DAM
13 mm
(0.5in.l
BUTYL
TAPE
\
\
l
*--T,7r--/r4--;
..
LOWER
RUBEER
DAM
Installthe quarter glasstrim on the quarter glass,
then glue the upperand lowerclipsas shown.
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied.
UPPER
OUARTER
GLASSTRIM
OUARTER
GLASS
GLASSTRIM
NOTE: Contactthe cljps againstthe
quarter glass trim at the areas
I n d i c a t e db y t h e a r r o w s .
20-42
GLASS
t
7.
With a sponge,apply a light coat of glassprimerto
the insideface of the quarterglass,as shown,then
lightlywipe it off with gauzeor cheesecloth.
NOTE:
. Do not apply body primer to the quarter glass,
and do not get body and glass primer sponges
m i x e du p .
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bond to the quar
ter glassproperly,causinga leak after the quarter glassis installed.
. Keep water, dust, and abrasivematerialsaway
from the primedsurface.
8. With a sponge,apply a light coat of body primerto
the originaladhesiveremainingaroundthe quarter
glassopeningflange.Let the body primerdry for at
least10 minutes.
NOTE:
. Do not apply glass primer lo the body, and be
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
sponges.
. Nevertouchthe primedsurfaceswilh your hands.
. Maskoff the rearside trim panelbeforepainting
t h ef l a n g e .
/////////
| apetl body erimer he,e.
16 mm
{0.63in.l
////////l : ^pptv stassprimerhe.e.
2 1m m
1 5m m
{0.83in.) (0.59in.)
l
UPPER
RUBBER
DAM
9 . Thoroughlymix the adhesiveand hardenertogether
on a glassor metalplatewith a pufty knife.
OUARTER
GLASS
BUBBEB
DAM
30 mm
1 5m m
in.l (r.2 in.)
10.59
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mr x l n g .
. Followthe instructionsthat came with the adhesive.
1 0 . Before filling a cartridge, cut the end of the nozzle
as shown.
C u t n o z z l ee n d
10 mm (0.39in.l
7 mm (0.27in.)
)
(cont'd)
20-43
OuarterGlass
Installation(cont'd)
11. Packadhesiveinto the cartridgewithout air pockets
to ensurecontinuousdelivery.put the canridgein a
c a u l k i n gg u n , a n d r u n a b e a do f a d h e s i v ea r o u n d
the edgeof the quarterglassas shown.
12. Use suctioncups to hold the quarterglassover the
opening,alignthe clips,and set it down on the adhesive.Lightlypush on the quanerglassuntil its edges
are fully seatedon the adhesiveall the way around.
NOTE:
. lf the old quarterglass is to be reinstalled,peel
the separatoroff the butyl tape afterapplyingthe
adhesive.
. Apply the adhesivewithin 30 minutesafterapply_
ing the glassprimer.
N O T E : D o n o t o p e n o r c l o s et h e d o o r s u n t i l t h e
adhesiveis drv.
i:.8i".,1/:ADHES,'E
8 rnm
(0.31in.l
OUARIER
GLASSTRIM
OUARTER
GLASSTFIM
CLIP
BUTYI.
TAPE
Scrapeor wipe the excessadhesiveoff with a putty
knifeor towel.
NOTE:To removeadhesivefrom a paintedsurface
or the quarter glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
dry, then sealwith sealant.
OUARTERGLASS
32 mm
{ 1 . 3i n . )
''='I
[-4m,^, '"r"\
GLASS
\
/
GLASS
20-44
drt".
TAPE
NOTE: Letthe car standfor at leastfour hoursafter
quarterglass installation.lf the car has to be used
within the first four hours,it must be drivenslowly.
1 5 . Reinstallall remainingremovedparts.
NOTE:Advisethe customernot to do the following
thingsfor two to three days:
.
.
Slam the doorswith all the windows rolledup.
Twist the body excessively(suchas when going
a na n d o u t o f d r i v e w a y sa t a n a n g l e o r d r i v i n g
over rough,unevenroads).
Removal
Upper portion:
2Oi
CAUTION:
. Put on gloves to protect your hands.
. Use seat covers to avoid damaging any surfaces.
1. To removethe quarterglass,first removethe:
. Rear seat-backand rear seat cushion (see page
20_81)
o Sldetrim panel(seepage20-611
. Rearshelf(seepage20-61)
o Upper anchor bolt from the front seat belt (see
page20-86)
. Ouartertrim panel(seepage20-6'l)
2.
From insidethe car. use a knife to cut through the
quarterglassadhesiveallthe way around.
ADHESIVE
PROTECTIVE
TAPE
Rear edge portion:
NOTE:
take care
. lf the quarterglassis to be reinstalled,
not to damagethe molding.
. Apply protectivetape alongthe edgeofthe entire
q u a n e rg l a s so P e n i n g
flange
D
Pillar portion:
TAPE
GLASS
3 . Carefullyremovethe quarterglass.
NOTE:Checkthe moldingfor damage,and replace
it if necessary.
I
20-45
OuarterGlass
Installation
1 . Using a knife,scrapethe old adhesivesmooth to a
thicknessof about 2 mm (0.08in.) on the bonding
s u r f a c ea r o u n d t h e e n t i r e q u a r t e rg l a s so p e n i n g
flange.
NOTE:
. Do not scrapedown to the paintedsurfaceof the
body; damaged paint will interferewith proper
bonding.
a Removethe fastenerfrom the body.
a lf any of the clips are broken,removelhem from
the body.
Mask off surroundingsurfacesbefore applying
pnmer.
Cleanthe body bonding surfacewith a spongedamp
enedin alcohol.
NOTE: After cleaning,keep oil, greaseand water
from gettingon the surface.
lf the quarterglassis to be reinstalled,use a putty
knife to scrapeoff all traces of old adhesive.then
cleanthe quarterglass surfacewith alcoholwhere
adhesiveis to be applied.
NOTE:Make sure the bonding surfaceis kept free
of water.oil and grease.
4.
Installthe molding around the edge of the quarter
glassas shown.
NOTE:
. lf the old molding is to be reinstalled,
scrapeoff
t h e o l d a d h e s i v et a p e f r o m t h e m o l d i n g ,a n d
c l e a nt h e m o l d i n gs u r f a c ew i t h a l c o h o lw h e r e
new adhesivetape is to be applied.Apply the
double-facedadhesivetape to the molding and
quarterglassas shown.
. Be carefulnot to touch the quarterglasswhere
adhesivewill be aoDlied.
Adhesiv€tspe A (3M 4215,or equivalent)
Thicknsss:o.il mm (0.02in.l
Widih: 5 mm {0.2 in.}
Length: /140mm {17.3in.)
Adhesivetap6 I (NITTO501, or equivatontl
Thickness:0.16 mm {0.006in.)
Width: I mm {0.3 in.}
Longlh: 4it0 mm (17.3in.)
Adhosiv€tape C (3M /P13. or equivalentl
Thickness:0.8 mm (0.03in.l
Width: 5 mm (0.2in.)
Length:30 mm (1.2in.)
ADHESIVE
CAUTION: Avoid setting the quarter glass on its
odges;small chips may later develop into cracks,
NOTE:Cleanthe shadowedarea.
20-46
t
5.
lf the old quarterglassis to be reinstalled,glue the
upperand lowerclips and fasteneras shown
N O T E : B e c a r e f u ln o t t o t o u c h t h e q u a r t e rg l a s s
where adhesivewill be applied.
>: Clip,fastenerlocations
A>,2
ALIGNMENT
B > ,1
2.5mm
(0.m in.)
7.
With a sponge,apply a light coat of glassprimer to
the insideface of the quaner glass,as shown,then
lightlywipe it off with gauzeor cheesecloth
NOTE:
. Do not apply body primer to the quarter glass,
and do not get body and glass primer sponges
mixed up.
. Nevertouchthe primedsurfaceswith your hands.
lf you do, the adhesivemay not bondto the quar
ter glass properly,causinga leak after the quarter glassis installed.
. Keep water, dust, and abrasivematerialsaway
from the Primedsurface
t///////7, , aootva"av crimerhere'
MOLDING
\
15.5mm 10 mm
10.61in.l {0.39in.l
b
6.
Gluethe fastenerto the body as shown.
location,1
>: Fastener
)
(cont'dl
20-47
OuarterGlass
Installation(cont'dl
8. With a sponge,apply a light coat of body primer to
the originaladhesiveremainingaroundthe quarter
glassopeningflange.Let the body primer dry for at
least l0 minutes.
NOTE:
. Do not apply glass primer to the body, and be
c a r e f u ln o t t o m i x u p g l a s s a n d b o d y p r i m e r
sponges.
. Neverlouchthe primedsurfaceswith your hands.
. Maskoff the rear side trim panel beforepainting
the flange.
///ffi
l'1. Packadhesiveinto the canridgewithout air pockets
to ensurecontinuousdelivery.Put the cartrigein a
c a u l k i n gg u n , a n d r u n a b e a d o f a d h e s i v ea r o u n d
the edgeof the quarterglassas shown.
NOTE:
. lf the old quarter glass is to be reinstalled,peel
the separatoroff the butyl tape afterapplyingthe
adhesive.
. Peel the separator off the adhesive tape after
applyingthe adhesive.
. Applythe adhesivewithin 30 minutesafterapply
ing the glassprimer.
: Appty aoay primer here.
1 6m m
10.63in.l
12mm 11
lo.tttn.lI l:ADHESIVE
8mm
{0.31in.)
CLIP
9 . Thoroughlymix the adhesiveand hardenertogether on a glassor metal platewith a putty knife.
NOTE:
. Cleanthe platewith a spongeand alcoholbefore
mixing.
. Followthe instructionsthat came with the adhesive.
1 0 . Beforefilling a cartridge,cut the end of the nozzle
as shown.
Cul nozzleend
10 mrn (0.39in.)
7 mm 10.27in.)
20-4A
MOLDING
12. Use suctioncups to hold the quarterglassover the
o p e n i n g ,a l i g n t h e c l i p s , a n d s e t i t d o w n o n t h e
adhesive.Lightlypush on the quarterglassuntil its
edges are fully seatedon the adhesiveall the way
around.
N O T E :D o n o t o p e n o r c l o s et h e d o o . s u n t i l t h e
adhesiveis dry.
}
CLIP
1 3 . Scrapeor wipe the excessadhesiveoff with a putty
knifeor towel,
NOTE:To removeadhesivefrom a paintedsurface
or the quaner glass,wipe with a soft shop towel
dampenedwith alcohol.
1 4 . L e t t h e a d h e s i v ed r y f o r a t l e a s t o n e h o u r , t h e n
spray water over the quarter glass and check for
leaks.Mark the leakingareas,let the quarterglass
dry, then sealwith sealant.
NOTE:Letthe car standfor at leastfour hoursafter
quarterglass installation.lf the car has to be used
within the first four hours,it must be drivenslowly
Reinstallall remainingremovedpartsNOTE:Advisethe customernot to do the following
thingsfor two to threedays:
)
a
.
.
Slamthe doorswith all the windows rolledup.
Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough,unevenroadsl.
20-49
Moonroof
Index
SWITCHPLATE
Adjustment,page20 56
--:=::
CABLEASSEMBLY
Replacement,
page2O-55
SUNSHADE
page20-52
Replacement,
0
\
g
TNNERCAELE
RAIL HOLDERB
RAIL HOLDERA
REAR
DRAIN
TUBE
Y<
/ \
u8E
LfP
ll
ll
I
/
U 6
./w
REARDRAIN
VALVE
FRONTORAINTUBE
20-50
?'''
Troubleshooting
Symptom
ProbableCause
1 . C l o g g e d r a i nt u b e .
2. Gap betweenglassweatherstrjpand roof panel.
3. Defectiveor improperlyinstalledglassweatherstrip.
4. Gap betweendrainsealand roof panel.
'1. Excessive
clearancebetweenglassweatherstripand roof panel.
Waterleaks
Wind noise
Motor noise
Glassdoes not move,but motor turns
Glassdoes not move and motor does not turn
{glasscan be movedwith moonroofwrench)
1. Loosemotor.
2. Worn gearor bearing.
3. Cableassemblydeformed.
'1.
Clutchout of adjustment.
2. Foreignmatterstuckbetweenguide rail and slider.
3. lnnercableloose.
4. Cableassemblynot attachedproperly.
1.
2.
3.
4.
5.
Blownfuse,
Faultyswitch.
Batteryrun down.
Defectivemotor.
Faultyrelay.
GlassHeightAdjustment
D
The roof panel should be even with the glassweathers t r i p , t o w i t h i n 1 . 7 : l r 3m m ( 0 . 0 7: 3 : 3i1n . ) a l l t h e w a y
around.lf not, openthe giassfully,and:
1.7tl.8mm
{0.07:33iin.}
1.
GLASSWEATHERSTRIP
Removethe bracketcover.
Loosenthe nuts, and installthe shims betweenthe
glassframe and glassbracketas shown.
Shim thickness:Frontmax.3 mm 10,12in.l
Rear max. 2 mm 10.08in.)
Repeaton oppositesidei{ necessary.
5x1.0mm
9.8N.m 11.0kgf m,
7.2rbtft)
SRACKET
COVEB
6x1.0mm
9.8 N.m {1.0kgtm,
7.2 tbf.ft)
----------1>
)
20-51
Moonroof
Glass,GlassBracketand SunshadeReplacement
l.
Closethe glassfully.
2.
Slidethe sunshadeall the way back.
3.
Removeboth bracketcovers.
6.
Removethe drainchannel.
DRAINCHANNEL
ERACKETCOVER
Forward
_--____->
4.
Remove the nuts from both glass brackets.
7.
GLASSEBACKET
R e m o v et h e h o l d e r c o v e r . t h e n r e m o v e t h e
h o l d e rB .
NUT
6x1.0mm
9 N.m {0.9 kgf.m.
? tbtftl
{i;t'm
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbt.ftl
Removethe glass by lifting up and pulling forward
as shown.
NOTE:Do not damagethe roof panet.
GLASS
20-52
RAILHOLDERB
Usingthe moonroofwrench,move the glassbracket
to the positionwhere the moonroofnormallypivots
down, and removethe screws.
scREws
b
9. Removethe rail holderA.
NUT
6x1.0mm
I N.m(0.9kgf.m,
12. Slidethe sunshadeforward,then removeit.
SUNSHAOE
\
GLASS BRACKET
Installationis the reverseof the removalprocedure.
NOTE:Checkthe glassheight(seepage20-51).
'14. Checkfor water leaks,
D
water.
NOTE:Do not use high-pressure
DRAIN CHANNEL
ROD
DRAINCHANNELROOSTOP
Rotateas shownto removeit from the guiderail.
10. Remove the drain channel rod slider by moving the
cable slider forward using the moonroof wrench.
I
'11. Detach the drain channel rod stop from the cutout
of the guide rail as shown.
20-53
Moonroof
Motor,DrainTubeand FrameReplacement
CAUTION:
. Put on gloves to protecl your hands.
. Be careful not to damagethe seats,dashboardand other interior trim.
'1. Removethe headliner
{seepage20-64).
2.
the motor connectorand glasspositionswitchconnector.
Disconnect
NOTE:When removingthe motor,detachthe connectorfrom the frame,removethe bolts and nuts,then removethe
motor.
3.
Removethe glass{seepage20-52).
4.
Disconnect
the draintubes,and detachthe ceilinglight harness.
5.
Removethe frame mountingbolts.
NOTE;
. An assistantis helpfulwhen removingthe bolts.
. Removethe front boltslast.
6.
Detachthe rearhooksby movingthe frameforward,then removethe frame.
BOLT
6x1.0mm
9.8 N.m {1.0kgt m,
7.2 tht.hl
6x1.0mm
9.8 N m (1.0kgl.m,7.2lbtft)
20-54
Assembly
GuideRails/Cable
L
Replacement
7.
Pullthe draintubesout the front and rearpillars.
CAUTION: Put on gloves to protect your hands,
NOTE:Beforepullingout the draintube,tie a string
to the end of it so it can be reinstalled.
1.
Removethe frame.
Removethe motor and glassbracket(seepage20-52).
Removethe nuts, and lift off each guide rail, then
removethe cableassemblywith slidersattached.
NOTE:Take care not to bend the cable tubes and
guide rails.
L
Installationis the reverseof the removalprocedure.
NOTE:
. Beforeinstalljngthe frame,clearthe drain tubes
and drainvalvesby usingcompressedair.
. Checkthe frameseal.
. Cleanthe surfaceof the frame.
. When installingthe frame, first attach the rear
hooksinto the body holes.
. When connectingthe draintube, slide it over the
frame nozzleat least10 mm (0.39in.).
. Installthe tube clip as shown.
Upward
I
I
I
GROMMET
Installation
is the reverseof the removalprocedure.
NOTE:
. Oamagedpartsshouldbe replaced.
. Greasethe slidingportionwith SuperHighTemp
UreaGrease,P/N08758- 9002.
. Fillthe groovein eachgrommetwith sealant.
TUBECLIP
DRAINTUBE
Checkfor water leaks.
NOTE:Do not use high-pressure
water.
a Installthe frame sealsecurely.
a Beforeinstallingthe motor. make sure both slid-
ers are parallel.
Beforeinstallingthe motor. installthe frame and
glass,then checkthe openingdrag (seepage20-
Ity
20-55
Moonroof
Switch Plate Adjustment (Fully Closed Positionl
1.
Removethe headliner{seepage20-64).
2.
Usingthe moonroofwrench,closethe glassfully.
NOTE:Checkthe glassfit to the rool panel.
3.
Usingan open-endwrench,loosenthe switchplatemountingbolts.
4.
Adjustpositionof the switchplate(switchcam)as shown.
5.
Checkthe operationof the glass(from tilt-up positionto fully closedposition,from the fully open positionto the fully
closedposition)by operatingthe moonroofswitch.
NOTE:Checkthe glassheight(seepage20-51).
SWITCHPLATE
GUIDE
PLATE
CAELEBRACKET
SWITCH CAM
INNER CABLE END
While moving the switch plate little bv little, secure the switch
plate at the position where the switch cam contactsthe switch
a (a faint click is heard).
Close the glass fully, and check for water leaks.
NOTE: Do not use high-pressurewater.
20-5 6
OpeningDrag Check
{Motor Removed)
Closing ForceCheck
(Motor Installedl
Beforeinstallingthe motor, measurelhe effort required
to openthe glassusinga springscaleas shown.
' 1 . A f t e r i n s t a l l i n ga l l r e m o v e dp a r t s ,h a v e a h e l p e r
hold the switch to closethe glasswhile you measure the force requiredto stop it. Attach a spring
scaleas shown. Readthe forceas soon as the glass
stops moving,then immediatelyreleasethe switch
and springscale.
CAUTION: When using a spring scale, pfotest the leading edge ol the glass with a shop towel.
lf load is over 40 N (4 kgf,9 lbf),checkthe side clearance
a n dg l a s sh e i g h t( s e ep a g e2 0 - 5 1 ) .
SHOPTOWEL
CAUTION: When using a spring scale, protect the
lerding edge ol the glasswith a shop towel.
Closing Force:200 - 290 N
(20 - 30 kst, 44 - 66 lbfl
SCALE
installa new
lf the torce in not within specification,
lockwasher,adjustthe tensionby turnangthe motor
c l u t c h a d j u s t i n gn u t , a n d b e n d t h e l o c k w a s h e r
againstthe motor clutchadjustingnut.
LOCK
WASHER
Replace.
COUNTER.
cLocKwrsE
l,e
To decrease
20-57
Interior
Component Location Index
SRScomDonentsare locatedjn the partsareasmarkedwith an asterisk(*). Reviewthe SRScomponentlocations,precau
tions,and proceduresin the SRSsection{24)beforeperformingrepairsor service.
2Dl3Dl4Dl
CENTERPILLAR
UPPERTRIM
{seepage20 591
CENTERPILLAR
LOWERTRIM PANEL
(seepage20-59)
FRONTPILLAR
TRIM
{ s e ep a g e s2 0 5 9 , 6 0 , 6 1 )
REARROOFTRIM
(seepage20-65)
HEADLINER
Replacement,
Page20'64
REARPILLAR
TRIM
{seepage20 59}
:
REAR
lseepage20 59)
TRUNK
TRIM
(seepage 20-62)
*OASHBOARO
ComponentRemoval/lnstallation,
page 20 68
Removal,page20-70
SEAT
SIDETRIM
{seepage20-59)
*CARPET
page20 66
Replacement,
REARTRIM PANEL
lseepage20-62)
PANEL
page20-67
Replacement,
3D:
REARSIDE
SHEI-F
(seepage 20-60)
2Dl
OUARTER
TRIM PANEL
(see page20-60)
HATCH
SIDETRIM
(seepase 20 63)
OUARTER
TRIM PANEL
{seepage20'61)
REARROOFTRIM
(seepage 20 65)
SIDETRIM PANEL
(seepage20-6'l)
REARROOF
TFIM
(seepage20'65)
HATCH
UPPER
TRIM
lseepage20 63)
CENTER
SHELF
lseepage20 60)
REAR
PANEL
lseepage20 60)
HATCH
TRIM PANEL
(see page 20-63)
20-54
SIDETRIM
{seepage20 60)
SIDETRIM
PANEL
(seepage20-60)
REAR
PANEL
(seepage20 62)
1
InteriorTrim
t
Replacement
CAUTION:
. Put on gloves to protect your hands.
o When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:Takecarenot to bendor scratchthe trim and panels.
4D:
>: Clip locations
a>,2
B>,6
r*'" nt-lt't
\wi,
i
'\tl
l
o>,2
c >,2'l
l /
E> , 2
_tr* @,
CENTERPILLAR
TRIM
UPPER
REARPILLAR
TRIM
REARSHELF
LOCKCYLINDERTRIM
tl'
I
E'
v
BELTUPPER
ANCHOR
(seepage20-85)
Disconnect
the
high mountbrake
lrghtconnector.
T SIDE TRIM
Removethe rearseatcushionand rear
seatsidebolsterlseepage20-19]'.
k"si
fEFT KICK
PANEL
)
lnstallationis the reverseof the removalprocedure.
NOTE:
. lf necessary,
replaceany damagedclips.
. Beforeinstallingthe front seat belt upperanchor
and rear shelf.make sure there are no twists or
kinksin the seatbelts.
(cont'd)
20-59
lnteriorTrim
Replacement(cont'dl
3D:
>: Clip locations
A>,2
CLIP
nt-.l
'"'\R\
I
I
")!
F >, lil
c >,8
^
B>,3
N;
o>,3
l
E> , 8
l
l
#, A@
s,4, ffi;T
"xe
F
Y *"0
\
I
"4"
\
s
o>,2
l@@
\---
REARSIDE
SHELF
B
FRONTPILLAR
TRIM
E
c>,1
H>,2
G>,2
>: Screw, bolt locations
8>,6
A>,3
V
t
SIDETRIM
PANEL
and
Removethe rearseat-back
rearseatcushion(seePage20_80)
the rearspeaker
Disconnect
connector(bothsides,
for somemodels).
FRONTSEAT
BELTUPPEB
ANCHOR
lseepage20 86)
REARTRIM
PANEL
SIDETRIM PANEL
PROTECTOR
PIVOT BRACKET
{seepage20-80)
q
lnstallationis the reverseof the removalprocedure
RIGHTKICK
PANEL
LEFTKICK
PANEL
20-6 0
NOTE:
replaceany damagedclips'
. lf necessary,
. Beforeinstallingthe anchorbolts,makesurethere
are no tlvistsor kinksin the seatbelts'
I l
2Di
>: Clip locations
a>,2
>i Screw location3.4
c>,14
8>,3
D> , 3
E>,2
CLIP
nJ
'.'rI\ZI
1\f-
F>,8
G>,4
TRIM
H>,2
N 4'dr
FRONTPILLAR
SIOETRIM PANEL
Removethe rearseat-back
and
(seepage
rearseatcushaon
20-a1l.
REARSHELF
\t,
FRONTSEAT
BELTUPPER
ANCHOR
Disconnect
the high
mountbrakelight
SIDETRIM
SEATBELT
LOWERANCHOR
(seepage20-86)
€'
/>"
RIGHTKICK
)
v
PANEL
Installationis the reverseof the removalprocedure.
.h,
't6d
\ r \
LEFTKICK
PANEL
NOTE:
. lf necessary,
replaceany damagedclips.
. Beforeinstallingthe anchorbolts and rear shelf,
makesurethere are no twists or kinksin the seat
belts.
20-61
TrunkTrim
Replacement
CAUTION:
. Put on gloves to proteci your hands.
. When prying with a flat-tip screwdriver,wrap it with protestive tap€ lo prevent damage.
NOTE:
. Takecarenot to bend or scratchthe trim and panels.
. When removingthe trunk sidetrim or trunktrim panel,fold the seat-back
forward.
Japan-produced:
4D:
REARTRIM
PANEL
RIGHT
TRUNK
SIDETRIM
>: Cliplocations
a>,6
NOTE:Do not push
the innerclip in too far.
I
|
/
|NNER
crLP
B> , 6
I J
-\--
'
\\-
B
/'/
^
l#srq-'
1
,-
g cLlP
LTro
--
i ) :Hook locations
TRUNKMAT
A i--), r
' 2D:
a : - ), 2
TRUNK TRIM
(
Installationis the reverseof the removalprocedure.
NOTE:
. lf necessary.
replaceany damagedclips.
. To installthe A clips.pull the innerclip up. install
the clip,then pushthe innerclip until it's flush.
20-62
HatchTrim
Replacement
CAUTION:
. Put on gloves to protect your hands.
. When prying with a flat-tip screwdrivel, wrap it with protestive tape to prevent damage.
NOTE:Takecarenot to bendor scratchthe trim and panel.
>:Clip locations
a>,2
NOTE:Donotpushth
l n n e rc l i p i n t o o f a r .
& ct-tp.
54d-
g + - \
2.
INNF
"
Ijy.\\
\-s
.V
ft
- k-"i-t-;-a-
a
LEFTHATCH
SIDETRIM
HATCH
TRIM
UPPER
Installationis the reverseof the removalprocedure.
NOTE:
. lf necessary,
replaceany damagedclips.
f luuns thi l
. T o i n s t a l l t h e A c l i p s , p u l l t h e i n n e r c l i p u p . i n s t a l l t h e c l i p , t h e n p u s h t h e i n n e ri ct 'lsi p
I
20-63
Headliner
Replacement
CAUTION: When prying with a flat-tip screwdriver,
wrap it with proioctiva tap€ to prevsnt damage.
2.
Removethe sunvisorand holderfrom eachside.
>: Screwlocations,4
-A-,-
NOTE:
. Takecarenot to bend and scratchthe headliner.
. B e c a r e f u ln o t t o d a m a g et h e d a s h b o a r da n d o t h e r
i n t e r i otrr i m .
1
'1. Remove:
4D:
. Frontpillartrim (bothsides.seepage20-59)
. Centerpillarlowertrim panel(bothsides,seepage
20 59)
Upper anchorbolt from the front seat belt (both
sides,seepage20-85)
Centerpillaroutertrim and centerpillaruppertrim
(bothsides,see page20-59)
a Ceilinglight (seesection23)
a Rearviewmirror (seepage20-25)
3.
Remove the grab handles and coat hanger.
ACCESS
Lto
3D:
. Frontpillartrim (bothsides,see page20-60)
. Right rear seat-backand rear seat cushion (see
page20-80)
. Rearcentershelf(seepage20-60)
. R e a rs i d e s h e l fa n d s i d e t r i m p a n e l( r i g h ts i d e ,
see page20-60)
. Upper anchorbolts from the front and rear seat
belts(rightside.see pages20-86,89)
. Ouartertrim panel(rightside,seepage20-60)
. C e i l i n gl i g h t( s e es e c t i o n2 3 )
. Rearviewmirror (seepage20-25)
2Dl
. Frontpillartrim (bothsides,see page20-51)
. Right rear seat-backand rear seat cushion (see
p a g e2 0 - 8 1 )
Sidetrim panel(rightside,seepage20-61)
a Upper anchorbolt from the front seat belt (right
side,seepage20-86)
a Ouartertrim panel(rightside,see page20-6'l)
a Ceilinglight (seesection23)
Rearviewmirror (seepage20-25)
20-64
^
scREws
COATHANGER
BRACKET
COATHANGER
t2D/3Dl
ACCESS
LID
SCBEW
4.
Remove the rear roof trim and clips, and remove
the roof trim and socket plug (moonroof model).
2D:
>: Clip locations
'l
A> 2DllD,7
B > With moonroof,
Without moonroof,3
3D.5
[ i l ' , f E l
':: t%
.l €E
=,/
_._-
,/
.l
2D l3D l4Dl
REARROOF
OUARTER
IRIM PANEL
TRIM
3D:
REARROOF
TRIM
5.
4D: Lowerthe rearpillartrim on both sides
3D: Removethe upper anchor bolts from the front
and rearseat belts(seepages20-86,89),then lower
the quartertrim panelon left side.
2 D : R e m o v et h e u p p e r a n c h o rb o l t f r o m t h e f r o n t
seat belt (see page 20-86),then lower the quaner
trim panelon left side.
6.
Lowerthe headliner.
7.
Carefullyremovethe headlinerthroughthe passenger'sdoor opening(2Dl4D)or hatchopening(3D).
8.
Installationis the reverseof the removalprocedure.
NOTE:
. When insertingthe headlinerthrough the opening, be carefulnot to fold or bendit. Also,be careful not to scratchthe bodY.
. C h e c kt h a t b o t h s i d e s o f t h e h e a d l i n e ra r e
securelyattachedto the trim.
. W h e n i n s t a l l i n gt h e r o o f t r i m , i n s t a l lt h e j o i n t
towardthe right side (moonrootmodel)
t
20-65
Carpet
Replacement
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions,
and proceduresin the
SRSsection{24}beforeperformingrepairsor service.
1.
2.
4.
Removethe tootrestand parkingbrakelevermounting bolts,and detachthe clips,then removethe car
pet.
>:Clip localions,3
Remove:
. Frontseat(seepage2O-7
4l
. Rearseatcushion(seepages20 79,80, 81)
o Kickpanel(seepages20-59,60,61)
o Centerpillarlowertrim paneli4D,seepage20-59)
. Frontseatbelt iower anchor(2Dl3D,seepage2086)
. Sidetrim (seepages20-59,60,61)
o Frontand rearconsoles
. C o n s o l ep a n e l
:ft
\
/
l
>: Bolt locations
A>.2
A>,2
l6x10mm
3
e2
H
::a
)
/
9.8N.mr1.okgr'm,
Y
E / 7.2tbtrtl
2Dl3Dl4D:
FOOTREST
Removethe SRSunit covers.
3 . Cut areas@ and @ in the carpet,then pull it backas
snown.
>: Clip locations,2
-lM- lI
lMt
ry-l
LEFTSRS
UNITCOVER
2D I3D:
SIOETBIM
5.
Installationis the reverseof the removalprocedure.
NOTE:
. Takecarenot to damage.wrinkleor twist the carpet.
. Makesurethe wire harnesses
are routedcorrectly.
. lf necessary,
replaceany damagedclips.
. Slip the carpet under the seat side trim (4D) or
sidetrim panel(2Dl3D)on eachside properly.
. Reattachthe cut areas@ and @ in the carpet
with wire ties.
20-66
Panel
Consoles/Console
Replacement
NoTE:Takecarenottoscratchthefrontandrealconso|es,frontseatandre|atedparts.
in numberedsequence
Disassemble
>: Screw locations
B>,4
a>,8
>: Clip locations
B>.2
A>,2
'
nnffir
"=)
:)
:__)
€] FRONTCONSOLE
Remove the shift lever knob (M/T)
REABCONSoLE
::r_l
(witharmrest)
lnstallationis the reverseof the removalprocedure
NOTE:
replaceany damagedclips.
. lf necessary,
are not pinched.
. Makesurethe wire harnesses
. Makesurethe connectoris connectedproperly.
{
.
I
I
20-67
Dashboard
ComponentRemovaUlnstallation
CAUTION: When prying with a flat-tip screwdriver,
wrap it with protoctivo tape, and apply protective tape
around tho r6lat6d parts, to prevent damag6.
NOTE:Takecare not to scratchthe dashboardand related
pans.
Instrument Danelremoval:
1.
Lowerthe steeringcolumn.
Removethe screws,and detachthe clips,then carefully removethe instrumentpanel.
>: Screwlocations,2
>: Clip locations,2
.il
^ l
@sl
Pt)_ i_ ,/
:)
|
Driver'sdashboardlower cover and knee bolster removal:
SRScomponentsare locatedin this area.Reviewthe SRS
componentlocations,precautions.
and proceduresin the
SRSsection(24)beforeperformingrepairsor service.
'1.
R e m o v et h e s c r e w s ,a n d d e t a c h t h e c l i p s , t h e n
r e m o v e t h e d r i v e r ' s d a s h b o a r dl o w e r c o v e r . l f
equippedwith power mirrorsand moonroof,disconnectthe connectors.
>: Screw,boh loc.tions
A>.3
B>,2
_
-rri
*\Y
_-_- J
I
/a_6x1.0mm
@{[) s 8 N'mtt o rst'm,
\J- 7 2_rbtftl
_
-_
>: Clip locations
A>.2
B>, 1
tu
PANEL
3.
Installationis the reverseof the removalprocedure.
DRIVER'S
DASHBOARD
LOWER
COVER
Removethe bolts,then removethe kneebolster.
Installationis the reverseof the removalprocedure.
20-6 8
Glove box removal:
Center dashboard lower covel:
Removethe bolts,then removethe glove box.
1.
Remove:
. Driver'sdashboardlower cover
. Glovebox
2.
Removethe screwsand bolt, then removethe center dashboardlower cover.Disconnectthe accessory socketconnector'
>: Bolt locations,2
>i Boh,screwlocations
a>,1
B>'5
A s*o.e-- I
A
@;*;ry'-1'-.J
_e)
Installationis the reverseof the removalproceoure
Side air vent/Side defogger trim removal:
SHOP
TOWET_
TRIM
SIOEDEFOGGER
C a r e f u l l yP r Y r t a t t h e s i d e e d g e ,
then remove it,
HOOKS
SIDEAIR VENT
Removethe driver'sdashboardlower
cover,or oPenthe gloveDox,
then push the cliPsfrom each
opening by hand, and Pull it
o u t . D i s c o n n e c tt h e c o n n e d o r s
LOWERCOVER
HOOKS
3.
Installationis the reverseof the removalproceoure'
(driver'sside).
DASHLIGHTS
BRIGHTNESS
CONTROLLER
CONNECTOR
{forsomemodels)
CFUISECONTROL
MASTERSWITCH
CONNECTOR
(forsomemodels)
(cont'd)
20-69
Dashboard
GomponentRemoval/lnstallation
(cont'd)
Center panel removal:
1.
2.
Remove:
. Centerdashboardlowercover(seepage20-69)
. Radio{seesection23)
Removethe rear window defoggerswitch and hazard warningswitch,then disconnectthe connectors.
5
>: Screwlocations,
fii*
-
>: Cliplocations
B>,3
A>,4
Removal
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforepreformingrepairsor service.
NOTE:
. An assistantis helpfulwhen removingand installing
the dashboard.
. T a k ec a r e n o t t o s c r a t c ht h e d a s h b o a r db, o d y a n d
relatedparts.
1.
Remove:
o Frontand rearconsoles(seepage20-67)
. Consolepanel(seepage2O67),
. Driver'sdashboardlower coverand kneebolster
(seepage20-68)
. Glovebox (seepage20-69)
. Centerdashboardlowercover(seepage20-69i
2.
Lowerthe steeringcolumn (seesection17).
)
CENTER
PANEI.
To avoid accidentaldeplovmentand
@
possible injury, always disconnect the driver's
airbag connector belore lowering the steering column lsee section 241.
rt-xR.
W
I
HAZARD
WARNING
swlTcH
r44
NOTE:To preventdamageto the steeringcolumn,
wrap it with a shoptowel.
"
F.IZ
v l
I
I
Disconnect
the dashboardwire harnessconnectors,
remove the nuts, then move the under-dashfuse/
relay box. Disconnectthe antennalead and moonroof relayconnectors.
SRSMAIN
MOONROOF
DASHBOARDcltPs
3.
Mtx
CONTNOL
CABLE
REAR
wtNoow
OEFOGGER
swtrcH
3.
Disconnect
the air mix controlcable,and removethe
screws,then pull out the centerpanel.
4.
Disconnectthe connectorsfrom the heatercontrol
un i t .
5.
Installationis the reverseof the removalprocedure.
RELAY
CONNECTORS
FRAME
HARNESS
(for some models)
NOTE:
. Makesurethe connectorsare connectedproperly.
. Adjustthe air mix controlcable(seesection21).
ANTENNA
LEAO
DATA
CONNECTOR WIREHARNESS
CONNECTORS
Detach.
20-70
9.8 N.m (1.0 kgf m,
7.2lbt.ltl
Removethe followingpartsIrom the dashboard'
. Driver'sdashboardside cover
dashboardlower cover
o Passenger's
. Dashboardcenterlid
the connectorsand air mix controlcable'
Disconnect
passeneer's
airbas
rhefront
disconnect
M,::;:"lx3T:iJnif:3lilH:fl"*:1::f"*'il;ili"'"
>: Bolt, screw locaiions
A>,7
8xl.25mm
I ,i(\
22 N.m12.2kgt'm,I (!,@
-v,
'"tt:___J
>: Clip locations
B>,1
A>, 1
,{nil Lll
ft#5
L //Hl
lj%u|5 i//Wt
D > ,1
c > ,1
B > ,1
8x125mm
22 N.mt2.2kstm,
16tbf.ftl
@
6x1.0mm
9.8 N.m 11.0kgl.m,
7 2'orftl
- ---//
@
_._J
c>,6
,
,"o
W
qT
W72-t11 7'::--J
I
DASHBOARD
AIR MIX CONTROL
Loosen the bolt.
CONNECTORS
FRONTPASSENGER'S
AIRBAGCONNECTOR
Remove the bolts, then lift and remove the dashboard'
pillar trim'
CAUTION: Use proteqtive plates on the bottom ot the front
(cont'd)
20-71
Dashboard
Removal (cont'd)
7.
lf necessary,
removethe dashboardframefrom the dashboard.
>: Screw localions
a>,21
B>,4
l
^
1
.
It Shl:'
v
Y
/
'
/
\
Olb'
l
\-]1
a: Nut locations,3
ra
6 x '1.0mm
Yi.!i[11"-"'".
>: Clip locations
FRONTPASSENGER'S
OASHBOARD
DASHBOARD
SIDECOVER
BRACKET
Installationis the reverseof the removalorocedure.
NOTE:
. Beforetighteningthe bolts,makesurethe dashboardwire harnessesare not pinched.
a Makesurethe connectors,antennaleadand air mix controlcableare connectedproperly.
20-72
Seatsand Seat Belts
Component Location Index
2Dl3Dl1Dl
ANCHOR
SHOULDER
(4D)
ADJUSTER
(seePage20-85i
REABSEATBELT(2DI4DI
page20-88
Replacement,
page20-91
lnspection,
REARSEATEELTBUCKLE/
BELTTONGUE(2DI4DI
CENTER
(seep6ge 20'90)
FRONTSEATBELT
Replacement,
Pages20 85,86
Inspection,
Page20-91
FRONTSEA
Removal,Page20'74
Replacement,
Page20 75
HarnessWiringand Recline
CableLocations,
Page20-77
Page2O'77
SeatCoverRePlacemenl,
REARSEATt2Dl4Dl
Removal,pages20-79,8'l
page20-82
LatchReplacement,
Seat-back
SeatCover RePlacement,Page20-83
SEAT
FRONT
BELTBUCKLES
{seepage20-87)
3D:
REARSEATBELTBUCKLE/
BELTTONGUE
CENTER
(seePage20'90)
BEARSEATBELT
Replacement,
Page20'89
page20-91
Inspection,
REARSEAT
Removal,page20 80
page20-8?
SeatbackLatchReplacement,
Page20_83
SeatCoverRePlacement,
20-73
FrontSeat
Removal
CAUTION: When prying with a flat-tip screwdriver,wrap
it with protectivetape lo prevent damage.
2.
Lift the driver'sfront seat,then disconnectthe seat
beltswitchconnector.
NOTE:Takecarenot to scratchthe seatcoversand body.
1.
Removethe seat track end cover,then removethe
bolts.
SEAT
BELT
swtTcH
CONNECTOR
SEATTRACK
COVER
)
Removethe headrest.
FRONTSEAT
4.
C a r e f u l l yr e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r
opening.
5.
Installationis the reverseol the removalprocedure.
NOTE:Make sure the connectoris connectedproperry.
SEATTRACK
ENDCOVER
BOLT
8 x'1.25mft
22 N..n 12.2kgl.m,
16 rbf.ft)
8 x 1.25mm
22 N.rn 12,2kgl.m,
16 tbtft)
20-74
Replacement
to prevent damage'
CAUTION: When prying with a flat-tip screwdrivet,wrap it with protective tape
NOTE:
. Takecarenot to scratchthe seatcoversand body
. Removethe front seatthroughthe door openlng'
Driver's:
NOTE:Referto page2O-77for the seatbelt switchharnesswiring location'
PIVOTNUT
8 x 1.25mm
22 N.m l.2.2
16 tbf.ft)
SEATCUSHION
v
l
CENTERCOVER
1 0x 1 . 2 5m m
47 N.m {4.8kgf m,
35 tbt.ft)
10 x 1.25mm
47 N.m {i1.8kgl m,
35 tbr.ft)
INNERSEAT
TBACK
RECLINEADJUSTER
LOWERCAP
d
10 x 1.25mm
47 N.m {4.8 kgf'm,
35 tbtftl
l
RECLINE
WIRE
CONNECTING
To connect,twist 180'
OUTERSEAT
TRACK
Installationis the reverseof the removalprocedure'
8 x 1.25mm
20 N.m 12.0kgf.m,
14 tbt.ft)
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
installedProPerly.
. T o p r e v e n tw r i n k l e sw h e n i n s t a l l i n gt h e s e a t back cover, make sure the materialis stretched
evenlyoverthe Pad.
. Greasethe slidingPortion
RECLINE
KNOB
(cont'd)
20-75
FrontSeat
Replacement(cont'd)
Passenger's(with reclino cablel:
NOTE;Referto page20-77for the reclinecablelocation.
HEADREST
SEAT-BACK
PIVOTNUT
8 x 1.25mm
22 N.m 12,2kgl.m,
tbt.ftt
SEATCUSHION
CENTERCOVER
PIVOT
WASHER
10 x 1.25mm
47 N.m {4.8kgf.m,
3s tbt.ft)
LOWER
CAP
10 x 1,25mm
47 N.m (4.8 kgf.m,
35 tbf.ftl
INNERSEAT
TRACK
RECLINEADJUSTEB
i
RECLINE
COVER
LowER CAP
b
RECLINE
CABLE
x 1.25mm
47 N'm (4.7 kgf.m,
35 tbtftl
SEAT
ruf,
To connect,twist 180'.
lnstallationis the reverseof the removalprocedure.
8 x 1.25mm
20 N.m {2.0kgf.m,
14 rbf.ft)
20-76
NOTE:
. M a k e s u r e t h e b u s h i n ga n d p i v o t w a s h e r a r e
installedproperly.
. To preventwrinkleswhen installingthe seat-back
cover, make sure the material is stretchedevenly
overthe pad.
. Adjustthe reclinecable.
. G.easethe slidingponion.
HarnessWiring and Recline
Cable Locations
Seat Cover RePlacement
NOTE:When installingthe seat cushion,make sure the
seatbelt switchharness,connectorand reclinecableare
fastenedcorrectlyon the seatcushionframe'
NOTE:Take care not to tear the seamsor damagethe
seatcovers.
>: Cliplocations
Driver's:
CAUTION: Put on gloves to protest yout hands'
Seat-backcover removal:
1.
cover'
the hook,and fold backthe seat-back
Release
HEADREST
Releaseall insidesprings,then fold back the seatbackcover.
Passenger's(with lecline cablel:
3. Removethe headrest.
Removethe headrestguide,then removethe seatbackcover.
TRACK
lnst;llationis the reverseof the removalprocedure'
NOTE:To preventwrinkleswhen installinga seatevenly
backcover,makesurethe materialis stretched
and
springs
inside
the
pad
securing
before
over the
hook.
(cont'd)
20-77
FrontSeat
Seat Cover Replacement(cont'd)
Seat cushion cover removal:
4.
1.
Removethe seatcushion{seepages20,75,76).
2.
Removethe clipsfrom underthe seatcushion,then
loosenthe seatcushioncover.
>: Cliplocataons
1 - .v
v
vl
Installationis the reverseof the removalprocedure.
NOTE:
. To preventwrinkleswhen installinga seat cushion cover, make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
UPHOLSTERY
RINGPLIERS
NEW CLIP
SEATFRAME
CUSHION
COVER
3.
Pull backlhe edge of the seat cushioncover all the
way around,then releasethe clips,and remove the
seatcushaoncover.
>: Cliplocations
SEAT
CUSHION
COVER
20-7 A
RearSeat
Removal
theseatcoversandbody.
NOTE:Takecarenotto scratch
4D:
>: Bolt locations
D>'
c>,1
l_):Hooklocations,2
] >mr
b,,***-,,.1*;iffiP-"*'piii::#r-,'-,
@t,
6x1.omm
l1Q-
s.aru.-tr.orer-. I
7.2lbf.ft)
)
E
:-
e"r.o--
s.i N.- ir.olgr.,i
7.2'tJrftl
'/
V
.
se-ri-cusxo"[-6*
>: Cliplocations,14
"@rz,
_
\
EE
E
S
/
_ot
/
v -
RIGHTSEAT
SIDEEOLSTER
2u
2u
CENTEB
PIVOT
BRACKET
SEATCUSHION
SEAT-BACK
Pivot boll conslruction:
SLITS
lnstallationis the reverseof the removalprocedure
ERACKET
PIVOTBOLT
8 x 1 . 2 5m m
22 N m (2.2kgf m, 16lbtftl
Apply liquidthreadlock
NOTE:
belts and
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinksin the rear seat
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushron'
. Makesurethe seat-backlockssecurely.
(cont'd)
. lf necessary,
adiusrthe seat-backlatch(seepage20-82)and seat-back
20-79
RearSeat
Removal(cont'dl
3D:
,.:): Hooklocations,2
>: Bolt locations
A>,6
6xr.omm I
(1.0
':^2
9.8 N.m
ksf.h,i
e
I
>: Clip locations,14
c>,1
B>,1
6x1ommI
@,
E
E )
qr
6x1.0mm
22 N.m {2.2kgf.m,l
tr ,"rrr,n2
,/
SEATCUSHION
STRIKER
Removethe sidet.im
panel(seepage20-60).
6x1.0mm
9.8 N.m (1.0kgI.m,
7.2 tbf.ft)
STRIKER
STBIKER
V
tt
A
CENTER
PIVOT
BRACKET
RIGHT
SEAT-BACK
\---.---
PIVOT
BRACKET
LEFT
SEAT.BACK
Pivot bolt constiuction:
-l:/*- -"
HOOK
TOOTHEO
LOCK
WASHER
BUSHING
Installationis the reverseof the removalprocedure.
PIVOT
Ptvor BoLT BRACKET
I x 1.25mm
22 N.m {2.2kgl.m. 16 lbf.ft)
Apply liquidthreadlock.
NOTE:
. Beioreanachingthe seat-backand seat cushion,make sure there are no twists or kinksin the rear seat beltsand
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seatcushion.
. Makesurethe seat-backlockssecurely.
. lf necessary,
adjustthe strikerand seat-back.
20-ao
2Dt
>: Bolt locations
a>,6
O : Hooklocations.2
6xr.omm
]
9.8N.ml1.Okgf.m,i
,:r:2
ffi
I
g
It
>: Cliplocation3,14
c>,1
B>,1
,r@.'
'----EF-|
6 x r . o m m I \ffz
8r.'r.o--
E
w
7.2rbf.ftl
,r:r",
_)
r
s.eN.mtr.o*gf.m,'
22N.m{2.2kgtm,'
E
)
,
H/
)
SEATCUSHION
SEAT.BACKMAT
vv
PIVOTBRACKET
PIVOTBRACKET
PIVOT
BRACKET
RIGHTSEAT.BACK
,^
Pivot bolt constauctaon:
TOOTHED
LOCK
WASHER
BUSXING
PIVOT
BRACKET
PIVOT BOLT
I x 1.25 mm
22 N.m (2.2 kgt m. 16lblft)
Apply liquidthreadlock.
lnstallationis the reverseof the removalprocedure'
NOTE;
.Beforeattachingtheseat-backandseatcushion,makesuretherearenotwistsorkinksintherearseatbe
centerbelt.
.wheninsta||ingtheseatcushion,sliptheseatbe|tbucklesthroughthes|itsintheseatcushion.
. Makesurethe seat-backlockssecurely
adjustthe seat-backlatch(seepage20-82)and seat-back'
. lf necessary,
20-41
RearSeat
Seat-backLatch Replacement
2Dl4Dl
3D:
R e m o v et h e l o c k c y l i n d e rt r i m , t h e n r e m o v et h e r e a r
s h e l f( s e ep a g e s2 0 5 9 ,6 1 ) .
Pullthe trunk mat awayfrom the seat'back(seepage2080).
NOTE:Takecarenot to bendeachlockrod.
>: Boll, screw locations
a>,2
>: Boh, screw locations
A>,4
6x1.0mm
9.8N.m (1.0kgt.m,
7.2 rbf.ftl
B > ,1
6x1.0mm
9.8 N.m (1.0kgf.m,
7.2 tbl.ft)
B> , 2
/+j
@
V
SEAT"BACK
LOCKCYLINOER
TRIM
LOCK
CYLINDER
.i.-::
LATCHCOVEB
LOCK
RODS
LEFTSEATEACKI-ATCH
Installationis the reverseof the removalprocedure.
NOTE:
. Makesureeachlock rod is connectedsecurely.
. [ / a k e s u r e e a c h s e a t - b a c kl o c k s s e c u r e l ya n d
opensproperly.
. lf necessary,
adjustthe seat-backlatch.
20-82
Installationis the reverseofthe removalprocedure.
NOTE:
. Replacethe releasedclipswith new ones.
. lvlakesurethe seat-backlockssecurelyand opens
properly.
Seat Cover Replacement
CAUTION: Put on glovesto protact your hands,
Installationis the reverseof the removalprocedure.
4.
NOTE:
. To preventwrinkleswhen installlnga seatcushion cover. make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones
NOTE|Takecarenotto tearthe seamsor damagethe seat
covers.
Seat-backcover removal:
2D l4Dl
3D:
1.
Removethe seat-back(seepages20-79,8'1).
2.
L o o s e nt h e s e a t - b a c kc o v e r b y r e l e a s i n ga l l t h e
clrps.
1 . Removethe seat-back(seepage20-80).
coverby releasingall the clips.
Loosenthe seat-back
2.
>: Cliplocations
NOTE:Removethe lock knob, lock collar and latch
cover.
>: Cliplocations
3.
o
o
o
o
o
o
o
SEAT-BACK
COVER
RIGHTSEAT.EACK
LEFTSEAT-BACK
COVER
COVER
Pull back the edge of the seat-backcover all the way
around. then releasethe clios.
>: Clip locations
o
3.
coverall the way
Pull backthe edgeof the seat-back
around,then releasethe cliPs.
>: Cliplocations
SEAT.BACK
COVER
RIGHTSEAT.BACK
Installationis the reverseof the removalprocedure.
NOTE:
. To preventwrinkleswhen installinga seat-back
cover,makesurethe materialis stretchedevenly
overthe pad beforesecuringthe clips.
. Replacethe releasedclipswith new ones.
(cont'd)
20-a3
RearSeat
SeatCoverReplacement(cont'dl
2DI3D:.
Seat side bolstor cover removal {,lDl
1.
Removethe seatside bolster(seepage20-79).
2.
Loosenthe seat side bolstercover by releasingall
the clios,then removeit.
t" I FEF4+#€
a
\
'J)
R-U
------)
,.oflU m
r_rolJr
>: Clip locations
SEATCUSXION
COVER
SEATSIDE
BOLSTER
COVER
3.
Pull backthe edge of the seatcushioncover all the
way around,releasethe clips,and removethe seat
cusntoncover.
>: Cliplocation3
/tD:
Installationis the reverseof the removalprocedure.
NOTE:
. To preventwrinkleswhen installinga seat side
bolstercover,makesurethe materialis stretched
evenlyoverthe pad beforesecuringthe clips.
. Reolacethe releasedcliDswith new ones,
2Dl3Dl
S€at cushion covgr r6moval:
1.
Removethe seatcushion(seepages20-79,80, 81).
2.
Loosenthe seat cushioncover by releasingall the
clips.
COVER
>: Cliplocrtion3
4D:
4.
Installationis the reverseofthe removalprocedure.
NOTE:
. To preventwrinkleswhen installinga seatcushion cover. make sure the material is stretched
evenlyoverthe pad beforesecuringthe clips.
a Replacethe releasedclipswith new ones.
-I
./a
l--lt___)l ) ( .)
Ll!!l^t!!l
1",
RINGPLIERS
UPHOLSTERY
available)
{Commerciallv
NEWCLIP
COVER
SEATFRAME
20-a4
Front Seat Belt
Replacement
CAUTION: Check the front seat belts for damage, and
replacethem it necessary.Be carolul not to damage
them during removal and installation.
Removethe centerpillaruppertrim (seepage20-59)
6.
Removethe shoulderanchoradjuster.
Front seat belt removal (4Dl:
1.
Slidethe front seatforwardfully.
2.
Removethe centerpillar lowertrim panel (seepage
20-59).
3.
Removethe upper anchorcover and lower anchor
cap.
SHOULDER
ANCHOR
8 x 1.25mm
23 N.m {2.3 kgt'm,
17 tbf.ft)
UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgitm,
24 lbf.ft)
Apply liquidthreadlock.
ANCHOR
ADJUSTER
7.
FRONTSEAT
BELT
RETRACTOR
MOUNTINGBOLT
6x1.0mm
9.8Nm(1.0kgf.m.
7.2 tbf.ftl
Installationis the reverseof the removalprocedure
NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page20-91.
. Makesureyou assemblethe washersand collars
on the uDDerand lower anchorbolts as shown.
. Beforeinstallingthe anchorbolts,makesurethere
are no twists or kinksin the front seatbelt.
Upper anchorboh construciion:
UPPER
RETRACTOR
COLLAR
UPPERANCHOR
BOLT
Apply liquidthread
7/1&20UNF
32 N.m (3.3kgl.m.
24 rbl.ftl
1
I
7/16-20UNF
32 N.m {3.3 kgf.m,24lbf.ft}
I
SUSHING
LOWER ANCHOR
CAP
Remove all the anchor bolts and the retractor bolt,
remove the retractor mounting bolt, then remove
the front seat belt and retractor.
(cont'd)
20-85
Front Seat Belt
Replacement(cont'dl
Front seat belt removal (2Dl3Dl:
Lower anchor bolt construction:
SPRING
WASHER
1.
Sljdethe front seatforwardfully.
2.
Removel
. Rearseat-backand rear seatcushion(seepages
20-80,81)
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D . s e e
page20'60)
. Reartrim panel(3D,seepage20-60)
. Sidetrim panel(seepages20'60,61)
3.
Removethe upperanchorcoverand loweranchorcap.
LOWERANCHOR
COLLARS
WASHEBS
LOWER
ANCHOB
BUSHING
UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgI.m,
24 tbf.ftl
Retractorbolt construqtion:
@<-'-.-.-.- ,PPERaNcHoR
RETRACTOR
BOLT
TOOTHED
LocK W\HER
I
)r
llo1r",ffi)
RETRACTOR
MOUNTINGBOLT
6x1.0mm
9.8 N.m (1.0kgt m,
7.2 tbtft)
tv-\y -"\s\,/
tnl
I
LOWEB
ANCHOR
CAP
RETBACTOF
I
I
t
o
RETRACTOR
BOLT
7/16-20UNF
32 N m 13.3kgf m,
24 tbf.ftl
4.
20- 8 6
LOWERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgl m, 24lbtft)
Removeall the anchorbolts and the retractorbolt,
removethe retractormountingbolt,then removethe
front seatbeltand retractor.
5.
Installationis the reverseof the removalprocedure.
Seat belt buckle removal:
NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page20-91.
. Makesureyou assemblethe washersand collars
on the uoDerand lower anchorboltsas shown.
. Beforeinstallingthe anchorbolts,makesurethere
are no twistsor kinksin the front seatbelt.
1.
R e m o v et h e f r o n t s e a tt h r o u g ht h e d o o r o p e n i n g
{seepage20-74).
2.
Removethe centercover(seepages20-75,76).
3.
Removethe centeranchorbolt,then removethe seat
beltbuckle.
SEATBELT
BUCKLE
SPRING
WASHER
INNERSEAT
TRACK
BUSHING
Lower anchor bolt construction:
SPRING
WASHER
4.
BUSHING
COLLARS
ANCHORBOLT
HARNESS 7/16.20 UNF
32 N m (3.3 kgt m, 24 lbf'ft)
CLIP
Driver's:Detachthe seat belt switch connectorand
harnessclip from the seatcushion(seepage20 77).
Removethe seat cushion mounting bolts from the
innerseattrack{seepage20-75),and movethe inner
seattrack,then pull the seatbeltswitchharnessout.
NOTE:Takecarenot to damagethe hingebracket.
Centsr anchor bolt construction:
CENTER
ANCHOR
BOLT
TOOTHEO
LOCKWASHER
WASHERS LowER
LOCKWASHER
LOWERANCHOR
ANCHOR BOLT
Reiractor bolt construction:
TOOTHEO
LOCKWASHER
RETRACTOB
SPRING
WASHER
WASHER
Installationis the reverseof the removal procedure.
NOTE: Make sure you assemblethe washers and
bearingon the centeranchorbolt as shown.
20-47
RearSeat Belt
Replacement
CAUTION:Chack the rear seat belts for damage,and
replacethem if necessary,8e carolul not to damage
lhem during removal and installation.
Rearseat belt removal {2Dl4D}:
1.
2.
Remove:
. Rearseatcushion(seepages20-79,81)
. Rearseat-back(2D,seepage20-81)
. Sidetrim panel(2D,seepage20-61)
. Rearshelf(seepages20-59,61)
. Reartrim panel{seepage20-62}
(seepage20-62)
. Trunksidetrim, Japan-produced
(seepage20-62)
. Trunktrim panel,USA-produced
3.
Installationis the reverseof the removalprocedure.
NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page20-91.
. lvlakesure you assemblethe washersand collar
on the upperanchorbolt as shown.
. Beforeinstallingthe anchorbolt.make surethere
are no twistsor kinksin the rearseatbelt.
Upper anchorboh condruqtion:
Remove all the anchor bolts and retractor bolt, then
remove the rear seat belt and retractor.
UPPERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgf.m,2,1lbtft)
SPRING
WASHER
RETNACTOR
BOLT
7/1F20 UNF
32 N.m {3.3kgf.m,
24 tbt.ft)
Lower anchor bolt construction:
LOWERANCXOR
EOLT
LOWERANCHOR
Retractorbolt construction:
7/16-20UNF
32 N.m {3.3 kgf.m,24lbt.ft)
t7\
l/rn\
.----. A
-nrfi|lH
/7--^,
tr\7-\
/
TOOTHED
LOCKWASHER
20-88
\
R€TRACTOB
\
\
RETRACTOR
BOLT
Rearseal belt removal (3Dl:
4.
1.
Remove:
. Rear seat-backand rear seat cushion (see page
20_80)
. Rear center shelf and rear side shelf (see page
20_60)
. Reartrim paneland sidetrim panel(seepage20
60)
2.
Removethe upperanchorcover
UPPERANCHORBOLT
7/16-20UNF
32 N.m {3.3 kgf.m,2it lblft)
Installationis the reverseof the removalprocedure.
NOTE:
. Checkthat the retractorlockingmechanismfunc
tions as describedon page20-91.
. Makesureyou assemblethe washersand collars
on the upperanchorbolt as shown.
. Betoreinstallingthe anchorbolt, makesurethere
are no twistsor kinksin the rearseatbelt.
Upper snchor boh construction:
COLLARS
UPPER
ANCHOR
RETRACTOR
RETRACTOR
BOLT
7/16-20UNF
32 N.m 13.3kgl.m.
24 tbf.ft)
Lower anchorbolt construction:
REARSEAT
BELT
LOWERANCHOR
LOWEF
7/r6-20UNF
32 N.m {3.3kgl.m. 24 lbf.ftl
3.
Removeall the anchorboltsand retractorbolt.then
removethe rearseatbelt and retractor.
TOOTHED
LOCKWASHER
(cont'd)
20-89
RearSeat Belt
Replacement(cont'dl
Soai belt buckle/Centerbolt tongue removal:
1.
Center anchor bolt construction:
Removethe rear seatcushion(seepages20-79'80,
81).
Removethe center anchor bolts, then remove the
seatbelt bucklesand centerbelttongue.
2Dl4Dl
BELT
CENTER
BUCKLE
TOOTHED
LOCKWASHES
Installationis the reverseof the removalprocedure
NOTE: Beforeattachingthe seat-backand seat cushion,makesurethereare no twistsor kinksin the cen
ter belts.
CENTERBELTTONGUE
3D:
CENTERANCHORBOLTS
7/1$20 UNF
32 N.m (3.3kgt.m,
2/r bl.ftl
CENTENEELT
20-90
Seat Belts
Inspection
3D:
Retractor InsDection
t.
Beforeinstallingthe retractor,checkthat the seatbelt
can be pulledout freely.
ao"
Makesurethat the seat belt does not lockwhen the
retractoris leanedslowlyup to 15'from the mounted
position.The seatbeltshouldlockwhen the retractor
is leanedover40'.
40'- -+
-40.
..'' 15' 15'
(.
\
CAUTION:Do not attempt to disassemblethe retractor.
.-j,
,)
RETRACTOR
*: Mounted Position
Front:
4D:
* 10-
3.
15
15'
i-Tl
I ],f
Forward
Replacethe seat belt with a new one if there is any
abnormality.
On-lhe-CarSeat Belt Inspeqtion
1.
Checkthat the seat belt is not twisted or caughton
anyrnIng.
2.
A f t e r i n s t a l l i n gt h e a n c h o r s c, h e c kf o r f r e e m o v e
ment on the anchorbolts. lf necessary,removethe
anchorbolts and checkthat the washersand other
partsare not damagedor improperlyinstalled
3.
Checkthe seatbeltsfor damageor discoloration.
C l e a nw i t h a s h o pt o w e li l n e c e s s a r y
Inside
2D l3D.
CAUTION: Use only soap and water to clean.
NOTE:Dirt build-upin the metal loops of the upper
anchorscan causethe seat belts to retractslowly.
Wipe the insideot the loopswith a cleanclothdamF
enedin isopropylalcohol.
ForwaJd
lnside
4.
Checkthat the seat belt does not lock when pulled
o u t s l o w l y .T h e s e a t b e l t i s d e s i g n e dt o l o c k o n l y
during a suddenstop or impact.
5.
Makesurethat the seatbeltwill retractautomatically
when released.
6.
For each passenger'sseat belt, make sure that the
l o c k i n gm e c h a n i s mi n t h e s e a t b e l t r e t r a c t o rw i l l
engagewhen the seatbelt is pulledall the way out.
7.
Replacethe seat belt with a new one il there is any
abnormality.
Rear:
2Dl4Di
20-91
Seat Belts
Child Seat Anchor Plate
Attachment points are provided for a rear seat mounted
child restraintsystemwhich usesa top tether.The attachment points are locatedon the rear shelf or rear trim
When usinga child
panel,just behindthe rearseat-back.
seatwith a top tether,installthe child seatanchorplates
securely.
2Dl4Di
NOTE; Remove the plug covers from the attachment
pointsof the rearshelf.
TOOTHEDWASHEB
PLUGCOVERS
NOTE:
Do not removethe toothedwasherfrom the childseat
anchorplate.Usethe child seatanchorplatewith the
toothed washer attachedto it.
When installinga child seat on the rear seat,follow
of the childseat
the instructionsof the manufacturer
Additionalanchorolatesare available.
@
r Do not us6 the child seat anchor plate for any othel
.
REARSHELF
3D:
NOTE: The reartrim panel has perforationsat eachattachment point. Cut the rear trim panel along the perforations
to makea hole.
REARTRIM
PANEL
POINTS
20-92
purposs; it is designedexclusivelytor installation of a
child 3eat.
Make suro the rear seat-back is locked firmly when
installing8 child seat.
Exterior
ComponentLocationIndex
'1996Model
Series,P/N.6150330,forthehood,trunk lid and hatchremoval.
NOTE:Referto the CivicBodVRepairManual,
2Dl30llDl
ROOFMOLOING
Replacement,
page 20-102
SIDEWINDOW
MOLDINGS
LICENSEPLATE
TRIM
Replacement,
page 20-102
Replacement,
page 20-100
HOOD
Adiustment, page 20 96
Hood Edge protector
page20 99
Replacement,
TRUNKLID
Adjustment,page20-97
TolsionBarRemoval,
20 99
TRUNKLID
WEATHERSTRIP
Replacement,
page20-100
REARBUMPER
Replacement,
page2O-95
REARAIR OUTLET
Replacement,
page20-106
FUELPIPE
PROTEfiOR
Replacement,
page20-106
TRIM
FENDERWELL
page20-106
Replacement,
SILLPANEL
R e p l a c e m e n t ,p a g e 2 0 1 0 5
Replacement,
page 20-106
3D:
HATCH
WEATHERSTRIP
HATCH
Adjustment,
page20-98
20-93
Front Bumper
Replacement
CAUTION:Puton glov$ to protectyour hands.
NOTE:
. An assistant
is helpfulwhenremoving
thefrontbumper.
. Takecarenotto scratch
thefrontbumDer
andbodv.
>: golt, screw locations
a>,2
B>,2
>: Clip
locations,
7
i A e r r : o'n'
o r-'e .A l m
L.'*
fl'T;Ll' \€5>_JI
c>,4
,D>,4
| -.6a
l(Dl[m
t'KJ)
8 x 't.25mm
o x 1.0mm
l,Rt
j(Qll@ s.eN.mrr.orsf.m,
22N.n'.t2.2kstnf'.
-ll
16 tbf.ft,
|.
7.2 tbf.hJ
FRONTBUMPERBEAM
FRONTBUMPER
SIDESNFFENER
:l
I ir
ABSORBER
FRONTEUMPER
BEAM
lnstallationis the reverseof the removalorocedure.
NOTE:
. Make sure the front bumper engagesthe front
bumperside stiffeneron eachside securely.
. lf necessary,adjustthe front bumper side stiffener
to obtainthe propergap.
20-94
FRONTBUMPER
SIDESTIFFENER
RearBumper
Replacement
CAUTION: Put on gloveslo protect your hands.
NOTE:
. An assistant
is helpfulwhen removingthe rearbumper.
. Takecarenot to scratchthe rearbumperand body.
. 2D and 4D shown here;3Dremovalproceduresare the sameas 4D.
>: Screw, boll locations
A>,2
B>,4
rtn
,/_-\
>: Clip locations,7
E
. -*E]s-
.A IVilIdfIT*ff
\r*,r/
\
\7
REARBUMPERBEAM
REARBUMPER
Installation
is the reverse
of the removalDrocedure.
NOTE:
. lf necessary,
replace
anydamaged
clips.
. Makesuretherearbumperengages
thesideclipon eachsidesecurely.
20-95
Hood
Adjustment
NOTE:Beforeadjustingthe hood,looseneachbolt slightly.
1. Adjustthe hood hingesright and left,as well as fore and aft, by usingthe elongatedholes.
2.
Turn the hood edgecushions,as necessary.
to makethe hood fit flush with the body at front and side edges.
3,
Adjustthe hood latchto obtainthe properheightat the forwardedge.
4.
After adjustment,tighteneachbolt securely.
)
6x1.0mm
9.8 N.m {1.0 kgt.m,
7.2 tbt.tll
NOTE: Move the hood latch right or left until the striker
is centeredin the hood latchas shown.
6x1.0mm
9.8 N.m {1.0kgf.m,
7.2 tbf.ftl
20- 9 6
TrunkLid
Adjustment
NOTE;Beforeadjustingthe trunk lid, looseneachbolt slightly.
1.
Adjustthe trunk lid hingesright and left,as well as fore and aft, by usingthe elongatedholes'
2.
to makethe trunk lid fit flush with the body at the rearand side edges.
Turn the trunk lid edgecushions,as necessary,
3.
Adiustthe fit betweenthe trunk lid and the trunk lid openingby movingthe striker'
4.
After adjustment,tighteneachbolt securely
TRUNKLIOEDGE
CUSHION
TRUNK LID
TRUNKLIO
NOTE:Takecarenot
to hit the rearwindow
when looseningthe
bolts.
NOTE:Move the strikerright or left until it's centeredin
the trunk lid latchas shown.
9.8 N.m {1.0kgf.m,
7.2lbl.ltl
STRIKER
20-97
Hatch
Adjustment
NOTE:
. Beforeadjustingthe hatch,looseneachbolt and nut slightly.
a The suDportstrutsshouldbe removed.
. To adjust,removeboth hatchsidetrim (seepage20-63)and the rearroof trim (seepage20-65).
1.
Adjustthe hatchhingesright and left,as well as fore and aft. by usingthe elongatedholes
2.
to makethe hatchfit flush with the body at eachside.
Turn the hatchedgecushions,as necessary,
3.
Adjustthe hatchfit to the hatchopeningby movingthe striker.
4.
After adiustment,tighteneachbolt and nut securely.
HATCH
EDGECUSHION
6x1.0mm
9 . 8 N . m ( 1 . 0k g f . m ,
HATCH
HINGE
Rearward
HA
EDGE
CUSHION
j
...
\
\
l0x1
38Nm(3.9kgfm,
2.8 rbf.ft)
22 N.m (2.2 kgf.m,
\,_1q tbf.ftl
HATCH
HINGE
STRIKER
coVER
HATCH
EDGE
CUSHION
NOTE:Move the strikerright or left until it's centeredin
the hatchlatch.as shown.
6x1.0mm
HATCH
LATCH
20-98
9.8 N.m 11.0kst.m,
7.2 tbf.ft)
Front Grille/HoodEdge
Protector
TrunkLid Torsion
Bars
Replacement
Removal
Front grille:
CAUTION:Pui on gloves to protect your hands.
NOTE:Takecarenot to scratchthe front bumper'
NOTE:Takecarenot to damagethe body
Removethe front bumper(seepage20-94)Bemovethe
clips and screws,then slide the front grille forward by
detachingthe hooks.
Removethe torsion barswith the torsion bar assembly
t o o l w h i l eh o l d i n gt h e t r u n kl i d a s s h o w n .
4
>: Screwlocations,
" q L
A
\t+lt
/
FRONTBUMPER
CENTERCLIP
E
Hood edge Ploteetor:
NOTE:
. When removingthe clips,usea cllp remover.
replaceany damagedclips.
. lf necessary,
18
>:Cliplocations,
lnstallationis the reverseof the removalprocedure'
NOTE:
. Adjust the torsion bars fore or aft with the torsion bar assemblYtool as shown
HOODEDGE
ll = NormalPosrtlon
a = Highertensron
'-l o[_]
/A.-
-----,_ ,,, \-
.
Make sure the trunk lid opens properly.
20-99
TrunkLid/Hatch
Weatherstrip
LicensePlateTrim
Replacement
Replacement
When installingthe trunk lid/hatchweatherstrip.align it
with the alignmentmarkon the trunk lid/hatchopening.
CAUTION: Put on glov€s to plotest your hands.
NOTE:Takecarenot to scratchthe trunk lid/hatch.
NOTE:
. Makesurethereare no wrinklesin the weatherstrip.
. Checkfor water leaks.
1.
Removethe licenseplate.
2,
3D: Removethe hatchtrim panel(seepage20-63).
3.
Removethe nutsand clips,and detachthe clip,then
removethe licenseplatetrim.
2DllDi
ALIGNMENTMARK
NOTE:Takecarenot to drop the nutsinsidethe trunk
lid/hatch.
a: Nut locations,2
6fi\5x0.8mm
I
rvr?//1,8N.m{0.18
kst.m,l
j llrftl
,/
>: Cliplocations,
nA
I
aa# )
- , /
WEATHERSTRIP
3D:
ALIGNMENTMARK
Installationis the reverseof the removalorocedure.
STEEI.
CORE
NOTE:lf necessary,
replaceany damagedclips.
ALIGNMENT
MARK (2Dl4D)
BODY
20-100
HatchSpoiler
Removal
NOTE:Takecarenot to scratchthe hatchand body
1.
Removethe hatchuppertrim (seepage20-63)
2.
Removethe nuts, and detachthe clip, then lift the
hatchspoileruP.
4.
removethe spoilertrim from the spoiler
lf necessary.
frame.
NOTE:The hatchspoilertrim for Canadaproduced
carscannotbe disassembled.
>: Cliplocations
A>,4
a: Nut locations,4
1 2lbt.ftl
_
j/
>: Scr€w
GROMMET
HIGHMOUNTBRAKE
LIGHTCONNECTOR
------,*;)
5.
Installationis the reverseof the removalprocedure'
NOTEi
replaceany damagedclips.
. lf necessary,
a M a k e s u r e t h e c o n n e c t o ra n d w a s h e rt u b e a r e
connectedProPerlY.
Disconnectthe high mount brake light connector and
rear window washer tube, then remove the hatch
spoiler.
20-101
SideWindow Moldings
RoofMolding
Replacement
Replacement
CAUTION:Put on glovos to protect your hands.
CAUTION: When prying with a flat-tip screwdriver, wrap
it with protestive taps to prevent damage, and use protoctiv€ tape on the body.
NOTE:
. Takecare not to scratchthe body
. Removethe screw,and pull th€ sidewindow molding
by hand.
NOTE: Take care not to scratchthe bodv.
>: Cliplocations
A>,13
K
WINDSHIELO
MOLDING
>: Screw locations,
PIN
lBody side)
I
)
1 l
*@
)
A
Installation
is the reverseof the removalprocedure.
MOLOING
Installationis the reverseof the removalprocedure.
NOTE:lf necessary,
replaceany damagedclips.
20-102
NOTE:
. Takecarenot to damagethe windshieldmolding.
. Makesurethe roof moldingis installedsecurely.
Doorand SideMoldings
Replacement
prevent damags'
CAUTION: When prying with a flat-tip scr6wdrivgr,wrap it with protective tape to
NOTE;
. To removethe front side molding,removethe innerfender(seepage20-106)'
. To removethe door moiding,removethe door panel(seepages20-4,10,16)and plasticcover.
. To removetherearsidemolding,removethe sidetrim panel(seepages20-60,611'
. Takecarenot to bendthe door moldings.
cleanthe door bondingsurfacewith a spongedampenedin alcohol'
. Beforereassembling,
. After cleaning,keepoil, greaseand water from gettingon the surface'
. lf necessary,
replaceany damagedclips.
4D:
FRONTDOOR
MOLDING
Adhesiveareas.
2Dl3Dl
REARSIDE
MOLOING
>: Cliplocations
A >: 4D,11
2')13D,7
a: Plasticnut loc€tion. 1
B>,3
c>,2
@)
(cont'dl
20-103
Doorand SideMoldings
Replacement(cont'dl
Door molding removal:
Door molding installation:
The following materialsand tools are requiredto repair
the door moldings.
1.
NOTE:Followthemanufacturer's
instructions.
Materials:(Reference)
. Striperemover
3M 08907
Stripeadhesiveremover
3M 08908
Adhesivetape
3M SuperAutomotiveAttachmentTape
Tools;
a Protective
tape
. Knifeor Cutter
. Spongeor Shoptowel
. Infrareddryer
.
.
.
Film
Putty knife
Alcohol
G l u e t h e n e w a d h e s i v et a p e t o t h e m o l d i n g sa s
snown.
[\\\\\\l
: Adhesive tape tocations
60 mm
t2 t i^l
4D:
40 mm
1 1 . 6i n )
Forward
L
REARDOOR
CLIP
HOLDER
2Dl3Dl
CAUTION: Put on gloves to protect your hands,
100mm
(3.94inl
1,050mm 141.34
inl
1 . Removethe door panel, and pull back the plastic
cover,
Forward
Apply protectivetape on and aroundthe molding.
!
DOORMOLDING
DOORMOLDING
5 mm {0.2inl
ADHESIVETAPE
Thickness:1.2 mm 10.05in)
3.
Releasethe clips from insideof the door. Carefullv
cut the adhesivetape with a knife or cutter while
pullingthe edgeof the moldingaway trom the door
as shown.
NOTE:Take care not to scratchor bend the mold-
Installthe
c l i p so n t h e m o l d i n g .
H e a t t h e b o n d i n g s u r f a c eo f t h e d o o r a n d d o o r
moldingwith an infrareddryer.
Door:
104- 140"F(40- 60.C)
Molding:68 - 86"F(20- 30.C)
Ing.
NOTE:Use carewhen heatingto preventdeformation of the molding.
KNIFE
Align the molding with the clip locations,and set
the molding. Lightly push on the molding until its
edgeis fully seatedon the adhesivetape.
NOTE: Do not spray water on the motding within
the first 24 hoursafterinstallation.
DOORMOLDING
20-104
Reassemble
all removedpans.
SideSill Panel
Replacement
NOTE:
. Takecarenot to scratchthe body
. 4D shown here;2Dand 3D removalprocedureis the sameas 4D'
>: Screw locations,4
W_1
NOTE:Loosenthe screw,
then removethe lowercliP
usinga clip remover.
SIDECLIP
Removethe sidecliPsfrom the body
by turningthem 45"
\
NOTErWhen removingthe side
sill panel,the sideclipswill
stayin the body.
SIOESILLPANEL
Removethe lowercliPs,
then removethe sidesill Panel
by sliding it forward.
To installthe side sill panel,removethe sideclipsfrom the body. installthem on the sidesill
panelon the car.
panel,then installthe sidesill
NOTE:
. Takecarenot to twist the sidesill panel.
replaceany damagedsideand lowerclips'
. lf necessary,
20-105
Inner Fender,Fenderwellrrim, FuelPipeprotectorand Rear
Air Outlet
Replacement
NOTE:lf necessary,
replaceany damagedclips.
Innertender:
>: Screwlocations,4
r\
tllpo"
l
: , /
>: Cliplocations,7
Fenderwelltrim/Fuel pipe protector/Rea. air outlet:
NOTE:
. Takecarenot to bendthe fenderwelltrim.
. Beforelnstallingthe fenderwelltrim, cleanthe body
b o n d i n gs u r f a c e
w i t h a s p o n g ed a m p e n e di n a l c o h o l .
. Aftercleaning,keepoil, greaseor waterfrom gettingon
the surface.
. To removethe fuel pipe protector,first removethe rear
wheel(seesection18).
. To remove the rear air outlet, first remove the rear
bumper(seepage20 95).
STEEL
20-106
FENDERWELL
>: Clip locations
A>,4
c>,2
B>,4
I
t'frv
Ah
l;1A
!--l1!
+
\:
and Latch/Wiperand Washer
OpenerCable/Opener
ComponentLocationIndex
2Dt3DItD'
o*t"
y"Tl,"nll,ib?*'r.*
LOCKCYLINDER
TRUNKLIOLATCH
{ s e ep a g e2 0 1 1 2 )
13
Replacement,
Page20_1
Adiustment,Page20'117
WINDSHIELD
WASHERNOZZLES
A d j u s t m e n t , P a g e 2 0 _ 11 7
HOODLATCH
{seepage20-110)
FUELLIDOPENER
CABLE
(seepage20-108i
LID OPENER
CABLE
(seepage20 108)
LID/FUEL
LIDOPENER
( s e ep a g e2 0 1 1 1 )
RELEASEHANDLE
(seepage20-110)
3D:
REARWINDOWWIPER
ARM and MOTOR
Replacement,
Page20-115
Adjustment,page20 117
REARWINDOW
NOZZLE
WASHER
page20-1
17
Adiustment,
REARWINDOW
WASHERTUBE
(seepage20-116)
WASHERRESERVOIR
Replacement,
Page20-115
HATCH/
FUELLIDOPENER
(seepage20 1'11)
FUELLIDOPENER
CABLE
(seepage20 110)
HATCHOPENER
CABLE
(seepage20 110)
( s e ep a g e 2 0 1 1 1 )
LOCKCYLINDER
(seepage20 113)
20-107
OpenerCables
Replacement
NOTE:
t When removingthe clips.use a clip remover.
. Takecarenot to bendthe openercables.
Hood op€ne. cable:
NOTE;Removethe front bumper (see page 20-94)and
innerfender(seepage20-106).
g
ry)
>: Clip loc.tions
A>,5
B >, 1
HOODREI.TASE
HANDI.I
(seepage20-110)
Tlunk lid/Fuel lid opener cabte (2Dl4D):
NOTE:Removethe following partsfrom rhe Ieft side of
the vehicle,then pull the carpetback,as necessary{see
page20-66).
.
.
.
.
o
.
.
.
.
.
.
.
Rearseatcushion(seepages20-79,81)
Rearseatside bolster(4D,seepage20,79)
Rearseat-back(2D,seepage20-81)
Centerpillarlowertrim panel(4D,seepage20-59)
Lower anchor bolt from the front seat belt {2D. see
page20-86)
Sidetrim (seepages20-59,61)
Seatsidetrim (4D,see page20-59)
Sidetrim panel(2D,seepage20-61)
Trunk mat and sparetire lid
Reartrim panel(seepage20-62)
(seepage20-62)
Trunksidetrim, Japan-produced
Trunktrim panel,USA-produced
(seepage20-62)
>r Clip, cable cushion locations
A >,4
B > , 4 D _1
2D,2
_
#lB
D>,3
:
_/
_-___)
E > , 4 D ,1
2D,2
@ i
_
cablethroughthe
hotein th6body.
Installationis the reverseof the removalprocedure.
NOTE:
a Make sure the hood openercable is routed and
connectedproperly.
. Makesurethe hood opensproperly.
20-10a
_,,
-/
c >, 1 l4D)
t@
TRUNK LID LATCH
(seepage20'112)
?e-=....-
4D:
To trunklid
latch.
TRUNKLID/FUEL
LID OPENER
( s e ep a g e2 0 1 1 1 )
latch.
a
A
\-
'--!
-
-l
TRUNKLID
OPENERCABLE
N"La
FUEL
FUELLID
OPEN€RCAELE
TRUNKLID/FUEL
LID OPENER
(seepage20-111)
LATCH
(seepage 20'112)
(cont'd)
20-109
OpenerCables
Openerand Latch
Replacement(cont'dl
Replacement
Hatch/Fuellid opener cable l3Dl:
NOTE:Takecarenot to bendthe openercables.
NOTE:Removethe following parts,then pull the carpet
backas necessary(seepage20-66).
Hood releasehandle:
.
.
.
.
.
.
.
Rearseatcushionand rearseat back(seepage20-80)
Lower anchorbolt from the front seat belt (seepage
20 86)
Sidetrim {seepage20-60)
Sparetire lid
Rearcentershelfand rearsideshelf{seepage20-60)
Reartrim panel(seepage20-60)
Sidetrim panel(seepage20,60)
>: Clip,cablecushionlocations
a>.9
B > ,1
c>,1
#,
NOTE:Removethe kickpanel(seepages20-59,60.61).
>: Bolt locations, 2
]
I
6 x 1 . 0 m mj
9.8Nm
{1.0kgf.m, i
HOOOOPENER
CABLE
(seepage20-108)
D> , 5
W#)
Hood latch:
Routethe opener
cablethroughthe
hole in the body.
FUEL LID LATCH
page20-112)
NOTE:Removethe front bumper(seepage20-94).
>: Eoltlocations,
3
6 x '1.0mm
I
9.8N.m
11.0kgf.m,
HATCH/FUEL
LIO
OPENER
Installationis the reverseof the removalprocedure.
NOTE:
. Make sure each openercable is routed and connectedproperly.
. Makesurethe hatchand fuel lid open properly.
20-110
Installationis the reverseof the removalprocedure.
NOTE:
. Makesurethe openercableis connectedproperly.
. M a k e s u r e t h e h o o d o p e n s p r o p e r l ya n d l o c k s
securely.
Trunk lid or Hatch/Fuellid opener:
Striker(3Dl:
N O T E :R e m o v et h e s i d et r i m ( s e ep a g e s2 0 5 9 , 6 0 . 6 1 )
NOTE: Removethe reartrim panel(seepage20-60)
>: Boll locations,2
a@-\
6xl.0mm
9.8Nm
11.0kgf.m,
7.2 tbl.ttl
OPENERLOCK
CYLINDER
>: Bolt locations, 2
Ya//t2't4Dl
ti
6xl.0mm
HATCH
CAELE
OPENER
(seepage20-110)
l:'.j
TBUNK LID/HATCH
OPENERCABLE
(see
2 0 - 1 0 81,1 0 )
To trunklid latch
or striker.
To fuel lid latch.
\
lnstallation is the reverse of the removal procedure.
FUELLID
OPENERCABLE
(seepages20-108,'110)
NOTE:
.
.
sure each openercableis connectedProPN4ake
erlY.
M a k e s u r e t h e hatch opens properly and locks
securelY.
Installationis the reverseof the removalprocedure
NOTE:
. lvakesurethe openercableis connectedproperly.
. M a k es u r et h e t r u n kl i d o r h a t c ha n df u e l l i d o p e n
properly.
(cont'd)
20-111
Openerand Latch
Replacement(cont'd)
Fuel lid latch:
Trunk lid latch/Lock cylinder:
NOTE:Removethe followingpa(s.
2Dl4Dl
.
.
>: Bolt locations
A>,3
Reartrim panel(seepage20-62J
Rear edge of the trunk side trim or trunk trim panel
(leftside,see page20-62)
6x1.omm
9.8 N.m (1.0kgf.m,
:::^
3D:
8>, 1
i
_=)
m
f f er t . o m
(1.0
ZS
.ty
9.8N.ln
7.2-tbr.ftt
kgt m,
I
,/
CYLINOER
.
Accesspanelon the sidetrim panel
>: Eolt locations,2
|
r'-\ 6x10mm
(1.0
9.8 N.m
kgf.m, I
FUEL I-IO LATCH
TRUNK LID
OPENER
TRUNKLID
LATCH
CYLINDER
ROD
FUELLID
After installingcheckfor
a flushfit with the body.
CONNECTOR
Disconnect.
-\
I
I
TRUNK LID
OPENER
CABLE
FUELLID OPENER
CABLE
(seepages20,108,1'10)
FUELLID LATCH
Removethe fuel lid latch
by turningit 90o
Installation
is the reverse
of the removalprocedure.
NOTE;
o Makesureeachopenercableis connected
prop.
elty
Make sure the fuel lid opens properlyand locks
securely.
20- 1 1 2
Installationis the reverseof the removalprocedure.
NOTE:
. Greasethe trunk lid latch.
. Makesurethe trunk lid opensproperlyand locks
securely.
a M a k e s u r e t h e c o n n e c t o ra n d c y l i n d e rr o d a r e
connectedproperty.
WindshieldWiperArms
and Linkage
Replacement
Hatch latch/Lock cylinder:
CAUTION: Pul on gloves to protect your hands
NOTE:Removethe hatchtrim panel(seepage20-63).
NOTE:Takecarenot to scratchthe hood and body.
1.
>: Bolt locations
A>,3
Removethe windshield wiper arms, then remove
the hood sealand cowl cover.
B>,1
6x1.0mm
I
E
ksfm,l
6
'cr 9.8N.mi1.0
6;:il;l,lr'.",
1.2lbl.trl
/
>: Clip locations
B>,9
A>,9
WINOSHIELD
WIPERABMS
10 x 1.25mm
18 N.m ll.8 kgf m,
CYLINDER
Hw
u
\j:_
.r\
cowl covER
-
r€\
L^\
!
rAs<.L ,/
LOCK
cYLTNDER
./
\faa"El
rl
Disconnectthe connector,then remove the windshieldwiper linkageassemblY.
Japan/Canada-produced:
lnstallationis the reverseof the removalprocedure.
NOTE:
. Greasethe hatchlatch.
. Make sure the hatch opens properly and locks
securely.
. Makesurethe cylinderrod is connectedproperly.
(cont'd)
20-113
WindshieldWiperArms and Linkage
Replacement(cont'dl
USA-produced:
USA-produced:
NOTE:Scribea line acrossthe link and windshield
wiper motor to show the originaladjustment.
>r Bolt locations,3
>: Bolt locations,2
R
Y
6 J (1 . 0m m
8 N.m to.skgtm, I
.E-7Y.nt
3.
)
NUT
1 0x 1 . 2 5m m
'18N.m
{1.8kgf.m.
13 tbtft)
S e p a r a t et h e w i n d s h i e l dw i p e r l i n k a g ea n d w i n d shieldwiper motor.
Japan/Canada-produced:
N O T E :S c r i b ea l i n e a c r o s st h e l i n k a n d w i n d s h i e l d
wiper linkageto show the originaladjustment.
>: Bolt locations,3
O 6r1.0mm
EF 8 N.m {0.8kstm,i
g 5.8 tbf.ft)
)
WINDSHIELD
WIPERMOTOR
NUT
10 x 1.25mm
l8 N rn (1.8kgtm,
13 tbtftl
4.
Installationis the reverseof the removalprocedure.
NOTE:
. Makesurethe connectoris connectedproperly.
. lf necessary,
replaceany damagedclips.
. l n s t a l lt h e w i n d s h i e l dw i p e r a r m s a s d e s c r i b e d
o n p a g e2 0 - 1 ' 1 7 .
. Checkthe windshieldwiper motor operation.
. Greasethe moving parts.
WIPERLINKAG€
20-114
RearWindow Wiper
Arm and Motor
WasherReservoir
Replacement
Replacement
' t . Removethe hatchtrim panel(seepage20 63).
L
Removethe front bumper(seepage20-94).
2.
Disconnectthe connectorsand washer tubes from
the washermotors.
2.
R e m o v et h e r e a r w i n d o w w i p e r a r m a n d w i p e r
motor as shown.
>: Bolt locations,3
/)^
Ql(S)
\./
6xt.omm
s.eru.-tt.oret'".
7.2 tbf.ft)
/
Routethe washer tubes
10the washe. reservoir
NUT
6x1.0mm
9.8 N.m 11.0kgf.m,
7.2 tbf.ft)
WIPERMOTOR
wtNDow
3.
WASHERMOTOR
(3D,for somemodels)
Installationis the reverseof the removalprocedure
NOTE:
. Makesurethe connectoris connectedproperly
.Install the rearwindowwiper arm as describedon
p a g e2 0 - 1 1 7 .
. Checkthe rearwindow wiper motor operation.
. Greasethe moving parts.
3.
Removethe bolts, then remove the washer reservoir.
4.
Installationis the reverseof the removalprocedure.
NOTE:
a M a k e s u r e t h e w a s h e r m o t o r c o n n e c t o r sa n d
washertubesare connectedproperly.
. Checkthe washermotor operation.
20-1 1 5
WasherTube
Replacement
NOTE:
. To removethe windshieldwashertube, removethe
left innerfender(seepage20-106),
. To removethe rearwindow washertube {3D),remove
the followingpartsfrom the leftsideof the vehicle.
-
-
Innerfender(seepage20-106)
Kickpaneland sidetrim (seepage20-60)
Rearseat-backand rearseatcushion(seepage2080)
Sparetire lid
Rearcentershelf and rearside shelf (seepage2060)
Reartrim panel and side trim panel (seepage 20
60)
Ouartertrim panel(seepage20-60)
Rearrooftrim {seepage20-65)
Hatchspoiler(seepage20-101)
>: W.sher nozzle,clip and cushion locations
a>,2
c > ,1
B>,3
wttrtosnteLo6}
usxea =-d
lNozzrE cv
"J>)
i
!$e
q
D>,1
E > ,1
@"[q
F>, 11
NtW)€
WINDSHIELD
TUBE
A
REARWINDOW
WASHERTUBE
washernozzle.
WIRE
HARNESS
Rootethe washertube
underthe wire harness.
Routethe washertubes
to the washer reservoir
washernozzle
(seepage20-101).
REABWINDOW
WASHER
TUBE
oo\
Installationis the reverseof the removalprocedure.
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,
replaceany damagedclips.
. After installing,adjustthe aim of the washernozzles(seepage20-117).
20-116
(Ior some models)
Wiper Arms/WasherNozzles
Adjustment
Windshield wiper/Washer:
RearWindow wiper/Washer (3Dl:
1. Adjust the wiper arms so that their park positions
matchthe illustration.
1.
View trom tront to rear
View trom raar to front
-.4
.//
,'l
x i
A
x
Adjust the rear window wiper arm so that its park
positionmatchesthe illustration.
\
r-
---..J_.__11,:l
A'
x . .
REARWINOOW
WIPERARM
WINDSHIELD
WIPER
ARMS
2.
B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y ,
adjustthe washer nozzlesso that they aim at positions A, A', B, and B'shown in the illustration.
CERAMIC
EDGE
B y i n s e r t i n ga t a c k a n d m o v i n g i t a s n e c e s s a r y ,
adjustthe washer nozzleso that it aims at position
C as shown in the illustration.
NOTE:The fluid jet should hit within a 50 mm (2.0
in,) radiusaroundpoint C.
NOTE:The fiuid jets shouldhit within a 50 mm (2 0
in.) radiusaroundeachof pointsA, A', B, and B'.
\
Distance from center
M;r.";-lll
lrne
from black
ceramrceoge
A and A'
400mm (15.7in.) 255mm (10.0in.)
B and B'
1 1 5m m ( 4 . 5i n . ) 322mm \12.7in.)
20-117
Emblems
Installation
Apply the emblemswhere shown.
NOTE:
. Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand water from gettingon the surface.
U n i t :m m ( i n . )
Aftachment Points (Reterence):
CIVICEMBLEM
CIVICemblem
CIVICemblem
TRUNKLID
TFUNK LID
Vorsion emblem
20-114
Version emblem
Versionemblsm
Sub-frame
Sub-frameTorque Sequence:
CAUTION: After loos€ningthe sub-frame mounting bolts, be sure to replacethem with new ones.
1 0x 1 . 2 5m m
38Nm{3.9kg{.m:
28 tbf.ft)
BOLTS
1 4x 1 . 5m m
90 N m (9.1ks{ m,
66 rbf.ft)
Replace.
20-119
FrameRepairChart
U n i t :m m ( i n . )
o: Innerdiameter
DETAILAREA.Y
CVT:
(5.121
177{6.971
20-120
I t:3D
SECTIONAA
012 {0.47)UpperArm
@20{0.8)Locat. Hole
LowerArm Center
Damoer Lower Bush Center
20-121
Body ('97 model)
FrontSeat Belt
Removal/lnstallatlon
RearSeat
RemovaUlnstallation
WasherTube
Windshield
fndex ..........
Outline of
....20-128
....20-126
20-124
'97 Model Changes
The molding side seal was added.
The method of installing the rear seat cushion was changed (2Dl3D).
A middle floor gusset was added and the method of detaching the seat belt retractor was changed (2Dl3D)
The installation position of the washer tube was changed.
Windshield
lndex
NOTE:The numbersafterthe part namesshow the quantitiesof the partsused.
wlNDSHIELD
UPPERRUBBER
DAM
MOLDING
2
FASTENER,
glass side)
(Self-adhesive-type,
FASTENER,2
{Clip-type,body sido)
WINDSHIELD
20-124
Molding Side Seal
lnstallation
Glue the molding side seal to the windshield molding on
each side.
20-125
RearSeat
RemovaUlnstallation
3D:
i_): Hook locations
4i.,,2
Bt-;,1
>: Bolt locations
a>,6
c > ,1
B>,'t
I
iI
6x1.Omm
-@e ' t.o.|
9.8N.m {1.0*nt.] S=222 N.m12.2kg{.m,I
7.2 tbt.trl
j
j g 16tbf.ft)
:
STRIKER
Removethe side trim
panel (seepage 20 60).
,
T=ttJX,.)
MIOOLEFLOOR
CENTERGUSSET
/
I
I
STNIKER
I
6x1.0mm
9.8 N.m {1.0fgf..,i
.2 tb,f.ft)
l
)
--::.........
VV
;*...
PIVOT
BRACKET
1
>: Clip locations,14
SEATCUSHION
l@n
HOOK
I
F
( E
\ q t
A
c
F
E
Pivot boft con3truction:
TOOTXED
LOCK
WASHER
SEAT.BACK
A
Instailationis the reverseof the removalprocedure.
PIVOTBOLT
BRACKET
8 x 1.25mm
22 N.m 12,2kgf,m, 16 lbl.ftl
Apply liquidthreadlock.
NOTE:
. Beforeattachingthe seat-backand seatcushion,make sure there are no twists or kinks in the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slits in the seat cushion.
. Makesurethe seat-backlockssecurely.
. lf necessary,
adjustthe strikerand seat-back.
20-126
,-.): Hooklocations
^(:).z
2D:
>: Bolt locations
A>,6
c>,1
B>.1
6
l
e
9rJ*'Ll-",-,
iV
H
B() ' t
16rbr'frl
,
)
/
g
v
6x1.omm
i
9.8N.m11.0
ksf.m,l
7.2rbf.ft)
i
SEAT-AACKMAT
>: Cliolocations,14
V
V
PIVOTBRACKET
V
CENTER
RIGHTSEAT-BACK
PIVOTBRACKET
LEFT
SEAT-BACK
TOOIHED
LOCK
WASHER
BUSHING
SEATCUSHION
PIVOTBOLT
BRACKET
8 x 1.25mm
22 N.m {2.2kgf.m, 16 lbIft)
Apply liquidthreadlock.
lnstallationis the reverseof the removalprocedure.
NOTE:
. Beforeattachingthe seat-backand seat cushion,make surethere are no twists or kinksin the rear seat belts and
centerbelt.
. When installingthe seatcushion,slip the seatbelt bucklesthroughthe slitsin the seatcushion.
. Makesurethe seat-backlockssecurely
. lf necessary,
adjustthe seat-backlatchand seat-back
20-127
FrontSeat Belt
RemovaUlnstallation
2D l3Dl
4.
1.
Slidethe front seatforwardfully.
2.
Remove:
. Rearseat-backand rear seat cushion(seepages
20-126,127l.
. R e a rc e n t e rs h e l f a n d r e a r s i d e s h e l f ( 3 D ,s e e
page20-60)
. Resrtrim panel(3D,seepage2G60)
. Sidetrim panel(seepages20-60,61)
3.
Removethe upper anchorcover and lower anchor
cap.
UPPERANCHOREOLT
7/16-20UNF
32 N.m {3.3 kgf.m,
24 tbf.ftt
UPPERANCHOR
COVER
RETRACTOR
MOUNTINGBOLT
6x1.0mm
9.8 N.m (1.0kgf.m.
7.2 tbl.hl
Pull back the carpet as necessary,and removethe
bolts,then removethe middlefloor gusset.
>: Boh locations,8
LOWER
ANCHOB
CAP
10x 1.25mm
38 N.m (3.9kgf'm,
28 rbtftl
I
I
i
o
RETRACTORAOLT
7/16-20UNF
32 N.m 13.3kgf.m,
24 tbttrl
LOWERANCHORBOLT
7/16-20UNF
32 N.m (3.3kgt.m, 24 lbf.ft)
Removeall the anchorbolts and the retractorbolt.
removethe retractormounting bolt, then removethe
Iront seat belt and retractor.
6.
Installationis the reverseof the removalorocedure.
NOTE:
. Checkthat the retractorlockingmechanismfunctions as describedon page 20-91
o Makesuri vou assemblethe washersand collars
on the upperand lower anchorboltsas shown.
. Beforeinstallingthe anchor bolts, make sure there
are no twists or kinksin the front seat belt.
20-124
WasherTube
Replacement
NOTE:To removethe windshieldwashertube, removethe left innerfender(seepage20-106).
>: Washarnozzle,clipandcushionlocations
c>,1
B>,1
a>,2
D>,'t
n,i#,T,1
F > ,1
E > ,1
lw)*)
W ) e 9)
)
l_N.j
I
ECM/PCM
BRACKET
c-------.WIRE
HARNESS
Routethe washertube
underthe wire harness
Routethe washertube
behindthe EcM/PcMbracket.
WINOSHIELD
TUBE
A
REARWINDOW
TUBE
WASHER
\/
RESERVOIR
Routethe washertubes
to the washer reservolr
Routethe washertubes
underthe wire harness.
is the reverseof the removalprocedure.
Installation
NOTE:
. Takecarenot to Dinchthe washertubes.
. lf necessary,replaceany damagedclips.
. After installing,adjustthe aim of the washer nozzles(seepage20-117l'
(cont'd)
20-129
WasherTube
Replacement(cont'dl
NOTE:To removethe rearwindowwashertube (3D),removethe followingpartsfrom the leftsideof the vehicle.
-
Innerfender(seepage20-'106)
Kickpaneland sidetrim (seepage20-60)
and rearseatcushion(seepage20-80)
Rearseat-back
Sparetire lid
Rearcentershelfand rearsideshelf(seepage20-60)
Reartrim paneland sidetrim panel(seepage20-60)
Ouartertrim panel(seepage20-60)
Rearroof trim (seepage20-65)
Hatchspoiler(seepage20-1011
>: Washer nozzle, clip and cushion locations
A> . 9
C > ,1
B>,2
I
sl
- . . . _1,
a j \ < j Q i
_ ____/
_>_t _ _/
(seepage20 101).
REARWINDOW
TUBE
WASHER
(forsomemodels)
Installationis the reverseofthe removalprocedure.
NOTE:
. Takecarenot to pinchthe washertubes.
. lf necessary,replaceany damagedclips.
. Afterinstalling,
adjusttheaim ofthe washernozzles(seepage2O-1111.
20-130
motor.
Body ('98 model)
Openerand Latch
HoodLatchCoverReplacement""'.' 20-132
20-132
..'.'....'...'
HatchHandleReplacement
HatchLatch/LockCYlinder
20-133
"...'.."..'.'...
Replacement
Outline of
.
.
'98 Model Changes
The hood latch cover was added
The hatch handle was added (3D)
Openerand Latch
Hood Latch Cover Replacement
HatchHandleReplacement
NOTE:Takeca.e not to the hood latchcoverand body.
'1.
Removethe hatchtrim panel{seepage20-63).
Removethe hatchhandlebolts,
>: Boltlocations,2
HOOOLATCHCOVER
HOOD LATCH
I
20-132
6x1,0mm
|
9.8N.mtl.Okgf.m,I
7'2tbt':---J)
Hatch Latch/LockCYlinder
Replacement
4.
Note the positionof the ioint on the handlerod (A)'
Prv the handlerod ol the joint using diagonalcutt e r s ; t a k e c a r e n o t t o b e n d t h e r o d R e m o v et h e
hatchhandle.
1.
Removethe hatchtrim panel(seepage20-63)'
2.
Removethe hatchlatchscrews
>: Screw locations,3
6x1,0mm
9.8 N.m 11.0kgf'm,
7.2 tbt f0
HATCH
LATCH
@
BUSHING
Replace.
l n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
theseitems:
Disconnectthe lock rod, the handle rod, the lock
cylinder rod. and the connector,then remove the
hatchlatch.
Makesure
the handlerod is connectedproperly
Beforeinstallingthe hatchtrim panel,makesure
the hatchopensProPerlY.
LOCKCYLINDER
ROD
''---t
CONNECTOR
HANDLE
ROD
(cont'd)
20-133
Openerand Latch
Hatch Latch/Lock Cylinder Replacement(cont'd)
4.
P u l l t h el o c kr o d o u t .
lf necessary,
removethe lockcylinder.
>: Boltlocelion.1
6xr.omm
I
9.8 N.m (1.0kq .m, I
,:!!_J
ry*)*,,
\""<,/
.z ,/\
6.
I n s t a l li n t h e r e v e r s eo r d e r o f r e m o v a l ,a n d n o t e
theseatems:
.
.
.
Apply greaseto the hatchlatch.
Makesurethe connectoris connectedproperly.
Beforeinstallingthe hatchtrim panel,makesure
the hatchopensproperlyand lockssecurely.
20-134
Body ('99 model)
Dashboard
CenterPanelRemovaland
20-136
lnstallation
Bumpers
FrontGrilleRemovaland
20-136
lnstallation
."'.....20-137
FrontAir SpoilerReplacement
Seats
and
FrontSeatDisassemblY
20-138
ReassemblY
FrontSeatTorsionBar
20-139
'.'...".'....'...
Replacement
Emblems
tnstallation
Outline of
'99 Model Changes
The centerDanelremovaland installationproceduresare different'
The front grille removaland installationproceduresare different'
The front air spoilerhas beenaddedfor some modelsof 2D'
driver'sseatwas addedto some models'
A height-adjustable
Emblemswere addedfor some modelsot 2D'
20-140
Dashboard
Bumpers
CenterPanelRemovaland
Installation
FrontGrilleRemovaland
Installation
1.
Removethe dashboardcenterlowercover.
NOTE:Takecarenot to scratchthe front bumper.
2.
Removethe screws,then pull out the centerpanel.
Remove the front bumper. Remove the screws. then
slidethe front grilleforwardby detachingthe hooks.
>: Sc.ewlocationi,4
>: Cliplocations
A> , 3
B>,4
r
l
@Y,
>: Scrowlocltion3,6
I
dbp i
UPPER
VENTI(NOB
FRONTBUMPER
Disconnectthe connectorsfrom the heatercontrol
unit and hazardwarningswitch.
Installationis the reverseof the removalprocedure.
NOTE: Make sure the connectorsare connected
propefly.
a&
I
Installationis the reverseof the removalprocedure.
20-136
FrontAir SPoilerRePlacement
CAUTION: Put on glovesto protect your hands'
NOTE:
. An assistantis helpfulwhen removingthe front bumper'
. Takecarenot to scratchthe front bumperand body'
>: Bolt, screw localions
A>,9
@l
B>,4
s*i
BUMPER
lnstallationis the reverseof the removalprocedure'
FRONTAIR SPOILER
NOTE:
. Make sure the front bumper engagesthe front
bumpersidestiffeneron eachsidesecurely'
adjustthefront bumpersidestiffener
o lf necessary.
to obtainthe Propergap.
20-137
Seats
FrontSeat Disassembly
and Reassembly
CAUTION: When prying with a flat-tip screwdriver,wrap it with protective tape to prevent damage.
NOTE:
. Takecarenot to scratchthe seatcoversand body.
. Removethe front seatthroughthe door openlng.
SEAT-BACK
HEADREST
Driver's:
SEATCUSHION
PIVOTNUT
I x 1.25mm
22 N.m 12.2kgf,m,
16 tbf.ft)
CENTERCOVER
RECLINEADJUSTER
8 x 1.25mm
20 N.m 12.0kgf.m,
lil lbtftl
EUSHING
LOWERCAP
10x 1.25mm
47 N.m (4.8kgf.m,
3s rbl.ft)
WASHERS
INNERSEAT
TRACK
RECLINE
COVER
WASHER
WASHER
LOWERCAP
I
8 x 1.25mm
20 N.m (2.0kg,f.m,
14 tbf.fit
8 x 1.25mm
20 N.m {2.0 kgI.rn,
l4 tbf.ft)
i\",-,"
HEIGHTHANDLE
20-13A
FrontSeatTorsionBar
Replacement
in the reverseorderof disassembly'and
Reassemble
notetheseitems:
.
.
.
.
.
Makesurethe bushingand pivot washerare installed
properly.
To connectthe connectingwire,twist it 90'.
Replacethe backcoverclipswith new ones
To preventwrinkleswhen installingthe seat-back
cover,makesurethe materialis stretchedevenly
overthe pad.
Apply multipurposegreaseto the moving portionof
the seattrack.
NOTE|Takecarenot to tear the seamsor damagethe
seatcovers.
1.
Removethe seatcushlon
2.
Removethe torsionbar from the hookwith a flat tip
then pull out the torsionbar from the
screwdriver,
seatcushionframe Put on glovesto protectyour
h an d s .
TORSION
SAR
SEATCUSHIONFNAME
TORSIONBAR
SEATCUSHION
FLATTIP SCREWDRIVER
3.
lnstall in the reverse order of removal'
20-139
Emblems
Installation
Align the applicationtape with the taillightand body,as shown,then pressthe emblem into place.
Removethe apptication
tape.
NOTE:
o Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. After cleaning,keepoil, greaseand waterfrom gettingon the surface.
. Whenapplying,makesurethereare no wrinklesin the emblem.
Attschment Point:
VERSIONEMBLEM
DOHCVTECaid€ omblom:
20-140
Vsrsion emblem:
Body {'00 model}
SeatBelts
ChildSeatAnchorPlateRemoval/
20-142
fnstallation
Emblem
20-144
fnstallation
Outline of '00 Model Changes
The childseatanchorplateremovaland installationproceduresare different'
An emblemwas addedfor some model of 3D.
Seat Belts
ChildSeatAnchorPlateRemoval/lnstallation
2DllDl
Attachmentpoints are providedfor a rear-seal-mounted
child restraintsystem that uses a top tether.The attachment
pointsare locatedon the rearshelf,tust behindthe rearseat-back.
The child seatanchorplatesare installedin the middle and on both sidesof the rearshelf.Eachchild seatanchorplate
is
coveredwith the child seatanchorolatecover.
NOTE:
' Do not removethe toothedwasherfrom the child seat anchor plate, Use the anchor plate
with the toothedwasher
attachedto it.
. When installinga child seaton the rearseat,follow the instructionsof the manufacturer
of the child seat.
. When installingthe anchorplates,the one with the shonerspacergoes in the middle.
. Makesurethe rearseat-backs
are lockedfirmly when installinga childseat.
U n i t :m m ( i n . )
ATTACHMENTPOINTS
REARSHELF
CHILOSEAT
ANCHOR
PLATECOVER
CIIILDSEATANCHOR
PLATECOVER
MIDOLECHILD
SEATANCHOR
PLA
I x 1.25mm
22 N.m 12.2kgl.m,
16 tbt.ftt
8 x 1.25mm
22 N.m 12.2kgl.m,
16 tbf.ft)
17 {0.67)
torward
.
15{0.s9)
WASHER
CHILDSEAT
ANCHOR
PLATECOVER
TOOTHEO
ll ff*,".rd,',i"'"o*
I x 1,25mm
N.m {2.2 kgf.m.
16tbtftl
12lO.47l
SIDE
SEAT
ANCHORPLATE
TOOTHED
20-142
rl)
.t
SIDE
SEATANCHOR
PLATE
8 x 1.25mm
22 N.m 12.2kgl m,
16 tbf ftl
19 (0.75)
3D:
a top tether' The attachment
Attachmentpoints are providedfor a rear-seatmounted child restraintsystem that uses
pointsare locatedon the reartrim panel.
panel Eachchild seat anchor
The child seat anchorplatesare rnstalledin the middle and on both sidesof the rear trim
p l a l ei s c o v e r e dw i t ht h e c h i l ds e a ta n c h o rp l a t ec o v e r '
NOTE:
plate with the toothedwasher
. Do not removethe toothedwasherfrom the child seat anchorplate. use the anchor
attachedto it.
child seat'
. when installinga child seaton the rearseat,follow the instructionsol the manufacturerof the
are lockedfirmly when installinga childseat'
. Makesurethe rearseat-backs
gn;16rn (in.)
ATTACHMENTPOINTS
CHILOSEAT
ANCHORPLATE
;x?',rff{-*.
CHILDSEAT
ANCHOBPLATE
COVER
8 x 1.25mm
22 N..n (2.2 kgl'm.
16 tbfft)
20-143
Emblem
Installation
Applythe emblemwhere shown.
NOTE:
. Beforeapplying,cleanthe body surfacewith a spongedampenedin alcohol.
. Aftercleaning,keepoil, greaseand water from gettingon the surface.
Attachment Point (ReferencG):
U n i t :m m ( i n , )
CIVICEMBLEM
SpecialEMBLEM
3D: Specialemblem {for CanadaSoscielEditionl
20-144
Heaterand Air Conditioning
Heater
Air Conditioning......."'..
'.'..""" 21'1
"' 22-1
SYSTEM(SRS}
RESTRAINT
SUPPLEMENTAL
models (exceptsome
The civic sRs includesa driver'sairbag locatedin the steeringwheel hub ln addition,all
glove
box'
the
above
airbaglocatedin the dashboard
modelsfor canada)havea passenger's
(*)
to safelyservicethe sRS is includedin this serviceManual ltemsmarkedwith an asterisk
Informationnecessary
these
or replacing
on the contentspage include,or are locatednear, sRs components.servicing,disassembling
dealer'
Honda
authorized
by
an
be
done
should
therefore
and
precautions
and
tools,
special
will
require
items
@
sev€re
rendsring the SRS inoperative, which could lead to personal iniury or deaih in the svent of a
-";;il
d€aler'
Honda
pertormed
an
authorized
by
be
must
work
service
frontal collision. all SRS
personal
. lmploper service procedures, including incorrest removal and instsllation of the sRs, could lead to
iniury causedby unintentional deployment of the airbags'
deploy
o Do not bump the SRS unit. Otherwise. the system may fait in case of a collision. or the airbags may
is
ON
{ll}'
when the ignition switch
in lhe
. sRs electrical wiring harncssesare id€ntified by yellow colol coding. Related components ale located
glove
box'
the
above
dashboard
panel,
in
the
and
steering column, front console, dashboard,dashboald lowet
Do not use electricaltest equipment on these circuits.
Heater
* HeaterUnit
lllustratedIndex
'96 - 98 Models ................................
....'....21-39
Replacement
21'2
'99 - 00 Models ................................
"""' 21-4'l
""""
overhaul
21'3
HeaterControl Panel
CircuitDiagram
'96 - 98 Models
.........21'42
Repfacement
.....21-4
'99 - 00 Models ................................
21-43
Overhaul-'96 - 98 Models ...........
21-5
'96
- 98 Models
Temperature Control
Troubleshooting'96 - 98 Models """" 21-44
Adjustment 21-6
SymptomChart ...............................
'99 - 00 Models .......21-45
AdiustmentHeaterControl PanelInput/
21-7
OutputSignals..............,..............
Air Mix Control Motor
.......21'46
Flowcharts
Test- '99 - 00 Models ...........'
'99
21-8
BlowerMotor Speed ...................
00 Models ....21'46
Replacement
,...21'10
Bfower Motor
Mode Control Motol
,.'.'21-13
Mode ControlMotor ...............
.,...'.21'47
Test ................,
'.'."...21-47
Recirculationcontrol Motor .......21-16
Replacement
-14
... 21
HeaterControl Panel ................
RecirculationControl Motor
'99 - 00 Models
.......21-48
Troubleshooting
Test .................
21-19
......."
21-48
SymptomChart ...............................
Repfacement
21-20 Relays
Seff-diagnosisFunction............,,,....
.......2'l-49
Flowcharts
Test .................
21-21
Motor
......,..........
Air Mix Control
Heater Fan Switch
.....21-25
Mode ControlMotor ...............
.......21-49
Test- '96 - 98 Models.............
RecirculationControl Motor .......21-27
Mode Control Switch
.....21'29
21-50
Bfower Motor Speed ..............
Test-'96 - 98 Models...........".......
....21-31
Bfower Motor
Power Transistor
21-35
HeaterControlPanel................,..
....".21-50
Test - '99 - 00 Models ....'........
HeaterControl PanelInput/
beforeworkingin this area.
21-36 *: ReadSRSDrecautions
OutputSignals.............................
Blower Unit
.........21-37
Repfacement
21-38
................
Overhaul
lllustratedIndex
'96 - 98 Models
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section{24)beforeperformingrepairsor service.
BLOWERUNIT
page21-37
Replacement,
Overhaul,page21-38
HEATER
UNIT
page21-39
Beplacement,
page21-41
Overhaul,
BLOWER
RESISTOB
Test,
CONTROLMOTOR
Test,page21-48
page21'48
Replacement,
a/c swtTcH
{wirhA/c)
MOO€
MOTOR
Test, page21 47
page21'47
Replacement,
HEATERFAN
swtTcH
AIR MIX CONTROLCABLE
Adjustment,page2'1-44
page21'43
Replacement,
Test,page2l'49
MODE
HEATERCONTBOL
PANEL
Test,page 21 50
R g p l a c e m e n t ,p a g e 2 ' l - 4 2
Overhaul,page 21-43
swrTcHEs
TEMPERATURE
CONTROL
LEVER
Adiustment,page21 44
Detroster-aqtivatedA/C System
Turningthe defrosteron activatesthe A,/Cand sets the air flow mode to FRESH.lt is possibleto turn the A,/Coff or to
changethe air flow to RECIRCULATE
by pressingthe A/C bunon or the FRESH/RECIRCULATE
button.
21-2
'99 - 00 Models
and proceduresin the SRS
SRScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions,
section(24)betoreperfomingrepairsor service.
BLOWEBUNIT
page21-37
Replacement,
Overhaul,page21 38
UNIT
HEATER
page21'39
Replacement,
O v e r h a upl ,a g e2 1 - 4 1
RECIRCULATION
CONTROLMOTOR
Test,page21-48
page21-48
Beplacement,
POWERTRANSISTOR
Test,page21 50
AIR MIX CONTROLMOTOB
Test,page21-46
page21 46
Replacement,
BLOWER
HIGH RELAY
Test, page 21-49
MODECONTROL
DIAL
HEATERVALVECABLE
Adjustment,page21 45
CONTROL
TEMPERATURE
DIAL
Adjustment,page21-45
REARWINDOW
DEFOGGER
swtrcH
See section 23
MODE
MOTOR
Test, page 21 47
R e p l a c e m e n t ,p a g e 2 l - 4 7
A/C SWTTCH
lwith A/cl
HEATERFAN
swtTcH
CONTROLSWITCH
21-3
CircuitDiagram
'96 - 98 Models
LINDEF
NoODFUSETFELAY
30x
No1l lS0Al
Ni42 (40A)
WNTTBLK
+WFT
8L|(YEi
LIGHT
Y
I
crca(.-A-o\
S;rt'| | lieti{,**i'-t
_ ? ' ?_[:]
! 9 [ 1 ' ? _ ? _L-:}
t _ _ ?|_ _h
t
21-4
\1
\-r.\
\-r-1
\'\
'99 - 00 Models
UNDEFDASH
FUSElRELAY
BOX
IGNTIONSWTCH
FUSE/RELAY
8OX
UNDER,HOOO
**",@
**,',,*
",.@f
u,n,",,
ELUAVHT
I
Y
BLOWER
MOTOR
PUSN
SWITCH
BLUi
BtK
BLUiBLK
1
ELOWER
MOTOR
HIGH
RELAY
tic
GRY
PNK/BLK
FED''WHT
RED,YEL
BRN
lHce
nvosrar
F)(WirhIVC)
YEL/FEO
neo
aLu
6RNiYEL
8LU/!VHT
YEL
YEL/BLU
DASH
LIGHTS-/1
BBTGNTNESS
< -! lCONTROLLER
VENT
MOOE
HEAT CONTFOL
MOTOF
M.COM
DEF
BRNfiHT
FEo
GFNM/HT
GRNiFED
[[f&H,,4*,",,
PANEL
HEATERCONTROL
BLK
O :8PCONNECTOR
! :20PCONNECTOF
E : 12PCONNECToR
Troubleshooting-'96
- 98 Models
SymptomChart
NOTE;
. Checkthe enginecoolantlevel.and allow the engineto warm up beforetroubleshooting.
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements
needed.use a multimeterwhen testing.
procedurescheck:
o Beforeperformingany troubleshooting
- FusesNo. 41 11.5Al, No. 55 (40A) in the under-hoodfuse/relaybox. and No. 17 (7.5A) in the under-dashfuse/relay
box
- GroundsNo. G401,G402
- Cleanliness
and tightnessof all connectors
Symptom
Hot air flow is low.
No hot air flow.
Romedy
Blowermotor runs.but one or more
speedsare inoperative.
Performthe proceduresin the flowchart (seepage 21-8).
Blowerruns properly.
Checkfor the following:
. Cloggedheaterduct
. Cloggedheateroutlet
. Incorrectdoor position
Blowermotor does not run at all,
Performthe proceduresin the flowchart(seepage21-10).
Blowermotor runs.
Checkfor the following:
. Clogged heater duct
. Clogged blower outlet
. Cloggedheatervalve
. Faultvair mix door
. Heatervalvecableadjustment(seepage21-44)
. Air mix control cable adiustment (see page 2'l-441
. Faultycoolingsystemthermostat(seesection10)
. Cloggedevaporator(with air conditioning)
. Frozenevaporator{with air conditioning)
Mode controlmotor does not run, or one or more modes
are inooerative.
Performthe proceduresin the flowchart (seepage 21-13).
Recirculation
controldoor does not chanqebetween
FRESHand RECIRCULATE.
Performthe procedu.esin the flowchan(seepage21-16).
Both heaterand A,/Cdo not work.
Performthe proceduresin the flowchart(seepage21-18),
21-6
HeaterControlPanelInput/OutputSignals
HEATERCONTROLPANELlilP CONNECToR
Wiresideof lemaleterminals
Terminal
No.
Wire
color
1
YEL
Terminal
No.
Wire
color
INPUT
8
YEVRED
VENT
INPUT
INPUT
9
GRNI/EL
HEATIr'ENT
INPUT
'10
BLK
GROUND
OUTPUT
11*
BLU/RED
A./CTHERMOSTAT
INPUT
12
GRN/WHT
FRESH
INPUT
Signal
HEAT/DEF
BLfiEL
WHT/BLU
+B
INPUT
4
YEUBLU
DEF
INPUT
5
RED
6
RED/8LK
LIGHT
COMBINATION
SWITCH
INPUT
13
GRN/RED
1
BLUMHT
HEAT
INPUT
14
GRN
DASHLIGHTS
OUTPUT
CONTROLLER
BRIGHTNESS
Signal
RECIRCULATE
HEATERFAN SWITCH
INPUT
OUTPUT
21-7
-'96 - 98 Models
Troubleshooting
Blower Motor Speed
Blower motor runs. but one or
rnore speedsare inoperative,
Chsck for a short or an open in
the wire{s}:
Turn the ignitionswitch ON {ll),
and the heaterfan switchOFF.
Doesthe blowermotor run?
To page21 9
HEATERFAN SWITCH6P CONNECTOR
Checkfor a shon in th6 wirels):
1. Turnthe ignitionswitchOFF.
2. Disconnectthe blower motor
2P connector,
3. Removethe center dashboard
lower cover (see section20),
the heaterlan
and disconnect
switch6Pconnector,
4. Disconnectthe blower resis
tor 4Pconnector,
5. Checkfor continuitybetween
t h e N o .2 , 3 , 4 a n d 5 l e r m i n a l s
o f t h e h e a t e rf a n s w i t c h 6 P
connectoa
r nd bodyground
individually.
ls there continuity?
Repair short in the wire(s)
beiween the blower resistor,the
heatertan switch and the blower
motor,
21-a
Wire sideof femaleterminals
Reolace the heater fan switch,
Check the blower resislor:
1. Turn the ignitjon switch OFF.
2. Disconnect the blower resis
tor 4P connector.
3, N4easure the resistance
between the No. 2 and No. 4
terminals of the blower resistor,
BLOWERRESISTOR
ls thereapprox.2 - 3 ohms?
HEATERFAN SWITCH6P CONNECTOR
Checkfor an openin the wire(s):
1. Reconnect
the blowerresistor
4Pconnector,
2. Removethe centerdashboard
lower cover (seesection20),
the heaterfan
and disconnect
switch6P connector.
3. Turnthe ignitionswitchON (ll).
4 . G r o u n de a c ho f t h e s et e r m i nalsindividuallyin the tollow_
ing order:No.4, 2, 5 and 3.
BLU/WHT
BLU/BLK
2
1
BLU
6
JUMPER
WIRE
BLU/YEL
Wiresideof femaleterminals
Does the blower motor run at
p r o g r e s s i v e l yh i g h e r s p e e d s ?
Reolace the hoater fan switch.
Repairopen or causeol excessive
r e s i s t a n c ei n t h e a p p r o p r i a t e
wire{sl between the blower resistor and the heater{an switch.
21-9
-'96 - 98 Models
Troubleshooting
BlowerMotor
glower motor does not run at all.
Checkthe No.55(40A)lusein the
under hood fuse/relaybox, and
t h e N o . 1 7 ( 7 . 5A ) l u s e i n t h e
undeFdashluse/relaybox.
Repl.ce th. fuse{rl, .nd rochack.
BLOWERMOTOR2P CONNECTOR
Checkthe blower motor:
1. Connectthe No. 2 terminalof
the blower motor 2P connoc
tor to body ground with a
lumperwrre.
2. Turnthe ignitionswitchON (ll).
Doesthe blowermotor run?
f=
l 1 l
r,l
**'I
ruumifalulau
T o p a g e2 1 - 1 1
Wi.e sideof fernaleterminals
Chockfor an opsn in the wire:
1 . D i s c o n n e ctth e , u m p e rw i r e
and the blowermotor 2P connector,
2. Measurethe voltagebetween
the No. 1 terminal and body
ground.
Fl
l1|_-_-l
t4 ,t
I
ls there batteryvoltage?
Ch6cktha blower motor relay:
1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e b l o w e r m o t o r
relayfrom the under-hood
fuse/relaybox, and test it (see
page21-49).
Replace tha blower moior reley.
fo page21'12
21-1 0
gr-urwnr
Frompage2l 10
HEATERFAN SWITCH5P CONNECTOR
Checkfor an open in the wire:
1. Turn the ignitionswitch OFF,
and disconnecthe iLrmPer
2. Removethe center dashboard
lower cover (see section20),
the heaterfan
and disconnect
switch6P connector.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the No. 3 terminal and body
ground.
WiresideoI femaleterminals
Repairop.n in th6 wiro betw€en
the blower motor and tho heater
fan switch.
Checkfor an open in the wire:
1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
the No. 1 terminalof the heater
tan switch 6P connectorand
bodyground.
Reolacotho heaterfan iwitch
Check tor an op€n in the wire
betw.en the heater tan switch
and body ground. ll th€ wilo b OK,
check tor poor ground at G401and
G102.
(cont'd)
21-11
-'96 - 98 Models
Troubleshooting
BlowerMotor (cont'dl
F r o mp a g e2 1 - 1 0
BLOWERMOTORRELAY'P SOCKET
Checkthe under-hoodfuse/relay
1 2 1 1
t_T
t-l
DOX:
N/leasure
the voltagebetweenthe
N o . 3 t e r m i n a lo f t h e b l o w e r
motor relay 4P socketand body
ground,
t
rv)
i
ls therebafteryvoltage?
Checklor an open in th€ wire:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltage between
the No. 4 terminalof the blower motor relay 4P socketand
body ground.
Repairopen in tho wire between
the No. 17 fuss and tho blowel
motor rclay,
Checkfor en opon in the wire:
1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
the No. 2 terminalof the blower motor relay 4P socketand
bodyground.
ls therecontinuity?
R e p a i ro p e n i n t h e B L U / W H T
wire b€tween the blower motor
relav and the blower motor.
21-12
Check foi an open in the wire
betwe€n the blower motor relav
and body glound. lf the wiro is
OK, check fo. poor ground at
G{01 and G4O2.
ModeControlMotor
Mode control motor does not run,
or one of more modes are inoPela-
'17(7.5A) fuse in
Checkthe No.
fuse/relaY
box.
the under-dash
Reolacethe fuse, and recheck.
MODECONTROLMOTOR7P CONNECTOR
'1
Checklor an open in the wire:
1. Disconnectthe mode control
motor7P connector.
2. Turnthe ignitionswitchON (ll).
3. Measurethe voltagebetween
l nd body
the No. l terminaa
ground.
ls therebatterYvoltage?
I
I
7
5
BLK/YEL
Repairopen in the wire between
the No. 17 tuse and the mode
control motor.
Check {or an open in the wire:
1. Turn the ignition switch OFF.
2. Check for continuity between
the No. 7 terminal of the mode
conlrol motor 7P connector
and body ground.
ls therecontinuity?
2
Wire sideof femaleterminals
I
3
4
5
6
1
BLK
[]
Check for an open in the wire
batwe€n the mode contrcl motol
and body ground.lf the wir€ is OK,
checkfor poor gtound at G/U)land
G402.
Testthe modecontrolmotor (see
page21-471.
ls the mode control motor OK?
Check the mod€ control linkage
and doors:
1. Bemove the mode control
motor (seepage 21-47).
2 . C h e c kt h e m o d e c o n t r o l l i n k a g e
and doors for smooth move
T o p a g e2 1 - 1 4
Dothe modecontrollinkage
anddoorsmovesmoothlY?
Reolace the mode control motor,
(cont'd)
-'96 - 98 Models
Troubleshooting
Mode ControlMotor lcont'dl
F r o mp a g e2 l - 1 3
HEATERCONTROLPANELlilP CONNECTOR
Checktor a short in the wi.e(s):
1. Removethe centerdashboard
lower cover (seesection20),
and disconnectthe heatercontrol panel14Pconnector.
2. Checkfor continuitybetween
the No. 1, 4, 7, 8 and 9 terminalsand body groundindividWiresideof lemaieterminals
Raprir.ny short in the wire(s)
betw€en the mode control motor
and the heatercontrol panel.
Checkfor a shon to power:
Checkthe same wires {or voltage.
ls thereany voltage?
T o p a g e2 1 1 5
21-1 4
Repair short to pow6r in the
wiro(3) betwoen the mode conlrol motor .nd tha heate. control
prnel, This short also damag.s
tho heater cont.ol prnel. Repail
the short to power b€{ore replacing the heeterconlrol pan6l.
F r o mp a g e2 1 - 1 4
HEATERCONTROLPANEL14PCONNECTOR
Checktor an open in the wire{s}:
Checkfor continuitybetweenthe
followingterminalsof the mode
control motor 7P connectorand
the heatercontrolPanel14Pconnector14P:
7P:
N o . 2- N o . 4
N o . 3- N o .1
N o . 4- N o . 7
N o . 5- N o . 9
No.6- No.8
Wire sideof {emaleterminals
MODECONTROLMOTOR7P CONNECTOR
Wire sideof femaleterminals
ls therecontinuitY?
Repair any opsn in the wirels)
bctwoan the mode control motor
and the hoator conlrol Panol
Check Io. loo3. wires or Poor
connoctionsat lhe hoat€r control
Danel 14P connactor, and 3t the
mod6 conilol motot 7P connector. It tho connoctionsara good.
rsDlacothe heat€r coilttol panel.
2 1-1 5
-'96 - 98 Models
Troubleshooting
RecirculationControlMotor
Becirculationcontrol door does
not change between FRESHand
RECIBCULATE.
c h e c kt h e N o - 1 7 ( 7 . 5A ) f u s e i n
the under-dash
fuse/relay
box.
Reolacethe tuse. and recheck.
RECIRCULATION
CONTROLMOTOR
4P CONNECTOR
Checkfor an open in the wire:
1 . 0 i s c o n n e ctth e r e c i r c u l a t i o n
controlmotor4P connector.
2. Tu.nthe ignitionswitchON (ll).
3. Measurethe voltagebetween
the No. l terminal and body
ground.
ls there batteryvoltage?
BLK/YEI-
Repairopen in the wir6 between
the No. 17Iuseand the recirculalion conlrol motor.
Wiresideof temaleterminals
Check lhe recirculation control
1. Turn the ignition switch OFF.
2. Test the recirculation control
motor {see page 21 48).
Checkthe recirculationcontrol
linkageand door:
1. Removethe recirculation
con'
trol motor {seepage21 48}.
2. Checkthe recirculation
control
linkageand door for smooth
I o p a g e2 1 1 7
Do the recirculation
controllink
age and door movesmoothly?
21-1 6
Reoairthe r€circulationcontrol
linkageor door.
HEATERCONTROLPANEL14PCONNECTOR
F r o mp a g e2 1 - 1 6
;-?
I
7
Check{or a short in the wire(s):
1. Removethe centerdashboard
lower cover (see section20),
the heatercon_
and disconnect
trol panel14Pconnector'
2. Checkfor continuitybetween
t h e N o . 1 2 a n d N o . 1 3t e r m i nalsand body groundindivid-
8
9
'olx
5
4
11
1 2 13 14
GRN/BED
GRN/WHT
0) (0
Wire side of female terminals
Repair5hort in the wire{sl between
the recirculationcontrolmotor and
the heatercontrolPanel
CheckIor a short to Power:
Checkthe samewiresfor voltage
I
2
3
7
8
I
1
i--?
5
6
'olx
11 12 13 14
GRN/RED
GRN/WHT
V)(v
ls there any voltage?
Repair short to Power in the
wire {s) between the recirculation
control motor and the heater
control panel. This short also
damages the heater control
panel. Repair the short to Power
betore replacing the heater control panel.
Check lor an open in the wire(s):
Checkfor continuity between the
following terminals of the recircu
lation control motor 4P connector
and the heater control Panel 14P
4P.
N o . 2No.4
4
1
7
I
rol\l rr
I
5
12 1 3
GRN/RED
14P:
N o .1 2
N o .1 3
GRN/WHT
ls there continuitY?
Repair open in the wirelsl
between the recirculation control
motor and the heater control
panel.
r
zl/lt
CONTROLMOTOR
RECIRCULATION
4P CONNECTOR
Wire sideof femaletetminals
Check for loose wires or Poor
connections at the heater control
Danel 14P connector, and at the
recirculation control motor 4P
connector. lf the connections are
good, replace the heater control
Danel,
21-17
-'96 - 98 Models
Troubleshooting
HeaterControlPanel
Both heater and A/C do not work.
Checkthe No. 17{7.5A) fusein the
underdashfuse/relaybox, and the
No. 47 (7.5A) fuse in the under
hoodfuse/relaybox.
R.phce the fuso{s),.nd rccheck.
HEATER
CONTROL
PANEL1,lPCONNECTOR
Chacktor an open in the wi.e:
1. Removethe centerdashboard
lower cover (see section20),
a n d d i s c o n n e c tt h e h e a t e r
controlpanel14Pconnector.
2. Torn the ignitionswitchON {ll).
3. Measurethe voltage between
the No. 2 terminal of the
heatercontrolpanel 14Pconnectorand bodyground.
ls there bafteryvoltage?
Wiresideof femaleterminals
Rcpair opGnin th€ wiro betwoon
the No. 17 tuse and the hoatcl
control panel.
Checkfor an opon in the wiro:
1. Turnthe ignitionswitchOFF.
2. Measurethe voitage between
t h e N o . 3 t e r m i n a lo f t h e
heatercontrolpanel 14Pconnectorand body ground.
ls there batteryvoltage?
Rgprii open in th6 wira b€twacn
the No. il7 tui. and the heat.t
cont.ol p.nal.
Checkfoi an open in the wi.e:
Checkfor continuitybetweenthe
No. 10terminalot the heatercont r o l p a n e l 1 4 Pc o n n e c t o a
r nd
body ground.
Check lor an opon in tho wire
b€{w6on the hoator control oanel
and body ground. lI the wirc is
OK, check tor poor ground at
G401.nd G4O2.
Check for looae wiaos or oool
connectionsat the hoater control
panol 14P connector. lf the connactions dre good. 3ubstitute t
known-9ood heater control
panel, and rech6ck.It tho symptom/indication 9oe3 .wry,
replacethe original heatel control oanol.
21-1 8
Troubleshooting-'99 - 00 Models
Symptom Chart
function (see next
system,refer to self-diagnosis
For electricalmalfunctionswhich are indicatedby the self-diagnostic
page).
a symptom'
Notetheseitemsbeforetroubleshooting
. Checkthe enginecoolantlevel,and allow the engineto warm up beforetroubleshooting'
. Any abnormalitymust be correctedbeforecontinuingthe test
.Becauseoftheprec|semeasurementsneeded,UseadigitaImu|timeterwithanoutputoflmAor|essatthe20k
rangewhen testing
procedurescheck:
. Beforeperformingany troubleshooting
fuse/relav
(40
A)]n the under-hoodfuse/relaybox' and No 17 (7 5 A) in the under-dash
- FusesNo. 41 115 Al,No 55
-
box
GroundsNo. G401,G402
and tightnessof all connectors
Cleanliness
See pags
Symptom
Mode controlmotor does not run, or one or more modesare inoperat've'
controldoor doesnot changebetweenFreshand Recirculate'
Recirculation
any other
Blowermotor only runson high speedposition;it does not run in
Blowermotor does not run at all.
Both heaterand Ay'Cdo not work
speedpositions
a1_tq
21-21
21-29
21-31
2 13 5
21-19
Troubleshooting-'99 - 00 Models
Self-diagnosis
Function
The heatercontrolpanelhasa self-diagnosis
function.
Runningthe Self-diagnosis
Funqtion
Set the mode controldial to the Vent position,and turn the ignitionswitchON fll).Withinsix seconds
afterturnangthe igni_
tion switchon. pressthe recirculation
controlswitchthe requirednumberof times dependingon the recirculation
indicator
lightstatus:
.lftheindicatorlightisON,presstherecirculationcontrolswitchfivetrmes.
. l f t h e i n d i c a t o r l i g h t i s O F F , p r e s s t h e r e c i r c u l a t i o n c osnwt irtoclhs i xr r m e s .
The recirculation
indicatorlight will come on for two seconds.then blinkthe DiagnosticTroublecode
{DTc}to indicatea
faultycomponent.lf no DTc'sarefound,the indicatorlightwill not blinkafterthe initialtwo second
liqht.
DTCIndicationPattern(S6eDTC2l:
Recirculation
indicato.
light on
Recirculation
indicator
light off
' 0,3sec
2 sec
W i t h i n s i x s e c o n d sa t t e r t h e
,/
t
0.3 sec
ignition switch is turned ON (lll, 1.5soc
pross the recirculationcontrol
VENTPOSITION
switch the required number ot
MODECONTROLDIAL
times dependingon the rocirculation indicetor light status
@
At
RECIRCULATION
CONTROLSWTCH
V'
DTCTroubleshootingIndex
Diagnostic
trouble
code (DTCI
2
Rgcirculation
indicator light
Component with problem
Possible cause
See page
O n eb l i n k
Air mix control motor
Obstructeddoor, laulty motor
21-21
Two blinks
Air mix control motor
Openor shortcircuit
21-23
ln caseof multipleproblems,the recirculation
indicatorlight will indicateonly one DTc with the leastnumberof blinks.
Resettingthe Self-diagnosisFunction
Turningthe ignitionswitchOFFwill cancelthe self-diagnosis
function,Aftercompletingrepairwork, run the setfdiagnosis
functionagainto makesurethat thereare no other malfunctions.
21-20
Air Mix GontrolMotor
door and
indicatorlight indicatesDiagnosticTroublecode (DTC)1l A problemin the air mix controllinkage,
Recirculation
motor.
heatercontrolpanel'
The air mix controlmotor regulatesthe mixtureof cool/hotair accordingto outputsfrom the
Self-diagnosiscircuit check indi'
cates a Problem in the air mix
conlrol motor circuit,
Checkth6 aii mix conirol motor:
the air mix control
1. Disconnect
motor 5Pconnector.
2. Testthe air mix controlmotor
(seepage21-46).
ls the air mix controlmotorOK?
check the air mix control linkage
and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
motor (seePage21-46)
2. Checkthe air mix controllinkage and doors lor smooth
movement.
Do the air mix control linkageand
doors move smoolhlY?
R€olacethe air mix control motor'
HEATERCONTROLPANEL2OPCONNECTOR
RED/YEL
RED/WHT
Check tor a short in the wiles:
1. Disconnectthe heater control
panel 20Pconnector2. Check for continuitY between
body ground and the heater
control panel 20P connector
t e r m i n a l sN o . 3 a n d 4 i n d i v i d '
uaIY.
Wire sideot femaleterminals
Ropairany short in th€ wire{s}
betweon the heatercontrol Panel
and the air mix control motor'
(cont'd)
fo page21-22
21-21
Troubleshooting-'gg - 00 Models
Air Mix ControlMotor (cont'dl
F r c mp a g e 2 1 - 2 1
Checkfo..n open in the wires:
Checkfor continuity betweenloll o w i n g t e r m i n a l so f t h e h e a t e r
controlpanel20P connectorand
the air mix controlmotor 5P con20P:
No3 _
No.4 -
5P:
N o .1
No.5
AIRMIX CONTROL
MOTOR
5PCONNECTOR
Wiresideot femaleterminals
Repairany open in the wiro(s)
bdtwoon tha hoator control panal
and air mix control motor.
Check for loo3e wires or poor
conneclionsat the heater control
panol 20P connoctor and at the
air mix control motor 5P connocto.. It the connections.rc good,
substitute a known-good hoaier
control panel, and rech6ck.lf the
symptom/indicrtion goes away,
replac6 the original heater control panel.
21-22
RecirculationindicatorIightindicatesDiagnosticTroublecode(DTc)2:AprobIemintheairmixcontro|motorcircuit
from the heatercontrolpanel'
The air mix controlmotor regutatesthe mi)dureof cool/hotair accordingto outputs
Self-diagnosiscircuit check indicrl6s a problgm in tho air mix
contiol motor circuit.
Checkth6 rir mix control motor:
the air mix control
1. Disconnect
motor5P connector'
2. Testthe air mix controlmotor
(seepage21-46).
ls the air mix controlmotor OK?
Checkthe air mix control linkage
and doors:
1 . R e m o v et h e a i r m i x c o n t r o l
motor(seepage21'46).
2. Checkthe air mix controllinkage and doors for smooth
Do the air mix controllinkageand
doorsmovesmoothlY?
Roglacethe air mix conlrol motor.
HEATERCONTROLPANEL2OPCONNECTOR
REO/YEL
Checkfor r short in the wiresl
the heatercontrol
1. Disconnect
panel20Pconnector.
2. Checkfor continuitybetween
body ground and the heater
control panel 20P connector
t e r m i n a fN
s o . 3 , 4 . 1 2 , 1 5a ^ d
20 individually
BEO/WHT
PNK/BLK
Wire sideof femaleterminals
ls therecontinuity?
Bep.ir any short in the wire{s)
between the h€rter control panel
and th6 air mix control motor.
(cont'd)
Io page 21-24
21-23
-'99 - 00 Models
Troubleshooting
Air Mix ControlMotor (cont'dl
Frompage21-23
HEATERCONTROLPANEL2OPCONNECTOR
Checktor a short to power:
C h e c kt h e s a m et e r m i n a l sf o r
voltage.
Wire side of female terminals
ls there any voltage?
Rapair short to pow6r in the
wirelsl botween the heater control panel and the ai. mix control
molor. This short also damag.s
the heater control panel. Ropair
the short to power betoro replacing the heater control panel.
Checkfor an open in the wire3:
Checkfor continuitybetweenfol
l o w i n g t e r m i n a l so f t h e h e a t e r
controlpanel20Pconnectorand
the air maxcontrolmotor 5P con
nector.
20Pt
5P:
No3 _
N o .1
No 4 _
N o .5
N o _1 2 N o .2
N o .1 5 No.4
No 20 No.3
Bepair any open in the wire(s)
between the heator control panel
and air mix control motor,
Check tor loose wires or poor
connectionsat the heator control
oanel 20P connector and at th.
air mix control motor 5P connector, ll the connectionsrre good,
substitute a known-good heater
control oanel. and recheck.lf the
symptom/indication goes awry,
replacethe original heater control oanel,
21-24
AIR MIX CONTROLMOTOR
5P CONNECTOR
Wire sideof lemaleterminals
Mode control motor does not run.
or one or more modesarc inope]ative.
C h e c kt h e N o . 1 7 ( 7 . 5A ) f u s e i n
fuse/relay
box.
the under-dash
Replace the Iuse. and recheck.
MODECONTROLMOTOR7P CONNECTOR
Checkfor an open in the wire:
1. Disconnectthe mode control
motor7P connector,
2. Turnthe ignitionswitchON (ll)the voltagebetween
3. MeasLrre
t h e N o . 1 t e r m i n a lo f t h e
mode control motor 7P con
nectorand body ground
t
2
3
1
5
BLK/YEL
Wiresideof femaleterminals
ls therebatteryvoltage?
Repairopen in the wire between
the No. 17 luse and lhe mode
control motor.
Check the mode control motor:
1- Turn the ignition switch OFF
2, Test the mode control motor
(see page 21 47).
ls the modecontrolmotor OK?
Checklhe mode control linkage
and doors:
1 . R e m o v et h e m o d e c o n t r o l
motor (seepage21 47).
2. Checkthe modecontrollinkage
and doors for smooth move
Do the mode control linkage
and doors move smoothlY?
ReDlace the mode control motor'
Check for a short to Power in the
wires:
1. Iurn the,gnitjon switch ON
(ll).
2, Disconnectthe heater control
panel20P connector.
3. Check for voltage between
the No. 2, 5, 6, 7, I and 9 ter'
minals of the heatercontrol
panel 20P connector and
body ground individuallY.
ls lhere any voltage?
NO
Io page 21 26
HEATERCONIROLPANEL2OPCONNECTOR
Wire side of female terminals
Repair shorl to power in the
wire{sl between the heater control oanel and the mode control
motor. This short also damages
the heater control Pan6l. RePair
the short to power before replac'
ing the heater control Panel
(cont'd)
21-25
Troubleshooting-'gg - 00 Models
ModeGontrolMotor (cont'dl
Frompage21-25
HEATERCONTROLPANEL2OPCONNECTOR
Chocktor a short to ground:
1. Turnthe ignitionswitchOFF.
2. Checkthe same terminalsfor
continuityto bodyground.
Wire sideof femaleterminals
ls therecontinuity?
Repairany 3hort in the wirelsl
between the heater control panel
and ihe mode control motor.
Checklor.n open in tho wires:
1, Disconnectthe mode control
motor7P connector.
2. Checkfor continuitybetween
the followingterminalsof the
heatercontrolpanel20Pcon
nectorand the mode control
motor 7Pconnector.
2OP: lPi
N o . 2- N o . 7
No.5- No.2
No.6- No.6
N o . 7- N o . 5
No.8- No.4
No.I- No.3
MODECONTROLMOTOR?P CONNECTOR
Wiresadeof lemaleterminals
ls therecontinuity?
Check for loose wiaes or ooor
connectionsat the heater control
panel 20P connector rnd at the
mode control motor 7P connectoa, lf the connoctionsere good,
substitute a known-good heater
control panol, and recheck.lf the
syfiptom/indication goes away,
replac€the original hoatercontrol
panel.
21-26
Repair any opon in the wire(s)
t€tween the h€ater control panel
and tha modc contol motor.
Recirculation control door does
not chango betwe€n Fresh and
Recirculate.
Checkthe No. l7 (7.5A) fuseanthe
underdashfuse/relaybox.
Replace the fuse, and recheck.
CONTROLMOTOR
CONTRC
RECIRCULATION
,lP CONNECTOR
q-?
Checklor an oPenin the wite:
1 . D i s c o n n e ct th e r e c i r c u l a t i o n
controlmotor 4Pconnector.
2. Turnthe ignitionswitchON (ll)
3. Measurethe voltagebetween
the No. 1 terminalof the recir
culation control motor 4P
connectorand body ground.
--T--T--T-|
1l2l/l1l
f( v )BLK/YEt
!
sideof temaleterminals
ls there batteryvoltage?
Repairopen in the wire between
the No. 17 luse and lhe recirculation control motor.
Check the rccirculationcontrol
motorr
'] Turn the ignitionswitchOFF.
2. Test the recirculationcontrol
motor (seePage21 48i
Check the recirculationcontrol
linkageand door:
con_
1. Removethe recirculation
trol motorlseePage2l 48).
control
2. Checkthe recirculation
linkageand door for smooth
movement.
page
controllink_
Do the recirculation
age and door move smoothlY?
Reoairthe recirculationconlrol
linkag€ or door.
(cont'd)
Troubleshooting-'99 - 00 Models
Recirculation
ControlMotor (cont'd)
Frcm page21-27
HEATERCONTROLPANEL8P CONNECTOR
Checkfor a short to power in the
1. Turnthe ignitionswitchON {ll).
2. Disconnect
the heatercontrol
panel8P connector.
3. Checkfor voltagebetweenthe
No.2 andNo.3 terminals
ofthe
heatercontrol panel 8P con,
nectorand body ground indi
vidually.
ls thereany voltage?
R e p a i r3 h o r t t o p o w e . i n t h e
wire{a) b.tween tho haetor control paneland the recirculation
Gontrol moto.. This short also
damagosthe heate. control
panel. Repairthe short to power
b€tore .eplecing the h€ater control panel.
Checkto. a short to ground:
1. Turnthe ignitionswitchOFF.
2- Checkthe same terminalsfor
continuityto ground.
Roprir lhon in tho wir.{s) b€tweo
the horter control panel and the
racircr alion conhol motoa.
Checkfor an open in the wires:
1 . D i s c o n n e ct th e r e c i r c u l a t i o n
control motor 4P connector.
2. Checkfor continuitybetween
the followingterminalsof the
recirculation
controlmotor 4P
connectorand the heatercon,
trol panel8P connector.
8P:
4Pi
N o . 2- N o . 2
N o . 3- N o . 4
GRN/WHT
GRN/RED
Repairopen in ths wirolsl betw€€n
the heate. co.rkol panol and the
recirculationcontrol motor .
Check lor loo3a wires or poot
conn€ctionsat the hoatercontrol
panel 8P connector and at the
aecirculationcontrol motor ilP
connector,It tho connectionsare
good. substitut€ e known-good
heateicontrol panel,and aecheck.
lf th€ symptom/indication goes
away, replacethe original hedter
contrclDanel.
21-28
I
1
RECIRCULATION
CONTROLMOTOR
4P CONNECTOR
Wiresideof femaleterminals
BIowerMotor Speed
Blower motor only runs on high
speed position; it does not run in
any other speedPositions
N O T E :l f t h e b l o w e rm o t o r d o e s n o t
run at all, referto page21-31.
3P CONNECTOR
POWEBTRANSISTOR
Checkfor an open in lhe wire:
the powertransis
1. Disconnect
tor 3P connector,
2. Checkfor continuitybetween
t h e N o . 3 t e r m i n a lo f t h e
powertransistor3P connector
and body ground.
l s t h e r ec o n t i n u i t y ?
3
BLK
o
Check tor an open in the wire
between the Power ttansistor
and body gtound. lf the wire is
O K , c h e c kf o r p o o r g r o u n d a t
G401and G402.
Wire sideol femaleterminals
JUMPER
WIRE
Check tor an open in the wire:
1 . C o n n e c tt h e N o . 1 a n d N o 3
terminals of the Power tran_
s i s t o r 3 P c o n n e c t o rw l t h a
jumperwire.
2 . T u r n t h e i g n i t i o ns w i t c h O N { l l )
Repair open in the wire belween
the blower motor and the Powet
tranststor.
HEATERCONTROLPANEL2OPCONNECTOR
Wiresideof femaleterminals
Check tor an open in the wire:
1. Turn the ignition switch OFF
2 . D i s c o n n e c tt h e i u m P e r w i r e .
3. Disconnectthe heater control
panel 20Pconnector.
4. Check for continuity between
the No. 1 terminal of the
heater control panel 20P connector and the No. 2 terminal
of the Power transistor 3P
ls there continurty)
LT GRN/8LK
Repair open in the wire between
the heater control Panel and tho
oower transistor,
To page 21 30
(cont'd)
21-29
Troubleshooting-'99
- 00 Models
BlowerMotor Speed(cont'dl
Frcm page21.29
Checktor a short in the wi.a:
Checkfor continuity between the
No. 1 terminalof the heatercon
trol panel20Pconnector
and body
ground.
HEATERCONTROLPANEL2OPCONNECTOR
LT GRN/BLK
Wire sideoJfemaleterminals
Repairshort in ths wire betwsen
the hoater control panel and the
oower transastoa.
Checkfor an open in the wire:
1. Disconnect
the heatercontrol
panel8P connector,
2. Turnthe ignjtionswitchON 1ll).
3. Measurethe voltagebetween
t h e N o . ' l t e r m i n a lo f t h e
heatercontrol panel 8P con
nectorand body ground.
HEATERCONTNOLPANEL8P CONNECTOR
Wire sideot femaleterminals
Repeiropen in the wiio between
the heater control panel and the
blower motoa.
Checkthe power transistor:
1. Turn the ignitionswitchOFF.
2. Reconnectthe heatercontrol
panel8P and 20Pconnectors.
3. Test the power transistor {see
page21 50).
ls the powertransistorOK?
Checkfor loos€ wiras or poor connections at the h€at€r control
panel 8P and 20P connectolsand
at th6 power transistor 3P conn€ctor. lf the connectionsare good,
substituto a known-good hoater
control panel, and recheck.It the
symptom/indication goes away,
replacethe originalheater control
oanel,
21-30
BlowerMotor
Blower motor does not run at all.
Checkthe No. 55 (40 A) Iuse in
the under-hoodfuse/relaybox,
and the No. 17 (7.5A){use in the
box.
fuse/relay
undeFdash
Boplaceth€ fuse(3),and rechock.
MOTOR2PCONNECTOR
BLOWER
Check th€ blow€r motor Powel
supply circuit:
1. Disconnectthe blower motor
2P connector.
2. Turnthe ignitionswitchON {ll).
3, Measurethe voltage between
the No. 1 terminaloI the blow
e r m o t o r 2 P c o n n e c t o ra n d
bodyground.
ls there batteryvoltage?
Checktha blower motor:
1. Turnthe ignitionswitchOFF
2. Reconnectthe blower motor
2P connector.
3. Connectthe No.2 terminalo{
the blower motor 2P connec
t o r t o b o d v g r o u n dw i t h a
tumperwire.
4. Turnthe ignitionswitchON {ll}
Wire sideof lemaleterminals
fo page 21-32
JUMPER
WIRE
Doesthe blowermotor run?
To page21-33
(cont'd)
21-31
Troubleshooting-'99 - 00 Models
Frompage21-31
Checkthe blower motor relay:
1. Turnthe ignitionswitchOFF.
2 . R e m o v et h e b l o w e r m o t o r
relayfrom the under hood
fuse/relaybox, and test it- (see
page21'49).
Replace the blower motor relay.
BLOWERMOTORRELAY4P SOCKET
Check the under-hoodtuse/relay
box:
Measurethe voltagebetweenthe
N o . 3 t e r m i n a lo f t h e b l o w e r
motor relay 4P socketand body
ground.
Checktor an open in the wire:
1. Turnthe ignitionswitchON (ll).
2. Measurethe voltagebetween
t h e N o . 4 t e r m i n a lo f t h e
blower motor relay 4P socket
and bodyground.
ls therebatteryvoltage?
Repairopon in lhe wire between
the No. 17 fuse and the blowet
Checkfor an open in the wire:
1. Turnthe ignitionswitchOFF.
2. Checkfor continuitybetween
t h e N o . 2 t e r m i n a lo f t h e
blower motor relay 4P socket
and body ground.
ls there continuityl
R e p a i ro p e n i n t h e B L U / W H T
wiae between the blower motor
relay and the blower motor,
21-32
Check lor an ooen in the wire
between the blowor motor relay
and body ground. It the wiie is
O K , c h e c kf o r p o o r g r o u n d a t
G401and G402.
Frompage21 31
C h e c kt h e b l o w e r m o t o r h i g h
relay:
1. Turn the ignitionswitchOFF,
and disconnecthe iumPer
2 . R e m o v et h e b l o w e r m o t o r
h i g h r e l a y ,a n d t e s t i t . { s e e
page21 49).
BLOWERMOTORHIGHRELAY4P CONNECTOR
Check lor an open in the wire:
1. Connect the No. 1 terminal of
the blower motor high relay
4P connector to body ground
with a jumPer wire.
2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) .
JUMPER
WIRE
Wire sideof femaleterminals
Doesthe blowermotor run?
Repairopen in the wire belween
the blower motor and the blower
motor high rolay.
Checkfor an op6n in the wir6:
1. Turn the ignitionswitch OFF,
a n d d i s c o n n e ct th e i u m P e r
2. Turnthe ignitionswitchON (ll).
3, Measurethe voltagebetween
t h e N o . 2 t e r m i n a lo f t h e
b l o w e r m o t o r h i g h r e l a y4 P
connectorand body ground.
ls there batteryvoltage?
Repairopen in the wire between
the No. 17 fuse and the blowor
motor high relay.
Checkfor an open in the wire:
switchOFF.
1. Turnthe ignitaon
2. Checkfor continuitybetween
t h e N o . 3 t e r m i n a ol f t h e
b l o w e r m o t o r h i g h r e l a y4 P
connectorand body ground.
ls there continuity?
YES
Ch6ck lor an op.n in the wire
botween the blower motor high
relay and body ground. ll the wire
is OK, ch6ck for poot ground at
G401 end G402.
(cont'd)
To page 21 34
21-33
-'99 - 00 Models
Troubleshooting
BlowerMotor {cont'dl
Frompage21-33
BLOWERMOTORHIGHRELAY4P CONNECTOR
Wire sideof femaleterminals
Checktor an opgn in the wiro:
1. Disconnect
the heatercontrol
panel8P connector.
2. Checklor continuitybetween
t h e N o . 1 t e r m i n a lo f t h e
heatercontrol panel 8P connectorand the No. 1 terminal
ot the blower motor high
relay4P connector.
BLU/BLK
2
3
4
o
BLU/ALK
t
2
a
Repsi. op€n in the wir. betw.en
the h..t.r contrcl p.ncl .nd tho
blowar motor high rahy.
Ch€ckfor an opon in the wir6:
1. Disconnect
the heatercontrol
panel20Pconnector.
2. Checkfor continuity between
t h e N o . 1 3 t e r m i n a lo f t h e
heatercontrolpanel20Pconnectorand the No. 4 terminal
of the blower motor high
relay4P connector.
8
5 6
HEATEROONTROLPANEL8P CONNECTOR
wir€ sido ot f€male torminals
HEATERCONTROLPANCL2OPCONNECTOR
Wire sideof femaleterminals
a
I
2
3
11
12 13
5
0
7
8
I
,/1,/1,/m
15
ORN/WHT
o
Ropairopon in tho wiro botwoon
tha hartor cor rol pangl rnd tha
blower motor high .elay.
1
2
3
4
OBN/WHT
Ch.ck for looso wiros or poor
conn€dions at th6 heato. control
panel 8P and 20PconnectoB and
at the blowol motor high relty
4P connoctor. It tho connoctions
are good, substitute a knowngood heatcr control panel, and
recheck. It the symptom/indication goos away, rgplacothe oiiginal heatercontrol oanol.
21-34
10
Both heater and A/C do nol work.
checktheNo.47(7.5A)fusein the
under-hoodfuse/relaybox, and the
N o . 1 7 { 7 . 5A ) f u s ei n t h e u n d e r dashfuse/relaybox.
ReDlacethe tuse{s),and recheck.
Check lor an open in the wire:
1. Disconnectthe heater control
panel 8P connector,
2 . T u r n t h e i g n i t i o ns w i t c h O N ( l l ) .
3. Measure the voltage between
the No. I terminal of the
heatercontrol panel 8P connector and body ground.
ls there batteryvoltage?
HEATERCONTROLPANEL8P CONNECTOR
1
I
4
BLK/YEL
v
Repairopen in the wire between
the No. '17luse and th6 heater
control oanel,
Wire side of female terminals
HEATER CONTROL PANEL 2OP CONNECTOR
Checkfor an open in the wire:
1. Turnthe ignitionswitchOFF.
the heatercontrol
2. Disconnect
panel20Pconnector.
3. Measurethe voltagelletween
t h e N o . 1 0 t e r m i n a lo f t h e
heatercontrolPanel20Pconnectorand body ground.
ls therebatteryvoltage?
Repairop6n in the wir€ between
the No. il7 tuse and the heater
controloanel,
Check for an open in the wite:
Check for continuity between the
No. 6 terminal of the heater con
trol panel 8P connector and body
ground.
ls there continuity?
Check for looso wires or Pool
conneciions at the heater control
oanel 8P and 20P connectors. lf
the connections are good, substi'
tute a known-good heat€r control Danel, and recheck. lI the
goes awaY,
symptom/indication
r6place the original h€ater controloanel.
Wire sideof temaleterminals
I
2
1
7
5
BLK
Ch6ck tor an open in lhe wire
betwoen the heator control Panel
and bodv ground. lf the wire is
O K , c h e c kf o r p o o r g r o u n d a t
G401and G402.
o
8
-'99 - 00 Models
Troubleshooting
HeaterControlPanelInput/OutputSignals
HEATERCONTROLPANELCONNECTORS
8P CONNECTOR
2OPCONNECTOR
12PCONNECTOR
Wire sideof femaleterminals
8P CONNECTOR(O qn Circuit Diagram)
Cavity
2
Wire color
Cavily
Signal
Whe color
BLU/8LK
BLOWER
FEEDBACK
INPUT
5
RED
GRN/lVHT
FRESH
INPUT
6
BLK
3
GRN/RED
4
RED/BLK
INPUT
7
BLU/YEL
COMBINATION
LIGHTSWITCH
INPUT
(ViaNo.30 (7.5A) fuse)
8
8LfiEL
Cavity
Wirecolor
RECIRCULATE
Signal
DASHLIGHTSBRIGHTNESS
OUTPUT
CONTROLLER
GBOUND
OUTPUT
REARWINDOWDEFOGGER
OUTPUT
RELAY
lG2{Power)
INPUT
20PCONNECTOR{D on circuit Diagram}
Cavity
Wire color
LT
GRN/BLK
Signal
POWERTRANSISTOR
EASE
OUTPUT
't1
2
BRNMHT
MODECONTROL
MOTOR
GROUND
INPUT
12
3
RED/YEL
AIR MIX HOT
OUTPUT
13
RED,ryvHI
YEUBLU
YEURED
AIR MIX COOL
OUTPUT
14
5
MODEDEF
MODEVENT
MODEHEAT/r'ENT
MODEHEAT
INPUT
6
7
I
9
10
GRNI/EL
BLUAVHT
YEL
WHT/BLU
MODEHEAT/DEF
+B (Power)
BLU/RED
BRN
ORNAA/HT
PNK,/BLK
INPUT
INPUT
INPUT
INPUT
16
11
18
19
INPUT
20
GRY
Signal
Ay'CTHERMOSTAT
MOTOR
AIR MIX CONTROL
ND
GROU
BLOWER
MOTORHIGH
RELAY
INPUT
INPUT
INPUT
AIR MIX POTENTIAL
OUTPUT
AIRMIX POTENTIAL
+5 V
OUTPUT
*: with Ay'c
(tr on CircuitDiagraml
12PCONNECTOR
Cavity
l
Wilecolor
Cavity
Signal
SWITCHLEDCOMMON
9
SWITCHCOMMON
OUTPUT
INPUT
INPUT
INPUT
10
A,/CSWITCH
OUTPUT
INPUT
11
REARWINDOWDEFOGGER
INPUT
SWITCHLED
12
3
5
6
21-36
Signal
I
2
4
Wi.e colol
SWITCHLIGHTS+
SWITCHLIGHTS-
OUTPUT
RECIRCULATION
CONTROL
SWITCHLED
A./CSWITCHLED
1
RECIRCULATION
CONTROL
OUTPUT
SWITCH
REARWINDOWDEFOGGEB
OUTPUT
SWITCH
Blower Unit
Replacement
controlmotor
NOTE:The blowermotor,recirculation
and blower resistorcan bs replacsdwithout rsmoving
th€ blowerunit (seeneldPage).
1.
controlto "HOT."
Movethetemperature
'96-98:Slidethetemperature
controllever.
'99-00:Turnthe ignitionswitchON (ll),thenturn
contolknob. Turnthe ignition
the temperature
switchoff,
Wrth Air Conditioning
4-b. Removoth6 ev8porator(sss pago 22-28).
6x1.0m|n
9.8 N'm
Removethe glovs box (ses ssction 20),
R€moveths s6lf-tappingscrew and ths passsng6r's
dashboardlow€r cover. Removothe bolt, the nut
and the kn€ebolst€r,then removethe fiv€ boltsand
the glove box trame,
KNEE
6x1.0mm
9.8 N'm lt'o tgf'm, t.2 lb{'ttl
Disconnoctthe connectorstrom th€ blower motor,
blowor r6sistor {'96 - 98 models), power transiator
('99 - 0Omodsls), blowor motor high telay ('99 - 00
models) and recirculationcontrol motor.
R€mov€ths wiro harnossclip from tho recirculation
control motor, and releasethe wir6 harnsssfrom ths
clamo on the blowor unit. Remove the two mounting bolts,tho mounting nut and ths blowor unit'
GLOVEBOXFRAME
6x1.0mm
9,t N'm 11.0lgi.m,
7.2 tbf.fil
Without Air Condhioning
4-a. Removethe wiro harnessfrom the h68t€rduct, then
remove the two self-tapping scrsws and the heatsr
duct.
9.8 .m 11.0tgfm,
1.2tblfrl
HEATERDUCT
lnstall in ths reverso order of removal. Mako surs
that thsre is no air leaka96.
21-37
BlowerUnit
Overhaul
NOTE:
a Beforereassembly.
makesurethat the recirculation
controldoor and linkagemove smoothlywithout binding.
controldoor
controlmotor, make sure its positioningwill not allow the recirculation
When attachingthe recirculation
to be pulledtoo far.
control motor,connectpower and ground,and watch the movementof the recirculaAfter aftachingthe recirculation
tion controldoor.
RECIRCULATION
CONTROLMOTOR
Test,page21-48
m
{'96 - 98 modebl
BLOWER
Test,page 2'l 9
POWERTRANSISTOR
l'99 - 00 modebl
Test,page21-50
MOTOR
Test,page21'10('96 98 models)or
page21'31('99 00 models)
2134
HeaterUnit
Replacement
SRS componentsare located in this area. Reviewthe
SRScomponentlocations,precautions,and procedures
in the SRSsection{24}beforeperformingrepairsor ser-
L
2.
4.
Disconnect
the heaterhosesfrom the heaterunit.
CAUTION:Enginecoolant will damagep8int.
Ouickly rinse any spilledengins coolant from painted
su aces,
Disconnect
the negativecablefrom the battery.
NOTE:Enginecoolantwill run out when the hoses
drain it into a cleandrip pan.
are disconnected;
Frcm underthe hood,open the clamp,then disconnect the heatervalve cable from the heater valve
arm. Turn the heatervalve arm to the fully opened
positionas shown.
CLAMP
HEATERVALVCCABLE
When the engine is cool. drain the engine coolant
from the radiator(seesection10).
Do not remove the radiator cap when
!@
the engine is hot; the ongine coolant is under pres'
surg and could severelyscald you.
5.
Removethe mountingnut from the heaterunit.
NOTE:When removingthe mountingnut, takecare
n o t t o d a m a g eo r b e n d t h e f u e l l i n e s ,t h e b r a k e
lines,etc.
I x 1.25 mm
22 N.m {2.2kgl.m, 16lblftl
21-39
HeaterUnit
(cont'dl
Replacement
6.
Removethe dashboard(seesection20).
7.
Removethe heaterduct (seepage 21-37)or evaporator (seepage 22-28).
8.
Disconnectthe connectorsfrom the mode control
motor and air mix control motor ('99 - 00 models),
then remove the wire harnessclips and wire harnessfrom the heaterunit. Removethe clip from the
heater duct, then remove the two mounting nuts
and the heaterunit.
6x1.0mm
9.8N.m11.0kgl.m,7.2lbf.ftl
HEATER
UNIT
9.
lnstallin the reverseorderof removal.Makenote of
the followingitems.
Apply sealantto the grommets.
Do not interchangethe inlet and outlet heater
hoses.Makesurethat the clampsare secure.
R e f i l lt h e c o o l i n g s y s t e mw i t h e n g i n ec o o l a n t
(seesection10).
Connectall cables,and makesure they are properly adjusted(see page 21-44(96 - 98 models)
or page21-45('99- 00 models)).
Makesurethat there is no air leakage.
21-40
Overhaul
'1. Removethe two self-tappingscrewsand the heater
corecover.
Pullout the heatercorefrom the heaterunit.
2.
Pullout the grommetfrom the heatercore pipes.
NOTE: Be careful not to bend the inlet and outlet
pipesduring heatercore removal.
3.
Removethe self-tappingscrewand the clamp.
Assemblein the reverseorderof disassembly.
HEATERCORECOVER
GROMMET
21-41
HeaterControlPanel
Replacement
'95 - 98 modolsi
'9!,- 00 modols:
1 . Remove the driver's dashboard lower cover, the
glove box and the center dashboardlower cover
(seesection 20).
Disconnect
the air mix controlcablsfrom the heater
unit {seepage21-44).
Removethe rearwindow defoggerswitch,the hazard
warning switch and the audio unit (seesection23).
Disconnectthe connectorsfrom the heatercontrol
panel.Removethe five self-tappingscrewsand the
centerpaneltogetherwith the heatercontrolpanel.
1 . Removethe center panel together with the heater
control panel (seesection 20).
Removethe self-tappingscrews and the heatercontrol panelfromthe centerDanel.
NOTE: The lockingtabs are on the bottom of the
connecrors.
Removethe four self-tappingscrews and the heater
Install in the reverseorder of removal.After installation, operatethe heatercontrol panel to see
whether it works properly.
Install in the .everseorder of removal.Adjust the air
mix control cable and the heatervalve cable {see
page 21-44)..
21-42
Overhaul-'96 - 98 Models
HEATERFAN SWITCH
Test,page21-49
Air Mix Control CableReplacomenl
1. Cutthe innercableon the leversideof the cableholder,then removeboth piecesof the innercable.
2. Usinga sharpknife,cut completelythroughthe end of the cablehousingat the two locations.
3. Slidethelargesectionofthecable housingoutofthe cableholder,beingcarefulnot to damagethe cablestops.
4. Carefullyremovethe cut piecesof the cablehousingwith a smallflat tip screwdriver.
5. Hookthe tip of the new air mix control cableto the temperaturecontrol lever,then push the cable housinginto the
cableholderuntil it locksinto place.
controlleverslidessmoothlythroughthe full strokelrom rightto left.
checkthatthe temperature
NOTE:Afterassembly,
21-43
TemperatureControl
Adjustment-'96 - 98 Models
1.
From under the hood, disconnectthe heatervalve
cablefrom the heatervalve.
6.
From underthe hood.move the heatervalvearm to
t h e f u l l y c l o s e d p o s i t i o n .t h e n a t t a c ht h e h e a t e r
valvecableto the heatervalvearm.
TER
HEATERVALVE ARM
2.
VALVE
CABLE
AIR MIX
CONTROL
ARM
3.
HEATERVALVE ARM
From underthe dash,disconnectthe air mix control
cablehousingfrom the cableclamp,
Set the temperaturecontrolleverto MAX. COOL.
With the air mix control cable attachedto the air
m i x c o n t r o la r m , g e n t l y p u l l o n t h e o u t e r c a b l e
housingto fully closethe door and to removeany
s l a c ki n t h e c a b l e D
. o n ' tp u l l t o h a r d ,o r t h e t e m p e r aturecontrolleverwill move.
Hold the air mix control arm againstthe stop. then
s n a p t h e a i r m i x c o n t r o l c a b l e h o u s i n gi n t o t h e
c a b l ec l a m p .
21-44
7.
Hold the heatervalve arm in the closed position,
and gentlypull on the heatercableouter housingto
take up any slack.then installthe heatervalvecable
housinginto the cableclamp.
Adjustment-'99 - 00 Models
1.
From under the hood, open the cable clamp, then
disconnectthe heatervalve cable from the heater
valvearm.
5.
From under the hood.turn the heatervalve arm to
t h e f u l l v c l o s e d o o s i t i o na s s h o w n , a n d h o l d i t ,
Attach the heater valve cable to the heater valve
arm, and gently pull on the heatervalvecablehousing to take up any slack,then installthe heatervalve
cablehousinginto the cableclamp.
HEATERVALVEARM
From under the dash. disconnectthe heatervalve
cablehousingfrom the cableclamp,and disconnect
the heatervalvecablefrom the air mix controlarm.
HEATERVALVE ARM
VALVECABLE
HEATER
Setthe temperaturecontroldial on MAX COOLwith
the ignitionswitchON {ll).
Attachthe heatervalve cableto the air mix control
arm as shown above. Hold the end of the heater
valvecable housingagainstthe stop, then snap the
heatervalvecablehousinginto the cableclamp.
21-45
Air Mix GontrolMotor
Test-'99 - 00 Models
-'99 - 00 Models
Replacement
't. Disconnectthe 5P connectorfrom
the air mix con-
1,
trol motor.
Connectbatterypower to the No. 1 terminalof the
air mix control motor, and ground the No. 5 termi,
nal; the air mix control motor should run, and stop
at MAX HOT.lf it doesn't,reversethe connections;
the air mix control motor should run, and stop at
MAX COOL.
Disconnectthe 5P connectorfrom the air mix control motor. Removethe self-tappingscrews,the air
mix controlmotor and the flangecollar.
5P OONNECYOB
lf the air mix controlmotor does not run, remove
i t , t h e n c h e c kt h e a i r m i x c o n t r o l l i n k a g ea n d
doorsfor smooth movement.
lf they move smoothly,replacethe air mix control motor.
AIR MIX CONTROLMOTOR
CONTROL
MOTOR
Measurethe resistance
betweenthe No.2 and No.3
terminals.lt shouldbe approximately4.8to 7.2 kO.
Measurethe resistancebetweenthe No. 2 and No. 4
terminals.lt shouldbe approximately
3.84to 5.76kO
at MAX HOT and approximately0.96to 1.44kO at
MAX COOL.
21-46
Install in the reverseorder of removal.After installation, makesure the air mix control motor runs
smoothly.
Mode Control Motor
Test
Replacement
the 7P connectorfrom the mode control
1 . Disconnect
motor.
1.
2. Connectbattery power to the No, 1 terminal, and
g r o u n dt h e N o . 7 t e r m i n a l ,
Disconnect
the 7P connectorfrom the mode control
motor,
7P CONNECTOR
CAUTION: Never connecl the battery in iho opposite direction.
U s i n ga j u m p e r w i r e , c o n n e c t h e N o . 7 t e r m i n a l
i n d i v i d u a l ltyo t h e N o . 2 , 3 , 4 , 5 a n d 6 t e r m i n a l si n
that order. Eachtime the connectionis made, the
mode controlmotor shouldrun smoothlyand stop.
NOTE:lf the modecontrolmotor doesnot run when
jumpingthe first terminal,jump that terminalagain
afterjumpingthe otherterminals.The mode control
motor is OK if it runs when jumping the first termin a la g a i n .
MODECONTROLMOTOR
Removethe rod from the arm of the mode control
motor.
Remove the tyvo self-tapping screws and the mode
control motor.
lnstallin the reverseorderof removal.After installa'
t i o n , m a k e s u r e t h e m o d e c o n t r o lm o t o r r u n s
smoothly.
4.
lf the mode control motor does not run in step 3,
removeit. then checkthe mode control linkageand
doorsfor smoothmovement.lf they move smoothly,
reolacethe modecontrolmotor,
21-47
RecirculationControl Motor
Test
L
Replacement
Disconnectthe 4P connectorfrom the recirculation
controlmotor.
Connectbattery power to the No. I terminal, and
groundthe No.2 and No. 4 terminals;the recirculation controlmotor shouldrun smoothly.
L
Disconnectthe 4P connectorfrom the recirculation
c o n t r o l m o t o r , a n d r e m o v et h e w i r e h a r n e s sc l i p
from it.
4P CONNECTOR
CAUTION: Never connest ths battery in the opposite direction.
Disconnect
the No. 2 or No. 4 terminalsfrom ground;
the recirculation
controlmotor shouldstop at FRESH
or RECIRCULATE.
NOTE: Don't cycle the recirculationcontrol motor
for a long time.
RECIRCULATION
CONTROLMOTOR
CONTROLMOTOR
Remove the two self-tapping screws and the recirculationcontrolmotor.
Install in the reverseorder of removal.After installa,
tion, make sure the recirculation
controlmotor runs
smoothly.
4.
lf the recirculationcontrol motor does not run in step
2, removeit, then checkthe recirculation
controllinkage and door for smooth movement.lf they move
smoothly,replacethe recirculation
controlmotor.
21-48
Heater Fan Switch
Relays
Test-'96 - 98 Models
Test
Thereshouldbe continuitybetweenthe No 1 and No. 3
terminalswhen power and ground are connectedto the
No.2 and No. 4 terminals,and thereshouldbe no contanuitywhen poweris disconnected.
Checkfor continuitybetweenthe terminalsaccordingto
the table below.
lerminal
Position
1
4
2
3
5
OFF
,I
t ;
'Y
I
€
)
1
I
2
o
oc)-
3
4
rJ
-o
a
{
Blowermotor relaY
.
Blowermotor high relay('99 00 models)
21-49
Mode Control Switch
PowerTransistor
Test-'96 - 98 Models
Test-'99 - 00 Models
Checkfor continuitybetweenthe terminalsaccordinqto
the table below.
1.
Disconnsctthe 3P connectorfrom the oower transtsror.
2,
Carefullyreleasethe locktab on the No. 2 terminalin
the 3P connector,then removethe terminal and insulate it from body glound.
Terminal
't0
7
1
--o
Def
o -o
oo-
Vent
G
HeaVVent
o-
Position
Heat
HeaVDef
1
7 8
9
;l t
-o
12V1.2-3,1W
-o
-o
4
No.1 laLU/aLK)
Connecta 1.2- 3.4 W bulb betweenthe No. 1 and
the No. 2 cavityon the 3P connector.
Reconnect
the 3P connectorto the powertranslstor.
Turn the ignitionswitch ON fll), and checkthat the
blowermotor runs.
21-50
Air Conditioning
Evaporator
.....",'22'24
Replacement
.....-.....""'22'29
Overhauf
Compressor{SANDEN}
Description
......'.'22-30
Repfacement
.......22-s
Outfine ............
22'32
fndex ......"..................'....
fffustrated
Circuit Diagram
......22-33
"............
'96 - 98 Models ......"..........".......'....
Cfutch Inspection.........
22-6
.......22-34
'99 Modef
I ........................
ClutchOverhau
"""""""' 22-7
Thermal Protector Replacement .... 22-36
Troubleshooting
ReliefValve Replacement......'..."".22-36
22-8
SymptomChart ".'......"".................
Compressor(DENSO)
Flowcharts
..""',' 22-37
Repfacement
22-9
Fan .........".................,..'.
Condenser
22-39
lflustratedIndex ...............................
.....""" 22-12
Compressor
"'....22-40
Clutchlnspection............."'......
.........'.22'17
A/C System
22-41
Cfutch Overhaul.....................'.........
A/C Thermostat
22-42
Refief Valve Replacement'..'......"'..
"""'22'21
Test ........'.......'
A/C Compressor Belt
Relays
............22'43
Adiustment
..""'22-21
Test ....."'.........
A/C ServiceTips and Precautions......22-22 Condenser
.......,,22'44
Repfacement
A/C System Torque Specifications'...22-23
A/C System Service
A/C System Service
...,,,.......22-45
Evacuation
"........'..22-24
Test ...'.".........
Performance
'..........--'..22'46
Charging
...."' 22-26
PressureTest Chart ..................
"""""""'22-46
Leakrest
22-27
...".........,"
Recovery
22-2
......'.....'
SpeciafTools
".......'
fffustratedfndex ......................... 22-3
22'4
Locations'.........'....
Wiring/Connector
SpecialTools
Bef. No.
Tool Number
o
* 0 7 J G G- 0 0 l 0 l 0 A
07sAz - 0010004
07947- 6340300
07965- 6920500
@
Description
Qty
BeltTensionGauge
BackprobeSet
DriverAttachment
Hub AssemblyGuldeAttachment
1
'1
1
' Includedin the BeltTensioncauge Set,07TGG-0010004.
a
6r
L
3r
22-2
I
PageReference
22-43
22-14,16
22-34
22-35
lllustrated Index
EVAPORATOR
page22-28
Replacement,
Overhaul,page22 29
SWITCH
A/C PRESSURE
pressureis below200kPa{2 0 kg7cm' ,
Whenthe refrigerant
(32kgf/cm' '
28 psi)due to ;frigerant leakageor above3200kPa
pressure
swrtch
lVC
the
blockage,
psi)
to
refrigerant
due
455
openslhe circuitto ihe AVCswitchand stopsthe air condilioning
to protectthe comPressor'
SERVICEVALVE
SIDE)
{LOW.PRESSURE
A/C THERMOSTAT
Test,page22 21
RECEIVER/DRYER
B e p l a c e m e n t ,P a g e 2 2 ' 4 4
COMPRESSOR
SANDENI
Replacement,
Page22 30
CIutchInspection,
Page22 33
page22 33
ThermalProtectorInspection,
ClutchOverhaul,Page22'34
page22 36
ThermalProtectorReplacement,
RefiefVafveReplacemenl,page 22'36
DENSO:
Replacement,
Page22-37
ClutchInspection,
Page22-40
ClutchOverhaul,Page22_41
page22-42
ReliefValveReplacement,
22-3
Wiring/GonnectorLocations
A/C DIODE.
CONDENSER
FAN RELAY,
COMPRESSOR
CLUTCHRELAY
(Locatedin the under,hoodfuse/relaybox)
COND€NSERFAN
CONNECTOR
COMPARTMENT
WIREHARNESS
CONNECTOR
22-4
Description
Outline
refrigerantthroughthe system
The air conditionersystemremovesheatfrom the passengercompartmentby circulating
as shown below.
EVAPORATOR
(Absorption
of heati
BLOWERFAN
EXPANSIONVALVE
(Metersthe required
amountof refrigerant
intothe evaporator)
THERMOSTAT
\
/
EOUALIZINGTUBE
(Meterspressureand
improvesthe expansion
valvereactiontime)
CAPILLATYTUBESENSINGBULB
of the
lControlsthe temPerature
refrigerantleavingthe evaporator
by meteringthe expansionvalve)
THERMALPROTECTOR
{Opensthe comPressor
clutchcircuitwhen the
temPerature
compressor
becomestoo high)
SWITCH
A/C PRESSURE
is below
Whenthe refrigerant
200kPa(2.0kgtcm' ,28Psi)
or above 3,200kPa132kgflcm',
455 psi),the Ay'Cpressure
switchopensthe circuitto
the A,/Cswitch and stops the
to Protectthe
airconditioning
compressor.
RELIEFVALVE
pressureat the
(Relieves
compressorwhenthe
pressureis too high)
S]
(Suctionand comPression,
I
RECEIVER/DRYER
(Trapsdebris,and
removesmorsturel
f-r--;
(Radiation
of heat)
VAPOR
HIGHPRESSURE
I
LIOUID
HtGHPRESSUBE
LIOUID
LOW PRESSURE
(R-134a)refrigerantwhich does not containchlorofluorocarbonsPay attentionto the following
This car uses HFC-134a
serviceitems:
(R-134a)'
They are not compatible'
CFC-12(R-12)and HFC-134a
Do not mix refrigerants
(PAG)refrigerantoil designedfortheR-134acompressor(SANDEN:SPUseonlythe recommendedpolyalkyieneglycol
(pAG)refrigerantoil with any other refrigerantoil will resultin
Intermixingihe re-commended
10; DENSO:ND_OIL8).
compressorfailure.
expansionvalve'
dischargeline,suctionline,evaporator,condenser,receiver/dryer,
. All A,,icsystemparts{compressor,
parts'
R-l2
with
O-ringsfor joints)haveto be properfor refrigerantR-134a Do not confuse
. Usea halogengas leakdetectordesignedfor refrigerantR-134a
station
. R-12and R-134arefrigerantservacingequipment are not interchangeable.Use only a recovery/recycling/charging
systems'
air
conditioning
R-134a
to
service
J2210
of
sAE
requirements
meet
the
to
is
certified
that is u,L.-listedand
station before disconnectingany
. Always recover the refrigerant R-134awith an approved recovery/recycling/charging
A,/Cfitting.
.
.
22-5
CircuitDiagram
'96 -
98 Models
UNDER.HOOD
FUSEi
BELAYBOX
N0.41(8rA)
GNITON
SWITCH
N0.42(40A)
UNDED
RASH
FUSE/RELAY
8OX
N 0 . 1 (77 . 5 4 )
COMPBESSOR
CLUTCH
BELAY
BLUMHT
,l
,T'
( E i)
BLUiBED
A/c
I
THERMOSTAI
BLU/REO
CONDENSEF
FANMOTOR
WHT/SLU BLKYEL
3
*F,.X,
2
HEATER
F A Nr l
+
BLK
G751
22-6
swrlcH
BLK
{
G401
G402
3
'o
I
8LK
I
G40l
G402
'99 - 00 Models
8OX
UNDERHOODFUSE/RELAY
N0.41(P,0A)
G N I T OSNW T C H
UNDERDASH
BOX
FUSE/BELAY
N o . l 7( 7 . 5 4 )
N0.42(404)
COMPRESSOR
CLUTCH
FELAY
$*"
BLK
I
G751
O :8PcoNNEcToF
n :20PCONNECToF
coNNEcroR
E 12P
PANEL
CONTROL
HEATER
BLK
d
G401
G402
22-7
Troubleshooting
SymptomChart
NOTE:
. Any abnormalitymust be correctedbeforecontinuingthe test.
. Becauseof the precisemeasurements
needed.usea multimeterwhen testinq.
. Beforeperformingany troubleshooting
procedurescheck:
- FusesNo. 47 l7-5 Al, No. 56 (20 A) in the under-hoodfuse/relay
box, and No. 17 (7.5A) in the under_dash
fuse/relav
box
- GroundsNo. c401, c402, G751
- Cleanliness
and tightnessof alt connectors
Symptom
Remedy
Condenserfan does not run at all.
Performthe proceduresin the flowchart {see page 22-9).
Compressorclutchdoes not engage.
Performthe proceduresin the flowchart lsee page 22-12).
Ay'Csystem does not come on (compressorand fan),
Performthe proceduresin the flowchan (seepage 22-17).
. '96 - 98 models-Performthe proceduresin the flowchart
{seepage21-18).
. '99 - 00 models-Performthe proceduresin the flowchart
(seepage21-35).
Both heaterand A,/Cdo not work.
22-8
CondenserFan
Conden3erfan does not run at all.
Checkthe No. 56 (20A) fuse in the
box, and the
unde.hood frJse/relaY
No. 17 (7.5A) fuse in the underdashfuse/relaybox.
Reolacethe fuse{s),and techeck
Removethe condenserlan rclaY'
andtest it (seepage22 21i
Replacethe condenseifan relav.
FAN RELAY4P SOCKET
CONDENSER
Checkthe under-hoodtus6/relaY
Measurethe vohagebetweenthe
fan
No.2 terminalofthecondenser
relav4Psocketand bodv ground.
ls there batteryvoltage?
JUMPER
wlRE
Check the condenser lan Power
supply circuit:
Connectthe No. 1 and No. 2 teF
fan relay
minalsof the condenser
4Psocketwith a jumperwire
Doesthe condenserfan run?
T o p a g e2 2 - 1 0
Io page 22 11
(cont'd)
22-9
Troubleshooting
CondenserFan(cont'd)
CONDENSER
FAN RELAY4P SOCKET
Checktor an opon in the wi.o:
1. Disconnect
the jumperwire.
2. oisconnectthe condensertan
2P connector.
3. Checkfor continuitybetween
the No. 1 terminalof the condenserfan relay4Psocketand
the No. 1 terminalof the condenserfan 2P connector.
ls therecontinuity?
Rapairop6n in the wirs bgtwcon
the condcnsor tan rclay and the
condgnlar fan.
-=F_
Checkto. en open in the wire:
Checkfor continuitybetweenthe
No. 2 terminalot the condenser
fan 2P connector and body
ground.
ls there continuity?
Replacothe condense.fan motor.
22-10
CONDENSEB
FAN 2P CONNECTOR
Wire side of female terminals
l ! . Ilslx
@
I
Check Ior rn opon in th6 wire
bctwoen the condcnser tan and
body ground, lf iho wirc ii OK,
chcck for poor ground at G751.
Checkthe diode:
the iumPerwire
1. Disconnect
2 . R e m o v et h e A / C d i o d ef r o m
box
the underhoodfuse/relaY
3. Checkfor currentflow in both
directionsbetweenthe A and
B terminals.
B()-=iFA
ls therecurrentflow in onlY
one direction?
A/C DIOOE2P SOCKET
Chockfor an open in the wire:
1 . T u r n t h e i g n i t i o ns w i t c hO N
(ll).
2. Measurethe voltagebetween
the No. 2 terminalof the AJC
d i o d e 2 P s o c k e ta n d b o d y
ground.
ls there battery voltage?
Repairopon in the wire betwe€n
the No. 17 luse and the A/c
diode.
Troubleshooting
Compressor
checkthe No. 56 (20A) fuse in the
under'hoodfuse/relaybox, and the
No. 17 (7.5A) fuse in the under,
dashfuse/relaybox.
Replacethe fussls),and .echeck.
Removethe compressorclutch
relay,and test it {seepage22 21).
COMPRESSOR
CLUTCHRELAY
.P SOCKET
Checkth6 und€r-hoodtu3e/reby
Measurethe voltagebetweenthe
No. 2 terminalof the compressor
clutch relay 4P socketand body
ground.
JUMPER
WIRE
C h e c k t h e c o m p r e s s o rc l u t c h
pow€r supply circuit:
Connectthe No. 1 and No. 2 terminalsof the compressorclutchrelay
4Psocketwith a jumperwire.
Doesthe compressor
clutchclick?
To page 22 14
22-12
fo page 22-13
Ftom page22 12
RELAY
CLUTCH
COMPRESSOR
iaPSOCKET
r--------t RED
Checkto. an opon in tho wire:
the jumperwire
1. Disconnect
2 . D i s c o n n e ctth e c o m P r e s s o r
clutch1Pconnector.
3. Checklor continuitybetween
the No. 1 terminalo{ the com_
pressorclutchrelaY4P socket
and the terminalof the compressorclutch1Pconnector'
L-r-]-_l
l 2 l
I
--r-
l 1 l 3 l
|
I
@
I
H
I
1___J-RED
CLUTCH1P CONNECTOR
COMPRESSOR
Wire sideof femaleterminals
ls there continuity?
Repeiropen in the wiro between
the compressoaclutch relaY and
the comDres3orclulch.
Inspect the comPre3sorclutch
clo.rance, lhe tharmal Protgdor
ISANDENI,and tha compr6ssor
clutch field coil {SANDEN:Soe
pag. 22-33; DENSO: See Pag.
22-10t.
(cont'd)
22-13
Troubleshooting
Compressor
lcont'dl
Frcm page22-12
COMPRESSOR
CLUTCHRELAY
4P SOCKET
CheckIor an open in the wire;
1. Disconnecl
the jumperwire.
2. Turnthe ignitionswatch
ON (ll).
3. l\4easure
the voltagebetween
the No. 4 terminalof the compressorclutchrelay4P socket
and body ground.
l--;l
1
2 |
---r--]
l . l 3|
L-J--J
Repairopen in the wire betw€en
the No. 17 fuso and the compressor clutch relav.
Checkfor an open in the wira:
1. Turn the ignitionswitch OFF,
then reinstallthe compressor
clutchrelay.
2 . M a k es u r e t h e A / C s w i t c hi s
O F F ,t h e n t u r n t h e i g n i t i o n
switchON (ll).
3. Using a *BackprobeSet (T/N
0 7 S A Z 0 0 1 0 0 0 4 )m
, easure
the voltage betweenthe No.
1 7t e r m i n ao
l I the ECM/PCM
connectorA (32P)and body
ground with the ECM/PCM
connectors
connected.
ls there batteryvoltage?
]
A
BLK/YEL
(v)
!
ECM/PCMCONNECTOR
A I32P}
Repairopen in the wirc betweon
the compressor clutch relay and
the ECM/PCtvt.
Wire side of female terminats
To page22-15
*Howto use the backprobe
sets
C o n n e c t t h e b a c k p r o b e a d a p t e r s t o t h e s t a c k a n gp a t c h c o r d s , a n d
connect the cords to a multimeter. Using the wire insulation as a
g u i d e f o r t h e c o n t o u r e d t i p o f t h e b a c k p r o b ea d a p t e r , g e n t l y s l i d e
the tip into the connector from the wire side until it comes in cont a c t w i t h t h e t e r m i n a l e n d o f t h e w i r e ( s e es e c t i o n 1 1 ) .
Frcm page22-14
SWITCH2P CONNECTOR
A/C PRESSURE
Checklor an open in the wire:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C pressure
switch2Pconnector.
3. Turnth ignitionswitchON lll).
4. Measurethe voltagebetween
the No. 1 terminalof the AJC
pressureswitch2P conneclor
and body ground.
wire sideof {emaleterminals
ls therebatteryvoltage?
Repairopen in the wire between
the condenserfan relay tnd the
A/C oressureswitch.
A/C PRESSURE
SWITCH
Check the A/C pressure switch:
1. Turn the ignition switch OFF.
2. Check for continuity between
the No. 1 and No. 2 terminals
of the Ay'Cpressure switch.
ls there continuity?
1o page22-16
Checkfor A/Csystemptessure.
l s t h e p r e s s u r ew i t h i n s P e c i _
f cations?
Repair the A/C pressure Problem
(cont'd)
22-15
Troubleshooting
Gompressor(cont'dl
Frompage22-15
'96 -98 models:
Checkfor an open in thg wire:
'1. Reconnectthe A"/Cpressure
switch2P connector.
2. Make sure the A/C switch is
O F F ,t h e n t u r n t h e i g n i t i o n
switchON (ll).
3. Using a *BackprobeSet {T/N
07SAZ- 001000A),measure
the voltagebetweenthe No. 5
terminalof the ECM/PCM
conn e c t o r C ( 3 1 P )a n d b o d y
ground with the EcM/PcM
connectorsconnected('96 98 models), or between the
No. 27 terminal of the
ECM/PCMconnectorA (32P)
and body ground with the
E C M / P C Mc o n n e c t o r sc o n
nected('99- 00 models).
ECM/PCMCONNECTOR
C 13lPI
Wire sideot femaleterminals
'9!t - 00 mod.bi
ECM/PCMCONNECTOR
A I32P)
3 1
ta
t6
5 0 1
l 1 1E 19
E 9
21 22
10
11
23
21
BLU/RED
Rapdiropen in tho wi?e botwaon
the A/C pr..-ruro lwitch rnd th.
ECM/PCM.
Wire sideot femaleterminals
Check lor loo3e wires or oool
connections at the ECM/PCM
connectoBA l32P)and at the A/C
pressure switch 2P connector, lf
the connectionsare good, substitute a known-good ECM/PCM,
and recheck. lf the svmptom/
indicationgoos away, repbce the
originalECM/PCM.
*How to use the backprobesets
Connectthe backprobeadaptersto the stackingpatch cords, and
connectthe cordsto a multimeter.Usingthe wire insulationas a
guidefor the contouredtip of the backprobe
adapter,gentlyslide
the tip intothe connectorfrom the wire sideuntil it comesin contactwith the terminalend ofthe wire {seesection11}.
22-16
A/C System
A/C system does not come on
{comDressorand fan).
C h e c kt h e N o . 5 6 f u s e i n t h e
u n d e r ' h o o df u s e / r e l a yb o x a n d
the No. 17fuse in the under-dash
box.
fuse/relay
ReDlacethe fus6{s},and recheck.
CONDENSER
FAN RELAY4P SOCKET
Checkfor tn open in the wire:
1 . R e m o v et h e c o n d e n s e rl a n
relayfrom the underhood
luse/relaybox.
2. Turnthe ignitionswitchON {lli.
3- Measurethe voltagebetween
the No. 4 terminalof the con
d e n s e rf a n r e l a v 4 P s o c k e t
and body ground.
Repairopen in the wire between
the No. 17 fuse and the condenserfan r6lay,
Checkthe under-hoodfus€/r6lay
box:
Measurethe voltagebetweenthe
No. 2 terminal of the condenser
f a n r e l a y 4 P s o c k e ta n d b o d y
ground,
YES
Io page 22-18
(cont'd)
Troubleshooting
A/C System(cont'd)
Frompage22-11
A/C THERMOSTAT
3PCONNECTOR
Checktor an open in the wire:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe A/C thermo
stat 3P connector.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the No. 3 terminalof the Ay'C
thermostat3P connectorand
body ground.
Wire side oI femaleterminals
Repai. open in the wire between
tho No. 17 tuso and the A/C the.mostat.
Checkloi an open in the wi.e:
Measurethe voltagebetweenthe
No. 1 terminalof the A,/Cthermo
stat 3P connector and body
ground,
ls there batteryvoltage?
Ropairopen in the wire betwoen
the condedlo. lan rolay and the
A/C thormostat.
Checkthe A/C th6rmostat:
1. Turnthe ignitionswitchOFF.
2. Reconnectthe A,/Cthermostat
3Pconnector.
3. Connectthe No. 2 terminalto
groundwitha iumperwire.
4. Startthe engine.
. _Ff,, __
I 1 1 2 1 3 [
,r,il*"-T",-.r-'..o
wrRE I
Do the fan run and the compressorclutchengage?
To page22-191'96- 98 models)
To page22-20('99- 00 models)
22-18
r'oA - qe m^.lalal
Ftom page22 18
HEATERCONTROLPANELlilP CONNECTOR
Checktor an open in the wire:
1. Turn the ignitionswitch OFF,
t h e n d i s c o n n e ctth e i u m p e r
t
7
I
I
'olx
a
r
6
't1 12 1 3 1 4
BLU/RED
2. Removethe centerdashboard
lower cover lsee section20),
the heatercon'
and disconnect
trol panel14Pconnector.
3. Turnthe ignitionswitchON (ll).
4. Measurethe voltagebetween
the No. 11 terminaland body
ground.
Wire sideof femaleterminals
Repairop6n in the wire bstween
the A/C th€rmostat and th6 hoater
controlpanel.
HEATERCONTROLPANEL1'P CONNECTOR
Checklor an open in the wire:
1. Turnthe ignitionswitchOFF.
2 . D i s c o n n e ctth e h e a t e rI a n
switch6P connector,
3. Checkfor continuitybetween
t h e N o . 1 4 t e r m i n a lo f t h e
heatercontrolpanel14Pcon_
nectorand the No.6 terminal
of the heaterfan switch6P connector.
Wiresideof femaleterrninals
Check for loose wiaes or poor
connections at the heater control
oanel 14P connoctor and hoeter
tan 3witch 5P conn€clor and at
the A/C thermostet 3P connector. ll the connections are good,
raplace the heator control Panel.
7
I
;--?
10
X
4
'll
5
12 13 1 4
1
2
3
a
5
6
GRN
HEATERFAN SW]TCH6P CONNECTOR
Checkfor an open in thGwire:
Checkfor continuitybetweenthe
No. 1 terminalof the heaterlan
s w a t c h6 P c o n n e c t o ra n d b o d Y
ground.
ls the heaterfan switchOK?
2
GRN
Repairopen in the wiro betweGn
the heal.r control Panel and the
heaterfan switch.
ls therecontinu;ty?
1
Wire sideof femaleterminals
Chock tor an open in tho wir€
between the heater lan switch
and body ground. lf the wire is OK,
checkfor poor groundat G401snd
G402.
ReDlacethe heater tan switch.
(cont'd)
22-19
Troubleshooting
('99 00 models)
Frompage22 18
Checklor an open in the wire:
1. Turn the ignitionswitch OFF,
t h e n d i s c o n n e ctth e j u m p e r
HEATERCONTROLPANELanPCONNECTOR
2. Disconnect
the heatercontrol
panel20Pconnector.
3. Turn the ;gnition switch ON
{ i.
4. Measurethe voltagebetween
t h e N o . 1 1 t e r m i n a lo f t h e
heatercontrolpanel20Pconnectorand body ground.
Wire sideof temaleterminals
ls there batteryvoltage?
Checkthe push switch:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe push switch
12Pconnector.
3. Checkfor continuitybetween
the No. I and No. 10terminals
of the push switch 12Pconnectorwith the A/C switch ON.
Ropai. opan in tho wira batwaon
the A/C thermostat and the
hoater control oanol.
PUSHSW]TCH12PCONNECTOR
,/1,/
7
1
5
6
8 1 9 t 0 1 1 12
II
I
Wiresideof femaleterminals
Check for loose wi.es or poor
connectionsel the hgater control
panel 20P connector and push
switch 12Pconnector and at the
A/C thermostat 3P connector. It
tha connectionsare good, substitute a known-good heatea control pan€|, and recheck. lf the
symptom/indication goe3 away,
replacelhe original healer control oan€|,
A/C Thermostat
Test
Test
1.
Relays
thermostat(seepage22-29).
Removethe Ay'C
Connectbafterypowerto the No. 3 terminal,ground
the No. 2 terminal,and connecta test light between
the No. 1 and No.3 terminals.
Thereshouldbe continuitybetweenthe No, 1 and No.2
terminalswhen power and ground are connectedto the
No.3 and No. 4 terminals,and thereshouldbe no continuitvwhen Doweris disconnected.
N O T E rU s ea 1 2V , 3 W - l 8 W t e s tl i g h t .
Dip the IVCthermostatinto a cup filled with ice water,
andcheckthe testlight.
Serp6ntine-typeevaporator
The light shouldgo off at 36 - 39'F{2 - 4"C}or less,and
shouldcome on at 39 - 41"F(4 - 5"C)or more
Laminale-typeevaporator
The light shouldgo off at 39 - 43'F (4 - 6'C) or less,and
shouldcome on at 43 - 45"F(6 - 7'C) or more
,I
'r
In
I
b
Io
I
2
a Condenser
fan relay
a Compressor
clutchrelay
l f t h e l i g h t d o e s n ' tc o m e o n a n d g o o f f a s s p e c i f i e d ,
replacethe PVCthermostat.
12V,3W-18W
t\----,'
t:n
,,l[4..-.
22-21
A/C ServiceTips and Precautions
(R-134a)
(PAG)refrigerantoil*, which are not
refrigerantand polyalkyleneglycol
The air conditionersystemusesHFC-134a
compatiblewith CFC-12(R-12)refrigerantand mineraloil. Do not use R-12refrigerantor mineraloil in this system,and do
not attemptto useR-12servicingequipmenUdamageto the air conditionersystemor your servicingequipmentwill result.
*DENSOND-OlL8l
*SandenSP-10:
. P/N38897- PR7- A01AH:120ml (4 fl.oz)
. P/N38897- P13- A0lAH: 120ml 14ll.oz,4.2lmp.oz)
. P / N3 8 8 9 9 P R 7 - A 0 1 : 4 0 m f ( 1 1 / 3 f l ' o z )
. P/N38899- P13- A0l | 40 mf 111/3ll.oz,1.4lmp'oz)
Use only serviceequipmentthat is U.L. listedand is certifiedto meet the requirementsof SAE J2210to removeR 134a
from the air conditionersystem.
CAUTION:Exposureto air conditioner ref;ige;ant and lubricant vapol or mist can irritate syes, nose and throat, Avoid
breathing the air conditioner refrigerant and lubricant vapor or misl.
lf accidentalsystemdischargeoccurs,ventilatework areabeforeresumingservice.
R-'134a
serviceequipmentor vehicleair conditionersystemsshouldnot be pressuretestedor leaktestedwith compressed
ai.
some mixtures of air and R-t3ila have been shown to be combustible at elevated pressuresand can result
!@@
in tire or explosion causing iniury or property damage. Never use compressedair lo pressuretesl R-134aservice equipment or vehicle 8ir conditioner systoms.
Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand Iubricantmanufacturers.
L
2.
3.
4,
5.
6.
Alwaysdisconnectthe negativecablefrom the batterywheneverreplacingair conditioningpans.
any lines,plug or cap the fittingsimmediately;don't
Keepmoistureand dust out of the system.When disconnecting
removethe capsor plugsuntiljust beforeyou reconnecteachline.
Beforeconnectingany hoseor line,applya few dropsof refrigerantoilto the O-ring.
Whentighteningo. looseninga fitting,usea secondwrenchto supportthe matchingfitting.
station;don't releaserefrigerant
When dischargingthe system,use a R-134arefrigerantrecovery/recycling/charging
into the atmosphere,
Add refrigerantoil after replacingthe followingparts:
NOTE:
. To avoidcontamination,
do not returnthe oil to the containeroncedispensed,and nevermix it with other refrigerant oils.
. lmmediatelyafter usingthe oil, replacethe cap on the container,and sealit to avoid moistureabsorption.
. Do not spill the refrigerantoil on the vehicle;it may damagethe paint;if the refrigerantoil contactsthe paint,wash
it off immediately.
.......2oml (2/3fl.oz,0.7 lmp.ozl
Condenser
.,.,.,.i[5 m{ 11213tl.oz,1,6lmp.ozl
Evaporator
.....10 mf (1/3fl.oz,0.4 lmp.ozl
Lineor hose
10 m{ (1/3fl.oz,0.'llmp.ozl
Receiver/Dryer
25 m{ (5/6 fl.oz, 0.9 lmp.ozl
Leakagerepair
... For compressor replacement. subtract the volume of oil drained trom the
Comptessor
removed compressorfrom A, and drain the calculatedvolume of oilfrom the new
compressor:A - Volume of removed compressor: Volume to drain from new
comoressor.
A: SANDEN 130 mf l/t 113ll.oz, 4.6 lmp'ozl; DENSO140 mf {4 213 ll'oz, 1.9
lmp.oz),
NOTE:Even if no oil is drainedfrom the removedcompressor,don't drain more
t h a nS 0m { 1 1 2 E l l . o z , 1 .l8m p . o zf)r o m t h e n e wc o m p r e s s o r .
NEW
REMOVED
rere
COMPRESSOR
W
0 0
-0_!Tol
| |
22-2 2
COMPRESSOR
W
0 0
-0_a
l00l
lffi 1onrrrutrcI
LEvEr...+jEf,voLUME
^
fi+-sAME
J
A/C SystemTorqueSpecifications
9.8 N'm {1.0kgf'm,7.2lbf'ftl
.. ...................'
O Dischargehoseto the compressor(6 x 1.0mml ...............
9.8 N'm 11.0kgf'm,7.2 lbf'ft}
'... ....... .........
@ Dischargehoseto the condenser{6 x 1.0mm1...................
9.8 N'm (1.0kgl'm, 7.2 lbt'ft)
. . ...........'.....
.
O Condenserpipeto the condenser16x 1,0mm)...............'.
(5
9.8
N'm (1.0kgl'm, 7.2 lbt'ft)
.....
.
...
.
'..........
pipe
x
1.0
mml.........
to the receivel/dryer
@ Condensel
N'm 11.0kgf'm.7.2 lbl'ft)
...
..........
..
.
.
....
9.8
pipe
x
1.0
mm).........
A
to
the
leceiver/dryer
Receiver
{6
O
13 N m (1.3 kgf'm, 9.'l lbf'ft)
@ Receiverpipe B to the receiverpipe A
13 N m (1.3 kgf'm, 9.4 lbnftl
O Receiverpipe C to the receiverpipe B
.......
9.8
N'm (1.0kgf'm,7.2 lbtftl
pipe
x
1.0
mm)
C to the evaporator{6
@ Receiver
(1.0kgf m, 7.2 lbf'ftl
(6
.........'......'.......
9.8
N'm
.
pipe
x
1.0
mml................
B
the
evaporator
to
O Suction
(3.2kgt'm,23 lbf'ftl
31
N'm
...'.
.
......
.
...
......
pipe
pipe
B
A
to
the
suction
Suction
e0
............
. . '.........
31 N'm (3.2kgl'm, 23 lbf'ft|
O Suctionhoseto the suctionpipe A...
.. . ... .. ............
9.8 N'm (1.0kgf'm' 7.2 lbf'ft|
@ Suctionhoseto the compressor(6 x 1.0mm)...................
(8
N'm (2 'l kgf'm, 17 lbf ftl
..-........'.'......-.......24
x
1.25
mm)...
bracket
to
the
compressor
Compressor
@@
44 N'm l'1.5kgf'm, 33 lbf ftl
@ Compressorbracket to the cytinder block (10 x 1.25mml
... ... 59 N'm (6.0kgf'm,'|i} lbf ftl
@ Compressorbracketto the left front enginemounl {12x 1.25mm}...... . . . .. .................
22-23
A/C System Service
Test
Performance
The performancetest will help determineif the air conditionersystemis operatingwithin specifications.
and is cerUseonly serviceequipmentthat is U.L.-listed
tified to meet the reouirementsof SAEJ2210to remove
(R-134a)
from the air conditionersystem.
HFC-134a
CAUTION: Exposure to air conditionor rofrigerant and
lubricant vapor or mist can irrilalo €yes, nose and
throat. Avoid breathing tho air conditioner rstrigerrnt
and lubricant vapor or mist,
lf accidentalsystem dischargeoccurs, ventilate work
areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with
compressedair.
some mixtur$ of air and R-134ahave been
@
shown lo b9 combustible rt glgvatadpr€ssur63and can
resull in tire 01 oxplosion causing inlury ot property
damage. Never uao compre33edair to pressure t99t R134a ssrvico 6quipmsnt or vohicla air conditioner systems.
Additional health and safety information may be obtained
from the refrigerantand lubricantmanufacturers.
'1. Connect a R-134a refrigerant recover/recycling/
chargingstationto the vehicle,as shown,following
instructions.
the equipmentmanufacturer's
2.
l n s e r t a t h e r m o m e t e ri n t h e c e n t e r v e n t o u t l e t .
Determinethe relative humidity and air temperature,
Testconditions:
. Avoid directsunlight.
. Openhood.
. Open front doors.
. Set the temDerature
controlleveror dial to MAX,
COOL,the mode control switch or dial on VENT
and the recirculation
controlswitchon RECIRCULATE.
. Turn the A,/Cswitch on. and the heaterfan switch
on MAX.
. Runthe engineat 1,500rpm.
. No driveror passengers
in vehicle
After running the air conditioningfor 10 minutes
under the above test conditions,read the delivery
temperaturefrom the thermometerin the dash vent
and the high and low system pressurefrom the A,/C
gauges.
22-24
Recovery/Rocycling/Charging
Station
5.
To completethe charts:
. Markthe deliverytemperaturealongthe venicalline.
. Markthe intaketemperature (ambientair temperature) alongthe bottomline.
. Drawa line straightup from the air temperatureto the humidity.
. Marka point 10%aboveand 10%belowthe humiditylevel.
. Fromeachpoint.draw a horizontalline acrossthe deliverytemperature.
. The delivervtemperatureshouldfall betweenthe two lines.
. Completethe low side pressuretest and high side pressuretest in the sameway.
. Any measurements
outsidethe line may indicatethe needfor furtherinspection.
kPa
lkgf/cm'l
lpsil
2900 (30)
I€OI
aoy.
2500 (25)
13601
2000 t20l
t280t
1500{151
12101
DELIVERY
PRESSURE
30io
DELIVERY
PRESSURE
80%
kPa
{kgf/cm')
lpsil
rct
400 86 -l
{4)
t571
980 (101
lr40l
INTAKE
PRESSURE
r3ol
I
300
{3}
I€I
A,-]
200
l2l
t28l
6 8 -
100
tll
1141
0
DELIVERY
TEMPERATURE
I
"'l
INTAXE
PRESSURE
{20r I
,r-]
uo --]
''o'
I
nt
68
(2ot
77
t2sl
86
t3o)
95
135)
10il
l4ol
'F
{"c)
INTAKETEMPERATURE
22-25
A/C System Service
PressureTestChart
Test is on page22-24,
NOTE:Performance
Test results
Relatedsymptoms
D i s c h a r g(eh i g h ) After stoppingcompressor.prespressureaDnor- suredropsto about200 kPa
m a l l yh i g h
{2.0kgflcm,,28psi)quickly,and
then fallsgradually.
Dischargepressureabnormally
Air in system
Reducedor no air flow through
condenser
. Cloggedcondenserfins
. Condenserfan not working properly
Lineto condenseris excessively
hot.
Restrictedflow of refrigerant in system
. Faultycompressordischargevalve
. Faultycompressorseal
. Faultyexpansionvalve
. Moisture in system
Highand low pressuresare balancedsoon afterstoppingcompressor,Lowsideis higherthannormal.
Outletof expansionvalveis not
frosted,low pressuregaugeindicalesvacuum.
Suction(low)
pressureabnormally low
Probabl€cause
Expansionvalve is not frosted,and
low oressureline is not cold. Low
pressuregaugeindicates
vacuum.
. Frozenexpansionvalve
. Faultyexpansionvalve
Frozenevaporator
Dischargetemperatureis low. and
the air flow from vents is restricted.
Suctionpressureabnormally
h i gh
Refrigerant leaks
22-26
Recover,evacuate,and
rechargewith specifiedamount.
Evacuation:see page 22-45
Charging:see page 22-46
Clean.
Checkvoltageand fan rpm.
Checkfan direction.
Restricted
lines
Replacethe compressor.
. Replace,
. Recover,evacuate,and
rechargewith specified
amount.
ReDlace
the exoansionvalve.
Runthe fan with compressor
off. then checkA,/Cthermostat.
Exoansionvalveis frosted.
Cloggedexpansionvalve
Cleanor replace.
Receiver/dryer
outletis cool,and
inlet is warm (shouldbe warm
duringoperation).
Clogged receiver/dryer
Replace.
Low pressurehoseand check
joint are coolerthan the temperature aroundevaporator.
. Expansionvalveopentoo
long
. Looseexpansioncapillary
tube
Repairor replace.
Suctionoressureis loweredwhen
condenseris cooledbv water.
Excessiverefrigerantin system
Recover.evacuate,and
rechargewith specifiedamount.
High and low pressureare equalizedas soon as the compressoris
stopped,and both gaugesfluctuatewhile running.
Faultygasket
Faultyhigh pressurevalve
Foreignparticlestuckin
high pressurevalve
Suctionand dis- Reducedair flow throughcondenser.
chargepressuresabnormally
hi g h
Suctionand dischargepressure
a b n o r m a l llyo w
Remedy
. Cloggedcondenserfins
. Condenserfan not working properly
Replacethe compressor.
Cleancondenser.
Checkvoltageand fan rpm.
Checkfan direction.
Low pressurehoseand metalend
areasare coolerthan evaporator.
Cloggedor kinkedlow pressure hose parts
Repairor replace.
Temperaturearoundexpansion
valveis too low comparedwith
that aroundreceiver/dryer.
Cloggedhigh pressureline
Repairor replace.
Compressorclutchis diny,
Compressorshaftsealleaking Replacethe compressor.
Compressorbolt{s)are diny.
Leaking around bolt(s)
Tightenbolt(s)or replacecompressor.
gasketis wet with oil.
Compressor
Gasketleaking
Replacethe compressor.
Recovery
and is cerUseonly serviceequipmentthat is U.L.-listed
of SAEJ2210to remove
tifiedto meetthe requirements
(R-134a)
from the air conditionersystem
HFC-134a
g/Cha19ingStation
R€covery/Recyclin
CAUTION: Exposure to air conditioner relrigerant and
lubricant vapor or mist can illitate eyes, noss and
throat. Avoid breathing the ail conditioner refrigerant
and lubricant vapor or mist.
lf accidentalsystemdischargeoccurs,ventilatework
areabeforeresumingservice.
R-134aserviceequipmentor vehicleair conditionersystems shouldnot be pressuretestedor leaktestedwith
compressedair.
some mixtures ot air and R'13'[ahavo been
!@@
strown to be combustiblg at elevated pressuresand Gan
resuh in fire or explosioncausinginiury or property damage, Never use compressed air to pressuretest R-134a
serviceequipment or vehicleair conditionersystems.
Additionalhealthand safetvinformationmay be obtained
and lubricantmanufacturers.
from the refrigerant
1,
Connect a R-'134arefrigerant recoverylrecycling/
chargingstationto the vehicle,as shown.tollowing
instluctions.
the equipmentmanufacturer's
2.
Measurethe amountof refrigerantoil removedfrom
the A/C svstem after the recoveryprocessis completed.
NOTE: Be sure to installthe same amount of new
refrigerantoil backinto the Iy'Csystem beforechargtno.
22-27
Evaporator
Replacement
1.
Movethe temperaturecontrolto "HOl"
'96-98: Slidethe temoeraturecontrollever.
'99-00: Turnthe ignitionswitch ON (ll),then turn
the temperaturecontol knob. Turn the ignition
switch off.
7.
Disconnectthe connector from th€ Ay'Cthermostat,
and r€movs the wire harnessfrom the ovaporator.
Remov6tho four self-tappingscrews,tho mounting
bolt and ths mounting nut. Disconnectth€ drain
hose,then remov€th6 avagorator.
Removethe battsry.
Rgcover the refrigerant with a rocovery/recycling/
charging station (see page 22-271.
4.
Remove the bolts, then disconnectth6 suction 8nd
receiverlines from th6 evaoorator.
NOTE: Plug or cap the lines imm€diatoly after disconnectingthem to avoid moisture and dust contamination.
srrcrrc u E
6xl.0mm
9.8 n*ln ll.0 tg6m.
7.2lbtfrl
6 x l.0.nm
9.8l$m lt.o ldm, 7.2bl.tt)
RECEiVER
UNE
Removethe glov6 box (seesection 20).
6.
Removothe self-tappingscr€w and the passeng€r's
dashboardlower cover. Removsthe bolt. the nut
8nd the kn€e bolst6r,th6n r6mov6 th6 fiv6 bolts and
the glove box frame.
22-28
Install in the reverseorder of removal. Make note of
th€ following items.
o lf you'r6 installinga new evaporator,add rofrigerANtOiI {SANDEN,SP-10Or DENSO,ND-OIL8)
lsas page 22-221.
. Replacethe O-ringswith now ones 8t 68ch titting,
and apply 8 thin coat of r€frlgersd oil before
installingthem.
NOTE: Be sure to use the right O-rings for HFC134a(R-134a)to avoid loakago.
. Apply s€alantto tha grommets.
. Mske sure that ther€ is no air leakage.
. Chargs ths system {s€€ page 22-161,and tost its
performance(see pags 22-211.
Overhaul
1 . Pull out the A,/Cthermostatsensorfrom the evaporatorfins.
Removethe self-tappingscrews and clamps from
the housings.
5.
Assemblein the reverseorderof disassemblyMake
noteof followingitems.
.
3. Carefullyseparatethe housings,then remove the
evaporator.
.
removethe expansionvalve.
lf necessary,
valvenuts,use
the expansion
NOTE:Whenloosening
a secondwrench to hold the expansionvalve or the
evaporatorpipe.Otherwise,they can be damaged
6th tin lrom inld side
.
HOUSING
Replacethe O-ringswith new onesat eachfitting,
and apply a thin coat of refrigerantoil before
installingthem.
NOTE:Be sure to use the right O-ringsfor HFCto avoid leakage.
134a(R-134a)
Installthe expansionvalvecapillarytube so that
it is in direct contactwith the suctionline. Then
wrap wathtaPe.
Reinstallthe Ay'Cthermostatsensorto its original
location.
TAPE
Replace.
lvakesurethereis no foreignmatterstuckbetween
Serpentinetype:
%
Laminatetypo:
EVAPORATOR
blow din out of lins
air,
with compressed
60t5mm
l'2.1! O.2inl
6th fin lrom outle'tside
TUAE
CAPILLARY
N
u'
ll
6\
8 N.m 10.8kgt m,
6 tbf.ftl
VALVE
1l
N.m (2.itkgt.m,
17 tbtftl
A/C THERMOST
fesr page22 21
EVAPORA
LOWER
22-29
Compressor(SANDENI
Replacement
1.
lf the compressoris marginallyoperable,run the
e n g i n e a t i d l e s p e e d ,a n d l e t t h e a i r c o n d i t i o n e r
work for a few minutes.then shut the engineoff.
7.
Disconnectthe negativecable from the battery.
Recoverthe refrigerantwith a recovery/recycling/
charging station (see page 22-27l..
Loosenthe center nut of the idler pulley and the
adjusting bolt. then remove the A,/Ccompressorbelt
from the pulleys.Removethe two mounting bolts
from the left front mount, then remove the ly'C compressor belt by passing it through the gap befiiveen
the bodv and the left front mount.
ADJUSTINGBOLT
CENTERNUT
Removethe bolts,then disconnectthe suctionand
dischargelinesfrom the compressor.
NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination.
6xl.0mm
1.0x 1.25mm
aa N.m 14.5kgf,m, 33 bnft)
8.
Remove the four mounting bolts and the compressor.
COMPRESSOR
Removethe condenser(seepage22-44).
NOTE:Do not disconnectthe dischargehose from
the condenser.
Removethe power steeringpump belt (seesection
1 7t .
24 N.m l2.iakgt.m, 17 lbf.ftl
22-30
9.
removethe compressorbracketas follf necessary,
lows.
.
10. lnstallin the reverseorderof removal.Makenote of
the followingitems.
.
Removethe nut and the washer.
NOTE:When tighteningthe nut of the left front
mount, make sure the washeris set properlyon
the left front enginemount as shown.
.
Removethe four mounting bolts and the compressorbracket.
12 x 1.25rrirn
59 N.m 16.0kgt'm,
43 tbf.ft)
COMPRESSOR
BRACKET
.
.
o
.
lf you're installinga new compressor,drain all
the refrigerantoil from the removedcompressor,
and measureits volume.Subtractthe volume of
'130m? 1/3 tl'o2,4 6 lmp'oz);
14
drainedoil from
the result is the amount of oil you should drain
from the new compressor(through the suction
fifting).
Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
beforeinstallingthem
NOTE: Be sure to use the right O-ringsfor HFCto avoid leakage
134a(R-134a)
for R-134aSandenand
Use refrigerantoil (SP-10)
Hadsysspiraltype compressorsonly'
To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
lmmediatelYafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
Do not spill the refrigerantoil on the vehicle;it
may damagethe painu if the refrigerantoil contactsthe paint,wash it off immediately
. Adjust the Ay'Ccompressor belt (see page 22-43)
and the power steeringpump belt (seesection17)'
. Chargethe system(seepage 22-46),and test its
oerformance(see Page22-241
.
WASHER
LEFTFRONT
1.0x 1.25mm
MOUNT
44 N.m (i1.5kg{.m,33 lbl.ft)
22-31
Gompressor(SANDEN)
lllustratedIndex
CENTER
NUT
Replace.
<--
ARMATUREPLATE
lnspection,page22-33
sHrM(s)
Replace.
SNAPRINGB
Replace.
ROTORPULLEY
Inspection,
page22-33
SNAPRINGA
Replace.
FIELDCOIL
lnspection,page 22-33
Replacement.
page22,36
COMPRESSoR
]
(Donot disassembte) ---------------->l
THERMALPROTECTOR
Replace.
page22-33
Inspection,
page22-36
Replacement,
t v
i -
22-32
ClutchInsPection
Checkthe platedpartsof the armatureplatefor color
changes,peelingor other damage lf there is damage.replacethe clutchset.
Releasethe field coil connectorfrom the holder'then
disconnectit. Checkthe thermal protectorfor continuity. lf there is no continuity.replacethe thermal
protecror,
.
Checkthe rotor pulleybearingplay and drag by rotating the rotor pulley by hand Replacethe clutch set
with a new one if it is noisy or has excessiveplay/drag
Measurethe clearancebetweenthe rotor pulleyand
the armature plate all the way around lf the clearance is not within specifiedlimits,the armatureplate
must be removed and shims added or removed as
required,followingthe procedureon page22-34
Cl€arance:0.5 ! 0.15 mm {0.020t 0.006in)
NOTE:The thermal protectorwill have no continuity
1122lo128'C).When the temabove251.6to 262.4oF
peraturedrops below 2408 to 219.8"F(116to 104"C),
the thermalprotectorwill havecontinuity
.
of the field coil
Checkresistance
Field Coil Resistance:3.05to 3.35 O at 68"F (20"C)
replacethe
lf resistanceis not within specifications,
field coil.
NOTE:The shims are availablein four thicknesses:
0 . 1m m , 0 . 2m m , 0 . 4m m a n d0 . 5m m
22-33
Compressor{SANDEN)
Clutch Overhaul
1.
Removethe center nut while holding the armature
platewith the tool.
CENTERNUT
17.6N.m {1.8kg{.m,'t3tbnft}
A/C CLUTCHHOLDER
{Commerciallvaveilable)
Robinair:P/N 10204
Kent-Moore:P/N J37872
3.
Removesnap ring B with snap ring pliers.
NOTE:
. Be careful not to damage the rotor pulley and
compressorduring removal/installation.
. Once snap ring B is removed,replaceit with a
new one.
A
\ /
G::.
r\t \\:g2rl
.
.
2.
-
!
L
;
j
'
-/
/
/
Removethe armatureplateby pullingit up by hand.
ARMATURE
PLATE
Removethe rotor pulleyfrom the shaftwith a puller
and the specialtool.
NOTE:Placethe claws of the puller on the back of
the rotor pulley,not on the belt area;otherwisethe
rotor pulleycan be damaged.
TWOJAW PULLER
{Commercially
22-34
5.
Removethe screwfrom the field coil groundterminal,then disconnecthe field coil connector.
R e m o v es n a p r i n g A w i t h s n a p r i n g p l i e r s ,t h e n
removethe field coil
NOTE:
. Be carefulnot to damagethe field coil and compressorduringremove/installation.
. Once snap ring A is removed,replaceit with a
new one.
. When installingthe field coil, align the boss on
the field coil with the hole in the compressor.
7.
A s s e m b l ei n t h e r e v e r s eo r d e r o f d i s a s s e m b l y
Makenote of the followingitems.
lnstallthe fieldcoilwith the wire sidefacingdown.
C l e a nt h e r o t o r p u l l e ya n d c o m p r e s s o sr l i d i n g
solvent.
surfaceswith non-petroleum
. Make sure the snap rings are fully seatedin the
groove.
. Make sure that the rotor pulley turns smoothly
after it's reassembled
. Routeand clamp the wires properlyor they can
be damagedbYthe rotor Pulley.
.
.
SNAP RINGA
Replace.
Positionthe rotor pulleysquarelyover the field coil.
Pressthe rotor pulley onto the compressor boss
with the specialtool. lf the rotor pulley does not
press on straight, remove it, and check the rotor
pulleyand compressorbossfor burrsor damage.
CAUTION: Maximum press load: 39,200 kPa
(,[00kgf/cm', 5,590Psi)
Press
T
HUB ASSEMBLY
GUIDEATTACHMENT
07965 - 6920500
ROTOR
PULLEY
t'l
i,'
22-35
Compressor(SANDENI
ThermalProtestorReplacement
ReliefValveReplacement
1.
'1.
Removethe bolt, the groundterminaland the holder. Disconnectthe field coil connector.then remove
the thermal Drotector.
7.{ N.m 10.75ksf.m,5lbtfr)
/
GROUND
IERMINAL
Removethe reliefvalveand the O-ring.
NOTE:
. Do not let the compressoroil runout.
. Make sure that no foreign matter enters the system,
HOI.I'ER
PNOTECTOR
o o
RELIEF
VALVE
9.8 N.m {1.0kgl.m,
7.2 tbl.lrl
O.RING
Replace.
Cleanthe matingsurfaces.
Replacethe thermal protectorwith a new one. and
apply siliconesealantto the top of the thermalprotector.
Replace
the O-ringwith a new one at the reliefvalve.
a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l b e f o r e
installingit.
NOTE:
. To avoid contamination.do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
o lmmediatelyafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint; if the refrigerantoil contactsthe paint,wash it off immediately.
Installand tightenthe reliefvalve.
SILICONESEALANT
3.
Install in the reverse order of removal.
22-36
Charge the system {see page 22-461,and test its
performance1se6page 22-241.
Compressor(DENSO)
Replacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er, u n t h e
work
engineat idlespeed,and let the air conditioning
off
engine
for a few minutes,then shutthe
the negativecablefrom the battery'
Disconnect
7.
Loosenthe pivot bolt of the idler pulleybracketand
the adjusting bolt. then remove the A,/Ccompressor
beltfrom the pulleys.lf necessary,removethe mounting bolts from the left front mount. then remove the
fuC compressorbelt through the gap betweenthe
bodv and the left front mount.
Recoverthe refrigerantwith a recovery/recycling/
charging station lsee page 22-271
PIVOTBOLT
10x 1.25mm
4,1N.m(4.5kgt'm,33lbfft)
Removethe each bolt, then disconnectthe suction
and dischargelines from the compressor'Plug or
them
cap the lines immediatelyafter disconnecting
to avoid moistureand dust contaminatlon.
6 x '1.0mm
9.8 N.m (1.0kgf m,7.2 lbfft)
'10x 1,25mm
4,0N.m (,1.5kgf'm. 33 lbt ftl
Disconnectthe compressorclutch connector,then
removethe mountingboltsandthe compressor'
COMPRESSOR
the disbut do not disconnect
Removethe condenser,
chargehosefrom the condenser(seepage22-441'
Removethe power steeringpump belt (seesectron
17]-.
24 N.m (2.4 kgf m, 17 lbf ftl
(cont'd)
22-37
Compressor(DENSOI
(cont'd)
Replacement
9. Removethe bolts,the suctionservicevalveand the
O-ringfrom the compressor,
2s.5N.m{2.6kgf.m.18.8tbtttl
1 0 . lf necessary,remove the compressor bracket as follows.
.
Removethe nut and the washerfrom the leftfront
mount.When tighteningthe nut to the left front
mount, make sure the washeris set p.operlyon
the leftfront mountas shown.
a Removethe mountingbolts and the compressor
bracket.
LEFTFRONT
MOUNT
12 x 1,25rnm
59 N.m 16.0kgfrm,
€ rbf.fi)
Roplace.
WASHEB
x 1.25mm
4/r N.m {4.5 kgf.m, 33 lbt ft}
22-3A
11. Installin the reverseorder of removal,and note these
rtems:
lf you'reinstallinga new compressor.
drainall the
refrigerantoil from the removedcompressor.and
m e a s u r ei t s v o l u m e . S u b t r a c tt h e v o l u m e o f
drainedoil from '140ml (4 28 fl{,z, 4.9 lmpoz); the
resultis the amountof oil you shoulddrainfrom
the new compressor(throughthe suctionfifting).
Replacethe O-ringswith new onesat eachfining,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the right O,rings
(R-134a)
for HFC-134a
to avoidleakage.
Use refrigerantoil {DENSO,ND-OtL8)for HFC-134a
DENSOpistontype compressorsonly.
To avoid contamination,do not returnthe oil to
the containeronce dispensed,and never mix it
with other refrigerantoils.
lmmediatelyafter using the oil, replacethe cap
on the container,and seal it to avoid moisture
absorption.
Do not spill the refrigerantoil on the vehicle;it
may damagethe paint;if the refrigerantoil contactsthe paint,wash it off immediatelv.
Adjust the ly'C compressor belt (see page 22-43)
and the power steeringpump belt (seesection 17).
Charge the system (see page 22-46),and test its
performance(see page 22-24!..
lllustratedIndex
BOLT
CENTER
PLATE
PBESSURE
Inspection,
Page2240
).-
sHrM(s)
SNAPRINGB
Replace.
PULLEY
Inspection,
Page22'40
SNAPRINGA
Replace.
FIELDCOIL
page22 40
Inspection,
RELIEFVALVE
page22'42
Replacement,
SUCTIONSERVICEVALVE
22-39
Compressor(DENSOI
ClutchInspection
Checkthe platedpartsof the pressureplatefor colo.
changes,peelingor other damage.lf there is damage,replacethe clutchset.
Checkthe pulley bearing play and drag by rotating
the pulleyby hand,Replacethe clutchset with a new
one if it is noisyor hasexcessiveplay/drag.
Measurethe clearancebetweenthe pullev and the
pressureplate all the way around.lf the clearanceis
not within specifiedlimits,the pressureplatemust be
removedand shim(s)addedor removedas required,
followingthe procedureon page22-41.
Clearanca:0.5
t 0.15mm {0.020r 0.006in}
NOTE:The shims are availabtein three thicknesses:
0 . 1m m , 0 . 3m m a n d 0 . 5m m .
22-40
.
Checkresistanceof the field coil. lf resistanceis not
within specifications,
replacethe field coil.
Fiald Coil Resistanc€:3.it to 3.8 O at 20.C l68.Fl
ClutchOverhaul
1.
Removethe centerbolt while holdingthe pressure
olatewith the sPecialtool.
3.
Removethe snap ring B with snap ring pliers,then
remove the pulley Be careful not to damage the
pulleyand comPressor'
CENTERBOLT
13.2N.m (1.35ksl m, 9.?6 lbf'ft)
SNAPRINGB
Replace.
A/C CLUTCH HOLOER
(Commercially
available)
Robinair: P/N 10204
P/NJ37872
Kent-Moore:
'.L-)
.'l
5$ f-t
1 / - -l l- (l ,
vll/
Removethe pressureplate and shim(s).takingcare
not to losethe shim{sl.
PAESSURE
PLATE
(cont'd)
22-41
Compressor(DENSO)
ClutchOverhaul(cont'd)
Removethe screwfrom the field coil ground terminal. Removethe snap ring A with snap ring pliers.
then removethe field coil. Be carefulnot to damaoe
the field coil and compressor.
ReliefValveReplacement
L
Recoverthe refrigerantwith a recovery/recycling/
charging station {see page 22-27),
Removethe relief valve and the O-ring. plug the
opening to keep foreign matter from enteringthe
systemand the compressoroilfrom runningout.
SNAPNINGA
Replace.
FIELO
corL
13.2N.m 11.35kgt m,9.76lbtttl
Reassemblethe compressorclutch in the reverse
orderof disassembly,
and notetheserrems:
o I n s t a l lt h e f i e l d c o i l w i t h t h e w i r e s i d e f a c i n g
down.
a Cleanthe pulleyand compressorslidingsurfaces
with non-petroleum
solvent.
. Installnew snap rings, and make sure thev are
fully seatedin the groove.
. Make sure that the pulley turns smoothly after
it's reassembled.
. Routeand clamp the wires p.operlyor they can
be damagedby pulley.
22-42
Cleanthe matingsurfaces.
4.
Replace
the O-ringwith a new one at the reliefvalve.
and applya thin coatof refrigerantoil beforeinstalling it.
Removethe plug, and installand tighten the relief
vatve.
Chargethe system (see page 22-46),and test its performance (seepage 22-24),
A/G GomPressorBelt
Adjustment
DetlectionMethod
Tension Gauge Method
'1. Apply a force of 98 N (10 kgf, 22 lbf), and measure
the deflectionbetweenthe A,/Ccompressorand the
crankshaftPulleY
1.
A/C CompressorBelt
Used Belt: 816A2 engine
390 - 540 N (40 - 55 kgf, 88 - 120 lbll
Except 816A2 engine
340 - 490 N (35 - 50 ksf, 77 - 110 lbfl
engine
B16A2
New Belt:
?40 - 880 N {75 - 90 ksf' 170- 200 lbf)
Except Bl642 engine
690 - 830 N (70 - 85 ksf, 150- 190 lbf)
A/C ComPressorBelt
Used Belt: 816A2 engine
6.0- 9.5 mm 102'l - 0.37inl
Except 816A2 engine
7.5- 9.5 mm (0.30- 0.37in)
engine
816A2
Belt:
New
4 . 5 - 6 5 m m ( 0 . 1 8 - 0 . 2 6i n )
Except 815A2 engine
5 . 0 - 5 5 m m ( 0 . 2 0 - 0 . 2 6i n l
Notetheseitemswhen adjustingbelttension:
. F o l l o wt h e m a n u f a c t u r e r 'isn s t r u c t i o n fso r t h e
belttensiongauge.
. lf there are cracksor any damageevidenton the
belt,rePlaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
for lessthan five minutes
Notetheseitemswhen adjustingbelttens'on:
. lf there are cracksor any damageevidenton the
belt,replaceit with a new one.
. "Used belt" means a belt which has been used
for five minutesor more.
. "New belt" means a belt which has been used
tor lessthan five minutes.
2.
or
Loosen,the centernut ofthe idlerpulley(SANDEN),
lock
the
and
pulley
bracket
idler
the
the pivot bolt of
nut ofthe adjustingbolt(DENSO).
3.
Turn the adjustingbolt to get properbelttension'
4.
5.
the centernut of the idlerpulley(SANDEN),
Retighten
pivot
boltof the idlerpulleybracketandthe lock
or the
nut of the adjustingbolt(DENSO).
Recheckthe deflectionof the A,/Ccompressorbelt'
Attachthe specialtool to the IVCcompressorbelt as
shownbelow,and measurethe tensionof the belt
2
or
Loosenthe centernut of the idlerpulley(SANDEN)'
the pivot bolt of the idler pulleybracketand the lock
nut of the adjustingbolt(DENSO).
3.
Turn the adjustingbolt to get properbelttension
4.
5.
the centernut of the idlerpulley(SANDEN),
Retighten
or the pivot bolt of the idler pulleybracketand the lock
nut of the adjustingbolt(DENSO)
Recheckthe tensionof the A/Ccompressorbelt'
22-43
Condenser
Replacement
1 . Recoverthe refrigerantwith a recovery/recycling/
charging station lsee page 22-271.
4.
Removethe bolt from the suctionhose bracket,and
removethe two bolts and the upper mount bracket.
Removethe condenserassemblyby liftingit up.
Disconnectthe condenserfan connectorfrom the
Ay'Cwire harness,then remove the A,/Cwire harness
from the condenserfan shroud.
NOTE:Be carefulnot to damagethe condenserfins
when removingthe condenserassembly.
UPPER
MOUNTBRACKET
6x1.0mm
9,8 N.m 11.0kg{.m,7.2lbtft}
6x1.0mm
9.8 N.m 11.0kst m, 7.2 lbf.ftl
Remove the bolts, then disconnectthe discharge
and condenserlinesfrom the condenser.
5.
NOTE:Plug or cap the lines immediatelyafter disconnectingthem to avoid moisture and dust contamination,
6x1.0mm
olscHARGE
L|NE 9.8N.m11.0
6r1.0
9.8 N.m 11.0kgl.m, 7.2 lbf.ftl
22-44
Install in the reverseorder of removal. Make note of
the followingitems.
.
lf you're installinga new condenser,
add refriger, P - 1 0o r D E N S O ,N D - O | L8 )
a n t o i l ( S A N D E NS
\see page 22-22l.. Replacethe O-ringswith new ones at each fitt i n g , a n d a p p l y a t h i n c o a t o f r e f r i g e r a n to i l
befo.einstallingthem.
NOTE;Be sure to use the right O-ringsfor HFC,
134a(R-134a)
to avoid leakage.
o B e c a r e f u l n o t t o d a m a g et h e c o n d e n s e rf i n s
when installingthe condenserassembly.
. Charge the system (see page 22-46),and test its
performance(see page22-24i.
A/C System Service
Evacuation
Useonly serviceequipmentthat is U L.-listedand is certified to meet the requirementsoJ SAEJ2210to remove
(R-134a)
from the air conditionersystem'
HFC-134a
g/Chal9ing Station
R6covory/Recyclin
CAUTION: Exposure to air conditioner reftig€lant and
lubricantvapor or misi can irrhaie eyes. noso and throat'
Avoid breathing the ail condhioner lefrigelant and lubri
cant vapor or mist.
lf accidentalsystem dischargeoccurs,ventilate work
areabeforeresumingservace.
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretested or leak tested with
air.
comDressed
some mixtures of air and R-13'[8haYoboon
!!@@
ffiiE-n to be "ombustible at elovatodpressurcsand can
result in fire or explosion causing iniury or propsrtY
damag€. Never uso complsssod air to pre3surs tost R1344 ssrvico equipment or vehicle air conditioner sy3tems,
Additional health and safety information may be obtained
from the refrigerantand lubricantmanuJacturers'
1 . When an A,/CSystemhas beenopenedto the atmosphere,such as during installationor repair,it must
be evacuatedusing a R-134arefrigerantrecovery/
station.(lf the system has been
recycling/charging
should be
open for severaldays,the receiver/dryer
for
evacuated
be
should
system
replaced,and the
severalhours.)
Connect a R-134a refrigerant recovery/
stationto the vehicle,as shown'
recycling/charging
e
q
u
i p m e n tm a n u f a c t u r e r 'isn s t r u c t
h
e
following
trons.
NOTE: lf low pressuredoes not reachmore than 93 3
kPa (7OOmmHg,27.6 in.Hgl in 15 minutes,there is
probablya leak in the system Partiallychargethe
system,and checkfor leaks(seeLeakTest)
22-45'
A/C System Service
Charging
LeakTest
Use only serviceequipmentthat is U.L.-listed
and is certified to meet the requirementsof SAE J2210to remove
(R-134a)
HFC-134a
from the air conditionersystem.
Use only serviceequipmentthat is U.L,-listed
and is certified to meet the requirementsof SAEJ2210to remove
(R-134a)
HFC-134a
from the air conditionersystem.
CAUTION: Exposure to air conditioner refrigerant and
lubricant vapor or mist can irritale eyes, nose and
throat. Avoid breathing the air conditioner retrigerant
and lubricant vaoor or mist,
CAUTION: Exposure io air conditioner refrigerant and
lubricant vapot or mist can itritats eyes,no36and thtoat.
Avoid breathing the air conditioner refrigeranl and lubricant vapor or mist,
lf accidentalsystem dischargeoccurs,ventilate work
a r e a b e f o r er e s u m i n gs e r v i c e ,A d d i t i o n a lh e a l t ha n d
safetyinformationmay be obtainedfrom the refrigerant
and lubricantmanufacturers.
lf accidentalsystem dischargeoccurs,ventilate work
areabetoreresumingservice.
Refrigerantcapacityt 600- 650 g 121.1- 22.9 ozl
CAUnON: Do not overcharg€ the system; the comprcssor
will be damaged.
R-134aserviceequipmentor vehicleair conditionersystems should not be pressuretestedor leaktestedwith
comoressedair.
Connect a R-134arefrigerant recovery/recycling/charging
stationto the vehicle,as shown,followingthe equipment
manufacturer'sinstructions.
some mixtures of air and R-134a have
@
been shown to be combugtibls at elevatgd prossures
and can result in tire or explosion causing iniuly or
plopgrty damage.Nev€r usc compre33odair to pressure
test R-13'laservica oquipment or yohiclo air conditionor
systems.
Recovery/Recycling/Charging
Station
Additional health and safetyinformation may be obtained
from the refrigerantand lubricantmanufacturers.
1.
Connect a R-134arefrigerant recoverylrecycling/
chargingstationto the vehicle,as shown in the previous column,followingthe equipmentmanufacturer's instructions.
NOTE;Be sure to installthe same amount of new
refrigerantoil back into the A,/Csystem before chargIn9.
Open the high-pressure
valveto chargethe system
t o t h e s p e c i f i e dc a p a c i t y ,t h e n c l o s e t h e s u p p l y
valve,and removethe chargingsystemcouplers.
Rofrigerantcapacity:600 - 650 g (21.1- 22.9 oz)
Checkthe system for leaks using a R-134arefrigerant leak detectorwith an accuracyof 14 9 10.5ozl
per yea. or better.
lf you find leaksthat requirethe systemto be opened
(to repair or replacehoses.fittings. etc.),recoverthe
system accordingto the RecoveryProcedureon page
22-27.
After checkingand repairing leaks.the system must
be evacuated(seeSystemEvacuationon page22-451.
22-46
l'f .
Electrical
....................23-89
. , . . . . . . . . . . . . . . . . . . . . , 2 3 - *2t g n i t i o nS w i t c h
S p e c i aTl o o f s
.......,.... 23-102
l
g
n
i
t
i
o
n
S
y
s
t
e
m
Troubleshooting
*
l
n
t
e
g
r
a
t
e
d
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . . . . . . . . .2. 3
. .-.1. .5. .6. . . .
U
n
i
t
C
o
n
t
r
o
l
.
2
3
3
.
.
.
.
.
.
.
.
.
.
.
.
.
.
,
.
.
.
.
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.
.
.
.
.
.
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.
.
.
.
.
.
.
.
P
r
e
c
a
u
t
i
o
n
s
T i p sa n d
. . , ,23-144
,........
fnterlockSystem
. . 23-5
.........
Five-stepTroubleshooting..............
23-161
. . . .. .........
LightingSystem
..........,23-5
w i r e c o l o rc o d e s
Lights, Exterior
. 3-6
S c h e m a t iS
c y m b o l s. . . . . . . . , . . . . . . . . . . . ..............2
..'............23'171
Back-upLights
Relayand ControlUnit Locations
23'174
..................
Lights
Brake
..
.
23'7
...
...,.....................
EngineCompartment
23'166
. . . . . . . . . . . . . . . . . . . . . . 2 3 - 8 DaytimeBunningLights(Canadal...............
Dashboard
F r o n tP a r k i n gL i g h t s. . . . . . , . . . . . . . . . . '... . . . . . . . .2. 3. - 1 6 7
. . . . . . . . .2 3 - 1 2
Dashboard/Door
*Airbags.................
l i g h t s. . . . . . . . ... . . . . . . . . .....,.. 2 3 - 1 6 7
F r o n tT u r nS i g n a L
.......Section24
.....23'167
....".'....-...
Headtights
21
.........
Section
Air Conditioning
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
...23'179
B
r
a
k
e
L
i
g
h
t
M
o
u
n
t
H
i
g
h
"
"
"
2
3
1
1
2
.
.
.
.
.
.
.
.
.
.
.
"
"
"
Aftelnator
......23'176
LicensePlateLights
Section19
Anti-lockBrakeSystem{ABS)
.......23'171
*A/T GearPositionIndicator.....................,.
T a i t f i g h t .s. . . . . . . . . . . . . . .
.......23-149
. 23-142
..-.......,,
lnterior
Lights
Svstem ..... .......Section14
AutomaticTransmission
.
.
,
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. .2, .3. -. .2. 3. .5.
M
o
o
n
r
o
o
f
.
.
.
.
.
.
.
.
.
.
.
.
.
2
3
9
1
.
.
.
.
.
.
B a t t e r v. . . . . . . .
........ . .23-61
PowerDistribution
.. . ... Section2l
Blowercontrols
.......,,,..23'251
....'...........23'112 PowerDoor Locks
ChargingSystem
,..............,.,...23'206
Mirrors
Power
Connectorldentilicationand Wire Harness
......23'13
........ ....... . .. 23-86
R o u t i n g. . . . . . . . . . . . . . . . . .
PowerRelays
............,,....23-220
............,........23-240PowerWindows
CruiseControl
.......23-180
. . ... . . 23-2OO
RearWindow Defogger..........................
DashLightsBrightnessController.............
.
.
. . . .. . . . . 2 3 - 1 1 1
23'126
.
.
.
.
.
.
.
""
Fan controfs
S p a r kP l u g s
................23-93
. . . . . . . . . . . . . s. .e c t i o n1 1
F u e lP u m D
S l a r t i n gS y s t e m
*stereo SoundSvstem ,.................
...............,.2
. ,3, .' .6 2
........ . ... ,.,.,,23'147
Fuses/Refay
'Supplemental Restraint System (SRS)... . Section 24
1
1
Section
PGM-FIControlSystem......................,.......
*Gauges
23-173
FlasherSystem .......'.'....-...
Turn Signal/Hazard
23-85
. . . . , . , . . . . . . . 2 3 - 1 3*Undel-dash
1
Box ............,..................
Fuse/Relay
C i r c u iD
t iagram
"""" ""' 23-140
. . . . . . . . . . . ' . ' . . . . . . . 2 3 - 1 4vehicfe
2
F u e fG a u g e
soeed sensor (VSSI
.. . .. 23-129 +Wipers/Washers
.........,.,.,...23-214
Gauge/lndicator
.. . 23-75
GroundDistribution
.. . .....Section21
Heateicontrols
*Horn.................
. . . . . . . . . . . . . . . 2 3 - 1 9NOTE:
6
Unlessotherwisespecified,referencesto auto(Mf) in this sectionincludethe CVT.
matictransmission
SpecialTools
Tool Number
Ref. No.
Description
Oty
V a c u u mP u m pG a u g e0, - 3 0 i n . H g .
B e l tT e n s i o nG a u g e
@Test Harness
FuelSenderWrench
@
SCSServiceConnector
KeylessEntryChecker
tol
': Included
i n B e l tT e n s i o nG a u g eS e t0 7 T 6 6- 0 0 1 0 0 0 4
O)
o
o
A 9 7 3 X _ 0 4 1_ X X X X X
07JGG 00l0l0A
OTLAJ- PT3O2OA
07NAC- SR20100
07PM - 0010r00
07MAJ- SP00300
or
(!
23-2
1
1
'I
1
1
1
/4,
PageReference
23-245
23-140,141
23-142
23-105
23-264
Troubleshooting
ll.
Tips and Precautions
N e v e rt r y t o d i s c o n n e c ct o n n e c t o r sb y p u l l i n g o n
their wires;pull on the connectorhalvesinstead
Alwavs reinstallplasticcovers.
Before Troubleshooting
. Checkapplicablefuses in the appropriatefuse/relay
box.
. Checkthe batteryfor damage,state of charge,and
cleanand tight connections.
. Checkthe alternatorbelttension.
CAUTION:
. Do not quick-chargea battery unless the battery
ground cable has been disconneqted,otherwise you
will damage the alternator diodes.
. Do not attempt to crank the engine with the battery
ground cable loosely connecled or you will severely
damagethe wiling,
Beforeconnectangconnectors,make sure the termlnalsare in placeand not bent.
Handling Connectois
. Makesurethe connectorsare cleanand haveno loose
wire terminals.
. Makesure multiplecavityconnectorsare packedwith
grease(exceptwatertightconnectors)
. All connectorshavepush-downreleasetype locks.
LOCKINGTAB
.
Some connectorshave a clip on their side used to
attach them to a mount bracketon the body or on
anothercomponent.This clip has a pulltype lock.
Some mounted connectorscannot be disconnected
unlessyou first releasethe lock and removethe connectorfrom its mount bracket.
Checkfor looseretainerand rubberseals.
RETAINER
T h e b a c k s o f s o m e c o n n e c t o r sa r e p a c k e d w i t h
lf the greaseis congrease.Add greaseif necessary.
taminated,replaceit.
LOCKING
PAWL ON
OTHER
Pullto
HALF OF
drsengage
CONNECTOR
BRACKET
(cont'd)
23-3
Troubleshooting
Tips and Precautions(cont'dl
Insertthe connectorall the way and make sure it is
securelvlocked.
Positionwires so that the open end of the coverfaces
down.
V
.
NOT GOOO
F6c6
op€n end
Handling Wires and Harnosscs
. Securewires and wire harnessesto the frame with
their respectivewire ties at the designatedlocations,
. Removeclipscarefully;don't damagetheir locks.
Slip pliers under the clip base and through the hole at
an angle,then squeezethe expansiontabs to releasethe
clrp.
Seatgrommetsin their groovesproperly.
l l
i l , /
il
,,
_ s*'
Y - - _ Y 5-.1}8."/
\
Testing and Repairs
o Do not usewires or harnesseswith brokeninsulation.
Replacethem or repairthem by wrspping the break
with electricaltaoe.
. After installing parts, make sure that no wires are
pinchedunderthem.
. W h e n u s i n g e l e c t r i c a tl e s t e q u i p m e n t ,f o l l o w t h e
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. lf possible,insert the probe of the tester from the
wire side (exceptwaterproof connector).
.
Use a probewith a taperedtip.
SNAP-BINGPLIERS
After installingharnessclips, make sure the harness
doesn'tinterferewith any moving pans.
Keep wire harnessesaway from exhaust pipes and
other hot parts. from sharp edges of bracketsand
holes,and from exDosedscrewsand bolts.
23-4
Referto the instructionsin the HondaTerminalKit for
identificationand replacementof connectorterminats.
t
Five-stepTroubleshooting
1.
V e r i f yT h e C o m p l a i n t
Turn on all the componentsin the problemcircuitto
verifythe customercomplaint.Note the symptoms.
Do not begin disassemblyor testinguntil you have
narroweddown the problemarea.
2.
AnalyzeThe Schematic
L o o k u p t h e s c h e m a t i cf o r t h e p r o b l e mc i r c u i t .
Determinehow the circuit is supposedto work by
tracing the current pathsfrom the power feed
throughthe circuitcomponentsto ground.lf several
circuitsfail at the sametime, the fuse or ground is a
likelycause.
Basedon the symptomsand your understandingof
the circultoperation,identifyone or more possible
causesof the problem.
3.
lsolateThe ProblemBy TestingThe Circuit
Makecircuitteststo checkthe diagnosisyou made
in step 2. Keepin mind that a logical,simple proceTestfor
dure is the key to efficienttroubleshooting.
make
first.
Try
to
the most likely cause of failure
points
accessible.
that
are
easily
at
tests
Wire ColorCodes
T h e f o l l o w i n ga b b r e v i a t i o nasr e u s e dt o i d e n t i f yw i r e
colorsin the circuitschematics:
w H T . . . . . . . . . . . . . . . . . . . .W
. . .h. i.t.e. . .
Y E L. . . . . . . . . . . . . . . . . . . . . Y
. .e
. .l.l.o. w
...
BLK............,.,...............81ack
B L U . . . . . . . . . . . . . . . . . . . . .B. .l.u. e
.....
GRN.............................Green
R E D. . . . . . . . . . . . . . . . . . . . .R. .e, .d. . . . .
. . r. .a. n. .g. .e
O R N . . . . . . . . . . . . . . . . . . . .O
P N K. . . . . . . . . . . . . . . . . . . . .P. .i.n. k. . . . .
B R N. . . . . . . . . . . . . . . . . . . . .B. .r.o. .w. .n. .
. .r.a. .y. . . .
G R Y. . . . . . . . . . . . . . . . . . . . .G
P U R. , . . . . . . . . . . . . . . . . . , .P, .u. .r .p. l. e. .
L T B L U . . . . . . . . . . . . . . . . . .L. i.g. .h. .tB. l u e
L T G R N. . . . . . . . . . . . . . . . .L. .i .g.h. .tG
. reen
T h e w i r e i n s u l a t i o nh a s o n e c o l o r o r o n e c o l o r w i t h
anothercolor stripe.The secondcolor is the stripe.
WHT/BLK
FixThe Problem
, a k et h e
O n c et h e s p e c i f i cp r o b l e mi s i d e n t i f i e dm
proceproper
and
safe
use
tools
Be
sure
to
repair.
dures.
MakeSureThe CircuitWorks
Turn on all componentsin the repairedcircuitin all
modes to make sure you've fixed the entire probl e m . l f t h e p r o b l e mw a s a b l o w n f u s e , b e s u r e t o
test all of the circuitson the fuse,Makesure no new
problemsturn up and the originalproblemdoes not
recur.
23-5
Troubleshooting
SchematicSymbols
BATTERY
E
@
RESISTOR
I
f
II
II
_d
:
_..
'-
ilHc
VARIAELE RESISTOR
MOTOR
PUMP
THERMISTOR
CIRCUIT BREAKER
I
0 H
Y II
rYr
T
ANTt:f\,NA
TRANSISTORlTrl
Mast
RELAY lln no fmal poaitionl
Normallyopon relay Normally closed relay
| ....--1
'rl*r
t
t"t^fi l
FUSE
GROU N D
GroLrndterminal
Componentground
ffl - + - |
l r l
l r l
fff
CONDENSER
I
T
--cn-.e
COIL,SOLENOID CIGARETTELIGHTER
r{r
tql
'|
BULB
IGNITIONSWITCH
-fo
+
+ +
o.t-
HORN
DIODE
SWITCH (ln nirrdal positionl
Normally open
Normally closed
I
/F\
ttL I
\Y/
I
:CTION
CONNT
Input
Output
V
J
I
'*i."n
@
I
CONNECTOR
A
lrl
P
HEATEB
A
t-l
F
SPEAKER,BUZZER
D
LIGHTEMITTING
DIODEILEDI
A+,
T T
REEDSWITCH
A
*>'l!
tftl
Y
Relayand Control Unit Locations
EngineCompartment
ELDUNIT
UNDER.HOOD
BOX
FUSE/RELAY
t:
tr
tr
I
I l
I
t l
u
I
FAN
CONDENSER
RELAY
ABS
UNDER.HOOD
BOX
FUSE/RELAY
MOTOR
RELAY
RADIATOR
A/C COMPRESSOR FAN RELAY
CLUTCHRELAY
23-7
Relayand ControlUnit Locations
'96- 97 models
Dashboard:
CRUISECONINOLUNIT
DAYTIME
RUNNINGLIG}ITS
CONTROLUNIT
lCan!dal
DASHLIGHTSBRIGHTNESS
CONTROLLER
{Hasbuilt-incontrolunit)
GRN/RED,l
IWirecolo.s:GRN/ORN,
IWHT,YEL,andBLK
I
. MOONROOF
CLOSE
RELAY
Cnru/VeLl
fwir. colorc:GRN/ORru,
andALK
I
IWHT.GRN/RED,
23-8
D
UNDER.OASH
FUSE/RELAYBOX
INTEGRATED
CONTROLUNIT
HORNRELAY
WXf/Cnru,l
I Wirecolors:WHT/GRttt,
,J
[GRY,andBLU/RED
tP"tat{}r)
(}t
F;;snHn-nnn"nf-H-n
!r rr rr rr r,r Lr Ll u u l,r
F
Fnnnnnnnrrrr-1
F rr rr rJ LJ rJ r-r t-r L-rLJLr ||J
' g
/ tt - - - - - - , )
o
POWERWINDOWRELAY
u_::;_:_:_:_:_l_;I::
INTERLOCK
CONTROLUNIT
*TCM (CVT)
*: Coupe
23-9
Relayand Control Unit Locations
Dashboard:'98 - 00 models
CRUISECONTROLUNIT
DAYTIME
RUNNINGLIGIfiS
CONTROLUNIT
lCrnrda)
DASHLIGHTSBRIGHTNESS
CONTROLLER
{Hasbuilt-incontrolunit}
CUI RELAY
STARTEB
exnfxf, I
[wi]ecolor.:BLX/WHT,
j
|nd BLK/RED
IBLU/BLK,
coloE: WHT/GRN,BLU/REO,I
andWHT/GRN
I
MOONROOFCLOSERELAY
CnrulYel,l
fwiro colors:GRN/O8ru.
endBLK
I
IWHT,GBN/RED,
23-10
O
REARWINDOW
DEFOGGEB
UNDER.OASH
BOX
FUSE/NELAY
WINDOWRELAY
POWER
oF-
-=----rr
Jl
r
c
CONTROLUNIT
INTERLOCK
. TCM (CVT):Coupe
'99 model {USAI
. KEYLESSDOORLOCKCONTROLUNIT:
23-11
Relayand Gontrol Unit Locations
Dashboard/Door
AUOIOUNIT
(Hasbuilt-inkeylessreceivercircuit)
POWERDOORLOCI(
CONTROLUNIT
ABS CONTROLUNIT
23-12
Connectorldentificationand Wire HarnessRouting
D
How to ldentify Connectors:
"C" for connectors,
ldentificationnumbershave been assignedto all connectors.The number is precededby the letter
"G" for groundterminalsor "T" for non-groundterminals.
Location
Harness
EngineCompartment
Startercables
T 1 ,T 2 a n d@
Batterygroundcable
G 1 a n dO
EnginegroundcableA
T3
G2
E n g i n eg r o u n dc a b l eB
T4
Under-hoodABS fuse/relaybox wire
harness(WithABS)
t5 ano (9
Enginewire harness
C l 0 1t h r u C 1 4 7
T 1 0 1a n dT 1 0 2
G101
Enginecompartmenlwareharness
C201thru C215
G201and G202
Main wire harness
C301thru C310
C351thru C361
Dashboard
Others {Floor, Door,
Trunk/Hatch, and Rootl
C401thru C452
G401and G402
Dashboardwire harness
C501thru C520
G501
FIoorwire harness
C551thru C573
G551and G552
Rearwire harness
C601thru C62l
G601and G602
Driver'sdoor wire harness
C631thru C640
door wire harness
Passenger's
Left reardoor wire harness(Sedan)
C651thru C657
Rightreardoor wire harness(Sedan)
Roofwire harness(Withoutmoonroof)
C671thru C674
Moonroofwire harness{Withmoonroof)
C 7 l ' lt h r uC 7 1 9
C661thru C664
C701thru C719
A
Heatersub-harness
C721thru C729
B
Heatersub-harness
C741 thtu C744
Ay'Cwire harness
C751thru C754
G751
Hatchwire harness(Hatchback)
C761thru C768
Rearwindow defoggergrgundwire
c771
G171
Secondaryheatedorygen sensorsubnarness
C781and C782
Fueltank pressuresensorsub-harness
C791thru C793
SRSmain harness
C801thru C807
G801
Rear window defogger wire
C831thru C833
Connectorldentificationand Wire HarnessRouting
Starter Cables
Connectoror
Terminal
Number of
Cavities
T,I
r2
Localion
Connec{sto
Rightsideof enginecompartment
Rightsideof enginecompartment
Under-hoodfuse/relaybox
Startermotor
Battery
Batterypositiveterminal
Notes
Battery Ground Cable
Connectoror
Terminal
Number of
Cavities
o
Location
Conn€ctsto
Rightfront shocktower
Bodyground,via batteryground
caDte
Baftery
Batterynegativeterminal
Notos
EngineGroundCableA
Conn€qtoror
Terminal
Number ot
Cavitios
Location
Connectsto
T3
Leftside of engine
Powersteeringpump bracket
G2
Leftsideof enginecompartment
Body ground,via engineground
cableA
Noles
EngineGroundCableB
Connectoror
Terminal
Number of
Cavities
T4
Location
Conneclsto
Rightside of enginecompartment
Transmission
Rightsideof front frame
Bodyground,via engineground
cableB
Noles
Under-hoodABS Fusa/RelayBox Wire Harness
Connectoror
Tgrminal
Number oI
Cavities
Location
Conneqtsto
T5
Rightside of enginecompartment
Under-hoodfuse/relaybox
@
Banery
Batterypositiveterminal
Notes
A/C Wire Harness
Connectoror
Terminal
c753
c754
23-14
Number of
Cavities
1
2
Location
Connectsto
Rightsideof enginecompartment
Rightside of enginecompartment
Rightside of enginecompartment
Rightside of enginecompartment
Enginecompartmentwire harness
(c209)
Compressorclutch
Condenserfan motor
A,/Cpressureswitch
Leftsideof enginecompartment
Bodyground,via A,/Cwire harness
Notes
d
STARTER
CABLES
BATTERY
GROUND
CABLE
UNDER-HOOO
ABS FUSE,/RELAY
BOXWIRE
HARNESS
GROUND
CABLEB
A/C WIRE
HARNESS
23-15
Connectorldentificationand Wire HarnessRouting
EngineWire HarnesslD16Y5,D16Y8enginss):'96 - 98 models
Connectoror
Torminal
Numbsr of
Cavitiss
c1 0 1
c102
c103
c104
c104
c105
c106
c107
c108
c 109
c110
c111
c112
c113
c114
c115
c116
cl17
c118
c119
c120
cl21
10
c122
c123
cl23
c124
c125
c127
c12A
c129
c130
c131
c132
c 133
c134
c135
c136
c138
c139
c140
c141
c142
c1 4 3
c144
cl44
c145
c'146
cl47
Left side of engine compartment
Middle of engine
Middle of engine
Left side of enginecompanment
Left side of enginecompartment
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
fvliddleof engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Left side of engine compartment
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Connectsto
14
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Middle of engine
Right side of engine companment
Behind right kick panel
Under right side of dash
Under riOhtside of dash
Under right side of dash
Under right side of dash
Under right side of dash
Under right side of dash
Mainwire harness(C303)
Crankshaft
speedfluctuation(CKF)sensor
Engineoil pressure
switch
Alternator
Alternator
No. 'l fuel injector
No. 2 fuel injector
No.3 fuelinjector
No.4 fuel injector
IACvalve
Throttleposition(TP)sensor
l\4anifold
absolutepressure(MAP)sensor
Intakeair temperature(lAT)sensor
Powersteeringpressure{PSPIswitch
EVAPpurgecontrolsolenoidvalve
Junctionconnector
Junctionconn€ctor
Vehiclespeedsensor{VSS}
Countershaftspeedsensor
Enginecoolanttemp€rature(ECT)switchA
Distributor
Enginecoolanttemperature(ECT)sending
unrt
(ECT)sensor
Enginecoolanttemperature
PrimaryHO2S(sensor'l)
PrimaryHO2S(sensor1)
Back-up
lightswitch
Lock-up
controlsolenoidvalve
Secondary
HO2S(sensor2)
Mainshaftspeedsensor
Linearsolgnoidvalve
Shift controlsolsnoidvalve
Startersolenoid
Junctionconnector
(C446)
Mainwire harnesE
ECM/PCM
PCM
ECMiPCM
ECM/PCM
Mainwire harness(C305)
14
Under right side of dash
Mainwire harness(C305)
Under right side of dash
Mainwire harness(C305)
Middle of engine
Middle ot engine
l iddle of engine
Middle of engine
Middle of ongine
Middle of engine
Left side of enginecompartment
Middle of engine
Middle of engine
Rightside of enginecompartment
Rightside of enginecompartment
Right side of engine compartment
Left side of engine companment
Rightside of enginecompanment
Middle of engine
Knocksensor(KS)
IACvalve
VTECsolenoidvalve
VTECpressureswitch
EVAPcontrolcanister
ventshutvalve
EGRcontrolsolenoidvalve
gearshaftspeedsensor
Secondary
EGRvalve
EGRvalve
Drivepulleyspeedsensor
Solenoidconnector
{CVT)
Drivenpulleyspeedsensor
Alternator
Under-hoodfuse/relaybox
1
2
2
14
l4
3
2
2
l0
I
2
2
2
2
1
20
3l
2
2
1
2
2
2
2
2
T101
r102
G1 0 1
*1: Dl6Y5 engine
*2: D16Y8engine
*3: D16Y5(Ay'T),
D16Y8engines
23 - 1 6
Location
Engineground, via engine wire harness
Not€s
USA
Canada
Afi
USA
-' (A/r)
*, (M/T)
M/T
*" INT\
*, tAtf)
NT:
'96model
*,(A,/T):
'97- 98
mooets
moqets
M/T
-1 (l,/T)
*, (A,/T)
-,(4,/T)
*1{M/T)
*, (A,/T)
*1 (CW)
*, (A,T)
t
'96 - 98 models:
c138
c109
c110
c113 T101
c141
r102
c1
c'I43
cl17
c144
c110
c118
c139
c120
c129
c146
ENGINEWIRE
HARNESS
cll5
c116
c13?
cr02
c145
c105
c106
23-17
Gonnectorldentificationand Wire HarnessRouting
EngineWire Harness(D16Y5,Dl6Yg engines):,99- 00 models
Connectot or
Terminal
c'101
cl02
c103
c104
c 104
c10s
c107
c 108
c'r09
c110
c111
cl12
c113
cl14
cl15
c116
cl17
c118
c119
c120
cl20
c121
c122
c123
c123
cl23
cl24
c124
c125
c127
c12A
c129
c 130
c131
cl32
c133
c 134
c135
c137
c138
c 139
c 140
c142
c143
c144
cl44
c145
c146
c147
T101
T102
Number ot
Cavities
10
3
,]
3
2
2
2
2
3
3
3
2
2
2
14
14
3
2
2
'10
8
,l
2
4
8
4
2
2
4
2
2
2
1
20
32
2
2
1
2
2
2
3
2
8
2
G1 0 1
* 1 :0 1 6 Y 5engine
*2: D16Y8engine
* 3 :D l 6 Y 5(CW), D16Y8engines
23-14
Location
Left side ot engine compartment
lvliddleof engine
M i d d l eo f e n g i n e
Left side ot engine compartment
Left side of enginecompartment
Middle of engine
Middle ot engine
Middle of engine
M i d d l eo f e n g i n e
Middle oI engine
Middle of engine
M i d d l eo f e n g i n e
M i d d l eo f e n g i n e
Middle of engine
Nliddleof engine
Middle of engine
Middle of engine
Middle of engine
Right side of enginecompartment
Middle of engine
Middle of engine
N4iddleof engine
Middle of engine
Middle of engine
Middle ot engine
Middle ot engine
Middlo of engine
Middle of engine
Middle ot engine
lrliddleof engine
Middle of engine
Middle oI engine
Middle ot engine
Rightsideof enginecompartmenl
Behind right kick panel
Under right side of dash
Behind right kick panel
Behind right kick panel
Behind righr kick panel
Behind right kick panel
Middle ot engine
[,liddleof engine
N4iddleof engine
Middle of engine
Middle oI engine
Left side of engine compartment
Middle of engine
Middle of engine
Rightside ol enginecompartment
Rightsideof enginecompanment
Rightsideof enginecompartment
Left side of enginecompanment
Rightside ot enginecompanment
Middleof englne
Conn€ctsto
Notes
Main wire harness1C303)
Crankshaftspeed fluctuation (CKF)sensor
Engineoil pressureswitch
Alternator
Alternator
No. 1 luel injector
No.2 fuelinjector
N o . 3f u e li n j e c t o r
No.4 fuelinjector
IACvalve
ThrottlepositionlTP)sensor
Manifoldabsolutepressure{MAP)sensor
(lAT)sensor
Intakeair temperature
Powersteeringpressure(PSP)switch
EVAPpurgecontrolsolenoidvalve
Junctionconnector
JUnct|OnCOnnector
VehiclespeedsensorlVSS)
Countershaftspeedsensor
Engine coolant temperature {ECT}switch A
Distributor
Distributor
Enginecoolanttemperature(ECT)sending
unit
Enginecoolant temperature(ECT)sensor
PrimaryH02S (sensor1)
PrimaryHO2S(sensor1)
PrimaryHO2Slsensor 1)
Back-uplight switch
Lock'!p control solenoidvalve
Secondary HO2S (sensor 2)
Mainshaft speed sensor
Linearsolenoidvalve
Shift control solenoidvalve
Starter solenoid
Junctionconnector
Main wire harness(C446)
ECM/PCM
ECM/PCM
ECM/PCM
USA
Canada
I
]
i
I an
I
I
USA
]
*' (A/TI
*1 (CVT)
*, (M/T)
Mfi
a (A/Tl
" (A,/T)
., (4,/r)
-' {AlrJ
*1 (M/T)
PCtvt
(KS)
Knock
sensor
IAC valve
VTECsolenoidvalve
VTEC pressure switch
EGRcontrol solenoidvalve
Secondarygear shaft speedsensor
EGRvalve
EGRvalve
Drive pulley speedsensor
Solenoidconnector(CVT)
Driven pulley speedsensor
Alternator
Under'hoodfuse/relaybox
I Engineground,via engine wire harness
tvliT
*1 (CVT)
*, (cvT)
*' (cw)
*1 (MiT)
*1 {CVT)
*1 {CVT)
*, (cvr)
D
'99 - 00 models:
c132
c133
c134
c135
c130
c123
c119
cl' l1
c112
c138
c113
c117
T102
Cli(l
c117
WIRE
HARNESS
c1+l
c1{{)
ct15
ct18
cl16
c139
c137
c120
c102
c129
Clir6
c1a5
c126
C121 c125 C123 c122 C121
23-19
Gonnectorldentificationand Wire HarnessRouting
EngineWire Harness{D16Y7engine}:'96 model
Conneclor or
Terminal
Number ot
Cavhies
c101
c102
10
Leftsideof enginecompartment
Middleof engine
c 103
c104
c104
c105
c'r06
c107
c 108
c 109
c110
c111
c112
cl13
c't14
1
4
Middleof engine
Leftside of enginecompartment
Leftside of enginecompartment
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Leftside of enginecompartment
Middleof engine
Middleof engine
L t t S
5
'14
cl16
cl17
c118
cl19
14
c120
c121
10
1
,,
c123
c124
c124
c125
c126
c't27
c12a
c129
c130
c131
c132
c133
c134
c135
T101
T102
G101
23-20
2
2
1
22
31
16
Location
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Rightsideof enginecompartment
Behindright kickpanel
Underright sideof dash
Underright side of dash
Underright sideof dash
Underright sideof dash
Underright side of dash
Connectsto
Notes
Main wire harness(C303)
Crankshaft
speedfluctuation(CKF)
sensor
Engineoil pressureswitch
Alternator
USA
Alternator
Canada
No. 1 fuel injector
I
No. 2 fuel injector
No. 3 fuel injector
I
No,4 fuel injector
IACvalve
l
Throttleposition(TP)sensor
I
Manifoldabsolutepressure(MAP)sensor
Intakeai. temperature(lAT)sensor
]
Powersteeringpressure(PSP)switch I USA
EVAPpurgecontrolsolenoidvalve
I
Junctionconnector
Junctionconnector
I
Vehiclespeed sensor (VSS)
|
Countershaftspeed sensor
AlT
Enginecoolanttemperature(ECT)
I
switch A
Distributor
Enginecoolanttemperature(ECT)
sendingunit
EnginecoolanttemperaturelECT)sensor
PrimaryH02S (sensor1)
Back-uplight switch
M/T
Lock-upcontrolsolenoidvalve
AtJ
SecondaryHO2S(sensor2)
Mainshaftspeedsensor
Linearsolenoidvalve
Shiftcontrolsolenoidvalve
Afi
Stanersolenoid
JunctionConnector
Main wire harness{C446)
ECM/PCM
PCM
ECM/PCM
ECM/PCM
Leftside of enginecompartment Alternator
Rightside of enginecompartment Under-hoodfuse/relaybox
Middleof engine
Engineground,via enginewire harness
!
'96 model:
ENGINEWIREHARNESS
C135
C13,1
T102
c r1 7
cl19
c120
cl18
c129
c105
c106
c'107 c103
i',zzct2'
c108
23-21
Connectorldentificationand Wire HarnessRouting
EngineWire Harness{Dt6Y7enginel:'97 - 9g models
Connectot or
Terminal
Number of
Csvities
c101
c102
10
c103
c104
c104
c105
c106
c107
c 108
c109
cl10
clll
c112
cl13
cl14
c115
c 1l 6
c117
c118
cl 19
1
Location
Connectsto
Notes
T101
r102
Leftsideof enginecompartment Main wire harness(C303)
M i d d l eo f e n g i n e
Crankshaft
speedfluctuation(CKF)
sensor
Middleof engine
Engineoil pressureswitch
Leftside of enginecompartment Alte|'nator
USA
Leftsideof enginecompartment Alternator
Canada
Middleof engine
No. l fuel injector
Middleof engine
No.2 fuel injector
Middleof engine
No. 3 fuel injector
I
M i d d l eo f e n g i n e
No. 4 fuel injector
Middleof engine
IACvalve
]
Middleof engine
Throttleposition(TP)sensor
I
Middleof engine
Manifoldabsolutepressure(MAP)sensor
Middleof engine
Intakeair temperature(lAT)sensor
]
Middleof engine
Powersteeringpressure(PSp)switch I USA
Middleof engine
EVAPpurgecontrolsolenoidvalve
Middleof engine
Junctionconnector
I
Middleof engine
Junctionconnector
I
Leftside of enginecompartment Vehiclespeedsensor(VSS)
Middleof engine
Countershaftspeed sensor
I en
Middleof engine
Enginecoolanttemperature(ECTI
switch A
Middleof engine
Distributor
Middleof engine
Enginecoolanttemperature(ECT)
sendingunit
Middleof engine
Enginecoolanttemperature(ECT)sensor
Middleof engine
PrimaryHO2S(sensor1)
Middleof engine
Back-uplight switch
Mtr
Middleof engine
Lock-upcontrolsolenoidvalve
Middleof engine
SecondaryH02S (sensor2)
Middleof engine
Mainshaftspeedsensor
Middleof engine
Linearsolenoidvalve
Middleof engine
Shiftcontrolsolenoidvalve
AIT
Rightsideof enginecompartment Stanersolenoid
Behindright kickpanel
Junctionconnector
Underright sideof dash
Main wire harness(C446)
Underright sideof dash
ECM/PCM
Underright side of dash
PcM
I Arr
Underright sideof dash
ECM/PCM
Underright sideof dash
ECM/PCM
Leftsideof enginecompartment Main wire harness{C305)
| Aft
Middleof engine
EVAPcontrolcanistervent shut valve
Leftsideof enginecompartment Alternator
Rightsideof enginecompanment Under-hoodfuse/relaybox
G1 0 1
Middle of engine
2
cl20
c121
10
c122
c123
cl24
c124
c125
c126
c127
c128
c129
c 130
c131
c132
2
I
2
'>
4
t
20
c134
c135
3r
cl41
2
23-22
Engine ground, via engine wire harness
D
'97 - 98 models:
WIREHARNESS
23-23
Connectorldentificationand Wire HarnessRouting
EngineWire Harness(D15Y?engine):,99- OOmodels
c101
c102
10
3
cl03
c't04
c 104
c105
cr06
'I
3
0107
?
c108
c109
c ' t1 0
c 1 1r
c112
c113
c114
c115
c116
c117
cl18
c119
2
c120
c121
c122
c123
c124
c124
c125
c127
c128
c129
c 130
c131
c134
c135
3
?
2
14
14
3
2
8
1
Leftsideof enginecompartment Main wire harness(C303)
Middleof engine
Crankshaft
speedfluctuation(CKF)
sensor
fvliddleof engine
Engineoil pressureswitch
Leftsideof enginecompartment Alternator
Leftside of enginecompanment AlternatOr
Middleof engine
No. l fuel injector
M i d d l eo f e n g i n e
No.2 fuel injector
Middlr
olsngins
M i d d l eo f e n g i n e
Middleof engine
Middleof engine
M i d d l eo f e n g i n e
M i d d l eo f e n g i n e
M i d d l eo f e n g i n e
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Rightsideof enginecompartment
Middleof engine
No.I fualitjecto,
No.4 fuel injector
IACvalve
Throttleposition(TP)sensor
Manifoldabsolutepressure{MAp)sensor
Intakeair temperature0AT)sensor
Powersteeringpressure(PSp)switch
EVAPpurgecontrolsolenoidvalve
Junctionconnector
Junctionconnector
Vehiclespeedsensor(VSS)
Countershaft
speedsensor
Enginecoolanttemperature{ECT)
switch A
Middleof engine
Distributor
M i d d l eo f e n g i n e
Enginecoolanttemperature(ECT)
sendingunit
Middleof engine
Enginecoolanttemperature(ECT)sensor
Middleof engine
PrimaryHO2S(sensor1)
Middleof engine
Back-uplight switch
M/T
Middleof engine
Lock-upcontrolsolenoidvalve
Atr
Middleof engine
SecondaryHO2S(sensor2)
Middleof engine
Mainshaftspeedsensor
Atr
Middleof engine
Linearsolenoidvalve
Alr
Middleof engine
Shiftcontrolsolenoidvalve
Al-|.
Rightsideot enginecompartment Startersolenoid
Behindright kickpanel
JunctionConnector
Underright sideof dash
Main wire harness(C446)
Behindright kickpanel
ECM/PCM
Behindright kickpanel
ECM/PCM
Behindright kickpanel
PCM
Leftside of enginecompartment
Rightsideof enginecompartment
M i d d l eo f e n g i n e
23-24
USA
Canada
Engineground,via enginewire harness
1O
'99 - 00 models:
c110
c114
cl11
cl13
c117
c1
c108 ct07
23-25
Connectorldentificationand Wire HarnessRouting
EngineWire Harness{81642engine}:.99- 00 models
c101
c102
10
2
cl03
c104
c 104
c'105
c106
cl01
c108
c110
cl11
cl12
c1'13
c114
c115
,]
c117
cl19
4
3
2
2
2
2
3
3
2
2
2
14
14
3
2
c120
c121
'10
'I
c122
c123
c124
c129
c130
c l31
c133
c134
c137
c 138
c139
c140
2
4
2
1
20
22
25
31
2
2
I
Leftside of enginecompanment
M i d d l eo f e n g i n e
Main wire harness(C303)
Crankshaft
speedfluctuation(CKF)
sensor
M i d d l eo f e n g i n e
Engineoil pressureswitch
Leftside of enginecompartment Alternator
Leftsideof enginecompartment Alternator
lvliddleof engine
No. 1 fuel injector
M i d d l eo t e n g i n e
No. 2 tuel injector
M i d d l eo f e n g i n e
No. 3 fuel injector
M i d d l eo f e n g i n e
No. 4 fuel injector
M i d d l eo f e n g i n e
Throttleposition(TP)sensor
Middleof engine
Manifoldabsolutepressure(MAP)sensor
M i d d l eo t e n g i n e
Intakeair temperature(lAT)sensor
Middleof engine
Powersteeringpressure(PSP)swjtch
M i d d l eo f e n g i n e
EVAPpurgecontrolsolenoidvalve
Middleof engine
Junctionconnector
M i d d l eo f e n g i n e
Junctionconnector
Middleof enginecompartment
Vehiclespeedsensor(VSS)
Middleof engine
Enginecoolanttemperature(ECT)
switch A
Middleof engine
Distributor
M i d d l eo f e n g i n e
Enginecoolanttemperature(ECT)
sendingunit
lMiddleof engine
Enginecoolanttemperature{ECT)sensor
M i d d l eo f e n g i n e
PrimaryHO2S(sensor1)
Middleof engine
Back-uplight switch
Rightsideof enginecompartment Startersolenoid
Behindright kickpanel
Junctionconnector
Underright side of dash
Main wire harness(C446)
Behindright kickpanel
ECM
Behindright kickpanel
ECtvl
M i d d l eo f e n g i n e
KnockSensor{KS)
M i d d l eo t e n g i n e
IACvalve
lMiddleof engine
VTECsolenoidvalve
M i d d l eo f e n g i n e
VTECpressureswitch
Leftside of enginecompanment
Rightsideof enginecompartment
Engineground,via enginewire harness
USA
Canada
'99 - 00 models:
c112
cl17
T102
c119
c140
c104
T101
c13t)
clt5
c116
c137
c102
23-27
Connectorldentificationand Wire HarnessRouting
EngineCompartment Wire Harness
conneqtor of
Terminal
Number of
Cavities
c201
c202
c202
c203
c204
c205
c206
c207
c208
c209
c210
10
6
2
Location
Connectsto
2
Leftsideof enginecompanment
Leftside of enginecompanment
Leftside of enginecompanment
Leftside of enginecompartment
Behindfront bumper
Behindfront bumper
Leftside of enginecompartment
Behindfront bumper
Leftside of enginecompartment
Leftsideof enginecompanment
Behindfront bumper
Main wire harness(C308)
Main wire harness(C309)
Main wire harness{C309)
Cruiseactuator
Windshieldwashermotor
Rearwindow washermotor
Leftfront turn signal/parking
light
Frontfog light
Left headlight
Ay'Cwire harness1C751)
Horn
c210
1
Behindfront bumper
HOrn
c211
c212
c213
c214
c215
2
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Behindfront bumper
Radiatorfan motor
Rightheadlight
Rightfront turn signal/parking
light
Main wire harness(C355)
Washer level switch
2
2
1
3
8
G201
G202
*1r With cruisecontrol
*2: Withoutcruisecontrol
23-2A
Rightsideof enginecompartment Bodyground,via enginecompartment
wire harness
Leftsideof enginecompartment Bodyground,via enginecompartment
wrre harness
Notes
Optional
'96 -
97
models
'98 99
models
Canada
'99 model
c20l
c202
ENGINECOMPARTMENT
WIREHARNESS
23-29
Connectorldentificationand Wire HarnessRouting
Main Wire HarnesslLeft side ot engine compartment branchl
Connectoror
Terminal
Numberof
Cavities
c301
c302
c303
c304
c305
c305
c306
c307
c308
c309
c309
c310
5
2
10
3
14
8
1
I
10
2
2
* l r D ' 1 6 Ye5n g i n e
* 2 : D 1 6 Y 8e n g i n e
*3: With cruisecontrol
*4r Withoutcruisecontrol
Location
Leftside of enginecompartment
Leftside of enginecompartment
Leftside of enginecompanment
Leftside of enginecompartment
Leftsideof enginecompartment
Leftside of enginecompartment
Leftsideot enginecompanment
Leftside of enginecompanment
Leftsideof enginecompartment
Leftside of enginecompanment
Leftside of enginecompanment
Leftside of enginecompanment
*5:'96 9gmodels
Connectsto
Notes
Windshieldwiper motor
Testtachometerconnector
E n g i n ew i r e h a r n e s (sC 1 0 1 )
Daytimerunninglightsresistor
Canada
Enginewire harness(C136)
;|.'
E n g i n ew i r e h a r n e s (sC 1 3 6 )
Brakefluid levelswitch(+)
Brakefluid levelswitch(-)
Enginecompartment
wire harness(C201)
Enginecompanmentwire harness(C202)
Enginecompartment
wire harness(C202)
Leftfront ABS wheelsensor
ABS
Main Wire Harness(Rightside of enginecompartmentbranch)
Connectoror
Terminal
Numberof
Cavities
11
c353
c354
c355
c356
c357
c359
c360
G403
'
9
9
*1:
- 00models
23-3 0
3
I
3
2
2
'10
2
2
Location
Rightsideof enginecompartment
Rightsideof enginecompanment
Rightsideof enginecompanment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompanment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Rightsideof enginecompartment
Connectsto
Under-hoodfuse/relaybox (CgoB)
Under-hoodfuse/relaybox (C906)
Underhoodfuse/retaybox (C905)
Under-hoodtuse/relaybox (C907)
Enginecompanmentwire harness{C214)
Under-hoodABS fuse/relaybox {C927)
Under-hoodABS fuse/retaybox (C926)
Rightfront ABS wheelsensor
ABS solenoid
ABS pump motor
EVAPcontrolcanistervent shut valve
Rightsideof enginecompartment Bodyground,via main wire harness
Notes
USA
ABS
ABS
ABS
ABS
ABS
D
UNDER-HOOO
FUSE/RELAYBOX
MAIN WIREHARNESS
(leftb.anch)
c301
23-31
Connectorldentificationand Wire HarnessRouting
Main Wir€ Harness(Loft side of da3h and floor branch):'96 - 97 models
Connectoror
Terminal
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c4l9
c420
c42'l
c423
c424
c425
c426
c427
c42A
c429
c430
c431
c432
c433
c434
c435
c431
c438
c439
Number of
Cavhios
'14
't4
I
I
10
't2
24
16
7
o
18
20
18
7
6
I
o
4
7
8
14
1
Location
Above under-dashfuss/relaybox
Underleft side ot dash
Underleft sid€ of dash
Underleft side of dash
Underleft side of dash
Und€rleft sideof dash
Underleft sideof dash
Underleft sideof dash
Underleft sideof dash
Behindunder-dashfuse/relaybox
Underleft side of dash
Underleft side of dash
Above under-dashfuse/relaybox
Underleft sideof dash
Under left side of dash
Above under-dashfuse/r€laybox
Underleft sideof dash
Underleft side of dash
Underleftside of dash
Behind under-dashfuse/relaybox
Eehind under-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Under left side of dash
Under left side of dash
In the steeringcolumncover
In the steering column cover
In the steeringcolumncover
In the steeringcolumncovEr
Underleft side of dash
Underleft side of dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Underleft sideof dash
Underleft side of dash
Eehind under-dashfus€/relaybox
G401
Left kick panel
*2:Without moonroof
*4: With moonroof
*5: M/T (with cruisecontrolor for D16Y5engine)
*6: With secondaryheatedoxygensensor(H02S)
23-32
Connoctsio
Floo.wire harness(C555)
Floorwire harness(C554)
Securitysystem
Cruisecontrolunit
Daytimerunninglightscontrolunit
Daytimerunninglightscontrolunit
Roofwire harness(C701)
Moonroofwire harness(C7l1)
Frontfog light connector
Integratedcontrolunit
Dashboardwire harness(C504)
Dashboardwire harness(C502)
SRSmain harness(C802)
Datalink connector
Starter cut relay
lgnitionswitch
Securitysystem
Clutch switch
Clutch interlockswitch
Under-dashfuss/relay box (C9191
Undor-dashfuse/r€laybox {C920)
Under-dashtuse/relaybox (C922)
Under-dashluse/relay box (C914)
Under-dashfuse/rBlaybox (C915)
Horn relay
Brakeswilch
Windshield wiper/washerswitch
Rearwindow wiper/washerswitch
Turn signal switch
Combinationlighvturnsignalswitch
Cablereel
lnterlockcontrolunit
Secondaryheatedoxygen sensorsubharn€ss(C781)
Ay'Tgear position switch
Shift locksolenoid
Parkpin switch and Ay'Tgear position
consolelight
Transmission
controlmodule(TCM)
Transmission
controlmodule{TCM)
Under-dashfuse/relaybox {C925)
Bodyground,via main wire harness
Notes
ABS
Optional
Canada
Canada
Optional
Atr
MTT
Optional
Mlf
NT
AN
Atr
Atf
CVT
CVT
Optional
t
'96 - 97 models:
MAIN WIRE
HARNESS
c412 C411 c410
o
-n---nnn-
c421
-nr
n-n--n---n-nn!!!!!!uu!u!u+u
UNDER.DASH
BOX
FUSE,/RELAY
23-33
Connectorldentificationand Wire HarnessRouting
Main Wire Harn€ss{Left side ot dash and floor branchl: '98 model
Connoctoror
Tgrminal
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c411
c4't2
c413
c414
c415
c416
c417
c418
c419
c420
c421
c422
c423
c424
c425
c426
c427
c428
c429
c430
c431
c432
c433
c434
c435
c437
c438
Number of
Cavities
't4
l4
8
,
1
10
12
24
7
6
18
20
18
7
6
8
7
8
14
2
Location
Aboveunder-dash
fuse/relaybox
Underleft sideof dash
Underleft side of dash
Underleft sideof dash
Underleft sideof dash
Underleft sideof dash
Underleft sideof dash
Underleft sideof dash
Underleft side of dash
Behindunder-dashfuss/relaybox
Underleft sideof dash
Underleft sideof dash
Above under-dashfuse/relaybox
Underleft sideof dash
Under-dashrelaybox
Above under-dashfuse/relaybox
Underleft side of dash
Underleft sideof dash
Underleft sideof dash
Eehind under-dashfuse/relaybox
Behind under-dashfuse/relaybox
Behind under-dashfuse/relaybox
Behindunder-dashfuse/rslaybox
Behindunder-dashfuse/relaybox
Under-dashrelaybox
Underleft sideof dash
In the steeringcolumncover
In the steeringcolumncover
In the steeringcolumncover
In the steeringcolumncover
Underleft sideof dash
Underleft sideof dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
Underleft sideof dash
Underleft sideof dash
G401
Left kick panel
*2: Withoutmoonroof
*4:With moonroof
*5: M/T (with cruisecontrolor for D16Y5engine)
*6: With secondaryheatedoxygen sensor (H02S)
23-34
Conneqtsto
Floorwire harness(C555)
Floorwire harness(C554)
Securitysystem
Cruisecontrolunit
Daytimerunninglightscontrolunit
Daytimerunninglightscontrolunit
Roofwiro harness(C7011
Moonroofwire harness(C711)
Frontfog light connector
Integratedcontrol unit
Dashboardwire harness(C504)
Dashboardwire harness(C502)
SRSmain harness(C802)
Datalink connector
Starter cut relay
lgnitionswitch
Securitysystem
Clutch switch
Clutchinlerlockswitch
Under-dash
fuse/relaybox (C919)
Under-dashfuse/relaybox (C920)
Under-dashfuse/relaybox (C922)
Under-dashfuse/relaybox (C914)
Under-dash
fuse/relaybox (C915)
Horn relay
Brakeswitch
Windshieldwiper/washerswitch
Rearwindow wiper/washerswitch
Turn signalswitch
Combinationlight/,turn
signalswitch
Cablereel
lnterlockcontrolunit
Secondaryheatedorygen sensorsubharness(C781)
Ay'Tgear position switch
Shift locksolenoid
Parkpin switch and Aff gear position
consolelight
Transmission
controlmodule(TCMI
Transmission
controlmodule(TCM)
Body ground,via main wire harness
Not€s
ABS
Optional
Canada
Canada
Optional
M
MIT
Optionsl
MlT
Alr
NT
NT
CVT
CVT
t D
€8 model:
c€0
cQa
I c129
"n,
ctza j81
WIRE
HARNESS
c,(},l
c112 c111 c110
c121
::::::::::: r ll:
UNDER-DASH
BOX
FUSE/RELAY
23-35
Connectorldentificationand Wire HarnessRouting
Main Wire HalnesslLoft side of dash 8nd lloor branchl: '99 - 00 mod€ls
Connosto! ol
Tsrminal
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c410
c411
c412
c4' I3
c4't4
c415
c416
c417
c418
c419
c420
c42l
c422
c423
c424
c425
c426
c427
c428
c429
c430
c431
c432
Number of
Cavities
20
4
14
I
6
1
10
12
24
16
4
7
6
2
18
20
18
7
4
8
o
7
8
Location
Above under-dashfuse/relaybox
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft side of dash
Underleft sideof dash
Behindunder-dashfuse/relaybox
Under left side of dash
Under left side of dash
Above under-dashfuse/relaybox
Underleft sideof dash
Under-dashrelay box
Above under-dashfuse/relaybox
Underleft side of dash
Underleft sideof dash
Underleft side of dash
Behind under-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Behindunder-dashfuse/relaybox
Under-dashrelaybox
Underleft sideof dash
In the steeringcolumncover
In the steeringcolumncover
In the steeringcolumncover
In the steeringcolumncover
Underlett sideof dash
Underleft sideof dash
Undermiddleof dash
c433
c434
c435
14
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
c447
c448
c449
c450
c451
22
Underleft side of dash
Underleft side of dash
Undermiddleof dash
Underleft side of dash
Underleft side of dash
18
G401
Left kick panel
*2: Withoutmoonroof
*4: With moonroof
*5: M/T (with cruisecontrolor for Dl6Y5 engine)
*6: With secondaryheatedoxygensensor(H02S)
23-36
Connoqtg to
Floorwire harness(C555)
Floorwire harness(C554)
Securitysystem
Cruisecontrolunit
Daytimerunninglightscontrolunit
Daytimerunninglightscontrolunit
Roofwire harness(C701)
Moonroofwire harness{C711)
Frontfog light connector
Intagratedcontrol unit
Dashboardwire harness(C504)
Dashboardwire harness(C502)
SRSmain ha.ness(C802)
Data link connector
Starter cut relay
lgnitionswitch
Securitysystem
Clutch switch
Clutch interlockswitch
Under-dashfus€/relaybox (C919)
Under-dashfuse/relaybox (C920)
Under-dashfuse/relaybox (C922)
Under-dashfuse/relaybox (C914)
Under-dashfuse/relaybox (C915)
Horn relay
Brakeswitch
Windshieldwiper/washerswitch
Rearwindow wiper/Washerswitch
Turn signalswitch
Combination light/turn signal switch
Cablereel
lnterlockcontrolunit
Secondaryheaiedoxygensensorsubharness(C781)
A/T gear position switch
Shift locksolenoid
Parkpin switch and A,/Tg€ar position
consolelight
Securitysystem
Securitysystem
IVT gear positionindicatortrim light
Securitysystem
Keylessdoor lockcontrolunit
Bodyground,via main wire harness
Notes
ABS
Optional
Canada
Canada
Optional
At-|.
M/T
Optional
M/T
Atr
AIT
AJ-|.
Atr
Optional
Optional
Optional
D
'99 - 00 models:
c418 c425
MAIN WIRE
HARNESS
c{33 Ca34
c412 C411 C410
o
c121
-r----------
UNDER.OASH
BOX
FUSE/RELAY
23-37
Gonnectorldentificationand Wire HarnessRouting
Msin Wire Harness(Right side oI dash branch)
Connectoror
Terminal
Number of
Cavities
c440
c441
c442
c443
c4M
c445
c446
c452
16
2
20
7
22
G402
23-38
22
Location
Connectsto
Notes
Undermiddleof dash
Underrightside of dash
Underrightside of dash
Underright side of dash
Behindright side of kickpanel
Behindright side of kickpanel
Underright sideof dash
Underright sideof dash
Heatersub-harness
A (C721)
Servicecheckconnector
Junctionconnector
PGM-Flmain relay
ABS controlunit
ABS controlunit
E n g i n ew i r e h a r n e s (sC 1 3 1 )
ECM/PCM
Rightkickpanel
Bodyground,via main wire harness
*'l: '99 - 00 models
D
DashboardWire Harness
Connector ol
Terminal
c501
c502
c503
c504
c505
c507
c508
c509
c510
c513
c514
c515
Numbel of
Cavities
B e h i n dd a s h b o a r ldo w e rp a n e l
luse/relaybox
Aboveunder-dash
Above underdashIuse/relaybox
Aboveunderdashtuse/relaybox
Leftside of steeringwheel
Leftside of steeringwheel
B e l o wg a u g e s
B e h i n dg a u g e s
B e h i n dg a u g e s
B e h i n dg a u g e s
B e h i n dg a u g e s
B e h i n dg a u g e s
R i g h ts i d eo t g a u g e s
R i g h ts i d eo I g a u g e s
B e hi n d m i d d l eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dg a u g e s
20
24
to
12
5
3
20
5
5
14
r0
5
c516
20
22
c518
c519
c520
5
2
5
Connects to
Location
U n d e r - d a s{hu s e / r e l abyo x ( C 9 1 2 )
s C411)
M a i nw i r e h a r n e s 1
Floorwire harness(C553)
M a i nw i r e h a r n e s s( C 4 1 0 )
Cruisemain switch
D a s hl i g h t sb r i g h t n e scso n t r o l l e r
Junctionconnector
G a u g ea s s e m b l y
G a u g ea s s e m b l y
G a u g ea s s e m b l y
G a u g ea s s e m b l y
Gaugeassembly
Hazardwarningswitch
Rearwindow defoggerswitch
Audio unit (Keylessreceivercircuit)
A u d i ou n i t
l nit
S e c u r i t cy o n t r o u
A u d i ou n i t
Securitysystem
Accessorypower outlet
G a u g ea s s e m b l y
Notes
A"r
SRS
A,/r
Optional*'
Optional*'
ABS
Body ground,via dashboardwire harness
* 1 : W i t h s h i i t - u pi n d i c a t oor r c r u i s ec o n t r osl y s t e m( ' 9 6- 9 7 m o d e l s ) *2: '96 98 models
*3: '99 - 00 models
Undermiddle ol dash
G501
With cruisecontrolsystem('98model)
c508
c509C511 c510 c515
13 lc5l7
DASHSOARDWIRE
HARNESS
c520
c501 c502 c504
23-39
Gonnectorldentificationand Wire HarnessRouting
Floor Wire HarnesslCoupe/Haichbackl
Connsclor or
Terminal
Numberof
Cavities
c551
c552
c553
c554
16
8
'16
14
20
c556
c556
c557
c558
c560
c561
c562
c564
c56s
2
25
,)
,I
2
1
14
20
2
2
?
1
10
G551
G552
*1r With power windows
*2: Withoutpowerwindows
*3: D16Y8engine{Coupe)
23-40
Location
Behindunderdashfuse/relaybox
Behindunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Underleft side of dash
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Driver'sdoor
Driver'sdoor
Passenger's
door
Passenger's
door
Middleof floor
Leftsideoffloor
Left B-pillar
lnsideof left rearwheel
Leftc-pillar
LeftC-pillar
LeftC-pillar
Fueltank
Fueltank
Insideof right rearwheel
RightB-pillar
Fueltank
Left side ot dash
Leftkickpanel
Leftside of floor
*4: '96 - 98 models
*5: '99 - 00 models
Connectsto
Notes
Under-dash
fuse/relaybox {C923)
fuse/relaybox (C921)
Under-dash
Dashboardwire harness{C503)
Main wire harness(C402)
ABS
Main wire harness(C401)
Main wire harness{C401)
Driver'sdoor wire harness(C631)
Driver'sdoor wire harness(C631)
Passenger's
door wire harness(C651)
Passenger's
door wire harness(C651)
Parkingbrakeswitch
Driver'sseatbelt switch
Driver'sdoor switch
Left rearABS wheelsensor
ABS
Rearwire harness(C601)
Rearwire harness(C601)
Rearwire harness{C602}
Fuelgaugesendingunit
Fuelpump
RightrearABS wheelsensor
ABS
Passenger's
door switch
Fueltank pressuresensorsub-harness
(c791)
Powermirror switch
Bodyground,via floor wire harness
Bodyground.via floor wire harness
l,-
FLOORWIREHARNESS
23-41
Gonnectorldentificationand Wire HarnessRouting
Floor Wire HarnesslSedanl:
Connectorol
Terminal
Number of
Cavities
6
c553
c554
c556
c557
c557
c558
c559
c560
c561
c562
c563
c564
c565
c566
c567
L5bY
c570
c511
c572
c513
14
25
2
25
'|
1
2
't4
1
'10
6
6
I
1
G552
*l:With powerwindows
*2; Withoutpowerwindows
23-42
'96 model
Location
Connectsto
Notes
Behindunderdashfuse/relaybox
Behindunder-dash
fuse/relaybox
Above under-dashfuse/relaybox
Underleft sideof dash
Aboveunder-dash
fuse/relaybox
Drlver'sdoor
Driver'sdoor
Passenger's
door
Passenger's
door
Middleof floor
Leftside of floor
RightB-pillar
lnsideof left rearwheel
LeftC-pillar
LeftC-pillar
Fueltank
Fueltank
Insideof right rearwheel
Left B-pillar
Left side of steeringwheel
R i g h tB - p i l l a r
LeftB-pillar
Leftquarterpanel
Rightquarterpanel
Under-dash
fuse/relaybox {C923)
fuse/relaybox (C921)
Under-dash
Dashboardwire harness(C503)
ABS
Main wire harness(C402)
Main wire harness(C401)
Driver'sdoor wire harness(C631)
Driver'sdoor wire harness(C631)
Frontpassenger's
doorwireharness(C651)
Frontpassenge/sdoorwireharness(C651)
Parkingbrakeswitch
Driver'sseat belt switch
Frontpassenger's
door switch
ABS
Left rearABS wheelsensor
Rearwire harness(C601)
Rearwire harness(C602)
Fuelgaugesendingunit
F u e lp u m p{ F P )
ABS
RightrearABS wheelsensor
Driver'sdoor switch
Power mirror switch
Rightreardoor wire harness(C671)
Leftreardoor wire harness(C661)
Left rear door switch
Rightreardoor switch
Leftkickpanel
Left side of floor
Body ground,via floor wire harness
Body ground,via floor wire harness
D
'96 model:
c573
FLOORWIREHARNESS
C556
C564
c570
c560
23-43
Gonnectorldentificationand Wire HarnessRouting
FloorWire Harness(Sedanl:'97 - 00 models
Connectoror
Terminal
c552
c553
c554
c555
c556
c557
c557
c558
c559
c560
c56'l
c562
c563
c564
c566
Numberof
Cavities
16
8
14
20
25
2
2
1
2
1
20
2
2
2
1
c568
c569
c570
c571
c572
l0
1
1
G551
"1r With powerwindows
*2: Withoutpowerwindows
23-44
Location
Behindunder-dash
fuse/relaybox
Behindunderdashfuse/relaybox
Above under-dash
fuse/relaybox
Underleft side of dash
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Driver'sdoor
Driver'sdoor
Passenger's
door
Passenger's
door
Middleof floor
Leftside of floor
R i g h tB - p i l l a r
Insideof left rearwheel
LeftC-pillar
LeftC-pillar
LeftC-pillar
F u e tl a n k
F u e tl a n k
Insideof righr rearwheel
Left B-pillar
F u e tl a n k
Leftsideof steeringwheel
R i g h rB , p i l l a r
Left B pillar
I ofr ^,,.riar
^.^al
Rightquarterpanel
Leftkickpanel
Leftside of floor
* 3 : ' 9 7- ' 9 8 m o d e l s
*4: '99 - 00 models
Connectsto
Notes
Under-dash
fuse/relaybox (C923)
Under-dash
fuse/relaybox (C921)
Dashboardwire harness(C503)
Main wire harness(C402)
ABS
Main wire harness(C401)
Main wire harness(C401)
Driver'sdoor wire harness(C631)
Driver'sdoor wire harness{C631}
(C651)
Frontpassenger's
doorwireharness
(C651)
Frontpassenger's
doorwireharness
Parkingbrakeswitch
Driver'sseatbeltswitch
Frontpassenger's
door switch
Left rearABS wheelsensor
ABS
Rearwire harness(C601)
Rearwire harness(C601)
Rearwire harness(C602)
F u e lg a u g es e n d i n gu n i t
F u e lp u m p( F P )
RightrearABS wheelsensor
ABS
Driver'sdoor switch
Fueltank pressuresensorsub-harness
(c791)
Powermirror switch
Rightreardoor wire harness(C671)
Leftreardoor wire harness(C661)
Leftreardoor switch
Rightreardoor switch
Bodyground,via floor wire harness
Body ground,via floor wire harness
D
'97 - 00 models:
HARNESS
23-45
Connectorldentificationand Wire HarnessRouting
RearWire Harness(Halchbackl
Connectoror
Terminal
Number of
Cavitiss
c601
c601
c602
c603
c604
c605
c606
c607
c608
G601
14
20
2
2
6
Location
Connectsto
Leftquarterpanel
Leftquarterpanel
Leftquaner panel
Leftquarterpanel
Left side of cargo area
Rightsideof cargoarea
Rightquarterpanel
Rightquarterpanel
Rightquaner panel
Floorwire harness{C562}
Floorwire harness(C562)
Floofwire harness(C563)
Leftrearspeaker
Leftoutertaillight
Rightoutertaillight
Rightrearspeaker
Hatchwire harness(C761)
Hatchwire harness(C762)
Middleof cargoarea
Bodyground,via rearwire harness
* 1 : ' 9 6- 9 8 m o d e l s
*2: '99 - 00 models
REARWIRE
23-46
s\
Notes
Optional
Optional
D
'96
'96
RearWire Harness{Coupe: - 99 models/Sedan; - 98 modelsl
Connectoror
Torminal
c601
c601
c602
c603
c604
c605
c606
c609
c610
Numbsr of
Caviiies
to
20
1
)
L O t l
c612
c613
c6'14
c616
c617
G601
1
4
2
2
2
4
Location
Connectsto
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftsideof trunk
Rightside of trunk
RightquarterPanel
Left side of rear window
Middleof rearshelf
Middleof rearshelf
Rightsideof rearwindow
Leftsideof trunk
Middleof trunk
Middleof trunk
Middleof trunk
Rightside of trunk
Floorwire harness(C562)
Floorwire harness(C562)
Floorwire harness(C563)
Left rear speaker
Leftoutertaillight
Rightoutertaillight
Rightrearspeaker
Rearwindow defogger(+)
High mount brakelight
T r u n kl i g h t
Rearwindow defogger(-l
Leftinnertaillight
LeftIicenseplatelight
Trunklatchswitch
RightlicensePlatelight
R i g h ti n n e rt a i l l i g h t
Middleof trunk
Body ground,via rearwire harness
Notes
REARWIREHARNESS
23-47
Connectorldentificationand Wire HarnessRouting
RearWir€ Harnsss(Sedan):'99 - O0models
Connactoror
Torminal
Numb€r ot
Cavhios
c501
c603
c604
c605
c606
c610
c611
c6r3
c614
20
4
3
2
c617
c618
c619
c620
c621
c622
c623
a
1
G601
G602
Location
Connects to
Left quarter panel
Left quarter pan€l
Left side of trunk
Rightsideof trunk
Rightquarterpanel
Middleof rearshelf
Middleof rearshelf
Left side of trunk
Middleof trunk
Middleof trunk
Middleof trunk
Rightside oftrunk
Left side of trunk
Rightside of trunk
Left side of trunk
Rightside oftrunk
Middleof rearshelf
Middleof rearshelf
Floor wir€ harness(C562)
Left rear speaker
Left outer taillight
Rightoutertaillight
Right rear speaker
High mount brakelight
Trunklight
Leftinn6rtaillight
Left licensoplate light
Trunk latch switch
Rightlicenseplatelight
Rightinnertai ight
Left outer taillight
Rightoutertaillight
Left innertaillight
Rightinnertsillight
Window antennacoil
Window ant€nnacoil
Middleof trunk
Middleof rsar shelf
Body ground, via rear wire harness
Body ground, via rear wire harness
Notog
RoarWindow DetoggerWire
Connectot or
Terminal
c831
u65Z
c833
Numbor of
Cavitios
2
1
1
Loc!tion
Middleof rearshelf
Left side of rear window
Rightsideof rearwindow
REARWIREHABNESS
c603
23-48
c&tl
c62
Connrct3 to
Window antennacoil
Rearwindow defogger O
Rearwindow defoggerO
Note!
ID
Driver'sDoor Wire Harness{Coupe/Hatchback}
Connector ot
Terminal
Numbei of
Cavities
c631
UOJ I
c632
c633
c634
c635
c636
c638
c639
c640
2
2
4
4
2
12
3
8
12
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Insideof left power mirror
Driver'sdoor
Notes
Connectsto
Location
Floorwire harness(C556)
Floorwire harness(C556)
Leftfront door speaker
Driver'spowerwindow motor
Driver'sdoor lockactuator
Tweeter
Powerwindow masterswltch
Driver'sdoor lockswitch
Leftpower mirror
Powerdoor lockcontrolunlt
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe
Coupe*3
* 1 : W i t hp o w e rw i n d o w s
*2: WithoutPowerwlndows
"3: Withoutkeyless
c639
DRIVER'SDOORWIREHARNESS
23-49
Connectorldentificationand Wire HarnessRouting
Passenger'sDoor Wire Harness{Coupe/Hatchbackl
Connectoror
Terminal
Numberof
Cavities
c651
25
2
2
2
2
5
8
2
c652
c653
c654
LO55
Location
Conneststo
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Insideof right power mirror
Passenger's
door
Floorwire harness(C557)
Floorwire harness{C557)
Rightfront door speaker
Frontpassenger'spower window moror
Front passenger'sdoor lockactuator
Frontpassenger'spower window switch
Rightpower mirror
Tweeter
*1: With powerwindows
*2; Withoutpowerwindows
PASSENGER'S
DOORWIREHANNESS
23-50
Notgs
Coupe
Coupe
Coupe
Coupe
Coupe
'
Driver'sDoor Wire Harness(Sedan)
Connectoror
Terminal
c63r
c632
c633
c634
c636
c637
c638
c639
c640
Number ol
Cavities
25
2
2
4
4
16
1
3
8
12
Location
Driver'sdoor
Driver'sdoor
I Driver'sdoor
Driver'sdoor
Driver'd
s oor
Driver'sdoor
Driver'sdoor
D r i v e r ' sd o o r
Insideof left Powermirror
I Driver'sdoor
Connectsto
Notes
Floorwire harness(C556)
s C556)
F l o o rw i r e h a r n e s 1
Leftfront door sPeaker
Driver'spowerwindow motor
Driver'sdoor lockactuator
Powerwindow masterswitch
Powerwindow masterswitch
Driver'sdoor lockswitch
Leftpower mirror
Powerdoor lockcontrolunlt
* 1 : W i t h p o w e rw l n d o w s
*2: Withoutpowerwlndows
DRIVER'SDOOR
WIREHARNESS
Connectorldentificationand Wire HarnessRouting
Front Passenget'sDoor Wire Harness{Sedanl
Connectoror
Terminal
Numberof
Cavities
c651
25
2
c653
c654
2
2
c656
8
*1: With powerwindows
*2: Withoutpowerwindows
23-52
Location
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
lnsideof right power mirror
Connectsto
Floorwire harness(C557)
Floorwire harness(C557)
Rightfront door speaker
Frontpassenge/spowerwindowmoror
Frontpassenger'sdoor lockactuator
Front passenger'spower window switch
Rightpower mirror
Notes
D
Left Rear Door Wire HarnesslSedan)
Conngctoror
Terminal
Number of
Cavities
c661
c662
c663
c664
2
5
t
Conneststo
Loc.tion
Left8-piller
Leftreardoor
Left rear door
Left rear door
Notes
Floorwire harness{C571)
Left rear power window motor
Left rear power window switch
Leftreardoor lockactuator
Right Rear Door Wire Harness{Sedan)
Connectoror
T€rminal
Numbsr of
Cavities
c671
c672
6
2
5
2
c674
Conn€ststo
Location
RightB-piller
Rightreardoor
Rightreardoor
Rightreardoor
Notes
Floorwire harness(C570)
Rightrearpowerwindow motor
Rightrearpowerwindow switch
Rightreardoor lockactuator
Left Rear Door:
t
LEFTREARDOOR
WIREHARNESS
Right Rear Door:
RIGHTREARDOOR
WIREHABNESS
23-53
Connectorldentificationand Wire HarnessRouting
Roof Wire Harness(Coupe/Hatchback)
Connector ol
Terminal
Numberof
Cavities
c701
c701
c702
c719
2
6
2
1
Location
Underleft sideof dash
Underleft sideof dash
Middleof roof
Frontof roof
Connectsto
Notes
Main wire harness(C407)
Main wire harness(C407)
C e i l i n gl i g h t
Spotlight
* 1 : ' 9 6- 9 8 m o d e l s
*2: '99 - 00 models
RoofWire Harness(Sedanl
Connectoror
Terminal
Numberof
Cavities
c701
c701
c702
c703
c719
2
1
1
1
Location
Underleft sideof dash
Underleft sideof dash
Middleof roof
Middleof roof
Frontof roof
Connectsto
Notes
Main wire harness(C407)
Main wire harness(C407)
C e i l i n gl i g h t( P o w e r )
C e i l i n gl i g h t( G r o u n d )
Spotlighr
* l : '96 - 98 models
+ 2 : '99 - 00 models
MoonroofWire Harness{Coupe/Sedan}
Connector or
Terminal
Numberot
Cavities
c711
c711
c1't2
2
6
c713
c713
c714
c714
c715
6
5
c117
c718
c719
* 1 : ' 9 6- 9 7 m o d e l s
"2: '98 model
*3: '99 00 models
23-54
5
4
3
2
4
1
Location
Connectsto
U nder left sideof dash
Underleft sideof dash
Behinddashboardlower panel
Main wire harness(C407)
Main wire harness(C407)
Under-dash
tuse/relaybox (C910)
Leftside of dashboardbracket
Leftside of dashboardbracket
Leftsideof dashboardbracket
Leftside of dashboardbracket
Leftsideof steeringwheel
Middleof roof
Rearof roof
Rearof roof
Frontof roof
Moonroofopen relay
Moonroofopen relay
Moonroofcloserelay
Moonroofcloserelay
Moonroofswitch
C e i l i n gl i g h t
Moonroofmotor
Moonroofmotor (Tiltswitch)
Sporlight
Notes
Optional
ROOFWIREHARNESS
\,-d',
/::
23-55
Connectorldentificationand Wire HarnessRouting
Hatch Wiro Harness(Hatchbackl
Connectoror
T€rminal
Number of
Cavities
c761
c762
6
c764
2
'|
2
c768
2
Location
Connectsto
Rightquaner panel
R i g h tq u a n e rp a n e l
Rearof roof
Rightsideof hatch
Middleof hatch
Middleot hatch
lViddleof hatch
Middleof hatch
Rearwire harness(C607)
Rearwire harness(C608)
High mount brakelight
Rea.window defogger(+)
Rightlicenselight
Left licenselight
Rearwindow wiper motor
Hatchlatchswitch
Middle of tailgate
Bodyground,via tailgatewire harness
Notes
RearWindow D€fogg€rcround Wir€ (Hatchbackl
Connoctoror
Terminal
G171
23-5 6
Number oI
Cavities
Location
Connectsto
Leftsideot hatch
Rearwindow defogger(-)
Left side of hatch
Bodyground,via rearwindow defogger
groundwire
Notes
l'36 - 97 models:
REARWINDOWDEFOGGER
GROUNDWIRE
TCHWIREHARNESS
'98 - 00 models:
REARWINDOWDEFOGGER
GROUNDWIRE
WIREHARNESS
23-57
Gonnectorldentificationand Wire HarnessRouting
Heater Sub-harnessA: '96 - 98 models
Connectoror
Terminal
Number ot
Cavities
c 72 1
c722
c723
c724
7
20
2
c727
Location
Conneqtsto
Underleft side of dash
Behindglove box
Behindglovebox
Behindglove box
Behindglovebox
Behindglove box
Behindglove box
Notes
Main wire harness(C440)
Mode controlmotor
Heatersub-harness
B 1C741)
Ay'Cthermostat
Blowermotor
Blowerresister
Recirculation
controlmotor
HeaterSub-harnessB: '96 - 98 mod€ls
Connoctor01
Terminal
Number of
Cavities
c741
c142
c743
20
14
Location
Conngctslo
Behindglove box
Behindmiddleof dash
Behindmiddleof dash
Heatersub-harness
A (C723)
Heaterfan switch
Heatercontrolpanel
HEATERSUB.HARNESS
A
HEATERSUB-HARNESS
B
23-58
Notes
'
'99 - 00 models
HeaterSub-harnessA:
Connectoror
Terminal
Numberof
Cavities
c721
c722
c723
c724
c725
c726
c727
c728
c729
c730
7
24
3
2
4
1
5
4
Heater Sub-harnessB:
Connectoror
Terminal
c741
c'742
c143
c744
Connectsto
Location
Underleft side of dash
Behindglove box
B e h i n dg l o v eb o x
Behindglove box
B e h i n dg l o v eb o x
B e h i n dg l o v eb o x
B e h i n dg l o v eb o x
Behindglove box
Behindglove box
Behindglove box
Notes
Main wire harness(C440)
Mode controlmotor
B (C741)
Heatersub-harness
lilc thermostat
Blowermotor
Powertransistor
controlmotor
Recircuiation
B (C744)
Heatersub-harness
Air mix controlmotor
Blowermotor high relaY
'99 - 00 models
Numberof
Cavities
20
8
20
1
Connectsto
Location
B e h i n dg l o v eb o x
B e h i n dm i d d i eo f d a s h
B e h i n dm i d d l eo f d a s h
B e h i n dg l o v eb o x
A (C723)
Heatersub-harness
HeatercontrolPanel
HeatercontrolPanel
A (C728)
Heatersub-harness
A
HEATERSUB.HARNESS
Notes
Connectorldentificationand Wire HarnessRouting
Rear HeatodOxygen Sensor Sub-harness
Connectoror
Terminal
Number of
Cavhies
c7a1
c782
Location
Undermiddleof dash
Undermiddleof dash
Connectsto
Notes
Main wire harness(C432)
Secondaryheatedoxygensensor
(SecondarvHO2S)
FuelTank PressureSensor Sub-harness
Connectoror
Terminal
Number of
Cavities
c791
6
c192
c793
Location
Middleof floor
Leftside of fuel tank
Leftside of fuel tank
Cono€ctsto
Floorwire harness(C568:Coupe/
Hatchback,
C574;Sedan)
Fueltank pressuresensor
EVAPtwo way valve
FUELTANK PRESSURE
SENSOR
23-6 0
Notes
rt
SRSMain Harness
Conneclor or
Terminal
Number of
Cavities
c801
c802
2
c803
2
c804
c805
c806
c807
2
2
?
Location
Connectsto
Notes
fuse/relaybox (C911)
Under-dash
Underleft sideof dash
A b o v e u n d e r - d a s hf u s e / r e l a Y N4ainwire harness(C412)
DOX
G801
18
Memoryerasesignal{MES)connector
R i g h t s i d e o f u n d e r - d a s hf u s e /
relayDox
Underleft side of dash
Underrightsideof dash
Middleof floor
Middleof floor
Cablereel
airbagassemblY
Passenger's
connector
Dummy resastor
S R Su n i t
Middleof floor
Body ground,via SRSmain harness
USA
Canada
SRS MAIN HARNESS
23-61
Fuses
Under-hood
Fuse/Relay
Box
DEr-1
tr
tr
tr
IJ
r"l
17
LI
n5 1
IJ
r"l
56
LI
r"l
57
IJ
cgo1
lTo condensorfan relayl
*: Not usod
lTo blower motor r€layl
Gr02
c903
fto l/c comprdssor]
lclutchrelay
I
[To radi.lor tan rolayl
NOTE;View from the backsideof the under-hoodfuse/relavbox.
cto5
[To main wir6 harne$ (C3521]
c905
lTo mainwire ha.ness(C353ll
ITo main w;re ha.ness(C351ll
23-62
(l'Component(s)or Circuitlsl Protect€d
FuseNumber
Amps
wire Color
41
80A
42
40A
WHT/BLK
To ignitionswitch(BAT)
43
7 . 5A
WHT/RED
Ceilinglight,data linkconnector,trunk light
44
1 5A
WHT/BLK
PGM-Flmain relay
Powerdistribution
Not used
46
40A
WHT/BLU
47
7 . 5A
WHT/BLU
48
30A
WHT
Powerwindow motors(via powerwindow relay)
Audio unit,clock,TCM (CVT),ECM/PCM(VBU)
No.33 (7.5A) fuse,To combinationlight switch(headlight)
Not used
49
50
30A
WHT/GRN
Rearwindow defogger(via rearwindow defoggerrelay)
c l
20A
WHT/GRN
Powerdoor lockcontrolunit,moonroofmotor
1 5A
WHT/GRN
Horn system,brakelights,brakesignal
1 0A
WHT/BLK
Hazardwarning light, turn signal/hazardrclay
54
404
WHT/RED
O p t i o n{ + B )
55
40A
BLU,A/VHT
WHT
Blowermotor (viablowermotor relay)
Condenserfan motor (viacondenserfan relay)
RED
l'lc compressorclutch(viaIVCcompressorclutchrelay)
204
204
BLVBED
Radiatorfan motor (viaradiatorfan relay)
23-6
Fuses
Under-dashFuse/RelayBox
c912
lTo d.rhborrd wire harnes lC50'l)l
c913
[To ignition 3witchl
c€l1
lTo SRSm.in
lTo m.in wir. ha]n.3s {Cra2iIll
c9l0
lTo moonroofwiroh.tn6s 1C712)l
a-)
clr15
lTo m.in wiro h.Jna3r lca23)l
r"r r"t r-r n rl 11r'l |;l r-r r-'l r-'l r-l
23
2a
25 26
21 2A A
aO3t
32
33
LI IJ IJ IJ IJ IJ IJ LJ LJ LJ tJ tJ
r-rr-r Fr
r-rr-r n n ra
r-1ratn r-1
1A 1a 20 21
t2 t3 ra 15 16
17
22
lTo powor window rcl.yl
LI IJ IJ IJ IJ IJ LI IJ IJ LI I"J tJ
- rfl |?t - n n rn r-'l n rat T1 T1 T"l T"l
t
2
3
a
5
6
r
3
9
t
o
l
l
LI I.J LI LI I.J LI I.J LI LI IJ IJ IJ LJ LI
.: Canadt
*: Not usod
O: C326loption
@: C927loption
O: C!r28loption
@: c!t29 loption
(+B)l
ld.3h light!)l
tAOCll
(lc2ll
c!17
lTo tu]n .ign.l/h.z.rd r.byl
: Not u3od l'96 -97 modelll
d.fogg.r rol.yl
NOTE:View from the backsideof the under-dashfuse/relaybox.
Clt25 (96, 97 mod.bl
lTo m.in wiro ha]n.!. (C439ll
lTo m.in wiro h!rn..s 1C419)l
23-64
lrFuseNumber
Amps
Component{slor Circuit(sl Protected
wire Color
,l
Not used
2
Not used
3
1 0A
4
1 0A
5
1 0A
GRN
Rear window wioer motor, rear window washer motor
RED/BLU
R i g h th e a d l i g htrh i g hb e a m )
RED/GRN
Leftheadlight(highbeam),high beam indicatorlight
Not used
6
7
204
RED/VVHT
Left rearpowerwindow motor
8
20A.
YEUBLK
Right rear power window motor
Not used('96- 97 models)
9
't5
10
204
GRN/BLK
powerwindow motor
Frontpassenger's
11
20A
BLU/BLK
Driver'spowerwindow motor
12
7 . 5A
YEUBLK
Turn signal/hazardrelay (via turn signal/hazardswitch)
YEL/GRN
PGM-Fl main relay
t5
1 5A
14
1.54
A
t6
17
7 . 5A
18
RED
Distributor(ignitioncontrolmodule)('98- 99 models)
GRYor BLK,^/ELSRSu nit (VA)
BLK/YEL
Cruisecontrolsystem,audio unit*1,keylessdoor lockcontrolunit*3
BLK/lr'r'HT
Alternator,VSS,ELDunit (USA),EVAPpurgevent shut valve,oxygen
sensors,TCM (CVT)*'
BLI(,/BLU
ABS pump motor, rear window defogger.power mirror*3,mirror delogger*3
BLK,/YE
L
A,/Csystem,power mirror*r.option (lG2)
YEUBTK
Daytime running lights relay (Canada)
19
7 . 5A
YEURED
B a c k ' u pl i g h t s
20
10A
BLK/VVHT
Daytimerunninglightscontrolunit (Canada)
21
1 0A
REDA/VHT
R i g h t h e a d l i g h t( l o w b e a m )
22
1 0A
REDI/E L
Left headlight (low beam)
1 0A
G R Yo r P N K
24
7 . 5A
GRN/ORN
25
7 . 5A
2a
YEL
204
GRN/BLK
1 5A
YEL/GRN
10 A,/' ]5A''
YEL/RED
M o o n r o o rf e l a y s
Gaugeand indicatorlights.interlockcontrolunit
Windshieldwiper motor,windshieldwashermotor,
integratedcontrolunit {Canada)
Accessorysocket(ACC)
Audio unit,option (ACC)
Not used
29
30
S R S U N i t( V B )
7 . 5A
RED/BLK
D a s hl i g h t so, p t i o n( d a s hl i g h t s )
1 . 5A
BLUA/VHT
PGM-Flmajn relay,integratedcontrolunit
ECM/PCl\4,
RED/BLK
Front parking lights, taillights, license plate lights
7 . 5A
33
'
9
6
*1r
- 98models
*2r '98 model
*3: '99 - 00 models
WHT/GRN
lnterlockcontrolunit. key interlocksolenoid
23-65
Fuses
ABSFuse/Relay
Under-hood
Box
lTo under-hoodABS tus€/relay box wire harnossl
c926
c92E
lTo main wire harness(C357)l
[To ABS pump motor relayl
@27
ITo main wir6 harno$ {C356}l
FusgNumber
61
Wire Colol
40A
BRN/YEL
63
204
23-66
WHT
WHT/GRN
Componont(s)or Circuit(sl Protscted
ABS pump motor (viaABS pump motor relay)
ABS controlunit (motorcheck)
ABS controlunit (+Bl)
Power Distribution
t
Circuitldentification
'96-98models
UNDER-HOODABS
BOX
FUSEi
RELAY
* 2 : 99-00models
WHT'GBN
-
CONTROL
l ABsconlrorun
V
I
ABSAimpmolor
GRNMHT
BRN,ryEL
YEURED
I
t
ABSconltolun
molor
Slaner
HOOD
UNDER
FUSEi
RELAY
BOX
..........WHT/BLK
ALTERNATOR
No15(7sA)FUSE
page
(From
2370)
f7
V
Y
|
r_1
waming
ligl
Hazard
reay
Tunsignal/hazard
{Viaswlch)
_WHT/GRN
HOTN
WHTiGBN
HOnreay
I_ .,.-.,
ABscontrollnil
ECMiPCM
T C M( C W ) r l
Cruiseconlrolunil
Erakelrghls
I-"-
GRN/RED
EC}?VPCM
('^')
lg|[|];gil.'
*,,,,,*_$
lighl
Ceiling
Trunkllghr
*'
Spollighl
Dalalinkconnecor(DLc)
Integraledcontrolunil
G401
G402
WHT/8LK
w_TBLU-13
PGMFl mainrelay
I...
>
t-
UNOER.DASH
F-SE?ELAY
BCx
Fa Nge23:t)
Audiounil
T C M( C W ) ' ,
ECM/PCM
Healerconlrolpanel
(cont'd)
23-67
PowerDistribution
Circuitldentification(confdl
UNDER
HOOD
FUSE/BELAY
BOX
UNDEN.DASH
FUSE/REIAY
BOX
flo page23-72)
COMBINATION
LIGHTSWITCH
[Io page23 73, 74)
UNDER,DASH
FUSgRELAY
BOX
Oo page23'74)
wnc'N---}>
wHT/GnN-
Hlgl;%,s,1
lsu'r"'
*,
Po#srdoorlockcontrol
unil
Moonrool
molor
*HT/RED
+
BLUMHT-
*t
Hoo5f;oA'.j1fu,uttto"
Blowor
fiolor
"*-f_
G()1
G402
BLu/rrit{t
(ViaA/C Fsssureswitch)
ECI4/PCM
BLU/lf {I -
,VCth€modA
v{HT-
Con(,ensef
lan molor
A/CcomFessor
dulci
23-6 8
BLI(/RED
ECWPCM
BLI(RED
Radiator
tanmolor
t
r 96'9€models
* 2 : 99modol
* 3 : GRY(96-97
models
: GRN(9&00models
(40A)FUSE
N0.42
page23.67)
(Frofir
FUSE/RELAY
BOX
UNDER.DASH
IGNTIONSWITCH
N0.16(7.5A)
WHTi
BLK
t
BLI(BLU-
ABScontrolunit
RELAY
REAR
WINDOW
DEFOGGER
deloggot
swch)
{ViaGarwndow
fro page23-71
)
BA1;.'
1
l€ht
Rearwindow
d8loloerswilchindicalo.
'.._ ACC
r?
::: ) mirroa
d€loQor
Hrgn, Ma mirori;loggersYritch)
lighl'2
Mirordolog06r
$ tdr indicalor
ri,,o,"qraor',
191
hEn,) oo*e,
ivrapow mircrsMdr
borsocl(el)
lFusdrelay
WHT/BLK
I
conna.ior
odional
1lG2)
I
. BLOWER
MOTOR
FELAY
. CONDETISER
FANRETAY
. ,VCCOMPRESSOR
RELAY
CLWCH
. NAONTOR
FANRELAY
pag€
2368)
0o
Heal€r
conlrolPan6l
,ryCher|lDshl
Modeconlrolmolor
Reorolalion
conlolmolor
Aow€rmoloriEh aelay
V
fro page23'70)
0o pag623-12)
q, (/vrr
-
I
|.fi
:::
F\
-113>
vELrtsLK
t'-
I
I mrcr mircraqua|ol'r
FUNNING
LIGHIS
DAY'IME
(Ceneda)
CONTFOL
UN|T
(f o We 23-71)
,n*,"',
,F1J'96-97mod6ls
""j
'98-99
models
No.l2(7.5A)
N 0 . 1 (31 5 A )
GRNGRN_
Rearwindowwashermolof
Rearwindow
wipermolor
YEUBLK
relay
Turnsrgnal/hazard
(Viaswilch)
YEUGRN
PGM-Flmain
relay
:rl l^r A k/YF l -
SRSunii(VA)
(7.54)
N0.14
B./"|YEL lL
BLKryEL-
Ctr|s€conlrclJn (Viamainswildr)
lEhl
C'uEema'4swildr'ndicalot
Audiounil(K€yossrece'ver
drol4)
Kevless
doortockconlroiunit
(Topage
23'70)
(cont'd)
23-69
PowerDistribution
Circuitldentification(cont'd)
i.1 :'96,98
modes
r.2 : 99mode
*3 :GRY('96-97
models)
:GRN(98'00models)
FUSE/REtAY
BOX
UNDEF.DASH
No1s(7sA)
Anernal0r
VSS
HO2S
EVAP
conlrol
canister
ventshr,,l
vafoe
EVAP
valve
Flrgeconrolsoenord
ECM/PCM"
sLrwHT+
Ft"t:itJY;i
BLI{WHT
-}rcutcwt.,
BLKr'r{HT
Chargir!syslemtrghl
Back-!plighls
*3 (orPNn -
SRSunri(VB)
GBN/OF\--
Moolroolopelrelay
relav
MOOlrOOldOSe
POWERWINDOW
RELAY
(Topage23-71
)
N0.25(7.5A)
(Fusoirelay
boxsockel)
InteEalei conLolunft
YEL-
Shinlocksoenod I r!/r\
lnleiockmnlrolunI J '- '
Galgeass€mbly
lighl
SRSindicalor
ABSindicrtor
lghl
A/Igearposilionnd€lorl
d,mmino
- qrcu,l
uru6e notcaoa
)
(Fuse/relay
boxsocl€l)
Inlegraledconlrclunt
Windshield
wipermolor
(ACo)
IGN|T
0N SWTTCH
page
23-69)
lFrom
Y_
*,n,,*
........GRN,B-<
|
-
ImeEaleo
cortolull
(viawndshieLd
wi9elswllci)
.nolor
wrrdsierdwasher
(Viaswrn)
power
Accessory
sockel(ACC)
(Acc)
oplioialconneclor
Audio
unil
23-70
l'N o5 4 1 4 0 AF)U S E
(Frompage23 68)
FUSERELAYBOX
UNDER.DASH
(Fuse/reay
borsockel)
(+8)
conneclor
opliona
(7.s4)
FUSE
page
2370)
7
POWER
WINDOW
RELAY
N0.46
{40A)FUSE
(From
paqe23'67)
vI
"*-l_
ooo,
c402
WHTiBLU
BLUts-^ -
L
towetwiroowmasle's,r;.h
Powerwtndow
COn[Ol
Jnil
(Viapower
window
master
swilch)
GRN/BLK
GRN/BLK
GRN/BLK_J
power
I Fronlpass€nger's
moor
wtnoow
maslersv
swilch\
window
masler
sr window
/Viapower
passengerspower
power I
I passengerb
I andfronl
-:: -.::::
I Lell'eatPowe'wndow-olot
'/v'a powerwiroowmasle'swch
\
\and lefl lear Powerwindowswilch./
':_:_:
I Rohlrearoolverwitow molol
'rv
a @werwlfoowmaslerswrlcl l
\end gh1re powerwndowswilch/
BL|(BLU -
Rearwindow
delogger
No 50 (3OA)FUSE
(Frcmpage
2368)
vI
N 0 . 1 (67 . 5 A ) F U S EWHT/GRN
(Viaswlch)
(Frompaqe23'69)
v
I
BLU/YEL
"*-f,_
oit
G402
(cont'd)
23-71
PowerDistribution
Circuitldentification(confdl
IM/T)
(sT)
rGNrTtoN
swrTcH
pag€
(From
23{9)
Y
t-
STAFTER
CUTRELAY
BLK,VHT
I
CLUTCH
SWITCH
r**"'.fffr,u,r.*@**-_
-|:1jlBLT(-^,I'/HT
l
BLT(RED
T
i
BLK^/HT-
l
$anersol€ndd
.
G401
BLIVREO
L-
(sT)
rGNrTroN
swtTcH
paoe
23{9)
{From
f'7
II
BLK/WHT
NEUTFAL
POSITION
swtTcH
/ln lL/Tgeat \
\posnionswldr/
BLT(RED
-
srarrer
sotsnoid
-BLK4rrHr
(Fus€felay
lox sockol)
ELUVHT-
PGM-F|
main
retay
BLUMHT_
ECI\T/PCM
lH#|1'#i,'f,5>-**
l e ockconnol
unit
(viaintedocf
switdr)
Keyints ocl solenoid
wHr
+
23-72
lrflagGt€dconlrolunit
&3T:$111.9|'ij""'n'"
!t
USA:
UNDER,DASH
FUSEiRELAYBOX
COMEINATON
LIGHTSWITCH
No.48(304)
FUSE
/Frcmpage\
\23{8
/
l 'o
to"'to
I
_
RED/BLU
(Highbeam)
Figltlh6adlighl
_
BED/GRN
Highbeamindi€torlight
FEO/GRN
(Highbeam)
Leflheadlighl
REDMHT
(Lowbeam)
Rightheadlighl
REo/{EL-
Letl headlighl(Lowbeam)
No.a8G0A)
FUSE
/Frcmpage
\
\23-72 )
(Fuse/relay
boxsocl(el)
(Fuss/relay
boxsockel)
optioml @nn6clorloash hghls)
InEgraledcontrolunil
HazardwamingsMch ligld
Gaugelighls
Audiounil
nearwndowdelog0erswild lighl
Cruisomainswitdrlighl
ctuis€ndrcalot
..
]crmminocircu,t
A/ | qsarposrrcnnor@IorJ
Dashlighlsbrighhessmnlroller
FEo/BLK
t
l'/T gea.pGilion consolelighl
Heald conlrolpanelligtn
RED/BLK
t
::: I lronloarkino
liohl
Hqm,
n-'i6J
*t"' t"itt'9t'6
inn"tu'll'gl't'
n-,shj
:: 1 | hcense
Dlaleliohts
Hgnri
(cont'd)
23-73
Power Distribution
Circuit ldentification (cont'd)
Canada:
UNDER,DASH
FUSE/RELAY
8OX
COMBINATION
LIGHTSWITCH
RED/BLU-
(Highboam)
Rightheadlighl
----<
FEDiBLU
N0.48{30A)
/Ffornpage\
\a-68
l
l |oPASSTNG
|
to
REstsTOR
REo/GRN
HiJhbeamindicator
lighl
BEo/GRN
-
Leftheadlighl
iH,ghbeam)
L{
BRN/BLK
LGl I
I EcM/PcM
lcz J
[..........{
j
CKFsensor
L.-!l
(KS)r'::{
Knocts€rlsor
PimaryH02S*?-
BFNaLK
8LU/FED
REDtsLU
wHT
ECIVPCM
Matnsnafi g]€eo sdnsoa -'1
Counlersiall
speed
sensor--={Fl
----Tal
Ecr#PcM
t I HEL)
)*"
BIU
Dl6YBengine
44:lil
WHT/BED
Dl6Y5,D16Y7
sngine
vtl
8BM/BLK
_ I
BBi1/BLK
I
Divetrjileyspeed
seftsor-1ll
pulley
0 ven
speedsensor.-lJ
gear
Seconftry shaltspeed
sansor.-!.1
I rcurcwr
**'-i I
WHT/RED
+ ]
WHT
WHT/RED
*lr" h"rn"""
El , Engln"
:
Main
*re harness
E
23-76
^l^1ll'.
FED,ALU
- - - - - - : Shietorns
* 1: D 1 6 Y 5 , 0 1 6e
Yn8g i n o
* 2 : ExceplDl 6Y5engine(i//T)
+3: D16Y5engine(Mfi)
rt
'99-00models:
(5i%ease)E>4 BRNiBLK
ERNi
BtK
i.,.,].
BRIVBLK
BFN/BLK
BRN/BLK
BRN]BLK
BRIl/8LK
BFN/BLK
r*s
CKFs€nsor
1
t
r;l ao^r,qtr
-1ll
'-l
Knoq(sonsor(r15J
P maryHo2s*?H
ELU/FEU
!l r{EUl6LU
wHT
Mainshaflspeeossnsor -1ll
fiEU
Coutershall sp€edsensor -+F
] BLU
Ly"::::::::
)
..",r.u,.0n
Dl6Y5(CW)ongines
016Y7,
;;=-"r,i,-l
sngine
015Y5(LVT)
41-.1
;'4:v-..1
816A2,Dl6Ygengiftes
I
Ho2s:{
Secondary
Dfiv6prirEyspeeosonsot-1l
gr leysp€edsensor-Driven
gea
Secondary siansp€edsensor.-ll
WHT/RED-
l hEL,bLU
F I WHT
WHT/RED
RED/BLU
I
wHT
f rau,rru(an)
pgTpse- J
Bl6AzerEines
Dl6Y8engines *4:016Y7,
sLlbharness *1i016Y5,
orygensensor
wreharness E : Rearh€al6d
E : Engine
D16Y8Bngines
([VT) *5: D16Y5,
D16Y7,
*2: Excepl
DI6YSengino
(CW)engines
*6:B16M,
shielding
D16Y8,016Y5
* 3:Dl6Y5
([VT)
wireharnsss -----sngine
IIJ : Main
lcont'd)
23-77
GroundDistribution
Circuitldentification(cont'dl
-
Erghrheadlighr
-
F r g rr: c l l p a ' h r rr3g r r
Srgnlronl rufnsqfal qhi
;,.-
"'-fflri#*l:;:r.,,
Wrdshield
washer
molor
Rear
window
washer
molor
Cruise
confolactualor
lvasher
level
swch(Canada)
E
Enqine
compenme
wrre
harness
23-78
t
'96-98models:
EL^ -
-
Y Y ' i i s n E o' F € " ' v ' u '
Bfale llJ d levetswlci
E
'D-cl
I DahInl col"eclot
q q . - _
wperhvasher
swildr
Windshield
--l ,o,?'.da.
BLK-..1
BLIJ/REo
|-|d
Horn
wip€r^vasher
swtch
Rearwindow
l_
l-
'''"_-, rA/Tl
p a ap i r s w i l c F t - ,
Clulcfnlelockswlcr rVT)
Cruise
conlrolunil
8LK
lrghtsconltolunil(CanaJa)
Da,'lm€runnrng
-
UNOEB,DASH
FUSE/RELAY
BOX
(M/Twilhcruise
erEine)
conlfolorlorD16Y5
(Fuserelay
boxsockel)
relay
Bearwindow
delogger
(Flserelay
borsockel)
Lnlegrated
conlrol
unil
(Fuse/relay
boxsocke0
(Fuse/relay
boxsockel)
Turnsignal/hazad
@lay
8LK
J
6L^
G402
/ Topage
\ 23,81
--...........--
Munn'un'
+
oot
l-
Dashhghlsbfrqrllessco 'oel
ftyess doorto* mnlrorLnil
Seorriry
@rl'olJn:
Cnrisemainswilchlighl
dirnming
orcuil
Cruiseindicalor
swilchlighl
Red window
deloggel
indicalor
dimming
cilo./il
A/Tgearposilion
JUndon
connedor
wireharness
companmenl
El : Engine
,
M"in*it" h"n"..
E
retay
Moofrootooen
MOOnTOOI
doserelay
B-(-llerX
5.nLi
?_
L
E
BLK-
Accessorypowersockel
lighlcirclil
SRSindicalor
BLK
endindicatols
Cauges
BLK
ABSindicalor
lighlcirq)rl
BLK
Gaugelights
: oashboatd
w€ haness
wreharness
@ : Moonrool
(cont'd)
23-79
GroundDistribution
Circuitldentification(confd)
'99-00models:
E
Wir'rdshield
wipe.nolor
BGkelluidlevelswildl
a-)
l-
€y sv lo
€nrnon
oala
hnk
conn€clol
lDlcl
i
6L^ --
8LK
Windshigld
dper^vash€r
switdt
BLK
Re windo wiperlflasher
ssitch
-r^ -..-l-
t m e n o o@( r o t u n nl . _ .
p a * o i ns w h r h l \ 4 t l
inlerlodswildr(M,T)
ClLrldr
Cruis€
confolunit
BL(---_
Oaymerunning
tights
(Canadal
controtund
Ctuldtsfich
(l,t/Tvrithruis€corrol)
Key'ess
doorlockcontrol
unit
UNOEN.DASH
FUSgRELAYSOX
(Fuserelay
boxsockst)
nearwindoYr
delogger
rclay
(Fus€/relay
boxsod(8t)
htograted
co.Irdunil
(Fusdrelay
borsockel)
(Fuserelay
boxsock€l)
BLK
Tumsignal/hazard
lelay
J
oh --t-
9aqe
( To
23.A2-
Moonroot
swnm
iroonrool
openrelay
Moonroot
dosereiay
t
-J
fil BLK
G401
,JUncll0n
@nfreclol
wirehamess
tr : Engine@mparlrnenl
E
: Main
wirehaness
23-80
wireharness
E : Dashboard
El , Mo*tool*ite har"..
8LK
SRSindicalor
lighlcirqtil
,y'Tgoerposition
indicator
dimming
cirdlit
BLK
poxersod@l
Accessory
BLK
Gaug€s
andindicators
BLK
ABSindicalor
lightciro.lil
8LK
Gauge
lighb
Cruis€
mainswil$lEhl
indicator
Cruiso
dimming
cirorit
oashlohlsbrighlness
confolbt
Hazard
s$tdl indicator
liohl
'96-98models:
(wirhABs)
8LK
A/Tjear Posilionswilch
-
seNic€check@nneclor
ABSFlmp motor
Audiounil
oit
-r-r:='
t
O
/
r
,!r'-,
BLK-
l
il-
B" t
-1:r'-
Powetdootlock@nlrolunil
D vet s dootlockaclualor
P yg15666110c1
swlgh
manswch
] po*ersindow
E'0,'""a.
*., *noo, ro,o,
Fuelunil
BLK-liJ#1!ll3n"**
G552
@ :
fi-']
wrrehaness
Dashboard
wireharness
U : Floor
hamess
doorwire
Drrve/s
E
E
E
A
Healer
sub'harness
: Healer
B
subharness
(cont'd)
23-A1
Ground Distribution
Circuitldentification(cont'dl
'99-00
models:
(WilhollABS)
r'1
6 | c40.tFroroaoe23-BC. I
BL( -<
I
L
E
_::I
A,/Igefi posilion
swilch
ELDunil
Servi@
checkconnector
UNDEF.H@D
FUSF]RELAY
BOX
rl--{ry--Browe,mororreray
BL-_14BL-
tL4
-11-51
,r^ -.;--a-r,*
n"*-fi-+aLx-lfuBLK-
-iff
eLx
BLK
panel
Hearer
Hearer
conrror
conrror
o6n
BLK
-
"n'
ff;?,m",:[:'
ABSglmpmotor
or*
_tr
l
G501
-
|t ,l - " * T - " ^
v
Pos€rdoorlockcortaolunit
Divers doorlockaclualor
Driver'sdoorlockswitch
Lefl miror delogger
I
l
-L"."
BLK--.+t
G551
_
Power
wndosmanswdch
J
Dive/sFo*grwindow
motor
F-.
T
F--{
BLK-.1
BLK-
Fighr.nirordetogger
ort,
*it" hanes
El ' Main
:
Dashboafd
wircharness
E
23-82
tr : Floorwirehamess
haness
tr : Drve/sdoorwife
E
: Healer
sub-haness
A
sub'harress
B
El : Healer
@
Passenger's
doofw're hamess
Highmolnlbrakelighl
wpermolor
R€arwindow
G601
Bighmounlbrakelighl
wipermolor
Rearwindow
TrLrnk
laldlswilch
l"fn,) o*"'''*'nnt"
'"t'n"'
l",$')'nnt'
lt$|n')''"nt"o'"'t,'nn"
Tronklalci switch
lighl
brake
Highmounl
ouo,
: 96-98models)
(coupe/sedan
li|n')o*".'tt'nn''
't*'n*"
l[., ] 'nn"'
.,"'jn,"""n"o'"t"''nnt"
)
G601
BLK
Trunklaldr swlcll
*'lli.,ilJ:"f_'$l
{Sedan: 99 00 models)
E
:Fearwrehaness
E
, H"t"hnit"h"tnes"
(cont'd)
23-83
Ground Distribution
Circuitldentification{confd}
Condens€r
lanoDlor
-AGi51
F,'o."
Re wrndow
d€,ogger
(Ftald|bac*)
I
_a_
E] , ,,vc*itenatness
ground
window
deloggs
wile
0 : Rear
E] , snst"in h.rn*
23-84
t GFY : '9&97ftod.ts
GRN| 98-00models
Box
Fuse/RelaY
Under-dash
Removal/lnstallation
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wl h e
SRScomponentlocations,precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor ser-
lnstallation:
1.
C o n n e c t h e c o n n e c t o r st o t h e u n d e r - d a s ht u s e /
relaybox,then installthe underdashfuse/relaybox
in the reverseorderof removal(seesection24)'
2.
Installthe driver'sdashboardlower cover (seesec
t i o n2 0 ) .
3.
Connectthe airbagconnectors{seesection24)
4.
Connectthe batterypositivecable,then connectthe
negativecable.
5.
Enterthe anti-theftcodelor the radio,then enterthe
customer'sradiostationpresets('99 00 models)'
6.
Confirmthat all sYstemswork properly'
vice.
Removal:
1.
2.
Makesure you havethe anti-lheftcode for the radio
then write down the frequencieslor the radio'spreset buttons('99- 00 modelsl.
Disconnectthe batterynegativecable.then discon
nectthe positivecable,and wait at leastthree min
utes,
3.
the airbagconnectors(seesection24)'
Disconnect
4.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20)
5.
Removethe two mountingnuts,and pull the under
dashfuse/relaybox out from underthe dash'
6.
D i s c o n n e ctth e c o n n e c t o r sf r o m t h e u n d e r - d a s h
fuse/relaybox, and take out the under-dashfuse/
relaybox (seesection24).
23-45
Power Relays
RelayTest
Turn Signal/Hazard
Relay:
.
Rearwindow defoggerrelay
Seepage23-172
Normally-opentype:
1.
Checkfor continuitybetweenthe terminals.
. Thereshouldbe continujtybetweenthe No. 1 and
No.3 terminalswhen powerand groundare connectedto the No. 2 and No.4 terminals.
. Thereshouldbe no continuitybetweenthe No. 1
and No. 3 terminalswhen power is disconnected.
Terminal
\
1
-i*rt"r-*or\
3
Disconnected
o
Connected
,I YI
I
F>
, ? I
rr
€
3
.
Blower motor relay
.
ABS pump motor relay
23-86
Startercut relayt'96 - 97 models
Horn relayi'96 97 models
a Blowermotor high relay:'99 - 0Omooers
Five-ierminaltype:
Normally-opsntYPe:
1.
Checkfor continuitybetweenthe terminals
1.
There should be continuity betlveenthe No. 1 and
No. 2 terminalswhen power and groundare connectedto the No. 3 and No 5terminals.
. Thereshouldbe continuitybetweenthe No 2 and
No. 4 terminalswhen power is disconnected'
.
. Thereshouldbe continuitybetweenthe No. 1 and
No. 2 terminalswhen powerand groundare connectedto the No. 3 and No 4terminals.
o Thereshouldbe no continuitybetweenthe No 1
and No.2 terminalswhen poweris disconnected'
\
Terminal
Power
iNo.3- No,4)
\
I
2
\
Terminal
4
Power(No.3 - No. 5)\
o- o
Disconnected
Disconnected
Connected
Checkfor continuitvbetweenthe terminals.
o
o
o-
Connected
--1
I
Power window relaY
Radiator fan relaY
Condenser fan relaY
a A/C compressor clutch relaY
'98 - 00 models
a Starter cut relay:
'98 - 00 models
a Horn relay:
-o
I I
t
'96
Moonroofopen relay: - 97 models
'96
Moonroofcloserelay: - 97 models
(cont'd)
23-87
PowerRelays
RelayTest (cont'd)
Five-terminsltype:
l.
Checkfor continuitybetweenthe terminals.
.
There should be continuity betweenthe No. 1
and No, 2 terminalswhen power and ground are
connectedto the No. 5 and No. 3 terminals.
o There should be continuity between the No. 1
and No. 4 terminalswhen power is disconnected.
Terminal
\
P"*"r{ltl"5-N".3)-\
Disconnected
Connected
.
.
1
oo-
4
---o
----o
Moonroofopen relay:'98-00models
Moonroofcloserelay:'98 - 00 mooets
23-88
lgnition Switch
Test
ElectricalSwitch RePlacement
SRS componentsare located in this area Reviewthe
SRScomponentlocations.precautions.and procedures
in the SRSsection{24}beforeperformingrepairsor ser-
SRS componentsare located in this area. Reviewthe
SRScomponentlocations,precautions,and procedures
in the SRSsection\24) beloreperformingrepairsor servtce.
1.
i / a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons('99- 00 models).
1.
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons{'99- 00 modelsl.
2.
the batterynegativecable.
Disconnect
2.
the batterynegatlvecable.
Disconnect
3.
Remove the driver's dashboard lower cover and
kneebolster(seesection20).
3.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r { s e e
section20).
4.
Disconnectthe 5P connectorfrom the under dash
fuse/relaybox and the 7P connectorfrom the main
wire harness.
Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox and the 7P connectorfrom the main
wire harness(seeleft column).
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
Removethe steering column covers {see section
11t.
Terminal
\
Position
1
(ACC)
(3)
5
(BAT) { t G 1 )
lnsertthe ignitionkey,and turn it to
(1)
G2)
(sr)
1.
o (LocK)
| (ACC)
o- - o
l (oN)
o-
{LOCK)".
Removethe two screws and the electricalswitch
from the steeringlock.
o
-o
o-
III (START)
"0
ELECTRICAL
swtTcH
I I :7Pconnector
Wire sideot femaleterminals
WHT IBAT}
BLK/WHT{STI
7P CONNECTOR
WHT/BLK
YEL(IG2}
BLK/YEL{IG1)
Wiresideof femaleterminals
6.
8.
Installin the reverseorderof removal.
lf the continuitychecksdo not agreewith the table,
replacethe electricalswitch.
23-a9
lgnition Switch
SteeringLockReplacement
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations.precautions,and procedures
in the SRSsection(24)beforeperformingrepairsor servtce.
Remove:
Installation:
l.
Installthe new steeringlock assemblywithout the
key insened.
Looselytightenthe new shearbolts-
L
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w i r e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons('99- 00 models).
Insertthe ignition key, and checkfor proper operation of the steeringwheel lock and that the ignition
keyturnsfreely.
2.
Disconnect
the batterynegativecable.
Tightenthe shearboltsuntilthe hex headstwist off.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20).
sr{€aRSroLT
Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox and the 7P connectorfrom the main
wire harness(seepreviouspage).
Removethe steeringcolumn covers,then remove
the mounting bolts and nuts from the steeringcolumn (seesectionl7).
Lowerthe steeringcolumnassembly,
1.
TWIST.OFFFORTION
Center-punch
each of the two shearbolts,then drill
their headsoff with a 5 mm (3/16in) dritt bit.
CAUTION: Do not damagothe steering lock body.
Installin the reverseorderof removar.
Enterthe anti-theftcode for the radio,then enterthe
customer's radio station presets.
Removethe shearboltsand the steeringlockassem,
oty.
23-90
Battery
Test
@l
your skin ol in your eyes Wear
. Battery lluid lelectrolytel contalns sulfuric acid. lt may causesevere burns it it gets on
protective clothing and a face shield.
- It eleqtlolyte gets on your skin or clothes, rinse it off with watel immediately
physician
- lf electrolyte gets in your eyes,flush it out by splashing water in your eyes for at least 15 minutes; call a
immediately.
battery case and splatter
. A battery gives off hydrogen gas. lf ignited, the hydrogen will explode and could crack the
acid on you. Keepsparks,flames, and Gigarettesaway from the battery'
spray out ot ths battery vents'
o Overchaigingwill raise the temperature oI the electrolyte.This may force electrolyte to
propcr
rate.
at
a
the
battery
Follow the charger manufacturel's instrustions, and chalge
procedures.lf you don't have one of thesecomputUse eithera JCI or BearARBSTtester.and follow the manufacturer's
erizedtesters,follow this conventionaltest procedure:
ToqetaccurateresuIts,thetemperatureoftheeIectro|ytemustbebetweenT0"F(21.c)and100"F(38.c}'
lf the caseis crackedor the postsare loose,replace
the battery.
lf rhe indicatorshows low electrolyte,add distilled
water if Possible.
EYElndicatesOK
(#l )
Test LoadCaPacitY
. A p p l y 3 0 0 a m p l o a d f o r 1 5 s e c o n d st o r e m o v e
surfacecharge.
. Allow 15 secondsrecoveryPerloo.
. Apply test load {seeTestLoadChan).
. Recordvoltageat the end of l5 seconds.
Staysabove9.6 volts;
battery is OK.
Dropsbelow9.6volts.
(cont'd)
23-91
Battery
Test (cont'd)
Chargeon High Sefting(40amps)
Chargeuntil EYEshows chargeis OK; plus an
additional30 minutesto assurefull charge.
NOTE: lf the battery charge is very tow, it may
be necessaryto bypassthe charger,spolarity
protection circuitry.
lf the EYEdoes not show chargeis OK within
three hours,the batteryis no-good;replaceit.
Write down how long the battery was
charged.
Test Load Capacity(#2)
Apply 300amp load for 15 secondsto removesurfacecharoe.
Allow 15 secondsrecoveryperiod.
Apply test load {seeTest LoadChan).
Recordvoltageat the end of 15 seconos.
Stays above 9.6 volts; battery is OK.
,
]
Drops below 9.6 volts; baftery is no-good.
TESTLOAD CHART
Usethe test load or 1/2the cold crankingamps {CCA)printedon the
labelon the top of the banery.lf neitheris indicated.usethe
informationbelow:
tu,
BArrERy
coDE
* : 5 5 8 2 4 1( S )- M F
23-92
I
coLb@
AMps(ccAl
4 0 5( * 4 1 0 )
|
{amps)
200
StartingSystem
ComponentLocationIndex
STARTERCUT RELAY(M/T}
Test, page 23-86,87
A/T GEARPOSITIONSW|TCH
Test,page23'154
page23-155
Replacement,
CLUTCHINTERLOCK
swlTcH
o
o
ool
BATTERY
Test,page23-91
STARTER
Test, page 23'95
SolenoidTest,Page23 96
Replacement,
Page23-100
PerformanceTest,Page23-101
23-93
Starting System
ComponentLocationlndex
G N I TO N
S WT C H
UNDEF.HOO
FU
OS E i F E LB
AO
YX
N04l (80A)
N042 (40A)
t,U,-*€,-l
ELKMHT
I
t
&T GEAR
POSITION
SWITCH
(CosednposilioN
n or E)
81X,4{HT
l
BLKIWHT
STARTER
CUTFELAY
-
STAPTER
(Permaneit
nragnel
type)
23-94
__l
-
Starter Test
Checkthe battery.battery positive cable, ground,
startercut relay,and the wire connectionsfor loosenessand corrosion,Testagain.
lf the starterstill does not crankthe engine,go to
step 4,
NOTE; The air temoeraturemust be between 59 and
100'F(15 and 38"C)beforetesting.
RecommendedProcedure:
.
.
Usea stanersystemtester.
C o n n e c ta n d o p e r a t et h e e q u i p m e n ti n a c c o r d a n c e
instructions.
with the manufacturer's
. Testand troubleshootas described,
wire and solenoid
Unplug the connector(BLK,/WHT
terminal)from the starter,
Connecta jumper wire from the batterypositive(+)
terminalto the solenoidterminal.
The startershouldcrankthe engine.
Alternate Procedurg:
.
Usethe followingequipment:
- Ammeter,0 - 400A
- Voltmeter,0 - 20 V (accuratewithin 0.1volt)
- Tachometer,0 - 1,200rpm
. Hookup a voltmeterand ammeteras shown.
NEGATIVE
TERMINAL
.
NOTE:After this test, or any subsequentrepair. reset
to clearany codes(seesectionl1)
the ECM/PCM
.
Checkthe Start€r Engagemont:
1.
2.
Removethe No. 44 (15A) fusefrom the under-hood
fuse/relaybox,
Checkthe ignitionswitch(seepage23-891.
7.
Turn the ignition switch to START(llll with the shift
lever in E or E position (rVT)or with the clutchpedal
depressed{M/T).The startershouldcrankthe engine.
.
lf the starter does not crank the engine, go to
step 3.
y,
l f i t c r a n k s t h ee n g i n e e r r a t i c a l l y o r t o o s l o wgl o
to "Checkfor Wear and Damage" on the next
page.
Checkthe startercut relay and clutch interlockswitch
(seepage23-86,87).
Checkthe A/f gear positionswitch(seepage23-154).
9.
.
l f t h e s t a r t e rs t i l l d o e s n o t c r a n k t h e e n g i n e ,
removeit, and diagnoseits internalproblem
lf the startercrankstheengine,goto step6.
Checkfor an open in the wire betweenthe ignition
switch and starter.
(cont'd)
23-95
Starting System
StarterTest lcont'dl
StarterSolenoidTest
Ch€cktor Wear and Damage
The startershould crankthe engine smoothly and
steadily,lf the starter engages.but cranksthe engine
erratically,removeit, and inspectthe starterdrive gear
and torqueconverteror flywheelring gearfor damage.
1.
.
Checkthe drive gear overrunningclutchfor binding
o r s l i p p i n gw h e n t h e a r m a t u r ei s r o t a t e dw i t h t h e
drive gear held,
- lf damaged.replacethe gears.
Checkthe hold-incoil for continuitvbetweenthe S
t e r m i n a la n d t h e a r m a t u r eh o u s i n g( g r o u n d )T. h e
coil is OK if thereis continuitv,
ARMATURE
HOUSING
(GROUND)
S TERMINAL
CheckCranking Voltsge and Curr€nt Draw
Crankingvoltageshouldbe no lessthan 8.5volts.
Currentdraw shouldbe no more than 350amperes.
lf crankingvoltageis too low, or currentdraw too high,
checkfor;
. dead or low batterv.
. o p e n c i r c u i t i n s t a r t e ra r m a t u r ec o m m u t a t o rs e g ments,
. starterarmaturedragging.
. shortedarmaturewinding.
o excessivedrag in engine.
CheckCranking rpm
Enginespeedduringcrankingshouldbe above 100rpm,
lf speedis too low, checkfor:
. loosebatteryor stanerterminals.
. excessively
worn starterbrushes,
. open circuitin commutatorsegments.
o dirty or damagedhelicalsplineor drive gear.
. defectivedrive gearoverrunningclutch.
CheckSiarter Disengag€ment
With the shift lever in El or @ position(A/T)or with the
clutchpedaldepressed(M/T),turn the ignitionswitchto
START(lll),and releaseto ON (ll).
The starterdrive gear shoulddisengagefrom the torque
converteror flywheel ring gear when you releasethe
Key.
lf the drive gear hangsup on the torqueconverteror flywheel ring gear,checkfor:
. solenoidplungerand switchmalfunction,
. dirty drive gear assemblyor damaged overrunning
clutch.
M TERMINAL
B TERMINAL
STARTER
CAELE
B TERMINAL
MOUNTINGNUT
I N.m {0.9kgf.m,
7 tbf.ft)
Check the pull-in coil for continuity between the S
and M terminals. The coil is OK if there is continuity.
J
ArmatureInspectionand Test
1 . Inspectthe armaturefor wear or damagedue to contactwith the permanentmagnetor fieldwinding.
VERNIER
CALIPEB
.
lf there is wear or damage.replacethe armature.
I n s p e c tf o r d a m a g e .
2.
Checkcommutatorsurfaceand diameter.
lf the surfaceis dirty or burnt. resurfacewith emery
cloth or a lathewithin the followingspecifications,
or reconditionwith #500or #600sandpaper.
. lf commutatordiameteris belowthe servicelimit,
replacethe armature.
.
3.
Measurethe commutatorrunout.
.
.
Commutator Diameter
Standard{NEW)
2 8 . 0- 2 8 . 1m m
( 1 . 1 0-2 1 . 1 0 6
in)
ServiceLimit
2 7 . 5m m
(1.083
in)
l f t h e c o m m u t a t o r u n o u ti s w i t h i n t h e s e r v i c e
limit, checkthe commutatorfor carbon dust or
brasschipsbetlveenthe segments.
lf the commutatorrunout is not within the service limit, replacethe armature.
Commutator Runout
Standard(NEW)
0 - 0 . 0 2m m
(0 - 0.0008in)
ServiceLimit
u-u!rmm
(0.002in)
COMMUTATOR
(cont'd)
23-97
Starting System
ArmatureInspectionand Test (cont'dl
4.
Checktor mica depth. lf necessary,undercutmica
with a hacksawblade to achieveproper depth. l{ servicelimitcannotbe maintained,
replacethe armature.
6.
Placethe armature on an armaturetester. Hold a
hacksawbladeon the armaturecore.
ARMATURE
TESTER
NOTGOOD
MICA D€PTH
Commutator Mica D€pth
Standard(NEW)
0 . 4- 0 . 5m m
- 0 . 0 2i n )
(0.016
ServiceLimit
ARMATURE
0 . 1 5m m
(0.006in)
.
5.
Checkfor continuitybetweenthe segmentsof the
commutator.lf an open circuit exists betweenany
segments,replacethe armature.
7.
lf the blade is attractedto the core or vibrates
while the core is turned,the armatureis shorted.
Replacethe armature.
Checkwith an ohmmeterthat no continuityexists
betweenthe commutator and armature coil core,
and betweenthe commutatorand armatureshaft.lf
there is continuity,replacethe armature.
corLcoFE
23-98
COMMUTATOR
J
BrushInspection
BrushHolderTest
1.
Checkthat there is no continuitybetweenthe O and
o brushholders.
l f t h e r e i s c o n t i n u i t y , r e p l a c et h e b r u s h h o l d e r
assemoly.
Measurethe brush length.lf not within the servicelimit,
replacethe brush(or brushholderassembly).
Brush Length
Standard(NEW)
1 5 . 8- 1 6 . 2m m
(0.62- 0.64in)
O BRUSHHOLDER
@ BRUSHHOLDER
2.
€) BRUSHHOLDER
Insertthe brushinto the brushholder,and b.ing the
brushinto contactwith the commutator,then attach
a springscaleto the spring.Measurethe springtension at the momentthe springliftsoff the brush.
SPRINGSCALE
ServiceLimit
11 . 0m m
{ 0 . 4 3i n )
NOTE:To seatnew brushesafterinstallingthem in their
holders,slip a strip ot #500or #600sandpaper.with the
grit side up, over the commutatorand smoothly rotate
the armature.The contactsurfaceof the brusheswill be
sandedto the samecontouras the commutator.
OverrunningClutchlnspection
L
Slidethe overrunningclutchalongthe shaft.Doesit
movefreely?lf not, replaceit.
2.
Rotatethe overrunningclutch both ways. Does it
l o c k i n o n e d i r e c t i o na n d r o t a t e s m o o t h l y i n
reverse?lf it does not lock in either directionor it
locksin both directions,replaceit.
CLUTCHGEAR
ERUSH
SpringTension
15.7- 17.7N (1.60- 1.80kgf.3.5- 4.0 lbf)
DRIVEGEAR
Starting System
Starter Replacement
StarterReassembly
1 . M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons('99- 00 models).
'1.
Pry backeachbrushspringwith a screwdriver,
then
positionthe brush about halfwayout of its holder.
and releasethe springto hold it there.
Disconnect
the batterynegativecable.
Disconnectthe startercablefrom the B terminalon
t h e s o l e n o i d t, h e n d i s c o n n e ctth e B L K t r H T w i r e
from the S terminal.
MOUNTINGBOLT
44 N.m l/t.s kgf.m.32 lbf.ft)
S TERMINAL
Installthe armaturein the housing.Next, pry back
each brush spring again,and push the brush down
until it seatsagainstthe commutator,then release
the springagainstthe end of the brush.
aw
MOUNTINGBOLT
6,1N.m {4.5kstm.32lbtftl
B TERMINAL
4.
MOUNTINGNUT
9 N,m {0.9 kgl.m,
6.s lbtftl
R e m o v et h e t w o b o l t s h o l d i n g t h e s t a r t e r ,t h e n
remove the starter.
lnstallin the reverseorderof removal.
3.
Installthe end coveron the brushholder.
NOTE:When installingthe staner cable,make sure
thatthe crimpedsideofthe ringterminalis facingout.
ERUSHHOLDER
Crimped side of ring
TERMINAL
Connectthe batterypositivecable and negativecable
to the battery.
7.
Enterthe anti-theftcodefor the radio,then enterthe
customer'sradiostationpresets('99- 00 models).
23-100
-
Test
Performance
NOTE:Beforestaning the following checks.disconnect
t h e w i r e f r o m t e r m i n a lM . a n d m a k e a c o n n e c t i o na s
describedbelow using as heavya wire as possible(preferto the wire usedfor the car).
ablyequivalent
RetractingTosi:
Pull-inCoilTest:
GAUTION: Do not loave the baftery conn€ctodtor more
than 10 seconds.
Disconnectthe batteryalso from the body. lf the pinion
retractsimmediately,it is workingproperly.
Connectthe batteryas shown, lf the staner pinion pops
out. it is working proPerly.
CAUTION: Do not leavo tho batterv connost€dfor more
than 10 seconds.
Startor No-loadTost:
1 . Clampthe starterfirmly in a vise.
Connectthe starterto the batteryas describedin
t h e d i a g r a mb e l o w , a n d c o n f i r mt h a t t h e m o t o r
starts and keepsrotating.
Hold-in Coil Test:
the batteryfrom the M terminal'lf the pinion
Disconnect
does not retract,the hold-incoil is working properly.
CAUTION: Do not loavc lhe battsry connectedfor mot6
than 10 ssconds.
3,
lf the electric current and motor speed meet the
when the batteryvoltageis a t 1 1 . 5V ,
specifications
the starteris workingProPerly.
Specifications:
8 0 A o r l e s s ( E l e c t r i cc u r r e n t ) , 2 , 6 0 0r p m o r m o r e
(Motor-speed)
23-101
lgnition System
ComponentLocationIndex
IGNITIONTIMING CONTROLSYSTEM
. Troubleshooting,
section11
. ldle speedInspection/Adjustment.
section11
. Inspectionand Setting,page23-105
SERVICECHECKCONNECTOR
{2P}
Iwiie colors:8RN and BLKI
CONNECTOB
TESTTACI{OMETER
IGNITIONWIRES
lnspectionand Test,page23-110
PLUGS
I n s p e c t i o n ,p a g e 2 3 1 1 1
R e p l a c e m e n t ,p a g e 2 3 ' 1 0 6
Overhaul, page 23-107
lgnition Coil Test, page 23'110
lgnition Control Module llCM)
Input Test, page 23-109
23-102
lgnition System
-
CircuitDiagram:'96 - 97 models
UNDERHOODFUSE/RELAY8OX
r U S EF E - A VB O }
*u r-. .-*---{<9ot #
\j/
u,,."r.
|
El
|
t
v
l
B L hT E L Y E LG B N
BLKlYEL
I
A l
T D C r T odpe a dc e n l e r
postion
CKP:Crankshall
C Y PC y l n d epro s l o n
.i-
B L K / Y E LY E L I G F N
IGN]TION
COL
"
*]BLU'
* 2 W H IB L U
I G N I T I OCNO N I R O L
M O D U L(EC M )
/ Hasb'rll n\
I iorse
I
T D C ] C K P ] CSYEPN S o R
' J-)
t I {sh,eldinsr
tf
+++
$t+ l
YEL
BBN/BLK
8LU
I
n
B L U B L UI
t l
lI TEST
n
I
\-7
TACHOMETEF
CONNECTOR
TACHOMETER
TCM(CW)
I
:
G101
23-103
lgnition System
CircuitDiagram:'98-00models
UNDER
HOOD
FUSUFELAY
BOX
'x'E;;;;-;;;;l
UNDER,DASH
FUSE/BELAY
BOX
IGN]TION
swtTcH
/;\
Ecw.cM
l-*;-
ffiwFnBLK<-wHr\9-
t
Y
l
BTKTYELYEUGRN
9
+
FED
*IBLU'
YEt
BLK
J
J
* 1 : HT A C H I
*2 :TEC
23-104
-
lgnitionTiming Inspectionand Setting
1 . Checkthe idle speed,and adjustit it necessary(see
'1
section 'l ).
6.
Pullout the servicecheckconnector2P (BRNand BLK
wires)from the connectorholder locatedunderthe
dash on the front passengerside,then connectthe
to it.
SCSserviceconnector(T/N07PAZ- 0010'100)
Adjust the ignition timing if necessary,as follows.
Loosenthe distributormountingbolts.and turn the
to
distributorignition(Dl)housingcounterclockwise
advancethe timing, or clockwiseto retardthe timing.
ro ADVANCE
-<;,
Startthe engine.Holdthe engineat 3.000rpm with
no load {A,/Tin E or E. M/T in neutral)until the
radiatorfan comeson, then let it idle.
Connectthe timing light to the No. 1 ignitionwire,
then pointthe light towardthe pointeron the timing
belt cover.
C h e c kt h e i g n i t i o nt i m i n g i n n o l o a d c o n d i t i o n s :
headlights.blower fan, rear window defogger,and
air conditionerare not operating.
lgnhionTiming:
BOLTS
MOUNTING
18N'm(1.8kgfm,13lblftl
D15Y5.D16Y7,Dl6Yg engines
M/T
1 2 ' t 2 " B T D C( R E Dd) u r i n gi d l i n gi n
neutral
l 2 ' r 2 " B T D C{ R E Dd) u r i n gi d l i n gi n S
orE
7.
Tightenthe distributormountingbolts,and recheck
the ignitiontiming.
the SCSserviceconnectorfrom the serDisconnect
check
connector.
vice
816A2engine
MIT
1 6 "1 2 ' B T D C( R E Dd) u r i n gi d l i n gi n
neutral
POINTEB
REDMARK
23-105
lgnition System
DistributorReplacement
4,
Removal:
1.
Disconnect
the connectorfrom the distributor.
2.
Disconnectthe ignition wires from the distributor
i g n i t i o n{ D l )c a p .
3.
Connectthe ignitionwires to the distributorignition
(Dl)cap as shown.
rracfit'
No. 1
CYLINDER
MARK
Removethe mounting bolts from the distributor,
then removethe distributorfrom the cylinderhead.
DISTRIBUTOR
END
CAMSHAFTEND
TEG:
No. 1
CYLINDER
MOUNTING
BOLT
18N.m11.8
kgtm,13lbf.ltl
No. 2
lnstallation:
NOTE:Beforeyou installthe distributor.bring the No. 1
piston to compressionstroke TDC.
1.
Coata new O-ringwith engineoil, then installit.
2.
Slip the distributorinto position
NOTE:The lug on the end of the distributorand its
mating grooves in the camshaft end are both offset
to eliminatethe possibilityof installingthe distributor 180"out of time.
3.
Installthemountingbolts,and tightenthem lightly.
23-106
No.a
5.
Connectthe connectorto the distributor.
6.
Setthe ignitiontiming (seepreviouspage).
7.
After settingthe ignitiontiming, tightenthe mounting bolts.
el -
DistributorOverhaul
HITACHI:
IGNITION
DISTRIBUTOR
{DI}HOUSING
Checkfor cracksand damage.
Test,page23_110
TOC/CKP/CYP
T r o u b l e s h o o t i n g ,s e c t i o n 11
Do not disassemble.
IGNITIONCONTROLMODULE(ICMI
InputTest,page23'109
CAPSEAL
Checkfor damage.
I G N I T I O N{ D I ) C A P
C h e c k f o r c r a c k s ,w e a r ,
damage, and fouling.
Clean or replace,
{cont'd)
23-107
lgnition System
DistributorOverhaul(cont'dl
TEC:
COVER
DISTRIBUTOR
IGNITIONIDI) ROTOB
CAPSEAL
Checkfor damage.
DISTRIBUTOR
IGNITION{DII CAP
Checkfor cracks,wear,
damage,and fouling.
Cleanor replace,
IGNITIONCONTROL
MODULEIICM'
InputTest,page23-1
WHT/BLU
IGNITIONCOIL
Test,page23-110
O-RING
Replace
\
I
@
DISTRIBUTOR
IGNITION{DI}HOUSING
C h e c k f o r c r a c k sa n d d a m a g e .
23-104
TDC/CKP/CYP
S€NSOR
Troubleshooting,
section11
Do not disassemble.
J
lgnitionControlModule(lCMlInputTest
Turn the ignition switch ON (ll). Checkfor voltage
wire and body ground.
betweenthe BLK/YEL
Thereshouldbe batteryvoltage.
NOTE:
. See section 1'l when the malfunctionindicatorlamp
( M l L )t u r n e do n .
. Performan input test for the ignitioncontrol module
( l C M )a f t e r f i n i s h i n gt h e f u n d a m e n t atle s t sf o r t h e
ignitionsystemand the fuel and emissionssystems
1.
Removethe distributorignition(Dl)cap,the distributor ignition(Dl)rotor and the leakcover(TEC).
2.
the wiresfrom the lCM.
Disconnect
lf there is no batteryvoltage,checkthe BLK/YEL
wire betweenthe under-dashfuse/relaybox and
r h el c M .
. lf there is batteryvoltage,go to step4.
.
Turn the ignition switch ON (ll). Checkfor voltage
betweenthe wire*r and body ground
Thereshouldbe batteryvoltage.
HITACHI:
lfthere is no batteryvoltage,check:
- the ignitioncoil.
- the wire*1 betweenthe ignition coil and the
tcM.
. lf there is battery voltage, go to step 5
.
* 1 : B L U ' w i r e( H I T A C H I )
WHT/BLUwire (TEC)
Disconnectthe EcM/PCMconnectorA (32P).Check
for continuity on the YEUGRNwire between the
and the lCM.
ECM/PCM
Thereshouldbe continuity.
Checkfor continuityon the YEUGRNwire to body
ground.
Thereshouldbe no continuity.
BLK/YEL
7.
TEC:
Checkfor continuityon the BLUl wire betweenthe
testtachometerconnectorand the ICM
Thereshouldbe continuitY.
Checkfor continuityon the BLUl wire to body ground.
Thereshouldbe no continuity.
lf all the testsare normal,replacethe ICM
23-109
lgnition System
lgnitionCoilTest
lgnition Wire lnspectionand Test
Using an ohmmeter, measureresistancebetweenthe
terminals.lf the resistanceis not within soecifications.
replacethe ignitioncoil.
C A U T I O N :C a r e l u l l y r e m o v e t h e i g n i t i o n w i r e s b y
pulling on the rubber boots, Do not bend the wires; you
might breakthem inside.
NOTE: Resistancewill vary with the coil temperature;
specifications
are at 68'F (20'C).
'1. Checkthe condition
of the ignitionwire terminals.lf
any terminalis corroded,cleanit, and if it is broken
or distorted,replacethe ignitionwire.
HITACHI:
Primary Winding Resistance
{Betwesn the A and B lerminalsl;
0.45- 0.550
SecondaryWinding Resistanc€
(Betweenthe A and secondarywinding terminals):
22.1- 33.6 kA
TERMINALB {-)
TERMINALA
Checkfor broken,
corroded,and bent
lermrnals.
IGNITION
WIRE
Connectohmmeterprobesand measureresistance.
TEC:
Primary Winding Resistsnce
{Betweenthe A and B terminalsl:
0.63- 0.770
SecondaryWinding Resistance
(Betweenthe A and secondarywinding terminals):
12.8- 19.2kO
lgnition Wire Resistance:
25 k0 max. at 68"F (20"C)
SECONDARY
WINDING
TERMINAL
IGNITIONWIRE
TERMINALA
23-110
TERMINALB (-)
3.
lf resistanceexceeds 25 kO, replacethe ignition wire.
Spark Plug lnspection
1.
Inspectthe electrodesand ceramicinsulatorfor:
Worn or detormed
[
|
i
|
I
.
.
.
.
3.
t.p,op", grp
Oil-fouling
Carbondeposits
Crackedcenter
electrodeinsulator
8 1 6 A 2e n g i n e :
. D o n o t a d j u s t h e g a p o f a p l a t i n u mt i p p l u g ;
replacethe spark plug il the centerelectrodeis
roundedor it the gap is not within the specifica
t r on s .
ElectlodeGap:
1 . 3 1 8 1 m m( 0 . 0 5 1! 3 o o i"n )
Standard
Cracked
insulator
Platinumtip
flOUNDEDELECTROOE
',/
@_
:
Burnedor worn electrodesmay be causeclby:
. Advanced
i g n i t i o nt i m i n g
. Loosesparkplug
. Plug heatrangetoo low
. Insufficient
cooling
F o u l e dp l u g sm a y b e c a u s e db Y :
. R e t a r d e idg n i t i o nt i m a n g
. O i l i n c o m b u s t i o cnh a m b e r
. I n c o r r e cstp a r kp l u gg a p
. P l u gh e a tr a n g e t o oh i g h
. E x c e s s i vi ed l i n g / l o w
s p e e dr u n n i n g
. C l o g g e da i rc l e a n eer l e m e n t
. Deteriorated
ignitioncoil or ignitionwares
2.
D 1 6 Y 5D, 1 6 Y 7D, ' 1 6 Ye8n g i n e l
. Adjustthe gap with a suitablegappingtool, and
replacethe plug il the centerelectrodeis rounded as shown below.
NOTE:Useonly the sparkplugslistedbelow
EngineTypes
SparkPlugs
D16Y5
Z F R 4 F1 1 ( N G K )
K J 1 4 C R - 1 (1D1 E N S O i
D16Y7,
D,I6Y8
Z F R S F - 1 (1N G K )
KJ16CR-111(DENSO)
81642
P F R 6 L . 1( 3N G K )
P K 2 O P R . L(1D3E N S O }
4.
Apply a small quantity of anti seizecompound to
the plug threads, and screw the plugs into the cylin
der head finger-tight. Then torque them to 18 N m
1 1 . 8k g f . m ,1 3 l b n f t ) .
ElectrodeGap:
Standard
1 . 1 r 8' m m ( 0 . 0 4 3 i 8 0 0 o i n )
1 . 1m m
{o.{X:lin)
1
ROUNDED
ELECTRODE
T
23-111
ChargingSystem
ComponentLocationIndex
CHARGINGSYSTEMLIGHT
(ln the gaugeassembly)
Test,page23-l14
UNDER.HOOD
FUSE/RELAY
BOX
ELECTRICAL
LOADI
/*Hasreplaceable
(ELD)UNIT
'
I DETECTOR
Troubleshooting,
page23-114
Replacement,
page23-120
BectifierRemoval,page23,121
Rectifier
Test,page23-122
RearBearingReplacement,
page23-j24
*ELDunit: USA
23-112
BATTERY
Test, page 23-91
[]
ALTERNATOR
BELT
Inspection
andAdjustment,
page23-t25
-
CircuitDiagram
BOX
RELAY
HOODFUSEi
IJNDER
BATTERY
N0.41(80A)
,-a\
No42(40A)
I
,'-F\
BAT
I LGNlTION
Gl / SWITCH
I
\
\l_/
I
GRN/RED
I
I
CHARGING
SYSTEM
LIGHT
T
WHTiBLU
ECM/PCM
f7
I
WHT/RED
ALTERNATOF
23-1 1 3
ChargingSystem
Troubleshooting
lf the chargingsystemlight does not come on or does not go off, or the batteryis deador low, test the followingitems
in
the order listedbelow:
1.
2.
3.
4.
5.
Baftery(seepage23-91)
Chargingsystemlight
Voltage
Alternatorcontrolsystem(USA)
Alternator/regulator
ChargingSystom Light Test
Charging Svstem Light Check-l :
lvlakesure the chargingsystem
lightcomeson.
Doesthe chargingsystem
lightcome on?
Check for a blown No. 15 t7.5A)
fuso .nd a blown charging systom light bulb. ll the fuse .nd
bulb .re OK, ropair the open in
th6 WHT/BLUwi16.
Charging System Light Chec*-2:
Startthe enoine.
Doesthe chargingsystem
light go off?
ALTERNATOR
4PCONNECTOR
IUSA)
Wire side of
femaleterminals
Volta96 Checkl
Measlrethe voltageat the No. 1
lNo.2l terminalof the 4P [3Plconnectorwith the ignition switch ON
flr).
ls there batteryvoltage?
IG
(8LK/YEL}
R6p.ir the op6n in the BLK/YEL
wire b€twsen tho altornator and
und€r-dashtuso/.glay box.
ALTERNATOR
3P CONNECTOR
lC.nadal
Wre sideof
temaleterminals
[ ]: Canada
23-114
ALTERNATOR4P CONNECTOR
(USAI
{Frompreviouspage)
r?-r
l 1 l 2 lWiresideof
FFI
Check tor an open in tho L cir'
cuit-1:
1. Turnthe ignitionswitchOFF
2 . D i s c o n n e ctth e 4 P [ 3 P l c o n nectorfrom the alternator.
3. Groundthe No. 3 terminalof
the 4Pl3Plconnector.
4. Turn the ignitionswitchON (ll)
Doesthe chargingsystem
lightcome on?
femaleterminals
L
]-twHT/8LUl
I
Turn the ignition swhch OFF,and
rep.ir tho open in tho wHT/
BLU wire.
3PCONNECTOR
ALTERNATOR
lCanada)
Wire side of
temaleterminals
L
IWHT/BLUI
.+1
l rl 2 l
-l-
l3T.l
Checkfor an open in the L circuit-2:
the No 3 terminalo{
Disconnect
the 4P [3PI connectorfrom the
ground.
L
{W}IT/BLU)
ir/
Doesthe chargingsystem
light go off.r
(WHT/BLUI
Turn lhe ignition 3whch OFF,and
.epair the 3hort to gtound in the
wHT/Bl-U wire.
I l: canada
(cont'd)
23-115
ChargingSystem
Troubleshooting (cont'd)
Alternator Control System Test (USA):,96 - 98 modets, ,99 _ 00 Dl6y5 (M/Tl engine
NorE: Beforetesting.checkproperoperationof the ELDby confirmingwith the MrL
{seesectionr 1).
Check for a 3hort in the circuit
IALTClinel:
1. Reconnectthe 4P connector
to the alternator,
2. Stan the engine,and turn the
headlights{highbeam)ON.
3. Measurevoltage between the
4P connectorterminal No. 2
and the positive terminal of
the battery.
BATTERY
CAUTION: Be 3ure to use a voltmot€.
with its plus terminal connectedto b.ttery plus and its minus terminal to the
{P connectoi tgmrinal No. 2.
c
{WHT/GRNt
ALTERNATOR
.P CONNECTOB
Wire sideoI
femaleterminals
A I32PI
ECM/PCMCONNECTOR
'I
a
ls there1V or less?
12 1 3 14 1 5
1
I
10 1 1
1 7 1 8 t 9 20 2'l 22
7
26 27
Check for rn opon in tha wire
(ALTClinol:
1 . T u r n t h e h e a d l i g h at n d i g n i tion switch OFF.
2. Disconnect
the 32Pconnector
trom the ECM/PCN4.
3. Checktor continuity between
the ECM/PCM32P connector
terminalNo. 19 and alternator
4PconnectorterminalNo.2.
8
Wire sideof
femaleterminals
21
30
ALTC
(WHT/GRNI
([l
Tc
{WHT/GRNI
1
Wire side oI
femaleterminals
2
ALTERNATOR
1
Bspair open in thg wire lrstween
the rhern.tor .nd ECM/PCM.
ECM/PCMCONNECTOB
A (32PI
Check for short in the wire (ALTC
linel:
1 . T u r n t h e h e a d l i g h at n d i g n i
tion switch OFF.
2. Disconnect
the 32Pconnector
trom the ECM/PCM.
3. Checktor continuity between
the ECM/PCM32P connector
t e r m i n a lN o . 1 9 a n d b o d y
ground.
I
23-116
3
4
7
1 2 13 14 15 16 17 1 8
8
9
10 t 1
20 21 22 23 21
26 27
30
Wire side of
femateterminats
I
A
Subslitute a known-good ECM/
PCM,.nd .och6ck.
It p.escribodvohago i! now available, replacethe original ECM/
PCM.
Ropair3hort in the wiro betweon
the ahe.nator and ECM/PCM.
2
AITC
(WHT/GRN|
'99 - 0Omodels, except Dl6Y5 {M/T} engine
Alternator Control System Test {USA}:
MIL (seesection11)'
NOTE:Beforetesting,checkproperoperationofthe ELDby confirmingwith the
BATTERY
Checklor a sho.t in the circuit
{ALTCline):
1, Beconnectthe 4P connector
to the alternator.
2. Startthe engine,and turn the
headlights(highbeam)ON.
3. Measurevoltagebetweenthe
4P connectorterminal No. 2
a n d t h e P o s i t i v et e r m i n a lo f
the battery.
CAUTION: Be sura lo use a voltmeter
with its plus te.minal conneqtedio battery plus and it3 minus tgrminal to ths
4P connoctottomrinal No. 2.
c
(WHT/GRNI
Wire sideof
femaleterminals
ALTERNATOR
.P CONNECTOR
C 13lPI
ECM/PCMCONNECTOR
ls there 1 V or less?
Chcck for rn opon in the wire
(ALTClin6l:
1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF
the 31Pconnector
2. Disconnect
trom the ECM/PCM.
3. Checkfor continuitybetlveen
the ECM/PCM31P connector
terminalNo. 2 and alternator
4PconnectorterminalNo. 2
wire sideof
femaleterminals
Repairopcn in the wire botweon
the alternstoi.nd ECM/PCM.
ls therecontinuity?
C (31PI
ECM/PCMCONNECTOR
Checktor short in the wire IALTC
line):
1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF
the 31Pconnector
2. Disconnect
from the ECM/PCM.
3. Checkfor continuitybetween
the ECM/PCM31P connector
terminalNo. 2 and body
ground.
1
2 3
23
8 I 10
5 6 1
zo 2122
/116 1 1 l o 191
25 26 21 ?8 2930 J I
ALTC
(WHT/GRN)
Wire side of
female terminals
o
Substitute a known'good ECM/
PCM,and recheck.
It prscribed voltagg is now avail'
abl€, replacetho original ECM/
PCM.
Raoairshort in the wite between
the alle.nator and ECM/PCM,
(cont'd)
23-117
ChargingSystem
Troubleshooting(cont'd)
Alt6rnator/RegulatorTest
NOTE:Makesurethe bafteryis sufficientlycharged(seepage23-9j).
Alte.nator/RegulatorTest'1:
L C o n n e c ta S u n V A T 4 0 ( o r
e q u i v a l e n t e s t e r ) ,a n d t u r n
the selectorsw;tchto position
1(staning).
2. Shift to neutral(A/T in E or
, n d s t a r tt h e
E) positiona
e n g i n e .H o l d t h e e n g i n ea t
3,000rpm with no load until
t h e r a d i a t o rf a n c o m e s o n ,
then let it idle.
3 . R a i s et h e e n g i n es p e e dt o
2,000rpm,and hold it there.
l s t h e v o l t a g e o v e r 1 5 . 1V ?
LOADAOJUSTER
{CARAONPILEI
tffil rCI
'aHrl
[ @lBt* . ,*n
Alternator/RegulatorTest-3:
Apply a load with a VAT-40 until
the battery voltage drops to
between12- 13.5V.
To next page
23-11A
VOLTMETER
POStTtVE
LEAD(REDI
FIELD
SELECTOR
swrTcH
ls the voltagelessthan 13.5V?
VOLTMETER
NEGATIVE
LEADIBLKI
L-;-;l rs-
TESTSELECTOR
Alternalor/RegulatorTe3t-2:
1. Release
pedal,
the accelerator
and letthe engineidle.
2. Make sure all accessories
are
turned ofi. Turn the selector
switchto position2 (charging).
3. Bemovethe inductivepick-up,
and zerothe ammeter,
4 . P l a c et h e i n d u c t i v ep i c k - u p
over the battery ground cable
so that the arrowpointsto the
batterynegatlveterminal.
5 . R a i s et h e e n g i n e s p e e d t o
2,000rpm,and hold it there.
FULLFIELO
TESTER
LEADIBLUI
INDUCTIVE
PICK-UP
IGRNI
NEGATIVETESTER
CABLEIBLKI
POSITIVE
TESTER
CABLEIREDI
INDUCNVE
PICK.UP
TIVE
TEBMINAL
J
Frompreviouspage
ls the amperage50 A or more?
Alternator/RegulatorTest-4:
W i t h t h e e n g i n e s P e e ds t i l l a t
2,000rpm,fulltieidthe alternator.
The charging system is OK.
Do not ellow
CAUTION:The voltage will rise quickly when the allGrnatoris flll-fielded
syslem
electrical
the
the vollage to exceed18 V; il may damage
probeintothe full field
NOTE:Attacha probeto a VAT 40 full fieldtest lead,and insertthe
"A (GroLrnd)"
posi
Switchthe fieldselectorto the
accessholeat the backof the alternator'
readlng
the
amperage
check
and
tion momentarilV,
23-119
ChargingSystem
AlternatorReplacement
NOTE:Removethe alternator
from belowthe vehicle.
'1.
2.
3.
5.
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons('99- 00 models).
Removethe batterynegativecable,then disconnect
the positivecable.
R e m o v et h e a d j u s t i n gb o l t a n d t h r o u g h b o l t n u t ,
then removethe alternatorbeltfrom the Dullev.
ALTERNATOR
AD.'USTING
BOLT
24 N.rhl2.akgf.m,17lbtft)
Disconnectthe 4P (or 3P) connectorfrom the alternaIor.
UPPERMOUNT
BRACKETBOLT
44 N.m 14.5kgt.m, 33 lbl.ftl
ALTERNATOR
TERMINALNUT
7.85N.m (0.8kgf.m, 5.79lbf.ftl
BOLT
a4 N.m 14.5kstm.33lbf'ftl
LOWER
MOUNT
BRACKET
BOLTS
a4N.ml{.5 kgf.m,33lbfft)
{ }:Cansd.
4.
P u l l o u t t h e a l t e r n a t otrh r o u g hb o l t , t h e n r e m o v e
the alternator.
R e m o v et h e t e r m i n a lnut and the WHT wire from
t h eB t e r m i n a l .
7.
lf necessary,removethe mount bracketbolts. and
the upperand lower mount brackets
Adjust the alternatorbelt tension after installation
(seepage23-125).
Enterthe anti-theftcodefor the radio,then enterthe
customer'sradiostationpresets('99- 00 models).
23-120
J
RectifierRemoval
1.
Removethe four through bolts.
3.
Separatethe rear housingfrom the drive-endhousing by insertinga flst tip screwdriverinto the openings and prying them a part. Be carefulnot to damage the stator with the tip of the screwdraver.
REARHOUSING
Seoaratethe rear housing and drive-end housing
with the statorattachedto the rearhousing.
Heatthe rear bearingseat with a 1,000W hair drier
tor aboutfive minutes(120- 140'F,50 - 60"C).
DEIVE-ENDHOUSING
STATOR
{cont'd)
23-121
ChargingSystem
RectifierRemoval (cont'd)
RectifierTest
Separatethe rear housingfrom the stator/rectifier
assemblyby removingthe four screwsand the terminal nut.
TERMINAL
NUT
NOTE:The diodesare designedto allow currentto pass
in one directionwhile blockingit in the oppositedirection. Since the alternator rectifier is made up of nine
diodes,eachdiode must be testedfor continuityin both
directionswith an ohmmeter that has diode checkino
capability;a totalof 18checks.
1.
6.
Checkfor continuityin eachdirectionbetween
- the B and P terminals.
- t h eB ' a n dPt e r m i n a l s .
- E {ground)and the P terminals.
All diodesshouldhave continuityin only one direcUOn.
Unsolderthe rectifierfrom the statorleads,
. To avoid damagingthe diodes with heat, pinch
the stator leads between pliers to carry heat off,
and applythe solderingiron only long enoughto
separatethe leadsfrom the rectifier.
. Usea 100W solderingiron.
STATOR
SOLDERING
SOLDERING
lf any of the diodesfails,replacethe rectifierassembly, (Diodesare not availableseparately.)
7.
Installthe new rectifierin the reverseorderof removal.
. A p p l y t h e s o l d e r i n gi r o n o n l y l o n g e n o u g ht o
ensure a good connectionso the heat will not
damagethe diodes.
a Use only a rosin coretype solderor solderjoints
will corrode.
23-122
J
AlternatorBrushInsPection
RotorSlip RingTest
1.
betlveenthe slip rings
Checkthe resistance
1
3 0 ohms
be
8
should
There
. lf resistancemeetsthe specification,go to step 2.
. l f r e s i s t a n c ed o e s n o t m e e t t h e s p e c i f i c a t i o n ,
reolacethe alternator'
1.
Separatethe drive-endhousingfrom the rear housing as describedon page23-121
Separatethe rear housingfrom the stator/rectifier
assemblyby removingthe four screwsand the terminal nutfrom the rearhousing{seepage23-121}
l v l e a s u r et h e l e n g t h o f t h e b r u s h e sw i t h v e r n r e r
calrpers.
ROTORSHAFT
Alternator Brush Length:
O Standard{NEW}
1 9 . 0m m ( 0 . 7 5i n )
1
@ ServiceLimit
5 . 0m m ( 0 2 0 i n )
SLIPBINGS
2.
Checkthat there is no continuitybetweenthe slip
ringsand the rotor or rotor shaft.
3.
lf the rotor fails eithercontinuitycheck,replacethe
alternator.
Stator Test
'1. Checkthat there is continuitybetweeneach pair of
leads.
LEADS
lf the brushesare lessthan the servicelimit, replace
them.
CORE
Checkthat there is no continuitybetweeneach lead
and the coil core.
lf the coil fails either continuitycheck,replacethe
alternator.
23-123
GhargingSystem
RearBearingReplacement
AlternatorReassembly
1.
1.
Pulloffthe rearbearing,
.
.
Makesure the tips of the bearingpullerjaws are
thin enough to fit betweenthe bearingand the
slip rings.
Do not reusethe bearing.
SLIPRINGS
P u s ht h e b r u s h e si n , t h e n i n s e r ta p i n o r d r i l l b i t
(about1.8mm diameter)to hold them there.
BEARINGPULLER
BRUSHES
REABBEARING
Heat the rear bearing seat in the rear housing as
describedon page 23-121.After heating,continue
immediatelywith assemblingbeforethe rear bearing seatcoolscompletely,
Use a hand pressto installthe new bearing.Apply
pressureonly on the inner raceto avoid damaging
the bearino.
Put the rear housing/stator
assemblyand drive-end
housing/rotorassemblytogether.tighten the four
throughboltsand pull out the pin.
BRUSHAOCESSHOI."E
THROUGHBOLT
I
q
%*z
REAR
STATOR ASSEMBLY
After assemblingthe alternator,turn the pulley by
hand to make sure the rotor rotatessmoothlv and
without noise.
23-124
It -
AlternatorBelt Inspectionand Adiustment
DeflectionMethod:
Apply a force of 98 N (10 kgl,22lbll, and measurethe
deflectionbetweenthe alternatorand the crankshaftpulley.
Detlection
Belt T€nsion Gauge Method:
instructions.attach
Followingthe gauge manufacturer's
the tension.
measure
belt,
and
to
the
soecial
tool
the
Tension
340- 490N (35- 50 kgf,77- 110lbf)
| 8.0- 10.5mm (0.31- 0.41in)
NOTE: On a brand-newbelt {onethat has beenrun for less
than five minutes).the deflectionshouldbe 6.0 - 8.5 mm
(0.26- 0.33in) when first measured.If the belt is worn or
damaged,replaceit.
NOTE: On a brand-newbelt {onethat has beenrun for less
than five minutes),the tension should be 540 -740 N
(55- 75 kgf, 121- 165lbf)when first measured.lf the belt
is worn or damaged,replaceit.
24 N.m (2.4kgl m,
CRANKSHAFT
PULLEY
PULLEY
GAUGE
BELTTENSION
07JGG- 0010104
lf adiustm€nt is necossary:
1.
Loosenthe lowermountingnut and the uppermounting bolt.
2,
Movethe alternatorto obtainthe properbelttension,
then retightenthe uppermountingbolt and the lower
torques.
mountingnut to the specified
3.
It adiustment is necossary:
1,
Loosenthe lowermountingnut andthe uppermounting bolt.
2.
Move the alternatorto obtain the proper belt tension.
then retightenthe uppermountingbolt and the lower
mounting nut to the specifiedtorques
3.
the tensionof the belt
Recheck
deflectionofthe belt.
Recheckthe
23-125
Fan Controls
ComponentLocationIndex
t lt lt lt tt l
tlTtlnr-l
m U ! L - J f l _ l'1
- f-t t-_l
RADIATORFAN RELAY
Test, page 23 87
I L--J L__JLJ f-----"1
CONDENSER
FAN RELAY
Test,page 23-87
UNDER.HOOO
^o
o
o"l
CONDENSER
FAN MOTOR
TOR FAN MOTOR
Removal,section10
ENGINE
COOLANT
(ECTI
TEMPERATURE
swtTcH
Removal,
section10
Test, section l0
23-126
I J
CircuitDiagram
IGNIT
O NS W I T C H
FUSElRELAY
BOX
UNDER.HOOD
No41 (8041
DASH
UNDER
F U S E I R E L8AOYX
|-;;;;l
ii6\ "ir"'t*Tl
No42 (40A)
-l
BLKyEL -J
BLKTRED
II
1,,*"_
T-'
I
GRN
II
I
I
\.7
V
ECM/PCM
E N GN E
COOLANT
l E M P E R A T U (REEC T )
SWTCH
'l
fclosed : Above
(
9
3
"
C
)
r
9
9
"
F
_l
L
B tK
II
G201
GaugeAssembly
ComponentLocationIndex
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(24)beforeperformingrepairsor service.
6x1.0mm
9.8 N.m 11.0kgf.m,
22lbt.lrl
VEHICLESPEEDSENSOR{VSS)
page23-140
Troubleshooting,
GAUGEASSEMBLY
Gauge/lndicator/Terminal
LocationIndex,page23-129
Removal,page23-135
BulbLocation,page23-136
page23 138
Disassembly,
PARKINGBRAKESWITCH
FLUIOLEVELSW]TCH
ENGINEOIL PR€SSURESWITCH
23-128
J
Locationlndex
Gauge/lndicator/Terminal
With tachometer;
"C"
CONNECTOB
(GAUGEend INDICATORI
"8"
CONNECTOR
{GAUGEand INOICATOR)
"A"
CONNECTOR
INDICATOR}
{A/TGEARPOSITION
c 1- - - - - - - - - > c 1 3
A1-----------+816
1ililil{ilrL
JlltlllulllllrL
o
oooo
') lo g | .
@
0006^
@ o^o @
o
E1_ _ -->E5
D1---+05
)
Fl- - -> F5
"D"
CONNECTOR
{ABS INDICATORI
SPEEDOMETER:
60 km/hat 637 rpm or
Indicates
60 mph at 1,025rpm o{the
vehiclespeedsensor(VSS).
oo/
A/T GEARPOSITION
INDICATOR
Seepage23 149
\oo
TACHOMETER:
I n d i c a t e s1 0 0 r p m a t
200 pulses per minute
ol the ignition control
module (lCMi.
FUELGAUGE
UnitTest,page23-142
Gauge/Sending
(ECT)GAUGE
ENGINECOOLANTTEMPERATURE
(cont'd)
23-129
GaugeAssembly
Gauge/lndicator/Terminal
LocationIndex (cont'd)
Without tachometer:
"A"
CONNECTOR
IA/T GEARPOSITIONINDICATORI
A1 ------> 46
----> al4
"8"
CONNECTOR
{GAUGEand INDICATOR}
"C"
CONNECTOR
(GAUGEand INDICAIORI
B 1 .- - - - - - - - - - - - - - - - > B 1 6
C 1 - -- - - - - - - - - . . + C 1 3
JilililHililil1
JililHililL
Oo_o-o
lus 0
O
0006
0 Bu-. )
"F"
CONNECTOR
{SRSINDICATOR)
"D"
CONNECTOR
{ABS INDICATORI
SPEEDOMETER:
Indicates
60 km/hat 637rpm or
60 mph at 1,025rpm ofthe
vehiclespeedsensor(VSS).
oo/
(ECT)GAUGE
ENGINECOOLANTTEMPERATUFE
23-130
\oo
A/T GEARPOSITION
INDICATOF
Seepage23 149
FUEL
G a u g e / S e n d i n gU n i t T e s t , p a g e 2 3 1 4 2
I J
GircuitDiagram
FUSE/RELAY
BOX
UNDEN
HOOD
IJNOER,DASH
FUSE/RELAY
BOX
(7.54)
N0.30
FUSE
f7
I
t
RED/BLK
GAUGE
LIGHTS
CHARGING
SYSTEM
LIGHT
l3wx4 l
0.4w)
l"'
WHT/BLU
v
ALTERNATOR
l
BEO/BLK
I c12
I
FFD
V
DASHLIGHTS
BRIGHTNESS
CONTROLLEF
fl ,,1:
tH
(Withshifi-up
indicatdlighl)
tE2
I
FED/BLU
l"l"
8LK
BLU
IJ
__l
CRUISE
CONTROT
UNIT
(wi1hcruiseconlrclsystem)
l'"^*
It
-
G401
G402
Gauge Assembly
CircuitDiagram{cont'd)
Fh"lurous
@)-
+
BLrcwHT
BLKryEL
-rl
fi'Sfvrous
16r.PAGE
eLui'rvrr
veL
(Wnhlachomolgr)
TURN
SIGNAU
HAZAROWARNING
swtTcH
No.s(104)
FUSE
LEFT
V
I
BEO/GRN
V
I
I
I
I
RIGHT
I
:
i .-i;,l l
|
i
8LU4RE0
ABS
CONTROL
UNIT
23-132
0cM)
t v l
V
I
GR&ryE
lru
G401
G442
cNfldt--]
CONTRoL I
MODULE
G401
G402
BRAKE
SYSTEM
LIGHI
(1.4w)
GRN/REO
I
TCM
RED/GRN
T
G552
A
Yimi+"
Yo
;i:l"la',.ll,,1!:,iT
"*,,
l[3&1"
;i#il;-"1
lrb'ff"
I
8LK
I
GFN/RED
I ' J- i
_,L
:
-
l
G401
G()2
(cont'd)
23-133
Gauge Assembly
CircuitDiagram(cont'dl
MATFUNCTION
INOICATOR
(Mr)
RED/BLU
BLU/BLK
YEURED
| ffitt'*'
I V
tt
l
l
R E DBi L U
I o,u,,,
/h,,SEii
HI
'f''#lu""',.'f
ENGINE
orL
PRESSURE
SWITCH
fcbsed Enqine
BLK
T
G552
I
PNK
ECM/PCM
Y rtt'J"T,r.0,.*"0
topen Buchred
I
GRN/ORN
WASHER
LEVEL
SWITCH
:Floatdownl
Tclosed
topen Floalup .l
BLK
-
-
T
G401
G402
J
Removal
1.
Removethe two screwsfrom the instrumentpanel.
2.
R e m o v et h e i n s t r u m e npt a n e l .
CAUTION:Carefullyremovethe instrumentpanelwithout damagingthe clips.
3.
Tilt the steeringwheeldown with the tilt adjustmentlever.
4.
Spreada protectivecloth overthe steeringcolumn.
5.
Removethe four mountingscrewsfrom the gaugeassembly.
6.
Prythe gaugeassemblyout, and disconnectall connectorsfrom it
7-
Takeout the gaugeassembly.
GAUGEASSEMBLY
INSTRUMENT
PANEL
23-135
GaugeAssembly
Bulb Locations(WithTachometer)
CI{ARGINGSYSTEMLIGHT(1.,1W)
GAUGELIGHTII.' WI
GAUGEI-IGHT{1,4WI
LOW ENGINEOIL PRESSURE
INDICATORLIGHT(1,' W}
SEATBELT
REMINDER
LIGHTI1.4WI
HIGHEEAM
INDICATORLIGHT
(1.4W)
LOW FUEL
LIGHT 13W)
MALFUNCTION
INDICATOR
LAMP{MIL}
BULE(1.{ Wl
WASHERI.'CVEL
INDICATORLIGHT
{1.4Wl (Canada)
RIGHTTURNSIGNAL
INDICATORLIGHTI1.4 WI
LEFTTURNSIGNAL
INDICATORLIGHT{1.4WI
A/T GEAR
(1.12x 6l
INDICATOR
(Onthe printed
circuitboard)
ABS |ND|CATOR(1.. Wl
{On the printed circuit board)
23-136
sRs
TOB(1.4Wl
{Onthe printedcircuitboard)
GAUGELIGHTS13W)
GAUGELIGHTl3.il Wl
CRUISEor SHIFT-UP
INDICATOR
11.
11.12
{Onthe orintedcircuitboard)
J
Bulb Locations{WithoutTachometer)
TRUNKINDICATOR
LIGHT
{1.i1W}
CHARGINGSYSTEMLIGHT11,4W}
(1.4W)
LTGHT
GAUGELIGHT .4 Wl
LOW ENGINEOIL PRESSUBE
INDICATOBLIGHT(1.4WI
SEATBELT
REMINDER
LIGHT(1.4WI
HIGHBEAM
INDICATORLIGHT
LOWFUELINDICATOR
LrGl{T(3W)
MALFUNCTION
INDICATOR
LAMP (MIL)
BULB{1.4WI
(1.1Wt
WASHERLEVEL
INDICATORLIGHT
{1.4W} lcanad.l
RIGHTTURN SIGNAL
INOICATORLIGHT
{1.ilW)
LEFTTURNSIGNAL
INDICATORLIGHT{1.4WI
o /
A/T GEARPOSITION
INDICATOR(1.12x 6)
(Onthe printed
circuitboard)
o
\ 7
GAUGELIGHTS{3 WI
aBs tNDtcAToR
t1.4W)
(Ontheprintedcircuitboard)
o
sRs TND|CATOR
11.4W)
circuitboard}
{OntheDrinted
(3.{Wt
23-137
GaugeAssembly
Disassembly(WithTachometerl
NOTE: Handlethe terminalsand Drintedcircuit boards
carefullyto avoid damagingthem.
booo .--:o'-..oooo.A
:-F.-sr';"€?;"')
A/T GEARPOSITIONINDICA
MOUNNNG SCREWS
tx 2)
aFl
FUELand ENGINECOOLANTTEMPEMTURE
GAUGEMOUNTINGSCREWS{x 6,
l!
MOUNTING
TACHOMETEB
SCREWSlx 3l
PRINTEOCIRCUIT
ao
,-o
ok+r
.,- ll $
t'{"{q.'
El
I ..il \:r
q,
6\
CRUISEor SHIFT-UPINDICATOR
PRINTEDCIRCUTT
EOARD
ABS INDICATOR
PRINTEDCIRCUITBOARD
@
TACHOMETER
S p e c i l i c a t i o n ,p a g e 2 3 1 2 9
METERPANEL
23-134
A/T GEARPOSITIONINOICA
PRINTEDCIRCUITBOARD
(ECTI
FUELend ENGINECOOLANTTEMPERATURE
GAUGE
J
Disassembly{WithoutTachometerl
NOTE:Handlethe terminalsand printedcircuit boards
carefullyto avoiddamagingthem.
MOUNTING
SPEEDOMETER
(x 4)
SCREWS
oOo ,.-'€'-., oOOo -/\
€3,'" ' "$?'----"')
)a.' '.,,'+':j
A/T GEARPOSITIONINDICA
MOUNTINGSCREWS{x 2l
\
l
l
L
t
o
ENGINECOOLANTTEMPERATUR€
GAUGEMOUNTINGSCREWS{x 3l
FUELGAUGE
MOUNTINGSCREWS{x 3)
PRINTEDCIRCUIT
BOARD
SRSINOICATOR
PRINTEDCIRCUITBOARD
'
a
@
-
-
.-@
o
o"i^>
\
Er t\t
lmw
p\
A/T GEARPOSITIONINDICATOR
PRINTEDCIRCUITBOARD
ABS INDICATOR
PRINTEDCIRCUITBOARD
{ECT}
ENGINECOOLANTTEMPERATURE
GAUGE
d*re
\*P
\
FUELGAUGE
Test, page23-142
METERPANEL
METERLENS
METERVISOR
23-139
Vehicle Speed Sensor (VSSI
Troubleshooting
Beforetesting,inspectthe No. 15 (7.5A) fuse in the under-dashfuse/relaybox.
Test the BLK wire:
1. Disconnect the 3P connector
from the vehicle speed sensor
TESTHARNESS
OTLAJ_ PT3O2OA
REOTESTHARNESS
CLIP
(vss).
2 . C o n n e c tt h e t e s t h a r n e s s
(07LAJ PT30200)only to the
enginewire harness,
3. Connectthe REDtest harness
clip to the positiveprobeof a
PROTECTIVE
TAPE
4. Checkfor continuitybetween
the REDtest harnessclip and
body ground.
ls therecontinuity?
Repairopon in the BLK wire
b€twe€n the VSS and G101.
vss
GRNTESTHARNESS
Te3tthe BLK/YELwire:
1. Connectthe WHT test harness
clip to the positiveprobeof a
voltmeter,and connecttheRED
test harnessclip to the negative
probe.
2. Turnthe ignitionswitchON {ll).
TESTHARNESS
OTLA' . PT3O2OA
REDTESTHARNESS
Repairopen in iho BLK/YELwire
between the VSS and the underd6sh tuse/relav box.
(To next page)
WHT TESTHARNESSCLIP
23-140
J
(Fromprevaous
page)
WHT TESTHARNESS
CLIP
Tost the BLU/WHTwirei
C o n n e c tl h e G R Nt e s t h a r n e s s
c l i p t o t h e p o s i t i v ep r o b e o f a
voltmeter,and connectthe RED
test harnessclip to the negative
probe.
ls thereabout5 V or more ?
TESTHABNESS
07LAJ - Plil020a
REDTESTHARNESS
CLIP
PROTECTIVE
APE
Repair open in the BLU/WHT wiro
b€twoon the VSS and ECM/PCM,
TCM (CVT),and cruise control untt.
Test the vss:
1. Turnthe ignitionswitchOFF.
2. Connect he othertest har
nessconnectorto the VSS.
3. Raisethe front ot the vehicle,
and support it with safety
stands,
4. Putthe vehiclein neutralwith
the ignitionswitchON (ll).
5. Slowly rotateone wheel with
the otherwheelblocked.
GRNTESTHARNESSCLIP
Doesvoltagepulsefrom 0 to
approx.5V or more ?
"8"
GAUGEASSEMBLY16PCONNECTOR
SpeedometerTosii
'1. Disconnect
the 16Pconnector
" B " f r o m t h e g a u g ea s s e m blv.
2. Toucha probeto the BLUMHT
wire, and connectit to body
groundthrougha voltmeter.
3. Slowly rotateone wheel with
the otherwheelblocked.
Doesthe meterindicatepulsing voltage?
femaleterminals
BLU
Repairopen in the BLU/WHTwi.e
belween th€ VSS and the 3pe€d-
23-14 1
FuelGauge
Gauge/Sending
Unit Test
Do not smoke while working on tho fuel
!@
system. Keepopen tlame away trom your wotk atea.
NOTE:Referto page 23-133for the fuel gauge system
circuit.
'1.
Checkthe No. 25 (7.5A) fuse in the under-dash
fuse/
relay box before testing.
Removethe accesspanelfrom the floor.
2.
1.
Checkthat the pointerof the fuel gaugestartsmoving toward the "F" mark.
CAUTION: Turn the ignition switch OFF before the
poinier reaches"F" on ihe gauge dial. Failureto do
so may damagethe fuel gauge.
NOTE:The fuel gaugeis a bobbin (cross-coil)
type,
hencethe fuel level is continuouslyindicatedeven
w h e n t h e i g n i t i o ns w i t c h i s O F F ,a n d t h e p o i n t e r
movesmore slowly than that of a bimetaltype.
ACCESSPANEL
.
.
lf the pointerof the fuel gaugedoes not move at
all, replacethe gauge.
lf the gauge is OK. inspectthe fuel gaugesending unit.
Removethe fuel gaugesendingunit as shown.
\
)
Disconnectthe 3P connectorfrom the fuel gauge
sendingunit.
Connectthe voltmeter positiveprobe to the No. 2
terminaland the negativeprobeto the No. I terminal,then turn the ignitionswitchON (ll).
Thereshouldbe between5 and 8 V.
.
.
lf the voltageis as specified,go to step5.
lf the voltageis not as specified.checkfor:
- an open in the YEUBLKor BLKwire.
- poor ground (G552).
Turn the ignitionswitchOFF.
Attach a jumper wire betweenthe No. 1 and No. 2
terminals,then turn the ignitionswitchON (ll).
23-142
Japan-produced
USA, Canada-produced
Low FuelIndicatorLight Test
J
9.
betweenthe No 1 and No. 2
the resistance
lMeasure
t e r m i n a l sa t E { E M P T Y ) ,1 1 2\ H A L FF U L L )a n d F
(FULL)by movingthe lloat.
{Ceramicboardtype):
USA,Canada-produced
FloatPosition
E
1t2
F
(0)
Resistance
1 0 5- 1 0 8
29.5- 35.5
3.5-5
NOTE:For the low fuel indicatorcircuitdiagram,referto
circuitdiagram(seepage23'2311.
the gaugeassembly
1 . C h e c kt h e N o . 2 5 ( 7 5 A ) l u s e i n t h e d r i v e r ' su n d e r
dashfuse/relaybox beforetesting
2.
P a r kt h e v e h i c l eo n l e v e lg r o u n d .
3.
Drainthe luel into an approvedcontainer.Reinstall
the fueltank drain bolt with a new washer.
4.
A d d l e s st h a n4 L ( 1 1 U . S G a l ,0 . 9 l m p G a l )o f f u e l ,
a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .T h e l o w f u e l
i n d i c a t olri g h ts h o u l dc o m eo n w i t h i nf o u r m i n u t e s '
. lf the light comes on within four minutes,go to
(Wire-woundtypel:
Jaoan-Ploduced
FloatPosition
E
(O)
Resistance
1 0 5- 1 1 0
1/2
2 5 . 5- 3 9 . 5
F
.
step8.
lf the lightdoesnot come on withinfour minutes,go to step5.
Removethe accesspanellrom the Iloor'
6.
T u r n t h e i g n i t i o ns w i t c hO F F ,t h e n d i s c o n n e ctth e
fuel tank sendingunit 3P connector.
1.
C o n n e ctth e f u e lt a n ks e n d i n gu n i t 3 Pt e r m i n a l sN o '
1 a n d N o .3 w i t h a j u m P e rw i r e
. l f t h e l i g h t c o m e s o n , r e p l a c et h e f u e l g a u g e
sendingunit (seePage23 1421
. lf the light does not come on, checkfor:
- A n o p e n i n t h e G R N / Y E Lw i r e b e t w e e nt h e
f u e lg a u g es e n d i n gu n i ta n dt h e f u e lg a u g e
- A b l o w nb u l b .
- A poor ground(G552)
Too ot lhe workbench (Bottom of the fuel tank)
ll the resistancereadingsare beyondthe range.replace
t h e f u e lg a u g es e n d i n gu n i t
female terminals
8.
A d d 4 L { 1 . 1U . S .G a l ,0 9 l m p G a l )o f f u e l T h e l i g h t
shouldgo off within four minutes.
23-143
InterlockSystem
ComponentLocationIndex
INTERI.OCK
UNIT
InputTest,page23-'146
KEYINTEBLOCKSOLENOID
rnd KEYINTERLOCK
SWITCH
(ln the steeringlockassemblyl
Test,page23-147
PARKPIN SWITCH
Test,page23-148
SHIFTLOCKSOLENOID
Test,page23-147
23-144
J
BOX
FUSARELAY
HOOD
UNDER
No41(80A) N0.42(404)
WHT/GFN
UNOEF,DASH
FUSE/RELAY
80x
GFNWHT
YEL
KEY
ll
TNTEnLOCK
||
swrTcH I I
I
lr
rEt
till
SHIFTLOCK
soLENO|0
(O,l: UNLoCK)
l'
5
GRNAVI{I
r
J
GR}.//WHT
I
V
l
I
LIGHIS
BRAI(E
I
UNITI
coNTROL
cRUrsE
UNIT I
ABSCONTROT,
rcM (cw)
I
YEUBLK
3
5
IJNIT
CONTFOL
INTERLOCK
CIRCUIT
KEYINTERLOCK
M GEAR
POStT|ON
INDICATOF
f7
WHT/BLK
I
II
t,
/P1 ennr
Inposon B
)
I
RED/BLK GFNWHT
BLK
I:
I
G401
G402
G401
G402
II
f7
POSTTTON
swlTcH
(Clos€d
: Inposilioa
lll )
e,."or
Vl$"ilT?l*r
bdon frsn€oI
lr I
PUsh
| \
BLK
] SENSOR
23-145
Interlock System
ControlUnit Input Test
1.
Disconnect
the 8P connectorfrom the interlockcontrol unit.
2 . I n s p e c t h e c o n n e c t o ra n d s o c k e tt e r m i n a l st o b e
surethey are all makinggood contact.
. lf the terminalsare bent,looseor corroded,repair
them as necessary,
and recheckthe system.
. l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
inputtestsat the connector.
- lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- l f a l l t h e i n p u t t e s t s p r o v e O K , s u b s t i t u t ea
known-goodcontrolunit, and recheckthe system. lf the checkis OK, the control unit must
be faulty;replaceit.
N O T E : l f t h e s h i f t l o c k s o l e n o i dc l i c k sw h e n t h e
ignitionswitchis turnedON {ll) and you step on the
brakepedal(with the shift lever in E), the shift lock
system is electronicallynormal; if the shift leve.
cannot be shifted from E], test the Aff gear position
switch,park pin switch,and seesection14.
INTERLOCK
CONTROLUNIT
Wire side of
femaleterminals
Key Interlock System:
Cavity
5
Wire
Test condition
WHT/BLU
lgnitionswitchturnedto
ACC(lland key pushedin
C h e c kf o r v o l t a g e t o g r o u n d i
There should be baftery voltage.
Underall conditions
Checkfor continuityto ground:
Thereshouldbe continuity.
Checkfor continu;tyto ground:
Thereshouldbe continuity.
WHT
BLK
Shiftleverin El
6
Test: Desiredresult
BLK./BLU
Possible cause if result is not obtained
BlownNo. 48 (30A) fuse in the under
hood fuse/relaybox
BlownNo.33 (7.5A) fuse in the under
dash fuse/relaybox
Faultysteeringlockassembly
lkey interlocksolenoid)
An openin the wire
' Poorground(G401,G402)
. An openin the wire
Poorground(G401,G402)
FaultyAy'Tgearpositionswitch
An openin the wire
Reconnect
the 8P connectorto the interlockcontrolunit.
Shift Lock System:
Cavity
2
Wifs
YEUBLK
6
BLI(BLU
C h e c kf o r v o l t a g e t o g r o u n d :
There should be banery voltage.
lgnitionswirchON (ll)
Checkfor voltageto ground:
Thereshouldbe bafteryvoltage.
Shiftleverin I
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
lgnition switch ON lll)
Brakepedaldepressed
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Checkfor voltageto ground:
There sho(Jldbe battery voltage.
lgnitionswitchON (ll)
WHT/RED B r a k ep e d a l a n d
acceleratordepressedat
the sametime
23-146
Test: Dgsiredresult
lgnition switch ON lll)
YEL
3
7
Test condition
Possiblecause if result is not obtained
. BlownNo.25 (7.5A) fuse in the under,
dash fuse/relaybox
. An openin the wire
BlownNo. 25 (7.5A) fuse in the underdash fuse/relaybox
Faultyshift locksolenoid
An openin the wire
Poorground(G401,G402)
FaultyA,/Tgear position switch
An openin the wire
BlownNo. 52 (15A) Iuse in the under
hoodfuse/relay
box
FaultyPCM
Faultybrakeswitch(seesection1l)
Faultythrottleposition{TP)sensor
(seesection1'l)
An openin the wire
Shift LockSolenoidTest
KeyInterlockSolenoidTest
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20)
1.
D i s c o n n e ctth e 7 P c o n n e c t o rf r o m t h e m a i n w ' r e
harness.
' t . Removeths front console(seesection20)'
the shift locksolenoid2Pconnector'
Disconnect
Connect battery power to the No. 1 terminal and
groundto the No. 2 terminalof the solenoidmomenIarrry.
NOTE:Do not connectpowerto the No 2(-) terminal (reversepolarity)or you will damagethe diode
insidethe solenoid
3.
CheckIor continuitybetweenthe terminalsin each
kev oositionaccordingto the table'
minal
- - T e r--\
\
i*i,r"
lgnition
switch
ACC fl)
4.
7
Key pushedin
o-
Key released
o-
-o
-o
Checkthat the key cannot be removedwith power
and ground connectedto the No. 7 and No 6 terminals
.
.
Checkthat the shift lock releaseswhen the release
lever is pushed,and checkthat it locks when the
releaseleveris released
lf the solenoiddoes not work, replacethe solenoid'
lf the key cannot be removed.the key interlock
solenoidis OK.
lf the key can be removed,replacethe steering
lockassembly(the interlocksolenoidis not available seParatelY).
23-147
InterlockSystem
ParkPin Switch Test
1,
Removethe front console(seesection2Ol.
Disconnectthe 4P connector from the park pin
switch.
Checkfor continuity betweenthe No. 3 and No. 4
terminalswith:
- the shift leverany positionotherthan
E, or
- the push buttonpushedin E.
Thereshouldbe continuity.
Checkfor continuitybetweenthe No. 3 and No. 4
terminalswith the shift leverin E and the push button released.Thereshould be no continuiw.lf necessary,replacethe park pin switch.
NOTE:Parkpin switch4p connectorNo. 1 and No.2
terminalsare lor Ay'Tgear position console light.
referto the circuitdiagramon page23-1S0.
23-14A
A/T Gear Position Indicator
ComponentLocationlndex
precautions,
and proceduresin the sRS
sRS componentsare locatedin this area.Reviewthe sRS componentlocations,
section(241beforeperformingrepairsor service'
A/T GEARPOSITIONINDICATOR
InputTest,page23-152
E
N
E
E
t
r
(cw)
E
N
E
E
E
(A/TI
A/T GEARPOSITIONSWITCH
Test,page23 154
page23-155
Replacement,
23-149
A/T Gear Position Indicator
CircuitDiagram
CW:
UNDER
HOOD
FUSE/RELAY
BOX
IGNITION
UNDER.DASH
FI.JSE/FELAY
BOX
swrrcH
6;\
rr,/-TPLK+r,,'rirac
|-;,,'r&l
coJ-aL("E1.<\c-t]
. PCM"
:i3M)''
V
\o3o'75A
---
I
Y
l./TGEAR
POSITION
INDICAToR
(h lhegauge
assembty)
A'/TGEABPOSITIONNDICATOR
OIMMING
C]RCUIT
I
L TG R N
TqM'l
YYYY
No30{7.5A)
f7v
t
l
YEL
GFN
V
I
RED/BLK
t,
|
|
l
| ,k sfi0f,|
Itg)coNsotEl
I Y i1?riI
t l l
t'
RED
v
23-150
PostTtoN
swrTcH
8LK
II
DASI|L GHTS
ERIGHTNESS
CONTNOLLER
A/TGEAR
*1 : 96'98modeis
+2 i '99t0 models
G401
G442
J
CircuitDiagram
A/T
-l
'^a"
fr-.-r^ """-*
-t
U__t-
T J N D EOFA S H
GNITON
S WT C H
BOX
BELAY
H C C DF U S E
UNDER
6l\
ir_i;_P_+irh\:f
f333{'*)
; h,:_
f7
I
RED,ELK
YEL
PCi\4
PCM
V
A r TG E A RP O ST I O NI N DC A T O (Fn l h e g a u gaes s e m b y l
V
II
CIRCUT
MD
M]NG
A I TG E A RP O S T O NN D L C A 1 O R
I
GRNlBLK
I
.T Gq
A13
l-
412
6LK8LU
f7
f7
I
f7
fl
t
l
I
W H T Y E L G F N SLU
\. -Ti:5A
FL]SE
I
II
DASHL GHTS
BRIGHTNESS
CONTFOLLER
VI
F:I BLK
I
l ' ,
5
2 (Nolused)
l l ^ , . , ^ , 1{'}'}'1,
I
A._.
L,-N
posr oN I
I(d].ONSCLEI
lYi:il
I--f'- l
I
I
I
RED
L GHTS
DASH
B BG H T N E S S
CONTFOLLER
12
rl
\ 4
l 7
L r l
|
t.--itA'T GEAR
6
--An i
9
_ P N K -
BLK
BLK
I
oio,
G402
23-151
A/T Gear Position Indicator
IndicatorInput Test
1 . Removethe gaugeassemblyfrom the dashboard(seepage23 135),and disconnect
the 14pconnectorfrom rne gauge
assemblv.
Inspectthe connectorand socketterminalsto be surethey are all makinggood
contact.
.
.
lf the terminalsare bent.looseor corroded,repair them as necessary,
and recheckthe system.
lf the terminalslook OK,makethe followinginput testsat the 14pconnector.
- lf a test indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input testsproveOK, but the indicator
is faulty,replacethe printedcircuitboard.
"A"
l{P CONNECTOR
REO
AI
BLK
M
A3
A8
A9
BLU
A4
A10
GRN
All
8RN
A6
412 A 1 3 4 1 4
LT
GAUGEASSEMBLY
+1:Not used
'2: AIT
'3i CVT
23-152
Test condition
Cavity
lgnition switch ON (ll)
AI
A2
A3
YEL
Combinationlight
RED/BLK switchON and dash
lightsbrightness
controldial on full
bright
RED
BLU
Shift leverin P or I
A10
GRN
Shift leverin E or E
A11
RED
Shift leverin E
412
WHT
Shift leverin E
Test: Desiredresult
Check for voltage to ground:
There should be banerY voltage.
Possiblecause it result is not obtained
. Blown No.25 (7.5 A) fuse in the
under dash fuse/relay box
. An open in the wire
Checkfor voltagebetween
and REDterminals:
RED/BLK
Thereshouldbe batterYvoltage.
Blown No. 30 {7.5A) fusein the
tuse/relaybox
under-dash
Faultycombinationlight switch
Faultydashlightsbrightness
controller
A n o p e ni n t h e w i r e
Checkfor continuityto ground:
Thereshouldbe continuitY
NOTE:Thereshouldbe no
continuityin anYother Position.
. FaultyA/T gear Positionswitch
. An open in the wire
Shift leverin E
A 1 3 BLK/BLU NOTE:Don'tdepress
the brakepedal.
YEL+]
A9
lgnitionswitchON (ll)
and shift leverin any
positionexceptPi
lgnitionswitchON {ll)
GRN/err*'and shift leverin anY
Checkfor voltageto ground:
Thereshouldbe batteryvoltagefor
two secondsafterthe ignition
switchis turnedON (ll),and then
'l
lessthan V.
FaultyTCM*' ,PCM*3
FaultyPCM*r
An open in the wire
positionexceptE
A8
414
BLK
U n d e ra l l c o n d i t i o n s
Checkfor continuitvto ground:
Thereshouldbe continuitY.
l g n i t i o ns w i t c h O N ( l l )
Checkfor voltageto ground:
. Thereshouldbe bafteryvoltage*'
. Thereshouldbe about5 V*r
LT GRN
. Poorground(G401,G402)
. An open in the wire
FaultyTCM*' ,ECM/PCM*'
FaultyPCM*1
An open in the wire
*2: CVT('96- 98 models)
*3r CVT('99- 00 modelsl
23-153
A/T Gear Position Indicator
A/T GearPositionSwitch Test
1.
Removethe front console(seesection2O).
2.
Disconnect
the 14Pconnectorfrom the A/T gearpositionswitch.
3.
Checkfor continuitybetweenthe terminalsin eachswitchpositionaccordingto the table.
'
'
Move the shift leverbackand forth without pushingthe shift leverat eachswitchposition,and checkfor
continuity
within the rangeof free play of the shift lever.
lf there is no continuitywithin the range of free play, adjustthe positionof the switch as described
on the next
page.
Terminalsideof maleterminals
A/T Gear Position Switch
+ 1 : Withcruisecontrolsystem
23-154
Eack - up
Light Switch
Neutral
Position Switch
A/T GearPositionSwitch
Adjustment
A/T GearPositionSwitch
Replacement
1 . Removethe front console,then disconnectthe 14P
connectorfrom the A/f gear positionswltch
2.
1 . Shiftto the E position,and loosenthe nuts.
slide the switchin the directionof El or E position
lwithin 2.0 mm (0.079in.)l so that there is continuity
betweenthe No. 1 and No 7 terminalsin the range
of free play of the shift lever'
Removethe two mountingnuts
swrTcH
SLIDEB
3.
Recheckfor continuitybetweeneach of the terminats.
NOTE:
. lf adjustmentis not possible,checkfor damage
t o t h e s h i f t l e v e r d e t e n t a n d / o rt h e b r a c k e t l f
there is no damage.replacethe consoleswitch
. The engineshouldstartwhen the shift lever is in
positionN in the rangeof free play
E position
A/T GEAR
POSITIONSWITCH
NUTS
MOUNT'NG
6 x 10 m m
98Nm(10kgtm'7lblftl
" N e u t r a l "a s s h o w n
P o s i t i o nt h e s w i t c h s l i d e rt o
above.
"Neutral",then slipthe switch
Movethe shift leverto
into position.
D j r e c t i o n o f - o n ,o r D l P o s i t i o n
lwithin 2.0 mm (0.079 in)1
Freeplay
-lfr-
Aftachthe swjtchwith the two mountingnuts.
Testthe switchin the E and E positionofthe shift
lever.The engineshould start when the shift lever
is in positionfl anywherein the rangeof free play
7.
Connectthe 14Pconnector,clampthe harness,and
installthe front console
LOCKPIN
23-155
IntegratedControl Unit
CircuitDiagram
UNDES
H@OFUSE/RELAY
BOX
IGNITION
SWITCH
UNDER,DASH
FUS€/RELAY
8OX
WINOSHIELD
WIPER/
WASHER
S-W|iCI.]
,
OFF/INT
INT
f7
Il
Y7
I
l
t
t
t
l
6
,8
BLU/BLKYEUELU
-q
INTEGRATED
CONTROL
UNIT
" JC O M B I N E O
WIPER.WASHEN
INTEEMITTENT
WIPER
RELAY
CIRCUIT
ctncutT
I wNDSHTELD I
I wrPEtuwAsHEF
I
I swrTcH
I
ELUMHT
I
I
WINDSHIELD
WIPEB
MOTOH
(As)
iI Yt_+ **i,,*
J
I
wHT,tsLK
8LK
I
V
WINOSHIELD
WASHER
MOTOR
* 1 : Wilhmmbrnedwiperwasheroperalion
*2 : 96-98models
G40t
G402
23-156
(A,4)
A,TGEAR
PosrfloN
swlrcH_
_
(Closed
h posilon
l?l ot [!l )
STARTER
CUTFELAY
-> [h'#fBLU/BLK
|
COMEINATION
LIGHTSWITCH
V
I
REO/GRN
BOX
FUSEi
RELAY
UNDEF.DASH
GFNiRED
YEL
I
I
a
E
A iEi,I,B"'T
vll".i,l
a
-
. BRAKE
FLUID
LEVELSWITCH
. PARKINGERAKE
(usA)
swrTcH
,rr.nrorro
.orrro,,*,,
|
t t -
t(
rffi
|
BEMI\DEB
crqcurl
\
l| / m
t
tffi
nEoTsru REDTBLU
-
I
clnculr
BLIJ/RED
neoieru
"ulTo
/Itr\
YI onrveqs VI or rtor
l3fifl&''' l5frl'.'
(3'&T' (3&Y
)
lBLK fiti'fJ"fl
lBLK 8iytr")
T
c552
Y
..aorr,rro
,,-,r.0 J
|
l,
/fP\
' CEILING
LIGHT
. KEYLESS
RECE
VERCIRCUIT
(lnlheaudio
unil")
T
A
Iu$ut,""'
DRIVER'S
DOOF
swtTcH
open)
folosed: Door
(Open :Doordosed/
I3fif'3#3trr,)
-::
G401
23-157
IntegratedControl Unit
Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section{24)beforeperformingrepairsor service.
1.
Removethe driver'sdashboardlowercoverand kneebolster(seesection20),
2.
Disconnect
the 10Pconnectorfrom the integratedcontrolunit.
3.
Removethe integratedcontrolunit from the under,dashfuse/relaybox.
4.
lnspectthe connectorand socketterminalsto be surethey are all makjnggood contact.
. lf the terminalsare bent,looseor corroded,repairthem as necessary,
and recheckthe system.
.lftheterminalslookOK,makethefollowinginputtestsattheconnectorandthefuse/relayboxsocket.
- lf any test indicatesa problem,find and correctthe cause,then recheck
the system.
- lf all the input testsproveOK,the controlunit must be faulty;replaceit.
INTEGRATED
CONTROL
UNIT
lOPCONNECTOR
Wire sideot
femaleterminals
23-158
All Systems:
Cavity
Wire
Al4
BLK
Test condilion
Test: Desiredresult
U n d e ra l l c o n d i t i o n s
Checkfor continuityto ground:
Thereshouldbe continuity.
Underall conditions
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
lgnitionswitchON (ll)
Checkfor voltageto ground:
Thereshouldbe bafteryvoltage.
A9
A6
Possiblecauseil rgsull is not obtained
. Poorground(G401,G402)
. An open in the wire
. Blown No. 43 (7.5A) fuse in the
under-hoodfuse/relaybox
. An open in the wire
. Blown No. 25 (7.5A) fuse in the
under-dashfuse/relaybox
. An open in the wire
Intelmittent Wiper System:
Cavity
B1
82
B3
Wire
Test condition
Test: Desiredresult
Possiblecauseif result is not obtained
l g n i t i o ns w i t c hO N ( l l ) ,
BLU/BLK and windshieldwiper
switchat OFFor INT
and
BLU,^/VHT
Checkfor continuitybetweenthe
BLU/BLKand BLU/WHTterminals:
Thereshouldbe continujty.
Blown No. 26 {20A) fuse in the
under-dashfuse/relaybox
Faultywindshieldwiper switch
Faultywindshieldwiper motor
An open in the wire
l g n i t i o ns w i t c hO N ( l l ) ,
and windshieldwiper
YEUBLU
switchat INT
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
Blown No.26 (20A) fuse in the
under-dashfuse/relaybox
Faultywindshieldwiper switch
An open in the wire
Checktor voltageto ground:
Thereshouldbe batteryvoltage.
. Blown No.26 (20A) fuse in the
under-dashfuse/relaybox
. An open in the wire
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
. Faultywindshieldwasherswitch
. An open in the wire
lgnitionswitchON (ll)
*A5
lgnitionswitchON {ll),
and
windshieldwasher
WHT/BLK
switch ON
*: With combined wiper'washer operatlon
{-
(cont'd)
IntegratedGontrolUnit
Input Test (cont'dl
A8--------.--all
Key-in/SeatBelt R€mind€r,Lights-on ReminderSystom:
Cavity
Wire
A8
B7
Test condhion
Tost: D€sirodr€guh
Combinationlight
switchON
Checkfor voltageto ground;
Thereshouldbe batteryvoltage.
B l o w nN o . 3 0( 7 . 5A ) f u s ei n t h e
under-dashfuse/relaybox
Faultycombinationlight switch
An open in the wire
lgnitionswitchON (ll),
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Poorground (G552)
Faulty seat belt switch
An open in the wire
RED/BLU and driver'sseatbelt
switchunbuckled
B9
GRN
Possiblecause if result is not obtained
Driver'sdoor open
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
. Faultydriver'sdoor switch
. An open in the wire
lgnitionkey inserted
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Poorground(G401.G402)
Faultyignitionkey switch
An open in the wire
B l 0 BLU/RED into the ignitionkey
switch
Bulb CheckSystem (BrakoSystem Light):
Cavity
A4
Test condilion
Wire
lgnitionswitchON {ll),
brakefluid reservoir
GRN/RED
full, and parkingbrake
teveroown
lgnitionswitchat
START(III)
A 1 3 BLUA/1r'HT
23-160
T6st: Dosiradresult
Possiblscauseif rasuft b not obtainod
Connectto ground:Brakesystem
light shouldcome on.
B l o w nN o . 2 5( 7 . 5A l f u s e i n t h e
under-dashfuse/relaybox
Blown brakesystemlight bulb
An open in the wire
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
Blown No.31 (7.5A) fuse in the
under-dashfuse/relaybox
Faultystartercut relay
An open in the wire
Lighting System
ComponentLocationIndex
DAYTIMERUNNINGLIGHTS
RESISTOR{Canada)
Test,page 23 167
DAYTIMERUNNINGLIGHTS
CONTROLUNIT (Canadal
InputTest,Page23 166
*HEADLIGHT
Adiustment,page23-168
page23-167
Replacement,
SIGNALLIGHT
page23 167
Replacement,
HIGHMOUNT BRAKELIGHT
page23-177
Replacement,
LICENSEPLATELIGHTS
Replacement,
Page23'174
INNERTAILLIGHT
R e p l a c e m e n t ,p a g e 2 3 - 1 6 9
OUTERTAILLIGHT
page23 I69
Replacement,
*: Headlight and front parking/front turn signal light cannot be separated.
(cont'd)
23-161
Lighting System
GomponentLocationIndex(cont'dl
HIGHBEAMINOICATOR
LIGHT
T U R N S I G N A L I N D I C A T O RL I G H T
DASHLIGHTSBRIGHTNESS
CONTROLLER
ControllerInputTest,
page23-119
L
COMBINATIONLIGHTSWITCH
Test,page23'165
ILI
LILI
LT
rr Lr rJ|r LJLr Lr rr !.r rr Lr rr
-nnr1nr1r1r1r1|-1nn
I l
L JJ
r1 n11t'1n Ttr1 r1 - 11t-1Tt-l T1
r-t L.lLt r-t r-t LJ ! ! LJ LJ ! LJ!J r-l
23-162
TURNSIGNAL/HAZARDRELAY
InputTest,page23-'172
CircuitDiagram(USA)
FUSEi
NELAY
8OX
UNDER,HOOD
'------
\
-TI" T,,: i..
--.-r\ ----.'r
To
8OX
DASHFUSE/RELAY
UNDER
l|-
No5
(104)
No22
(r0A)
A
T
No.4
lilffl ( 0 0 4 )
I
I
I
II
I
I
r'
HIGHBEAM
INDCATOR
LIGHT
DASHLIGHTS
DASHLIGHTS
ERIGHTNESS
CONTROLLER
(r4w)
I
G401
G4A2
8LK
I
:
G202
I
)N0.32
A {7.5A)
I
RED/ELK
REDiGRN
BLK
No30
(7.5A)
RED/BLK
II
I
\?
PABKNGLIGHTS
T AL LG H T S
L CENSEPLATEL GHTS
BLK
I
G201
23-163
Lighting System
CircuitDiagram(Canada)
FUSEi
RELAY
UNDER.HOOD
BOX
BATTERY
l\------tr\
d,$,E" T
RED/BLU
-1
d
RED/
REDiGEN
UNDEFDASHFUSE/RELAY
BOX
I
l
l
,
ll-l
llltti
/i[ii
i Illri, zll",ll iu"x
,
I
T
T
No.5
0 0A)
t
l
!
-tl--l
FEDiGRN
R € DYEL
tI
t
I
+
V
REDTWHT FED/BLU
RED/GRN
RED/GBN
FED/8LK
|
I
|
|
I
l-,ro,u,rffl,
t
I
il]liiqff'|
A l r
Y,o"r.o" I
BLK
t
d
G401
G402
BLK
T--
l
G202
YEL/BLK
+
V
RED/
BLK
I
qUNNING
DAYT'ME
LIGHTS
FESSTOF
RED/GHN
I
G201
REDiGFN
I
IT
5
o
I
I
I
BLK
I
FED/GRN
DAYTIME
RUNNING
LIGHTS
CONTROL
UNIT
lt*"','
I
BFAKE
SYSTEM
LIGHT
NTEGRATED
CONTROL
UNIT
f-7
L.ENSEoLATELTG'TS
33''9+il4[','o
l
qsnlq,rr
\---J-------J
No.1g
(7.5A)
)'
^-^^-.*^,{*"'"0-
t t
-rGHr
) N0.20
tl0Al
. D A S FL . G H T S. o A B ( ^ r G- T G H T S
.DAS-LGH'S.TALL'GCTS
|
I
|t .+_
t L nd--f)
I
|| ttuLj
| las*,irt*| | Trt*Iorr
\_i-f
---J
)
,,r'o
Yro*,
LEVELSWTCH
[i.mi:-",,,
I
t
BLK
n:
G40l
G402
lclosed: Floaldownl
|
BLK
I
.:
-L
..
G401
G402
CombinationLight Switch Test
1 . Removethe driver'sdashboardlowercoverand steeringcolumncovers(seesection20)
2.
the 4P and 7P connectorsfrom the switch.
Disconnect
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact
.
.
and recheckthe system.
lf the terminalsare bent,loose.or corroded,repairthem as necessary,
lf theterminalslook OK,checkfor continuitybetweenthem ineach switchpositionaccordingtothetables lfthere
is no continuitybetweenany of them.checkfor continuityin the switchharness
- lf there is continuityin the switchharness.replacethe combinationlight switch
- lf there is no continuityin the switchharness,replaceit.
4P CONNECTOR
rrr r-l
l(rr mf I
tffiT
A 3A 1 1 l
I
COMBINATIONLIGHTSWITCH
7P CONNECTOR
HsadlighUDimmer/PassingSwitch :
Terminal
82
B1
B3
*84
B5
86
Position
OFF
o- --o
o- --o
o- ----o
Headlight
switch
LOW
HIGH
OFF
switch
Passing
o-o-
---o
--o
o- ----o
ON
* : Canada
Turn Signal Switch :
Teminal
\
A1
A2
A4
;',*;----__\
RIGHT
o
o
NEUTRAL
LEFT
o
o
23-165
Lighting System
DaytimeRunningLightsControlUnit InputTest(Canadal
L
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r a n d
kneebolster(seesection20).
2.
D i s c o n n e ct th e c o n n e c t o r sf r o m t h e d a y t i m er u n ning lightscontrolunit.
3. Inspectthe connectorand socketterminals to be
surethey are all makinggood contact.
lf the terminalsare bent,looseor corroded.repair
them as necessary,
and recheckthe system.
l f t h e t e r m i n a l sl o o k O K , m a k e t h e f o l l o w i n g
input testsat the connector,
- lf anytest indicatesa problem,find and correct
the cause,then recheckthe system.
- lf all the input testsproveOK, the controlunit
must be faulty;replaceit.
Cavity
Wire
BLK
A2
et
A4
A1
TGst condition
U n d e ra l l c o n d i t i o n s
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
B l o w nN o . 2 0( 1 0A ) f u s ei n t h e
under-dashfuse/relaybox
An open in the wire
lgnitionswitchON (ll)
Checkfor voitageto ground:
Thereshouldbe batteryvoltage.
B l o w nN o . 1 8{ 7 . 5A ) f u s ei n t h e
under-dashluse/relaybox
Faultyignitionswitch
An open in the wire
Combinationlight
switchin " =D " posi-
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
Blown No. 48 (30A) tuse in the
under-hoodfuse/relaybox
Faultycombinationlight switch
An open in the wire
UOn
Combinationlight
switchOFF;connecta
jumperwire between
WHT/RED the YEUBLKand
WHT/RED
terminals,
then turn the ignition
switchON (ll)
H e a d l i g h t s( h i g h b e a m ) s h o u l d
come on, (andhigh beam
indicator should come on).
l g n i t i o ns w i t c h O N ( l l ) ,
brake fluid reservoir
GRN/RED
full, and parking brake
lever down
Connect to ground: The brake
system light should come on.
23-166
. Poorground (G401,G402)
. An open in the wire
Checkfor continuityto g.ound:
Thereshouldbe continuity.
YEUBLK
REDiGRN
Possiblecauseit result is not obtained
Un d e ra l l c o n d i t i o n s
BLK /VHT
RED
Test: Desiredresult
Parking brake lever Lrp
Check for continuity to groundl
There should be continuity.
. Poorground(G201,G202,G40'1,
G402)
. B l o w nb u l b s
. Faultydaytimerunninglights
resrstor
. An open in the wire
B l o w nN o . 2 5( 7 . 5A ) f u s ei n t h e
under-dashf use/relaybox
Blown brakesystemlight
An open in the wire
. Faultyparkingbrakeswitch
. A n o p e ni n t h e w i r e
Turn
Headlights/Front
Signal/ParkingLights
DaytimeRunningLightsResistor
Test(Canada)
CAUTION: The daytime running lights resistor becomes
very hot when the daytime running lights are on; do not
touch il or the attaching hardware immediatelyafter
the lights have been iurned off.
1.
the 3Pconnectorfrom the resistor.
Disconnect
Replacement
CAUTION: Halogen headlights b€come very hot in use;
do not touch them or the attaching hardware immediately after they have been turned off.
1.
Removethe front bumper(seesection20).
2.
Removethe mountingbolts,
3.
Disconnecteach connector,then removethe headlight assembly.
lighVfrontturn signal/parking
MOUNTING
EOLT
ItTUFNSIGNAL/
HEADLIGHT/FRONT
LIGHTASSEMBLY
PARKING
Terminal side of male
terminals
HEADLIGHT:60/55 W
FRONTTURN SIGNAL/PARKINGLIGHT:21l5 w
N4easure
the resistancebetweenthe resistortermi
nals(No. 1 and No. 2) and the powerterminalNo. 3.
Resistance:1.6 O t 0.08 O
Replacethe resistorwith a new one if any of the
are beyondspecification.
resistances
23-167
Headlights
Adjustment
Headlightbecomevery hot in use;do not touch them
or any attachinghardwareimmediatelyafterthey
have been turnsd off.
Eoforo adiu3tingth€ h.adlights:
. Parkthe vehicleon levelsurface.
. Makesurethe tire prgssuresare correct.
a The driveror someonewho weighsthe same should
sit in the driver's seat.
Adjustthe headlightsto localrequirementsby turning the adjusters.
After headlight replacement,it may bs necessaryto
readjustthe horizontalindicatorgear.
.
.
96 - 98 modols
1.
Openthe hood.
2.
Checkthe horizontaladjustmentindicator.
T h e " 0 " m a r k o n t h e h o r i z o n t a li n d i c a t o r g e a r
should be alignedwith the mark on the horizontal
indicator.
INDICATOR
HORIZONTAL
MARK
Checkthe verticaladjustmentindicator.The bubble
should be centeredunderneaththe longestscribe
markon the gauge.
VERTICALINDICATOR:
(Bubblol
23-164
"0"mark as
lf eitherindicatoris not alignedwith its
describedleft column,an adjustmentcan be made
by usinga Phillipsscrewdriver.
Firstinstallthe headlioht,and adjustits horizontal and vertical aimings accordingto local requirements.
Then checkthat the arrow on the horizontalindicator gear is alignedwith the mark on the horizontalindicator.
- l f t h e y a r e n o t a l i g n e d ,r e m o v et h e s c r e w ,
adiust the indicator gear, and retightenthe
screw.
NOTE:As the outer lensesare made ot an acrylicoated,polycarbonatedmaterial,do not cover the
headlightswhen they are turnedon.
'99 - 00 models
1.
2.
Cleanthe outer lens so that you can see the center
of the headlights(A).
Parkthe vehiclein front of a wall or a screen(A).
A
7.5 m (25ft)
Openthe hood.
4.
l,-
Turn the horizontaladjusterso that the arrow on
the horizontalindicatorgear (A) is pointingup.
Headlights
Adjustment(cont'dl
Turnthe low beamson.
Determineif the headlightsare aimed properly.
7.
lf necessary,adjustthe headlightsto local requirementsby turningthe horizontaladjuster(A) and the
verticaladjuster(B).
Vsrtical adiustmsnt:
Measurethe heightof the headlights(A).The lights
should reflect52 mm \2.1 in.) below (B) headlight
height.
Horizontal adi$tment:
The width of the refractingpoints(C)should be the
same as the width of the headlightcentralpoints(D,
After headlight replacement,it may be necessaryto
readjustthe horizontalindicatorgear.
.
Firstinstalltheheadlight,and adjustits horizontal
and verticalaimings accordingto local requirements.
. Then checkthat the arrow on the horizontalindicator gear is alignedwith the mark on the horizontalindicator,
- lf they are not aligned,removethe screw,adjust
the indicatorgear,and retightenthe screw.
NOTE:As the outer lensesare made of an acrylicoated,polycarbonatedmaterial,do not cover the
headlightswhen they are turnedon.
23-170
Taillights
Replacement(Except'99- 00 Sedanl
NOTE:
. Inspectthe gasket;replaceit il it is distortedor stays
compressed.
. After installingthe taillights,run water over them to
makesurethey do not leak.
Inner Taillights(Coupe'96- 00 models/Sedan'96- 98
models):
1.
Openthe trunk lid, then removethe accesspanel.
2.
Disconnect
the 4P connectorfrom the innertaillight.
3.
R e m o v et h e f o u r [ t h r e e ]m o u n t i n gn u t s ,t h e n p u l l
o u t t h e i n n e rt a i l l i g h t .
I l: Sedan
OuterTaillights('96- 00 models,except'99- 00 Sedan):
1 . O p e nt h e t r u n kl i d / h a t c h .
2.
D i s c o n n e ct h
t e 4 P o r 6 P c o n n e c t otrr o m t h e o u t e r
taillight.
Coupei
TAILLIGHT
INNER
3.
R e m o v et h e f o u r m o u n t i n gn u t s ,t h e n p u l l o u t t h e
o u t e rt a i l l i g h t .
4P or 6P CONNECTOR
lSedan:
INNERTAILLIGHT
Hatchback:
BRAKE/TAILLIGHT:2115W
TURNSIGNALLIGHT:21 W
21 W
BACK-UPLIGHT:
BRAKE/TAILLIGHT:2115W
TURNSIGNALLIGHT:21 W
4P CONNECTOB
2115W
BRAKEiTAILLIGHT:
BACK-UPLIGHT: 21 W
Taillights
Replacement('99- 00 Sedanl
NOTE:
. Inspectthe gasket;replaceit if it is distortedor stays
compressed.
. After installingthe taillights,run water over them to
makesurethey do not leak.
Inner Taillights:
'1.
Openthe trunk lid, then removethe accesspanel.
2.
Disconnectthe 3P and 2P connectorfrom the inner
taillight.
3.
Removethe three mounting nuts,then pull out the
i n n e rt a i l l i g h t .
[ ]: Sedan
Outer Taillights:
1.
Openthe trunk lid/hatch.
2.
Disconnectthe 4P and 2P connectortrom the outer
taillight.
3.
Removethe four mounting nuts, then pull out the
outertaillight.
TAILLIG}fi
r * i
/
e
t
.
/
3P CONNECTOR
4PCONNECTOR
BRAKE/TAILLIGHT:2115W
TURNSIGNALLIGHT:21 W
23-172
BRAKE/TAILLIGHT:
2r15 W
BACK.UP
LIGHT: 21 W
Turn SignallHazardFlasherSystem
I J
GircuitDiagram
UNOER.DASH
FUSE/RELAY
80X
FUSE/RELAY
8OX
UNDER.HOOD
N o . 1 2 l 57 A )
l*v
GRN/YEL
t,
(NOt
,'|,."J
I'
RED
II
q
I
II
J
DASHLJGIlTS
BRIGHTNESS
CONTROLLER
BLK
Turn SignallHazardFlasherSystem
Turn Signal/HazardRelayInput Test
S R Sc o m p o n e n t sa r e l o c a t e di n t h i s a r e a .R e v i e wt h e
SRScomponentlocations,precautions,
and procedures
in the SRSsection{24}beforeperformingrepairsor service.
Removethe turn signal/hazard
relayfrom the underdashfuse/relaybox.
1.
Inspectthe relayand fuse/relaybox socketterminals
to be surethey are all makinggood contact.
.
l f t h e t e r m i n a l sa r e b e n t ,l o o s eo r c o r r o d e d ,
repairthem as necessary,
and recheckthe system.
. l f t h e t e r m i n a l sl o o k O K , m a k et h e f o l l o w i n g
input testsat the fuse/relaybox socket.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input testsprove OK,the turn signal/
hazardrelaymust be faulty;replaceit.
8Bffii
\_
t-E |
l\n
rl.]l
l l
n'rl
,.ff T-'
t:
FUSE/RELAYBOX
SOCKET
Cavity
2
3
Testcondition
Test: Desiredresults
Possible cause it result is not obtained
Poorground\G201,G202,G401,
G 4 0 2G
, s 5 1G
, 5 5 2G
, 6 0 1G
, 761)
Faultyhazardwarningswitch
A n o p e ni n t h e w i r e
Hazard warning switch
ON; connect the No. 1
t e r m i n a lt o t h e N o . 3
rermtnat.
H a z a r dl i g h t ss h o u l dc o m eo n .
l g n i t i o ns w i t c hO N ( l l )a n d
turn signalswitchin right
or left;connectthe No. 1
t e r m i n atlo t h e N o .3
terminal.
R i g h to r l e f tt u r n s i g n a l i g h t ss h o u l d
c o m eo n .
. Faulty turn signal switch
U n d e ra l l c o n d i t i o n s
Checkfor continuityto ground:
Thereshouldbe continuity.
. Poorground (G401,G402)
. An open in the wire
lgnition switch ON (ll)
Connectfor voltageto ground:
Thereshouldbe batteryvoltage.
'12(7.5
Blown No.
A) fuse in the
under-dash fuse/relay box
Faulty hazard warning switch
An open in the wire
Hazard warning switch ON
Connectfor voltageto ground:
Thereshouldbe batteryvoltage.
B l o w n N o . 5 3 ( 1 0A ) f u s e i n t h e u n d e r hood fuse/relay box
Faulty hazard warning switch
An open in the wire
23-174
HazardWarningSwitchTest
CAUTION:Be carefulnot to damagethe hazardwarning switch or the center outlet panel when prying the
switch out.
'96 - 98 models:
'1. Prythe hazardwarningswitchout of the centeroutl e tp a n e l .
2.
'l0Pconnectorfrom the hazardwarnthe
Disconnect
ing switch.
3.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table
HAZARD
WARNING
'99 - 00 models:
1.
Removethe centerpanellseesection20).
2.
Removethe two screws,then remove the switch
from the centerPanel
PANEL
CENTER
scREws
.
HAZARD
WARNING
swlTcH
lOPCONNECTOR
qCheckfor continuitybetweenthe terminalsin
switchpositionaccordingto the table.
\
Terminal
t**
1
2
3
5
6
9
I
\
ON
o
o
OFF
o -o o o
T e r m i n aN
l o , 4 i s n o tu s e d .
l0
o
t !.1
o
@
o
o
o
.o
LicensePlate Lights
Replacement
'96 - 98 Sedan/Coupe:
L
Removethe two screwsfrom the licenseplate light,
and pull the light out pan ot the way.
2.
Disconnect
the 2Pconnectortrom the light.
3.
Takethe lensoff, then replacethe bulb.
2P CONNECTOR
Hatchback/'gg- 00 Sedan:
1.
Carefullypry the licenceplatelight out of the license
platetnm.
2.
Disconnect
the 2Pconnectorfrom the light.
2PCONNECTOR
23-176
Back-upLights
CircuitDiagram
BOX
UNOERHOODFUSE/RELAY
]GNTION
SWITCH
-"--""\-zI
+*HT*;L
*HT/BLK
BLKTYEI
fTil"liUiEEs,x',
fr
q-,
YEURED
l$*,'l
YEL
,,
l^.0.,.
rb\ !'fi+l'
Y(ifi'frr-')
nrosrron
El
tcroseo'
I
GRNiBLK
23-177
Brake Lights
CircuitDiagram
UNDEH
HOOD
FUSEiRELAYBOX
BATTERY
/-l
I
Nos2(1sA) |
u/T'\--]-wHrGFNTwfciN_l
t
WNT/GRN
v
HORNSYSTEM
INNER
TAILL]GHT
ffi; I
GRNMHT
I
A
b'rt^t-,
Yllf,ll
I
BLK
i r i I II''i
Li*''] I Li;
I P } BRAKE
Y ilT'
II
23-178
ffi; I
GRNMHT
I
l**,,,,
I
l,"l
i$*i
BLK
+ 21W:Coup€/Sedan
18W:Halchback
control
J I : Wilhcruise
GRN,4fiHT
I
II
I
I
gLK
II
:
G601: Haldbackiooup€/Sedan
G761: flatchback
G601: Coupe/Sedan
G602: Sedan99 mode
BLK
II
I
G601r Halchback/Coupe/Sedan
AE-'ii,t
Yut#l
I
BLK
HighMountBrakeLightReplacement
Coupe/sedan:
Hatchback:
1.
2.
L o o s e nt h e t w o s c r e w s ,t h e n r e m o v et h e h i g h
m o u n t b r a k el i g h t . B e c a r e f u ln o t t o d a m a g et h e
hatchspoiler.
1.
Removethe rearshelf(seesection20).
2
R e m o v et h e t w o s c r e w s ,t h e n r e m o v e t h e h i g h
mount brakelight from the rearshelf.
Removethe bulb socketfrom the light.
HIGHMOUNT
BRAKELIGHT
BULBSOCKET
SCREWS
l23-179
DashLights BrightnessController
CircuitDiagram
UNDEFHOODFUSE/RELAY
BOX
cotvBiNATloN
LIGHT
SW]TCH
wHT-tlf-
,4.
UNDEF.DASH
FUSEi
RELAY
8OX
|-;il;I
-l-*-Tl
RED/GBN
I
I
REDi
8LK
G401
G402
23-180
ControllerInputtest
NOTErThe controlunit is built intothe dashlightsbrightnesscontroller.
'1. Carefullypry the controllerout of the dashboard.
2.
the 3P connectorfrom the controller'
Disconnect
3.
Inspectthe connectorterminalsto be sure they are
a l l m a k i n gg o o dc o n t a c t .
.
.
lf the terminalsare bent,loose,or corroded,repair
and recheckthe system.
them as necessary,
lf the terminalslookOK, makethe followinginput
testsat the connector.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the input tests prove OK, the controller
must be faulty;replaceit
Wire sideof
lemaletermlnals
Test condition
Cavity
1
RED/BLK
2
BLK
RED
Test Desited results
Combination light
switch ON
Check for voltage to ground:
There should be battery voltage.
U n d e ra l l c o n d i t i o n s
Checkfor continuityto ground:
Thereshouldbe continuity.
C o m b i n a t i o nl i g h t
switch ON
Connectto ground:
DashIightsshouldcome on full
bright.
Possiblecause if rgsult is not obtainGd
BlownNo.30 (7.5A) fusein the
Iuse/relaybox
under-dash
Faultycombinationlight switch
An open in the wire
. P o o rg r o u n d( G 4 0 1G
, 402)
. An open in the wire
. An open in the wire
23-181
lnteriorLights
Component Location Index
CEILING
LIGHT
Test,page23-183
SPOTLIGHTS
Test,page23'184
FRONTPASSENGER'S
DOORSWITCH
RIGHTREARDOORSWITCH
TRUNKLIGHTlcoupe/Sedan)
Test,page23-184
DRIVER'SDOOR
LEFTREARDOORSWITCH
TRUNK LATCH
{Coupe/Sedan)
HATCHBACKLATCHSWTTCH
lHatch bec(l
23-1A2
CircuitDiagram(WithoutSpotlightsl
BOX
UNDEFHOODFUSE]FELAY
ON
\
OFF
BLUiBLK
q-
I
I
lI ,l3g"
**
|ll ,J.,
I
SLUlBLK
A
Jiuir,
Iflri:B::,
]
l[3Fff'
BLK
I
| -r-l:'iil:
|l Fr+
LTGFN/REO
GRNiRED
FRONT
PASSENGERS
DOOR
SWTCH
open )
folosed': Door
(Open Door
cosed-l
L TG R NR/ E D
A
L TG R N / R E D
A
Y;'.'; Y,"^t'
13fi?s" 13fi?'1"
3;::"
B::::r". 8::':tl"l
|
1,3,;;:'
.
L
l
G601.G76l Halchback
G601 CoupeiSedan
3.4W. USA. Canada
ProdLrced
5W W lhouimoonrool
23-18 3
InteriorLights
CircuitDiagram(WithSpotlights)
UNDEB
HOOD
FUSEi
RELAY
BOX
WHT/RED
WHT/RED
r*r
I' T
F1,,'-1
!
SPOT.
LGHTS
I
I
2
LTGRNlRED
t_:kr
t-t
, LTGRN/BLK
KEYLESS
RECEIVER
CIBCUIT
(lntheaLid
o unil)
8LU/8LK
II
| *ttt-
| ,Y.
I
BLUlBLK
A
Yiri'n
It3f.r'+m:r:r,l
BLK
{
G601G761rHalchbac(
G601 Coupe/Sedan
xI
*2
3 . 4 W: t i S A ,C a n a dpar o d u c e d
5W Japanproduced
8w W lh moofroot
5W Wlho!lmoonroof
23-144
-
(Wilhkeyessenlrysyslem)
LTGRN/RED
GBN
LTGRN/RED
L
A
Ttp;:'
Itsl";g;"
I
FFONT
PASSENGERS
DOOR
SWITCH
'l
ictoseo :
I Dooropen
I Open:
L Doorclosed_J
I3331."..,J
:
A
Y""
t;:x::
| | 333i"
I REAR
I DooF
CeilingLight Test
Without moonroot:
1.
Turn the light switchOFF
2.
Pryoff the lens.
3.
Removethe two mountingnuts (or a bolt)from the
housing,then removethe housing.
Coupe/Hatchback:
4.
from the housing.
the connector{s)
Disconnect
5.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
\
rermrnal
Position
2
or
2'
1
\
OFF
MIDDLE
ON
ooo-
/a\
\7
,.\
\:/
\:/
/
3
or
3'
-o
--o
--o
BULB(5 WI
With moonroof:
3P CONNECTOR
2'
4
1
3
q,
23-185
Interior Lights
SpotlightsTest
Trunk Light Test
1. Turn the spotlightswitchOFF.
1.
Openthe trunk light coverfrom the housing.
2.
Pry off the lens.
2.
Pryout the light assembly.
3.
Removethe two screwsand the housing.
3.
Disconnect
the 2Pconnectorfrom the housing,
4.
Disconnect
the 1Pconnectorfrom the housing.
4.
5.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
Make sure that the bulb is OK. Checkfor continuity
betweenthe No. 1 (+)and No.2 (-) terminals.
EULB{.')
\
Terminal
2
3
t*'*-__\
o-{
OFF
ON
23-186
o-
-*i
e,
//:\
\:,/
@
/a\
\:.,/
4
--o
--o
-_o
--o
*1 3.4 W: USA, Canada-oroduced
5 W: Japan-produced
Stereo Sound System
ComponentLocationIndex
and proceduresin the SRS
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions.
section(24)beforeperformingrepairsor service.
'96 - 98 models
AUDIOUNIT
(STEFEORADIOTUNERI
page23 189
Beplacement,
Terminals,page23-190
ANTENNAMAST
page23 193
Replacement,
LEFTTWEETER
Replacement,
Page23 191
RIGHTTWEETER
Replacement,
Page23 191
RIGHTFRONTSPEAKER
page23'191
Replacement,
ANTENNALEAD
LEFTFRONTSPEAKER
Replacement,
Page23'191
SUB
ANTENNA
LEAD
PLAYER
CASSETTE
Replacement,
Page23-189
q-
REARSPEAKERS
page23-19'l
Replacement,
(cont'd)
23-147
Stereo Sound System
Component Location Index {cont'd)
SRScomponentsare locatedln this area.Reviewthe SRScomponentlocations,precautions,
and oroceduresin the sRS
section(24)beforeperlormingrepairsor service.
'99 - 00 models
AUDIOUNIT
page23-189
Feplacement,
Terminals,page23-190
ANTENNAMAST (Coupe/Hatchbeck)
Replacement,
page23,193
LEFTTWEETER
page23-191
Replacement,
RIGHTTWEETER
Replacement,
p6ge23-191
RIGHTFRONTSPEAKER
page23-191
Replacernent,
WINDOWANTENNA{Sedanl
Wire Test,page23 192
Wire Repair,page23-192
ANTENNALEAD
LEFTFRONT
R e p l a c e m e n t ,p a g e 2 3 - 1 9 1
SUB
I.TAO
REARSPEAKERS
page23-191
Replacemont,
23-1AA
CircuitDiagram('96- 98 modelsl
UNDERDASH
FUSE/RELAY
80X
IGNTIONSWITCH
BOX
FUSE/FELAY
UNDER.HOOD
r*.i,,";l
I
I
II
II
ANTENNA
LEAD
WHTiELU
I
NoJ0(7sA)
v
I
YEUFED R E D ] B L K
AUDIO
U NT
(STEREORAOLO
TUNER)
@
A16
A15
BRN/WHT
I
I
t
I
SPEAKER
I
I
BLK
RED,^/Er
I
BLU/YEL
I
l
L
RIGHTREAR
SPEAKER
GRY]BLK
LEFTFHONT
D O O FS P E A K E R
LEFT
q-
RED
I
I
I
J
DASHLIGHTS
BRIGHTNESS
CONTROLLER
RIGHT
TWEETER
G501
23-189
Stereo Sound System
CircuitDiagram('99- 00 models)
UNDER-DASI.]
FUSEi
RELAY
8OX
FUSE/RELAY
UNDER.HOOD
BOX
l-'-r,*;l
I
II
--l
(Sedan)
I
II
(Coupe/Horchbach)
F;*";
I
No30(7.54)
FUSE
V
I
YEUFED RED/BLK
a*[rrl
,,,[.J:,
BLK
I
I
LEFTREAR
SPEAKEF
_-\
/
;diFnoNi
RIGHTREAF
SPEAKEB
|
|
D o o RS P E A K E F
|
LEFT
TWEETER
neolcn
|
I
v
|
HlGHT
TWEETER
DASH
LGHTS
BHIGHTNESS
CONTROLLER
G501
23-190
Removal
StereoRadioTuner('96- 98 modelsl:
1.
Removethe centerdashboardlower cover (seesect i o n2 0 ) .
2.
Removethe two mountingbolts,and pullthe stereo
radaotuner out.
3.
CassettePlayer('96 - 98 modelsl:
1.
Removethe front consolepanel(seesection20).
2.
Removethe DIN cord from the stereoradiotuner.
Removethe four mounting bolts,then removethe
cassetteplayer.
D i s c o n n e ct th e 1 6 Pc o n n e c t o r ss,u b a n t e n n al e a d
and DIN cord (with cassetteplayerl,then remove
the stereoradiotuner.
MOUNTINGBOLTS
16PCONNECTORS
Stereo Radio/Cassette Player ('99 - 00 modelsl:
1.
Make sure you have the anti-theft code for the
radio, then write down the frequencies for the
radio's oreset buttons.
2. Removethe centerpanel(seesection20).
3.
Removethe four mountingscrews,and disconnect
the 20P connectorand antennalead,then remove
player.
the stereoradio/cassette
scREws
Enterthe anti-theftcodefor the radio,then enterthe
customer'sradiostationPresets.
23-191
Stereo Sound System
StereoRadioTunerTerminals
'99 - 00 models:
'96 - 98 models:
Forkeylessentry
.
(andsecurrty)
syslem
t6p coNNEcroR
To DIN CORD
To DIN CORD
Csvity
(forsecurity
system)
A1
RED/GRN
Rightfront door speakero,
righttweeter@
BLU
Leftfront door speaker@,
left tweeter @
Conncctsto
2
YEL/RED
ACC(mainstereopower
suppry)
5
REDI/EL
Rightrearspeaker@
Wire
Cavity
Wire
BLUI/EL
Leftrearspeaker@
7
RED/GRN
Rightfront door speaker@,
righttweeter@
8
BLU
Leftfront door speaker@,
left tweeter @
9
RED/BLK
Lights-onsignal
Constantpower (tuning
memory)
A3
RED/BLK
A4
WHT/BLU
Constantpower (tuning
memoryl
10
WHT/BLU
A5
YEL/RED
ACC(mainstereopower
suppry)
15
BRN,ryVHT RightrearspeakerO
A7
BLUI/EL
LeftrearspeakerO
A8
REDI/E L
RightrearspeakerO
A9
BRN/BLK
A10
GRY/BLK
412
Lights-on signal
GRYMHT
Left rearspeakerO
17
BRN/BLK
Rightfront door speakerO,
righttweetero
Rightfront door speakerO,
righttweeterO
18
GRY/BLK
Leftfront door speakerO,
left tweeter O
Lefttront door speakerO,
left tweeter O
'19
RED
RED
Dashlightsbrightness
controller
Dashlightsbrightness
controller
20
BLK
u r o u n o t ( l 5 ut ,
A14
BLK
G r o u n d( G 5 0 1 )
415
GRYMHT
LeftrearspeakerO
Al6
BRN/VVHT
RightrearspeakerO
T e r m i n a lA
s 6 ,A 1 1a n dA 1 3 :N o t u s e d
23-192
T e r m i n a l sN o . 1 , 3 , 4 , 1 1 , 1 2 , 1 3 , a n d 1 4 : N o t u s e d
SpeakerReplacement
Rearspeaker:
Front speaker:
1.
Removethe speakercover.
2.
Removethe threescrewsfrom the speaker.
3.
Disconnectthe 2P connector,and removethe door
speaker.
1.
Removethe rearside shelfor rearshelf (seesection
20t.
2.
Disconnect
the 2P connectorfrom the speaker.
3.
Removethe four screws,then removethe speaker.
Hatchback:
FRONTSPEAKER
Tweeter:
(}-
2P CONNECTOF
1.
Removethe door panel(seesection20).
2.
the 2Pconnectorfrom the tweeter.
Disconnect
3.
Removethe mirrorgarnish.
4,
Removethe two screws,then removethe wveeter.
TWEETER
Coupe/Sedan:
REAR
2P CONNECTOR
23-193
Stereo Sound System
Window AntennaWire Test
WindowAntennaWireRepair
1 . W r a p a l u m i n u mf o i l a r o u n d t h e t i p o f t h e t e s t e r
probeas shown.
NOTE:To make an effectiverepair,the brokensection
must be no longerthan one inch.
1.
Lightlyrub the areaaroundthe brokensectionwith
fine steelwool, then cleanit with alcohol.
2.
Carefullymaskaboveand belowthe brokenportion
of the window antennawire with cellophanetape.
OPEN
CELLOPHANE
TAPE
Using a small brush, apply a heavy coat of silver
c o n d u c t i v ep a i n t e x t e n d i n ga b o u t 1 / 8 " o n b o t h
sidesof the break,Allow 30 minutesto dry.
NOTE|Thoroughlymix the paintbetoreuse.
Touch one testerorobe to the window antennaterminal near,and move the other tester probe along
the antennawiresto checkthat continuityexists.
WINDOWANTENNA
Checkfor continuityin the repairedwire.
Apply a secondcoat of paint in the sameway. Let it
dry three hoursbeforeremovingthe tape.
23-194
Window AntennaCoil Test
MastAntennaReplacement
1.
Remove the rear shelf (see section 20).
1.
Disconnect
the connectorbetweenthe antennalead
a n ds u b a n t e n n al e a d .
2.
D i s c o n n e ctth e 2 P a n d l P c o n n e c t o r sf r o m t h e w i n d o w a n t e n n ac o i l .
2.
Removethe two mountingscrews,then removethe
m a s ta n t e n n a .
MOUNTINGSCREWS
l q 8 11 l
tf--l
lLB2ll
lL-,--rl
1P CONNECTOB
-l
2P CONNECTOR
MAST ANTENNA
wtNoow
ANTENNA
cotL
3.
Checkfor continuitybetweenterminalA1 and body
g r o u n da n d b e t w e e n
t e r m i n a l4
s 1 a n d8 1 .
lf there is no continuityat eithercheck,replacethe
w i n d o wa n t e n n ac o i l .
23-195
Horn
ComponentLocationIndex
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(24)beforeperformingrepairsor service.
(:-,
. ,,/ \t
(6\'
\K2
HORNRELAY:'98 - 00 modelslWirecolorsrWHT/GRN,cBY,l
IWHT/GRN,BLU/RED
]
Test,page 23 87
CABLEREEL
Replacement,
section24
HORNRELAY:'96 -97 modelslwire colors:WHT/GRN.GBY,I
I
IWHT/GRN,BLU/RED
Test, page23-86
UNDER-DASH
FUSE/RELAY
BOX
23-196
'96
CircuitDiagram: - 97 models
BATTERY
HornTest:'96 - 97 models
1.
Removethe front bumper(seesection20).
2.
Disconnect
the 2P connectorfrom the horn.
HORN
RELAY
LOW HORN
3.
WHT/GRN
I
Removethe horn.
Test the horn by connectingbattery power to one
terminaland groundingthe other,lf the horn failsto
sound,replaceit.
(H)HoRN
Y
I
BLU/REO
II
I
BtK
I
t
-l
l-
G40l
G1A2
23-197
Hor n
CircuitDiagram:'98 - 00 models
Horn Test:'98 - 00 models
'1. Remove f.ont
the
bumper(seesection20).
BATTEFY
2.
D i s c o n n e tcht e 1 Pc o n n e c t of r o m t h e h o r n .
HCRI]
tEtA'a
TERMINAL
T e s tt h e h o r n b y c o n n e c t i n gbattery power to the
t e r m i n aI a n d g r o u n d i n gt h e m o u n t i n g b o l t . l f t h e
h o r nf a i l st o s o u n d r, e p l a c ei t .
1 '98 model: WHT/GRN
'99 - 00 modelsrBLU/RED
23494
Switch Test
1 . l M a k es u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o ,t h e n w r i t e d o w n t h e f r e q u e n c i e fso r t h e
radio'spresetbuttons('99- 00 models).
2.
Disconnectthe batterynegativecable,then disconnect
the positivecable,andwait at leastthreeminutes.
1 . Removethe driver's airbag assembly(see section
24), then disconnectthe horn connectorfrom the
steeringwheel.
8 . Checkfor continuitybetweenthe No. 2 terminalof
the cable reel sub-harness3P connectorand horn
positiveterminal.
3 . Disconnectthe driver's airbag connector(see sect i o n2 4 ) .
4.
R e m o v et h e d r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e e
section20).
5.
3P connector
the cablereel sub-harness
Disconnect
main
wire
harness.
from the
-\
MAIN WIRE
HARNESS
3P CONNECTOR
lf there is no continuity,replacethe cable reel
(seesection24).
lf there is continuity,repair or replacethe horn
swtlcn,
Terminalsideol
maleterminals
6.
HORNCONNECTOR
REEL
SUB-HABNESS
3P CONNECTOR
Checkfor continuitybetweenthe No. 2 terminalof
the cable reel sub-harnessand body ground with
the horn switchpressed.
9 . l f a l l t e s t s p r o v e O K , r e i n s t a l tl h e d r i v e r ' sa i r b a g
assembly(seesection24), and reconnectthe cable
connector.
reelsub-harness
1 0 . Reconnectthe driver'sairbag connector,and reinstallthe accesspanelon the steeringwheel.
' I1 . Reconnectthe batterypositivecable,then the negative
termtnar.
12. After installingthe airbagassembly,confirm proper
systemoperation:
Turn the ignition switch ON (ll); the SRS indicator light should come on for about six seconds
and then go off.
Make sure both horn buttons work.
l-
a lf thereis continuity,the horn switchis OK.
lf there is no continuity,go to step 6
13. Enterthe anti-theftcodefor the radio,then enterthe
customer'sradiostationpresets('99- 00 models).
23-199
RearWindow Defogger
GomponentLocationIndex
36 - 98 modols:
UNDER.DASHFUSE/RELAYBOX
REARWINDOWDEFOGGER
SWITCH
InputTest,page23-203
REARWINOOWDEFOGGER
RELAY
Test,page 23-86
REARWINOOWOEFOGGER
FunctionTest,page23'202
DefoggerWire Repair.page23 202
23-200
'99 - 00 models:
REARWINDOWDEFOGGER
FUSE/RELAYBOX
UNDER.OASH
Test,page 23-86
f
L'
' ' r olf_i af = t r F . - l j
REARWINDOWDEFOGGER
(Builtinto climatecontrolunit)
REARWINDOWDEFOGGER
ANTENNACOIL(Sedsn)
l-
I est, page lr- lv.t
23-201
RearWindow Defogger
CircuitDiagram
36 - 98 models:
IGNITION
UNOEF,HOOD
FUSE/RELAY
BOX
(e,oA)
N0.41
swtTcH
Noa2(aoA)
+WHT
WHT/BLK
+
/ BAT \
\:7
ots't
|
I
II
YE
BLKBLU
I
T
t-l
t-l
wtNDow
BLK
G601 : Coupe/Sedan
G77t :Nalchback
23-202
G40l
G402
'99 - 00 models
IGNITON
SWTCH
FUSEi
RELAY
BOX
HOOD
UNDER
No4r (80A)
No42 (40A)
+WHT
WHT/BLK
-fO
Ctsr
\j7
|
II
BLK
8
CONTROL
CLIMATE
UNIT
delogg€t
/ R€arwindow
\
blill nlo J
I I merorcLril
\climaleconlrounil /
{/\A-4<-I
1 6
HEATER
PUSH
swtTcH
NDICATOS
(LE0)
\
sv
--o
23-211
PowerMirrors
PowerMirror Test
1.
Mirror ActuatorReplacement
(Donnelly
Typel
Pryout the cover panel(seesection20).
'1. Remove
the power mirror from the door {seesection 20).and disconnectthe 8P connector.
COVER
2.
R e m o v et h e m i r r o r b a s e c o v e r f r o m t h e m i r r o r
housing.
MIRRORHOUSING
MIRROR
HOLDER
Removethe mirror holderfrom the mirror housing.
Gentlypull it out by hand.
4.
Terminalside
of
maleterminals
Removethe three screwsfrom the actuatorand the
two screws from the bracket at the base of the
assemory.
'99- 00models
*: Canada
Disconnect
the 8P connectorfrom the power mirror.
Checkactuatoroperationby connectingpower and
groundaccordingto the tables.
L___r"'ry1
7
I
TILTUP
o
@
TILTDOWN
@
Position
6
SWINGLEFT
o
SWINGRIGHT
@
@
DofoggerTest:
4.
Checkfor continuitybetweenthe No. 3 and No. 4
terminalsof the 8P connector.
Thereshouldbe continuity.
23-212
BRACKET
5.
Removethe bracketfrom the housinq.
6.
Removethe two screws,cut the wire harness,and
removethe actuator.
10, lnsertthe terminalsinto the connectorin the origin a l a r r a n g e m e n (t r e c o r d e di n s t e p 7 ) , a s s h o w n
Detow.
Right:
Left:
SLK/WHT*
BLK/WHTi
BLU/REO'
o
,t
L, I
LT GRN
7.
Recordthe terminallocationsand wire colors'
8.
Routethe wire harnessof the new actuatorthrough
t h e h o l e i n t h e b r a c k e t .B e s u r et o p a s st h e w l r e
underthe bracketcliP.
.;{
a
GRY
I
PNK
PNK
'99- 00models
": Canada
1 1 . Apply tape to sealthe intersectionof the connector
boot and the wire harness.
in the reverseorderof disassemblyBe
12. Reassemble
BRACKET
carefulnot to breakthe mirror when reinstallingit
to the actuator.
1 3 . Reinstallthe mirror assemblyto the door.
't4. Operatethe power mirror to checkthat the actuator
workssmoothlY.
9.
Passthe connectorboot overthe wire harness
23-213
Wipers/Washers
ComponentLocationIndex
SBScomponentsare locatedin this area,Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(241betoreperformingrepairsor service.
WIPER/WASHER
SWITCH
Test,page23-215
REARWINDOW WIPER
MOTORlHatchback)
Test,page23'216
WINDSHIELD
WIPERARMS/BLADES
WINDSHIELD
WIPERMOTOR
Test,page23-215
WASHERFLUID
RESERVOIR
t_l
iTIilr
WASHERMOTOR{Hatchback)
Test,page23'216
INTERMITTENT
WIPERRELAY
(ln the integrated
CIRCUIT
controlunit)
23-214
I J
CircuitDiagram(Windshield)
DAS'I
UNDER
F U S EF ' - A Y B 3 X
BOX
FUSElFELAY
UNDER,HOOD
G R NB t (
o ooo?, I t Y",i
NTEGRATED
CONTROL
IINIT
/ Hasb! ll.Ln \
1 nlernrltent I
perreray
\w
l
a/
W PEF MOTOR
WLNDSHIELD
.r^_",,,*:
{ M } WASHEF
r,roroR
Y
I
BLK
8LK
BLK
I
l-'
II
-
GzO2
G401
G402
G40l
G402
ONWIPEF/WASHER
NEDOPERAT
COMB
23-215
Wipers/Washers
"l-
CircuitDiagram(RearWindow)
UNDEN
HOOD
FUSE/RELAY
BOX
WHTi
BLK+WI]T
REAFWINDOW
WIPERMASHER
SWITCH
,'/-t:<--
-----,-l
GRN/BLK
A
I
B !K
t
-
ooo,
G402
23-216
ouo,
G761
Wiper/WasherSwitch Test
WindshieldWiperMotor Test
1 . Removethe driver's dashboardlower cover {see
section20).
Removethe steeringcolumncovers.
D i s c o n n e c t h e 8 P a n d 6 P c o n n e c t o r sf r o m t h e
switch, remove the two screws,and pull out the
switch.
1.
Openthe hood, and removethe cap nuts.Carefully
remove the wiper arms so that they do not touch
the hood.
Removethe cowl cover by prying out the trim clips
(seesection20).
D i s c o n n e ct th e 5 P c o n n e c t o lrr o m t h e w i n d s h i e l d
wiper motor.
SWITCH
WIPER/WASHER
Windshield:
l 1 2 3 1 4|
li.l7a,lil
RearWindow:
1 1z 3 l
lT-,rtl
4.
Checktor continuitybetweenthe terminalsin each
switchpositionaccordingto the table
Windshield Wiper/WasherSwitch:
Terminal
\
1
2
7
5
3
I
\
Position
OFF
INT
LO
o
-o
o
o
oo
o
HI
l\4ist
switch"0N"
"
switch"0N
Washer
o
o
Test the motor by connectingbattery power
groundaccordingto the table.
o
o
o
\
o
o
i**l*-
Terminal
-_\
o
LOWSPEED
HIGHSPEED
4
1
o
@
@
RearWindow WiPer/WasherSwitch:
I
'i"*
--JTerminal
"0N"
switch
Washer
"OFF"l
(Wiper
switch
OFF
ON
"0N"
switch
Washer
"0N")
switch
{Wiper
2
3
4
lf the motor does not run or fails to run smoothiy,
replaceit.
6
o- -o
o- -o
o- -o
o- -o
o- -o o- -o
5.
Connectan analogvoltmeterbetweenthe No. 5 {+)
and No.3 {-) terminals.and run the motor at low or
high speed.
The voltmetershould indicate0 V and 4 V or less
alternately.
23-217
Wipers/Washers
RearWiperMotor Test (Hatchback)
WasherMotor Test
1 . Removethe hatch lower trim panel (seesection20).
1 . Removethe front bumper (seesection20).
Disconnectthe 4P connectorfrom the wiper motor
assemDry,
Disconnect
the 2P connectorsfrom the washer,
REARWINDOW
WASHERMOTOR
(Hatchbackl
WASHERFLUIO
RESERVOIR
Test the motor by connecting battery power to the
No. 1 terminaland groundto the No.3 terminal.
3.
lf the motor does not run or fails to run smoothly,
reptacerI.
Reconnectthe 4Pconnectorto the wiper motor.
Connectan analog voltmeter between the No. 4 (+)
and No.2 (-)terminals,
Runthe motor by turning the wiper switch ON.
The voltmetershould indicate0 V and 4 V or less
alternately.
23-218
L
Test the washer motor by connecting battery power
and groundaccordingto the table.
f:,ry1
Battery
1
Disconnected
Connected
@
a lf the motor failsto run smoothly,replaceit.
a lf the motor runssmoothly.but littleor no wasner
f l u i d i s p u m p e d .c h e c kf o r a d i s c o n n e c r € o r
blockedwasher hose,or a clogged pump outlet in
the motor.
WasherLevelSwitchTest (Canadal
1.
Removethe front bumper{seesection20)
2.
the 2Pconnectorsfrom the washer.
Disconnect
WASHERFLUIO
RESERVOIR
3.
\
WASHERLEVELSWITCH
Checkfor continuitybetweenthe terminalsin each
float positionaccordingto the table.
Terminal
1
2
o
o
;r"l,'t"--l
FLOATUP
FLOATDOWN
23-219
Power Windows
GomponentLocationIndex
POWERWINDOWRELAY
Test, paqe 23 87
O
-.---,---;-;n
-rr----r----
_
-n--n-nn--r-
! l
fl]l
O
FRONTPASSENGER'S
WINDOWSWITCH
Test.page 23-230
UNDER-DASH
BOX
FUSE/RELAY
POWERWINDOW
MASTERSWITCH
(Hasbuilt in controlunit)
InputTest,page23-226
f e$, page23 224
FRONTPASSENGER'S
WINDOWMOTOR
Test,page 23-232
RIGHTREARWINOOWSWITCH{Sedanl
Test, page23-230
BIGHTREARWINDOWMOTOR
lSedanl
Test,page 23-232
DRIVER'SWINOOWMOTOR
Test,page23-231
LEFTREARWINDOWSWITCH(Sedan)
Test,page 23-230
LEFTBEARWINDOWMOTOR{Sedanl
f e$, page23-232
I J
CircuitDiagram('96-98Coupe/Hatchbackl
BOX
FUSE/RELAY
UNDER.HOOD
+WHT
WHT]BLK
WHTtsLU
l /
BLK
l,
G551
PASSENGEB'S
WNDOWMOIOR
G401
G()2
23-221
Power Windows
CircuitDiagram('96-98Sedan)
UNDER
HOOD
FUSE/RELAY
BOX
UNDER.DASH
FUSUBELAYEOX
BLU/ELK
I.iASTER
SWITCH
3 I BIGHT
BEAR
l$',]ilP3,y
FBONT
PASSENGER'S
WINDOW
swtTcH
BLK
t
LEFT
HEAF
WINDOW
MOTOR
23- 2 2 2
R GNTREARWINDOW
MOTOR
B3
FRONT
PASSENGER'S
WINOOW
MOTOR
G551
BLK
I
G551
c401
G402
CircuitDiagram('99-00Coupe/Hatchback)
FUS€/RELAY
BOX
UNDER.DASH
PASSENGER'S
a/
BLU'YEL BLU/ORN
BLU/RED
t,
#*
lul
PASSENGERS
MOTOR
WINDOW
DRIVERS W NDOWMOTOR
BLK
l
G401
G402
23-223
Power Windows
GircuitDiagram('99-00Sedanl
UNDEF.HOOO
FUSE/RELAY
BOX
BLK
I
-.=
G551
23-224
G401
G402
FRONT
PASSENGER'S
l*
''o
BLU,YEL BLU/OFN
|
GRN,ryEL
YEL
810
YEUGRN
8LK
l
l "UB^YEUGRN
YEL
l s
4I
3IFFONT
PASSENGER'S
l z
3 I RIGHTREAB
4
wINDOW
SWTCH
wrNDow
.I+
FEDI{EL
REDiBLU
PASSENGER'S
FRONT
MOTOF
WINDOW
LEFTREARW]NOOW
MOTOR
BLdRED lSwlTCH
El.l
2
1
RED/BLU
!
G55l
RIGHTREAFWINOOW
MOTOR
23-225
Power Windows
MasterSwitch Test (Coupe/Hatchbackl
1.
Removethe master switch from the driver's door
panel (see page 23-2281.
Passenger'sSwitch:
\
D i s c o n n e c t h e 1 2 P c o n n e c t o rf r o m t h e m a s t e r
switch.
Terminal
P""*;l-m;\
ON
OFF
OFF
MAIN
SWITCH
UP
ON
OFF
DOWN
ON
OFF
I
A1
A1
A8
A3 A4 A5
,/l/
412
Terminal side of male terminals
3.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
Driver's Switch:
The driver'sswitch is combinedwith the control unit so
you cannot isolatethe switchto test it. Instead.run the
masterswitch input test proceduresat terminals41. A3,
44. A8 and Al2 on page 23-226.lf the tests are normal,
the driver'sswitchmust be faulty.
23-226
A2
A5
ooc'- --o
A6
A7
--o
--o
o- --o
o- --o
--o
o--o
o--o
o-
MasterSwitch Test (Sedan)
1.
Removethe armrest from the driver's door panel
(seepage23-228).
Front Passenger'sSwitch:
Terminal
\
B1
P*,j--f$t,l"\
D i s c o n n e ctth e 1 6 P a n d 1 P c o n n e c t o r sf r o m t h e
masterswitch.
ON
OFF
OFF
MAIN SWITCH
UP
ON
OFF
ON
DOWN
OFF
82
811
cl
--o
CF
o
o- --o
c\- --o
o
o
o
oo
o- --o
o
-o
o
Left RearSwhch:
\
Terminal
P".r,-'-f-mn\
ON
OFF
OFF
rFl
lt.:::::::l
l"'ll
UP
ON
OFF
Terminalsideof
maleterminals
ON
DOWN
OFF
B1
814
815
816
c1
--o
G
o
o
o- -oo
o- --o
o- o
o --o
o
o-_o
o-
B4 B5 B6 B7
B3
/l/leu
B8 89 8 1 08 1 1
Bl5 816
Right Rear Switch:
\
Terminal
'**-T-*m
ON
OFF
OFF
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the tables
ON
UP
OFF
Driv€r's Switch:
The driver'sswitch is combinedwith the control unit so
you cannot isolatethe switchto test it. Instead,run the
masterswitch input test proceduresat terminals83, 84,
85. BOand 87 on page 23-22A.lt the tests are normal,
the driver'sswitchmust be faulty.
ON
DOWN
OFF
B8
89
B' t0
c1
o- o 'o
o- --o
o- --o
CF --o
Cr- --o
--.o
o--o
o--o
o-
23-227
Power Windows
Master Switch Input Test {Coupe/Hatchback)
NOTE:The controlunit is built into the powerwindow masterswitch,and only controlsdriver'sdoor window operatlons.
l
Removethe driver'sdoor panel,and disconnectthe 12Pconnectorfrom the masterswitch.
2.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
.
.
lf the terminalsare bent,looseor corroded,repairthemas necessary,
and recheckthe system.
lf the terminalslook OK,makethe followinginput testsat the connector.
- lf a test indicatesa problem,find and correctthe cause.then recheckthe system.
- lf all the inputtestsproveOK,the powerwindow masterswitchmust be faulty;replaceit.
Waresideof femaleterminals
23-228
Cavity
Wire
Test condition
Test: Desiredresult
Un d e ra l l c o n d i t i o n s
Checkfor continuityto ground:
Thereshouldbe continuity.
lgnitlon switch ON (ll)
Checkfor voltageto ground:
Thereshouldbe batterYvoltage.
Possiblecaus€if result is not obtainsd
. P o o rg r o u n d( G 5 5 1 )
. An open in the wire
BLK
A8
A']
BLU/BLK
A6
GRN/BLK
RED/BLU
A3
A7
A2
RED/YEL
Checkthe driver'swindow motor:
Connectthe BLU/BLK
terminalto the RED/YEL It shouldrun (thewindow moves
t e r m i n a la, n dt h e R E D / o o w n , .
BLUterminalto the
B L Kt e r m i n a lt,h e nt u r n
the ignitionswilchON
( ).
connectthe GRN/BLK Check the passenger'swindow
(the window
BLUI/EL terminalto the BLUryEL motor: lt should run
qown,.
moves
B
L
U
/
t e r m i n a la, n dt h e
O R Nt e r m i n atlo t h e
B L Kt e r m i n a lt,h e nt u r n
BLU/ORN the ignitionswitchON
1 i.
412
BLU
A8
BLK
Connectthe BLU/BLK
terminalto the REDI/EL
t e r m i n a la, n dt h e B L K
t e r m i n atlo t h e R E D /
B L Ut e r m i n a lt,h e n
turn the ignitionswitch
Check for voltage between the
BLU and BLK terminals: APProx. 6
V should be indicated as the driver's window motor runs.
'11(20A) fuse in
Blown No. 10 or
the under-dashfuse/relaybox
Faultypowerwindow relay
A n o p e ni n t h e w i r e
F a u l t yd r i v e r ' sw i n d o w m o t o r
An open in the wire
window motor
Faultypassenger's
window switch
Faultypassenger's
An open in the ware
F a u l t yp u l s e r
FaLiltydriver'swindow motor
An open in the wire
oN (||).
23-229
Power Windows
MasterSwitch Input Test (Sedan)
NOTE:Thecontrolunit is built intothe powerwindow masterswitch,and only controlsdriver'sdoor window operations.
1.
Removethe driver'sarmrest,and disconnectthe 16Pand 1Pconnectorsfrom the masterswitch.
2.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
a lf the terminalsa re bent,looseorcorroded,repairthemas necessary,
and recheckthe system.
. lf the terminalslook OK, makethe followinginputtestsat the connector.
- lf a test indicatesa problem,find and correctthe cause,then recheckthe system.
- lf all the inputtestsproveOK.the powerwindow maserswitchmust be faulty;replaceit.
POWEBWINDOWMASTERSWITCH
23-230
Cavity
Test condition
Wire
U n d e ra l l c o n d i t i o n s
to:
Test: Desiredresult
C h e c kf o r c o n t i n u i ttyo g r o u n d l
Thereshouldbe continuity.
Possible caus! d r"suh rs nol obtrincd
, An ope^
^ :he tt .e
BLK
c1
B3
BLU/BLK
B2
GRN/BLK
l g n i t i o ns w i t c hO N ( l l )
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
. B l o w nN o . 7 . 6 1 0r ' " 2 0 A
f u s ei n t h e u n d e .o a s t f . s e ' e a ,
box
. Faultypowerwindo$ 'e a,
. An open in the wire
Checkthe driver'swindow motorl
I t s h o u l dr u n ( t h ew i n d o wm o v e s
oown).
. Faultydriver'swindow motor
. A n o p e ni n t h e w i r e
YEL/BLK
8 1 5 REDA/VHT
81
C o n n e c tt h e B L U / B L K
to the RED/YEL
terminal
RED/BLU
t e r m i n a l ,a n d t h e R E D /
B L U t e r m i n a lt o t h e
B L K t e r m i n a l ,t h e n t u r n
RED/YEL t h e i g n i t i o ns w i t c h O N
1 Ii .
B1
C o n n e ctth e G R N / B L K Checkthe front passenger's
BLUIVEL terminalto the BLU|YEL wrnoowmotor:
t e r m i n a la, n dt h e B L U / It shouldrun (thewindow moves
Faulty front passenger'swindow
motor
Faulty front passenger'swindow
An open in the wire
B L Kt e r m i n a lt,h e nt u r n
8 1 1 BLU/ORN the ignitionswitchON
0r ) .
connect the YEL/BLK
terminal
to the YEL terYEL
B9
m i n a l ,a n d t h e Y E U
G R N t e r m i n a lt o t h e
B L K t e r m i n a l ,t h e n t u r n
B t 0 Y E U G R N the ignition switch ON
Checkthe right rearmotor:
I t s h o u l dr u n ( t h ew i n d o wm o v e s
down).
Fauityright rearwindow motor
Faulty rightwindow switch
A n o p e ni n t h e w i r e
0r ) .
8 1 4 GRNI/EL
816
GRN
connect the RED,ryVHT Checkthe left rearmotor:
It shouldrun (thewindow moves
terminal to the GRN/
Y E Lt e r m i n a l ,a n d t h e
G R N t e r m i n a lt o t h e
B L K t e r m i n a l ,t h e n t u r n
t h e i g n i t i o ns w i t c h O N
Faultyleft rearwindow motor
Faultyleft rearwindow switch
A n o p e ni n t h e w i r e
0r ) .
B6
BLU
B4
BLK
Connectthe BLU/BLK
terminalto the RED/
Y E Lt e r m i n a la, n dt h e
B L Kt e r m i n atlo t h e
R E D / B LtUe r m i n a l ,
t h e nt u r nt h e i g n i t i o n
s w i t c hO N ( l l ) .
Checkfor voltagebetweenthe
B L Ua n d B L Kt e r m i n a l s l
Approx.6 V shouldbe indicatedas
the driver'swindow motor runs.
Faultypulser
Faultydriver'swindow motor
An open in the wire
23-231
PowerWindows
Passenger'sWindow Switch Test
Switch sids of 5P t.rminal:
Coupo/H8tchback:
1.
Remove the armrest pocket from the door panel
{seesection20}.
2
1
5
a
WINDOWSWITCH
PASSENGER'S
Terminal
sideol
maleterminals
Checkfor continuitybetweenthe terminalsin each
switch position accordingto the table.
\
Terminal
il;--l
UP
Disconnectthe 5P connector from th€ passenger's
window switch.
Sodan:
1.
Removethe armrest(seesection20).
5P CONNECTOR
Disconnectthe 5P connector,then .emove the mounting screwfrom the passenge/sswitch.
23-232
5
2
-o
-o
-o
OFF
o- -o
DOWN
o- -o
5PCONNECTOR
2.
I
Driver'sWindow Motor Test
Puls€rTest:
Motor Test:
l.
Removethe driver'sdoor panel(seesection20).
5.
Connectthe test leadsof an analogohmmeterto the
No. 3 and No. 4 terminals.
6.
Run the motor by connectingpower and ground to
the No. 1 and No.2 terminals.The ohmmeterneedle
shouldmove backand forth alternately.
Terminalsideof maleterminals
Disconnectthe 4Pconnectorfrom the motor.
3.
Testthe motor in each directionby connectingbattery power and groundaccordingto the table.
Terminal
-_l\
1
UP
o
@
DOWN
o
o
\
;."t1."
CAUTION: When th€ molor stops running, disconn€ct one lead immediat€ly.
4.
lf the motor does not run or fails to run smoothlv.
reDlaceit.
l.,,
23-233
Power Windows
Window Motor Test
Passenger's
Re!r:
Front:
1.
Removethe passenger'sdoor panel (see section
1.
Remove the passenger'sdoor panel {see section
20).
2.
D i s c o n n e c t h e 2 P c o n n e c t o ff r o m t h e w i n d o w
motor.
20t.
2.
D i s c o n n e c t h e 2 P c o n n s c t o rf r o m t h e w i n d o w
moIor.
NOTE:The illustrationshowsthe right rearwindow
motor;the left rearwindow motor is symmetrical.
2P CONNECTOR
\
2P CONNECTOR
Terminalsideot msle
terminals
3.
\
Checkwindow motor operationby connectingpower
and groundaccordingto the table.
Terminal
;;,r";--l
UP
DOWN
I
@
3.
Terminal
\
o
DI;t;;---l
UP
DOWN
@
CAUTION: When the motor stops running. dbconnest ono load immadiatoly.
4.
lf the motor doas not run or fails to run smoothly.
replaceit.
23-234
Checkwindow motor operationby connectingpower
and ground accordingto the table.
o
@
@
GAUTION:Whon the motor ctops running, disconnact one lead immodiatoly.
4.
lJ the moto. does not run or fails to run smoothly.
rcDlaceit,
Moonroof
ComponentLocationIndex
MOONBOOFSWITCH
Test,page23-236
a-/
. MOONROOFCLOSERELAY
lwire colors:WHT.GRN/YEL, l
IGRN/oBN,BLK,and GRN/REDI
Test,page23 87,88
. MOONROOFOPENRELAY
f wire colors:WHT,cRN/RED,l
IGBN/ORN,BLKand YEL
l
Test,page 23'87,88
MOONROOFMOTOR
Test,page 23-236
l-,
23-235
Moonroof
CircuitDiagram
qELAY
FUSE
JNDEB.FOOD
BOX
*1 9697modes
:+2r'98-00
models
IGNITIONSWTCH
MOONFOOF
SWITCH
BLK
I
_lr
--
G40t
G402
23-236
OPEN/CLOSE
SWITCHI
.ourrElhelifinoooglalron
F! ycto6ed)
{T[!b AandClerminals
areconnecled.
. ournolhesldnoo$ralron
*: Futly
(Fully?osed
op€n)
A andBlermrnals
areconnecled.
TILT/CLOSE
SWITCHI
. Durinq
lhelihina
oDeralion
Fillycosed)
[Ir]tuir
DandFterninaliare
conned€d.
. Durino
lheslidrno
oDoraton
--:
lFulvdossd Fllv ooenl
0 anilElemnalsare(inhecied.
FunstionTest
CAUTION: Bo careful not to damago the moonroof switch
or ths driv6r's dashboard lowsr cover when prying the
3witch out.
Connectthe No. 1 (YELIterminal to body ground
with a jumperwire,then turn the ignitionswitchON
(ll).The moonroofshouldopen.
NOTE:Checkthe No. 51 (20 Al fuse in the under-hood
tuse/relaybox and No.24 (7.5A) fuse in the under-dash
fuse/relaybox, before testing.
.
.
1.
Prv the switch out of the driver'sdashboardlower
cover.
lf the moonrootopens,checkthe switch.
lf the moonrootdoes not open,checkfor:
- an open in the YELwire.
- faulty moonroofopen relay.
- faulty moonroofcloserelay,
- poor ground(G401,G402).
- fa ulty open/closeswitch.
terminalto body ground
Connectthe No. 3 (YELnED)
jumper
wire. then turn the ignitionswitchON
with a
(ll).The moonroofshouldclose.
4P CONNECTOR
.
.
lf the moonroofcloses.checkthe switch.
lf the moonrooldoesnot close,checkfor:
- an open in the YEUREDor GRN/RED
wire'
- faulty moonroofcloserelaY.
- faulty moonrootoPenrelaY.
- faultytilvcloseswitch.
Connectthe No. 2 (BLU)terminalto bodygroundwith
a jumper wire, then turn the ignitionswitchoN (ll).
The moonroofshouldtilt up.
.
.
swtTcH
lf the moonrooftilts up, checktheswitch.
lf the moonroofdoesnottilt up, checkfor:
- an open in the BLUwire.
- taultytilvcloseswitch
terminal to bodYground
6 . Connectthe No. 3 (YEURED)
with a jumperwire,then turn the ignitionswitchON
(ll),The moonroofshouldtilt down.
lf the moonroofdoes not tilt down, the open/close
relay must be taulty.
Wire sideof femaleterminals
2.
7.
Checkfor continuityto body ground on the No. 4
{BLK}terminal.
Thereshouldbe continuity.
Disconnectthe 4P connector from the switch
.
.
lf there is continuity,checkthe switch
lf thereis no continuity,checkfor:
- an open in the BLKwire
- poor ground (G401,G402).
l-t
23-237
Moonroof
Motor Test
Switch Test
1 . Carefullyremovethe switchfrom the driver'sdashboardlowercover{seepage23-205}.
'1.
D i s c o n n e ctth e 2 P c o n n e c t o rf r o m t h e m o o n r o o f
motor.
Checkfor continuitvbetweenthe terminalsin each
switchpositionaccordingto the table.
Terminal
\
Removethe headliner(seesection20).
Terminalsideof maleterminals
I
2
3
o
-o
o- --o
--o
4
t*',*-----__\
ut-t-
OPEN
o-
CLOSE
TILT
Checkthe motor by connectingpower and ground
accordingto the table.
\_____lTr1
,l
Position
4.
OPEN
o
CLOSE
@
@
lf the motor does not run, replaceit (seesection20).
NOTE: See Closing Force Checkin section 20 for
motor clutchtest.
23-234
Switch Test
Open/Close-Tilt/Close
1.
Removethe headliner(seesection20).
2.
from the moonthe 2P and 4Pconnectors
Disconnect
roof motor andthe switch.
3.
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
\
-\
Terminal
*r*"-
.*
CLOSE
TILT
..--. OPEN
CLOSE
4.
1
2
3
o- - o o- --o
-o
o-
lf thereis no continuity,adiustor replacethe switch'
Terminalsideof maleterminals
l-t
23-239
GruiseControl
ComponentLocationIndex
MAIN SWITCH
TesVReplacement,
page 23-242
CABLEREEL
Replacement,section24
BRAKE
SWITCH
, fest, page23-244
CRUISECONTROI.UNIT
InputTest,page23-240
. PedalHeightAdjustment,
section19
swrTcH{M/T)
atf
SWTTCH
. Test.page 23-244
. Clutch PedalAdjustment,
section12
. Test,page 23-154
' Replac€ment,page 23-'155
ACTUATORCABLE
Adjustment,page23-246
VACUUMTANK
.
.
.
'
23-240
TORASSEMBLY
Test,pag€ 23-245
Replacement,page23-246
SolenoidTest,page23-247
Disassembly,page 23-248
CircuitDiagram
swlrcH
tGNlTtoN
FUSEiRELAY8OX
UNDER.HOOD
N0.41(80A)
N0.42{40A)
BOX
FUSARELAY
UNDEB.OASH
N0.30(7.5A)
f/
+WNT
WNT/BLK
I
REO/BtX
INOICATOR
LIGHT
(0.84rY)
GRY+
BLUiGRN
BLU/RED
V
HORN
lP
IO SET
I J ,
lo
I Q suue
GAUGE
ASSEMBLY
JRN,/WH
V
gRAKE
LGHTS
l-t
CBUISE
CONTROL
ACTUATOR
* : 9900models
wlli A/T
23-241
CruiseControl
GontrolUnit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations,precautions,
and proceduresin the SRS
section(24)beforeperformingrepairsor service.
1.
Removethe driver'sdashboardlowercoverand kneebolster(seesection20).
2.
Disconnect
the l4P connectorfrom the controlunit.
3.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact.
lf the terminalsare bent,loose,or corroded,repairthem as necessary,
and recheckthe system.
lf the terminalslook OK, makethe followinginpul testsat the connecror.
- lf any test indicatesa problem,find and correctthe cause,then recheckthe system,
- lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
14PCONNECTOR
Wiresideof femaleterminals
CRUISECONTROLUNIT
GRN/WHT LT GRN/RED LT GRN/BI-K
8LU/GRN*
*i '99
00 models with A/T
23-242
)
Cavity
BRNA/VHT
1
BRN
11
BRN/BLK
2
GRY
3
BLK
5
Test condition
Wire
GRNA,A/HT
U n d e ra l l c o n d i t i o n s
U n d e ra l l c o n d i t i o n s
lgnjtion switchON (ll),
main switchON and
brakepedalpushed,
then released
Checkfor voltageto ground:
Thereshouldbe 0 V with the Pedal
pushedand batteryvoltagewith
the pedalreleased.
' F a u l t yb r a k es w i t c h
. A n o p e nI n t h e w l r e
Un d e rall conditions
Checkfor continuitYto groundl
Thereshouldbe continuity
Brakepedalpushed,
then released
Checkfor voltageto groundl
Thereshouldbe batterYvoltage
with the PedalPushed.and 0 V
with the pedalreleased
, 402)
' P o o rg r o u n d( G 4 0 1G
. A n o p e ni n t h e w i r e
. B l o w nN o .5 2 ( 1 5A ) f u s ei n t h e
box
under-hoodfuse/relaY
. Faultybrakeswitch
. An open in the wire
Set button pushed
Check for voltage to ground:
There should be batterYvoltage.
B l o w nN o .5 2 ( 1 5A ) f u s ei n t h e
box
under-hoodfuse/relaY
Faultyhorn relay
Faultysevresumeswitch
Faultycablereel
An open in the wire
Attach to ground:
C r u i s ei n d i c a t o rl i g h t i n t h e g a u g e
assembly should come on.
B l o w nb u l b
Blown No. 25 (7.5A) fuse in the
underdashfuse/relaybox
F a u l t yd i m m i n gc i r c u i it n t h e
gaugeassemDly
An open in the wire
LT GRN/
BLK
ResumebuttonPushed
RED/BLU
lgnitionswitchON (ll)
and main swilch ON;
raisethe front of the
BLU,A/VHT
car,and rotateone
wheelslowlywith the
otherwheel blocked.
LT GRN
14
PNK
Checkfor voltagebetweenthe
BLUMHT@ and BLKO terminals:
T h e r es h o u l db e 0 - 5 V o r m o r e
-0- 5 V or more repeatedlY
. Faultyvehiclespeedsensor{VSS)
. An open in the wire
lgnitionswitchON (ll)
and main switchON
Checkfor voltageto ground:
Thereshouldbe batterYvoltage.
B l o w nN o . 1 4( 7 . 5A ) f u s ei n t h e
under-dashluse/relaYbox
Faultymain switch
An open in the wire
A,T: Shift lever in E,
ojorE
M/T:Clutchpedal
released
Checkfor continuityto ground:
Thereshouldbe continuity.
NOTE:Thereshouldbe no continuitywhen the clutchPedalis
depressedor when the shift lever
is in other positions.
FaultyA/f gear positionswitch
Faultyor misadjustedclutch
switch(M/T)
Poorground(G401,G402)
An open in the wire
Underall conditions
Checkfor continuitybetweenNo. I
terminaland No. 5 terminalof the
PCMconnectorA.
Thereshouldbe continuity
BLU/GRN
l-,
Faulty actuatorsolenoid
P o o rg r o u n d( G 2 0 2 )
A n o p e ni n t h e w i r e
to ground:
Checkfor resistance
7
0
1 1 00 .
b
e
T h e r es h o u l d
lgnition switch ON (ll)
10
to ground:
Checkfor resistance
Thereshouldbe 80 - 120O.
to ground:
Checkfor resistance
Thereshouldbe 40 - 60 0.
Possiblecauseif result is not obtained
U n d e ra l l c o n d i t i o n s
LT GRN/
RED
7
Test: Desiredresult
. An open in the wire
*: '99 - 00 modelswith A,/T
23-243
CruiseGontrol
Main Switch Test/Replacement
1.
Removethe driver'sdashboardlowercover(seesection 20).
2.
Carefullypush out the switchfrom behindthe dash
board.
3.
Disconnect
the connectorfrom the swtrcn.
Set/ResumeSwitch
Test/Replacement
M a k e s u r e y o u h a v e t h e a n t i - t h e f tc o d e f o r t h e
r a d i o , t h e n w r i t e d o w n t h e f r e q u e n c i e sf o r t h e
radio'spresetbuttons.('99- 00 models).
2 . Disconnectthe batterynegativecable,then disconnectthe positivecable,and wait at leastthree minutes.
Disconnectthe driver's airbag connector(see section 24).
Removethe dashboarddriver'slowercover(seesec,
tion 20).
5. Disconnectthe cablereel sub harness3p connector
from the main wire harness.
1.
MAIN SWITCH
BULBS{0.84Wt
CABLEBEEL
SUB-HARNESS
3P CONNECTOS
MAIN WIRE
HARNESS
3P CONNECTOR
Terminalsideof
maleterminals
4.
\
Check for continuity between the terminals in each
switch position according to the table.
Terminal
--\
2
r**
OFF
ON
oo-
\:./
/a
\:/
-o
3
5
G
-o o-
lf there is no continuity.reDlacethe switch.
23-244
a\
\a/
\:/
-o
-o
Checkfor continuitybetweenthe terminalsof the
cable reel sub-harness
3P connectorin each switch
positionaccordingto the table.
Terminal
L
Position
SET(ON}
BESUi,|E
IONI
1
2
3
o- ---o
o-- ---o
l f t h e r e i s c o n t i n u i t ya, n d i t m a t c h e st h e t a b l e ,
the switchis OK.
lf there is no continuityin one or both positions,
go to step7.
7.
Removeth€ two screws,then remove the switch'
SET/NESUME
q
lf all tests prove OK, reconnectthe cable reel and
connector,then reinstallthe
cable reel sub-harness
steeringcolumncovers
1 0 . Reconnectthe driver'sairbag connector.and reinstallthe accesspanelon the steeringwheel.
the batterypositivecable,then the nega1 1 . Reconnect
tive cable.
1 2 . A f t e r c o n n e c t i n gt h e a i r b a gc o n n e c t o r sc, o n f i r m
propersystemoperation;Turnthe ignitionswitchON
(ll);the SRSindicatorlight shouldcome on for about
six secondsand thengo off.
Enterthe anti-theftcode for the radio,then enterthe
-00 models)'
customer'sradiostationpresels{'99
8.
Checkfor continuity betweenthe terminals in switch
positionaccordingto the table.
Terminal
-\
\
t"-"t*
SET(ON)
RESUI\4E
{ON}
2
3
-o
oo- ---o
lf there is continuity,and it matchesthe table,
replacethe cablereel.
lf there is no continuityin one or both positions,
reDlacethe switch.
l-l
23-245
CruiseControl
BrakeSwitch Test
clutch switch Test (M/Tl
1.
1.
Disconnect
the 4Pconnectorfrom the switch.
Disconnect
the 2P connectorfrom the switch.
4P CONNECTOR
swtTcH
BRAKE
PEDAL
Checkfor continuitybetweenthe terminalsaccording to the table.
2.
Terminal
\
t"r. **
\
RELEASED
DEPRESSED
1
2
Checkfor continuitybetweenthe terminalsaccording to the table.
3
o- --o
Terminal
-\
\
o
o
2
RELEASED
DEPRESSED
3.
I
.***aal
o--
o
l f n e c e s s a r yr. e p l a c et h e s w i t c h o r a d j u s t p e d a l
height(seesectionl9).
3.
23-246
l f n e c e s s a r yr, e p l a c et h e s w i t c h o r a d i u s t p e d a l
height(seesection'12).
)
Actuator Test
' t . Disconnectthe actuatorcablefrom the actuatorrod
5.
and the 4Pconnector.
2.
With voltageand vacuumstill applied,try to pull the
actuatorrod out by hand.You shouldnot be ableto
oull it out. ll you can,it is defective
Connect battery power to the No 4 terminal and
g r o u n dt o t h e N o . 1 , N o .2 a n d N o .3 t e r m i n a l s .
Connecta vacuumpump to the vacuumhose Then
applyvacuumto the actuator.
VACUUMPUMP
GAUGE,0- 30 in.Hg.
{A973X- 041 -
xxxxxl
ACTUATOR
groundfrom the No.3 terminal.The actuDisconnect
ator rod should return lf it does not return, but the
vent hose and filter are not plugged,the solenoid
valveassemblyis defective.
,lP CONNEcToR
1.
Repeatsteps 2 through 5, and disconnectground
. he actuator od should
f r o m t h e N o . 1 t e r m i n a lT
but the vent hose and
return,
not
lI
it
does
return.
filter are not plugged.the solenoidvalve assembly
is defective.
8.
It you replacethe solenoidvalve assembly,be sure
to usenew O-ringson eachsolenoid.
Terminalsideo{
maletermrnals
4.
The actuatorrod shouldpull in completely.lf the rod
pulls in only pan-wayor not at all' checkfor a leaking vacuumlineor defectivesolenoid.
Disconnectpower and ground from the 4Pconnector.
Disconnectthe vent hose from the actuator.Connect
a vacuumpump to the actuatorvent hose port, and
applyvacuum.The actuatorrod shouldpull in comp l e t e l y .l f n o t , t h e v a c u u m v a l v e i s s t u c k o p e n .
Replacethe actuator'
ACTUATOFROD
l-t
23-247
CruiseControl
AstuatorReplacement
ActuatorCableAdjustment
1 . Pull backthe boot,and loosenthe locknut.Then disconnectthe cablefrom the bracket.
1 . Checkthat the actuator cable operatessmoothly
with no bindingor sticking.
Disconnect
the cableend from the actuatorrod.
t
t
D
=
Stan the engine.Hold the engineat 3,000rpm with
no load (Afl'in N or E, M/T in neutral)untit the
radiatorfan comeson, then let it idle.
Measurethe amount of movementof the actuato.
rod until the cable pulls on the acceleratorlever
(enginespeedstartsto increase).Free Dlayshould
be 11t 1.0mm (0.43I 0.04in).
ACTUATORROD
Disconnectthe 4P connectorfrom the actuator.
Disconnect
the vacuumhosafrom the vacuumtank.
Pullout the vent hose.
Removethe three mounting bolts and the actuator
with the bracket.
VACUUMHOSE
LOCKNUTFREEPLAY:11 1 1.0 mm
{o.i|:lr 0.oit in}
lf free play is not within specs,loosenthe locknut,
and turn the adjustingnut as required.
NOTE: lf necessary.check the throttle cable free
play (seesection11).then recheckthe actuatorrod
free play.
Retightenthe locknut,and recheckthe free play.
CABTI
aPCONNECTOR
lf necessary,
disconnectthe cableend from the linkage over the acceleratorpedal,then turn the grommet 90' in the bulkhead,and removethe cable,
7.
Installin the revers€order of removal,and adjust
free play at the actuator rod after connectingthe
cable(seene)dcolumn).
23-244
ActuatorSolenoidTest
)
the 4Pconnectorfrom the actuator'
Disconnect
1.
ACTUATOR
Terminalsideot
maleterminals
2.
\
J
Checkfor resistancebetweenthe terminalsaccording to the table.
Terminal
(O)
Resistance
4
3
2
\
o- --o
VENTSOLENOID
40 600
VACUUMSOLENOID
30- 500
SOLENOID
SAFETY
40- 600
--o
G-
--o
o-
NOTE: Resistancewill vary slightly with temperais at 70"F(20'C).
ture;sDecifiedresistance
SAFETYVALVE
VACUUM VALVE
l )
From VENT
HOSE
+
To VACUUM
TANK
23-249
GruiseControl
ActuatorDisassembly
ACTUAYORCABLE
ACTUATORBRACKET
WIRESUPPORTBRACKET
ACTUATOR
Test,page23 245
SOLENOIDVAI-VES
Test, page 23 247
0
o
I
SOLENOID
SEAL
+*R
lAC
E
23-250
Power Door Locks
ComponentLocationIndex
NOTE(With keylessentry systeml:
is faulty;
. It the doors unlockor lock with the transmitter,but the LEDon the transmitterdoes not come on, the LED
replacethe transmitter'
(However,
. when vou unlockthe doorswith the transmitter,the ceilinglight (middleposition)comeson for 30 seconds.
if the audio unit is not installed,the light does not come on )
. lf any door is open,you cannotlockor unlockthedoorswith the transmitter'
the horn
. The horn soundsonly the first time you pressa transmitterbutton. (Pressingrepeatedlydoes not activate
again.)
the doors relock
o lf vou unlockedthe doors with the transmitter,but do not open any of the doors within 30 seconds,
automatically.
. The doorsdo not lockor unlockwith the transmitterif the ignitionkey is insertedin the ignitionswitch
and the transm'fer
. lf you pressthe PANICbutton for more than two seconds,the horn soundsfor about 30 seconds,
The panic mode is
switch
)
ignition
is
in
the
key
ignition
iJ
the
(The
be
activated
panic
will
not
mode
LEDcomes on.
cancelledby pressingany of the transmitterbuttons'
activatethe transmitter'
o After replacingthe transmitterbattery,pressthe lockand unlockbuttonsfive or six timesto
RIGHTREARDOORLOCKACTUATOR
Test, page 23-263
Replacement,section20
I.IFT REARDOORLOCKACTUATOR
Test,page 23 263
Replacement,section20
DOORLOCKACTUATOR
FRONTPASSENGER'S
Test,page 23-263
section20
Replacement,
AUDIOUNIT
(STER€ORADIOTUNER)
{'96- 98 models)
lHasbuilt-inkeylessl
circuit
I
\receiver
page23-189
Replacement,
Input Test,page 23-260
Terminals,page23-262
KEYLESSDOORLOCK
CONTROLUNIT l'99 - 00 modelsl
InputTest, Page23-257
LOCKACTUATOR
Test, page 23-263
Replacement,section20
ORIVER'SDOORLOCKSWITCH
Test, page23'262
Qi
,,a/
/'-'6
/----
L(ru
l-l
i'.-8,-'l
TRANSMITTER
99 - 0Otransmittershown;'96-98 transmifter
alsohasan OPTIONbutton
Test,page 23-264
page23_265
TransmitterProgramming,
DOORL@X
CONTROLUN]T
InputTest,page23 255
23-251
Power Door Locks
CircuitDiagram(With KeylessEntrySystem:'96 - 98 modelsl
UNDER.HOOD
FUSEiRELAYBOX
No.4l180A)
N0.42(40A)
WHTiBLK
WHT/BED
WHT/BLU
WHT/GRN
POWER
OOOR
LOCKCONTROL
UNT
uNLocK@
rocK
@
t'
I'
8 L K YELTRED
8LU/RED
WHT/RED
LOCK
KNOB
n
Y
|
WHT/FED
l,l,
GRNiORN
KEY
-----.f--;-)
i-q__!J
GRN/]/VHT
tA-r
rA]
r.
qJ_*:[:,,,:
L
ll,o".,
I PASSENGER'S
I DoOFLOCK
I ACTUATOR
I
liqi*"""r
llqi*'€tr
YELIRED
G551
23-252
Y E LRi E D
I
YEUREO
BLK
I
BLK
G55l
)
1
w l
r,*1.,.
,,Tr,
,
I
'r-1-|
I
llltii irl:rx
l5|i;e''lv
TRUNK
LIGHT
I
I
@
BLU/YEL
RECEIVER
CIRCUIT
KEYLESS
(lnlheaudio
unrl)
l"'l"l''
o'*i*"
| |
-"'i:"j^,"
l'*tectotro
UNIT
I coNTROL
TGFIVRED
I *r.oro,ro
uNrr
I coNTRor
fF7
I Y
I ,Y, | L < r )
I
A A
A
A
A
Y6su-' YFHrLo,,"
Ii,llh*
T#,
-,..".l:!llT
',"**,
r e*,**,
r
I T
BLU/RED
\
\
GRNiRED
GRN
LTGRN/NED
Y.r'ro,u
l-ope1 (eytemoved
I
BLK
I
)
;
liili.} liHi:
l
-
l
;
: Door
open)
I lctoseo
dosed
J
Looen Doot
I
t
l
-:
l
. ooo,open
| (ctoseo
Loner :oootcloset
I
l
-l
G402
23-253
Power Door Locks
CircuitDiagram(With KeylessEntrySystem: '99-00models)
UNDEF.HOOO
FUSE/RELAY
BOX
N0.411804)
N0.51(20 )
KEYLESS
DOOFLOCK
COIJTROL
UNIT
DRIVEF'S
DOOFLOCK
SWITCH
BL(
I
G551
23-254
)
1
CircuitDiagram(WithoutKeylessEntrySystem)
BOX
UNDERHOODFUSE/RELAY
ORIVER'S
DOORLOCK
S WT C H
I r
l -,t
POWER
DOOR
LOCK
CONTROT
UNT
l'
BLK
8LK
G55l
G551
23-255
PowerDoor Locks
Troubleshooting
sequence.
NOTE:The numbersin the tableshow the troubleshooting
Itemto be inspected
I
E
;
s
{ o
€ 5
5
O
q)
o :
E ,
3 .9
x 6
t n 6
o
o o
o >
> t
l 5
: ':
o
E
c
6 <
o
Symptom
o :
o F
<5
ucc I
WHT/GRN
Powerdoor locksvstemdoes not work at all.
1
Doorsdon't lockwith driver's
door lockknob switch.
All doors
I
One or more
doors
YEUREDor
WHT/RED
Doorsdon't lockor unlock
with driver'sdoor lockswitch.
All doors
GRN/WHT,
GRN/ORN,
YEUREDor
WHT/RED
BLU,ryVHT
2
1
YEUREDor
WHT/RED
One or more
ooors
*The powerdoor locksystemworksproperlybut
the keylessentry system doesn't.
1
G401
G402
or
GRNAVHT
GRNiORN
*: With keylessentrysystem
NOTE:
. When the remotetransmitterbutton is pressedthe first time, only the driver'sdoor will unlock.When the button is
pressedthe secondtime, all the doorswill unlock.
lly after30 secondsif a door is not opened,or the key is out ot the ignition switch.
. Thedoorswill relockautomatica
will
not
lockor unlockthe doorswhen the key is in the ignitionswitch.
. The keylessentrysystem
23-256
ControlUnit InputTest('96- 98 modelsand'99- 00 modelswithout
KeylessEntrySystem)
1.
Removethe driver'sdoor panel(seesection20).
2.
D i s c o n n e tcht e 1 2 Pc o n n e c t ofr o m t h e c o n t r o ul n i t .
3.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contact
and recheckthe svstea lf the terminalsare bent,looseor corroded,repairthem as necessary,
at
the
connector.
. lf the terminalslook OK, makethe followinginput tests
- lf any test indicatesa problem,find and correctthe cause,then recheckthe syslem
lf all the inputtestsproveOK,the controlunit must be faulty;replaceit.
.I2PCONN€CTOR
YEL/RED
BLU/RED
5
1
1
8
12
BLU/WHT
Wire side o{ femele terminals
*: With keylessentry system
l-l
lcontd)
23-257
Power Door Locks
Control Unit lnput Test ('96- 98 modelsand'99 - 00 modelswithout
KeylessEntrySysteml(cont'dl
Disconnect
the 12Pconnectorfrom the powerdoor lockcontrolunit.
CAUTION: To prevsnt damageto the actuator, apply battery voltage only momentarily.
Cavity
Wire
4
BLK
Test condition
Test: Desiredresult
U n d e ra l l c o n d i t i o n s
Checkfor continuityto ground:
Thereshouldbe continuity.
U n d e ra l l c o n d i t i o n s
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
WHT/GRN
2
Connectthe YEURED
terminal to the WHT/
GRNterminal,andthe
YEURED
WHT/RED
terminalto
the BLKterminal
momenraflty.
Checkdoor lockoperation:
All passenger's
doorsshould
untocK.
Checkdoor lockoperation:
Driver'sdoor shouldunlock.
3
Connectthe BLU/RED
terminalto the WHT/
G R Nt e r m i n a la. n dt h e
BLU/RED
WHT/RED
terminalto
the BLKterminal
momenraflry.
Checkdoor lockoperation:
All passengerdoorsshouldlock.
5
connectthe WHT/RED
terminalto the WHT/
G R Nt e r m i n a la, n dt h e
WHT/RED
YEL/RED
terminalto
t h e B L Kt e r m i n a l
momenraflty.
U n d e ra l l c o n d i t i o n s .
BLU/YEL
Checkfor continuitybetweenthe
power door lockcontrolunit l2P
connectorNo. 6 terminaland
audio unit 16PconnectorNo. 3 terminal:The.eshouldbe continuity.
Possiblecause if result is nol obtained
. Poorground (G55'l)
. An open in the wire
. Blown No. 51 (20A)fuse in the
under-hoodfuse/relaybox
. An open in the wire
Blown No. 51 {20A) fuse in the
under-hoodfuse/relaybox
Faultyactuator
An open in the wire
An open in the wire
*: With keylessentrysystem
Reconnect
the 12Pconnectorto the power door lockcontrolunit.
Cavity
Wire
Test condition
Driver's door lock
switch in LOCK
GRN,ryVHT
Tssl: Desirsd losull
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Faultydriver'sdoor lockswitch
P o o rg r o u n d{ G 5 5 1 )
An open in the wire
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Faultydriver'sdoor lockactuator
P o o rg r o u n d{ G 5 5 1 )
An open in the wire
Driver'sdoor lock
switchin UNLOCK
8
GRN/ORN
7
Driver'sdoor lockknob
BLUA/VHT in LOCK
Possiblecauseit resull b not obtained
ControlUnit Input Test ('99- 00 modelswith KeylessEntrySystem)
)
1 . Removethe driver'skickpanel.
Disconnect
the 18Pconnectorfrom the controlunit.
Inspectthe connectorand socketterminalsto be surethey are all makinggood contacl.
and recheckthe system
. lf the terminalsare bent,looseor corroded,repairthem as necessary,
. lf the terminalslook OK,makerhe followinginput testsat the connector.
- lf anv test indicatesa problem,find and correctthe cause,then recheckihe system
- lf all the input testsproveOK,the controlunit must be faulty;replaceit
RED/SLK
BLK/YEL
5 6
'15
2
9 1 0/,'2
,/
1
8
17 18
WHT
LT
WiresideoI femaleterminals
the 18Pconnectorfrom the power door lockcontrolunit.
Disconnect
CAUTION: To provent damageto the actuator, apply battery Yoltageonly momentarily.
Cavity
Wir€
17
BLK
t8
4
l-r
Test condition
Underall conditions
Checkfor contlnuityto ground:
Thereshouldbe continuity.
Underall conditions
Checktor voltageto ground:
Thereshouldbe batteryvoltage.
lgnitionswitchON (ll)
checkfor voltageto ground:
Thereshouldbe batteryvoltage.
WHT/GRN
BLK/YEL
Test: Desiredresult
Possiblecause if result is not obtained
. P o o rg r o u n d( G 5 5 1 )
. A n o p e ni n t h e w i r e
. Blown No. 5'1(20A) luse in the
under-hoodtuse/relaybox
. An open in the wire
Blown No. l4 (7.5A) fuse in the
fuse/relaybox
under-dash
An open in the wire
(cont'd)
23-259
Power Door Locks
ControlUnit Input Test ('99- 00 modelswith KeylessEntrySystem)(cont'd)
BLU/RED
2 3 4
9 10
12
WHT/RED
BLU/RED
8LK/YEL
8LU/WHT
YEL/RED
RED/BLK
5 6 1 8
/t/
17 td
t5
WHT/GRN
LT GRN,/RED
BLK
GRN/WHT
Wiresideof femaleterminals
Disconnect
the 18Pconnectorfrom the oower door lockcontrolunit.
CAUTION:To prevent damageto the actuator, apply baftery voltage only momentarily.
Cavity
Wile
Test condition
Test: Desiredresult
I
Connectthe YEURED
terminalto the WHT/
GRNterminal,and the
YEURED
WHT/RED
terminalto
t h e B L Kt e r m i n a l
momenraflty,
5
Connectrhe BLU/RED1 Checkdoor lockoperation:
Driver'sdoor shouldunlock.
terminalto the WHT/
G R Nt e r m i n a la, n dt h e
BLU/RED
WHT/RED
terminalto
the BLKterminal
momenlaflry_
7
Connectthe WHT/RED
terminalto the WHT/
G R Nt e r m i n a la, n dt h e
WHT/RED
YEUREDterminalto
the BLKterminal
momenlaflry.
23-260
Checkdoor lockoperation:
All passenger's
doorsshould
untocK.
Check door lock operation:
All passenger doors should lock.
Possiblecause if result is not obtained
Blown No. 51 (20A) fuse in the
under-hoodfuse/relaybox
Faultyactuator
An open in the wire
I
the 18Pconnectorto the power door lockcontrolunit
Reconnect
Cavitv
Wire
Test condition
'10 GRNA/VHT Driver'sdoor lock
switchin LOCK
GRN/ORN
2
BLU,ryVHTi n L O C K
GRY
. Faultydriver'sdoor lockswitch
. P o o rg r o un d ( G 5 5 1 )
. A n o p e ni n t h e w i r e
Faultydriver'sdoor lockactuator
P o o rg r o u n d{ G 5 5 1 )
An open in the wire
lgnitionkey inserted
into the ignitionkey
swttcn
Checkfor voltageto groundl
Thereshouldbe 1 V or less
lgnitionkey removed
from the ignitionkey
swtrcn
Checkfor voltageto ground:
Thereshouldbe 4 V or more
Poor ground (G401,G402)
Faulty ignition key switch
An open in the wire
Shon in the wire
Ch."k f"r ".lt"r" t. g|'"r^d
Thereshouldbe baneryvollage
A o*n tto gO ,i5 A' fr." in tf'"
Lrnderhood fuse/relay box
Faulty combination light switch
An open in the wire
Eachdoor open,one at
a trme
Checktor voltageto ground:
Thereshouldbe 1 V or less.
Faultydoor swilch
An open in the wire
Un d e ra l l c o n d i t i o n s
Connectto ground:
H o r ns h o u l ds o u n d .
B l o w n N o . 5 2 ( 1 5A l f u s e i n t h e
under hood fuse/relay box
Faulty horn
Faulty horn relay
An open in the wire
C o m b i n a t i olni g h t
switchin " :m:"
RED/BLK position
LT GRN/
RED
Possiblecauseit r€sult is not obisinod
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
Driver'sdoor lockknob
BLU/RED
Check for voltage to groundl
There should be 1 V or less.
Driver'sdoor lock
swirchin UNLOCK
9
3
Tost: Desiredresult
l-l
23-261
Power Door Locks
Audio Unit {KeylessReceiverCircuitl Input Test ('96- 98 models}
L
R e m o v et h e a u d i o u n i t , t h e n d i s c o n n e c t h e A a n d B c o n n e c t o r s( s e e p a g e 2 3 - 1 8 9 ) .
2.
Inspectthe connector and socket terminals to be sure they are all making good contact
.
.
lf the terminals are bent, loose or corroded, repair them as necessary,and recheckthe system
lf the terminals look OK, make the following input tests at the connector.
- lf anv test indicates a problem, find and correct the cause, then recheckthe system
lf all the inout tests prove OK, the control unit must be faulty; replace it.
B CONNECTOR
A CONNECTOB
WHT/BLU
YEL/RED
16PCONNECTORS
AUDIOUNIT
RECEIVER
CIRCUIT}
{KEYLESS
23-262
)
Disconnect
the A and B connectorsfrom the audio unit.
Wire
Cavity
A4
Test: Desiredresult
Test condition
Check{or voltage to ground:
There should be battery voltage.
lgnitionswirchACC(l)
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
0l)
Checkfor voltageto ground:
Thereshouldbe batteryvoltage.
U n d e ra l l c o n d i t i o n s
C h e c kf o r c o n t i n u i ttyo g r o u n d r
T h e r es h o u l db e c o n t i n u i t y .
P c . ' E ' o - - d r G 4 0 1 ,G 4 0 2 )
A- ooen n lhe wire
lgnition key inserted
i n t o t h e i g n i t i o nk e y
swrtch
Check for voltage to ground:
There should be 1 V or less
lgnition key removed
from the ig nition key
swtlcn
C h e c kf o r v o l t a g et o g r o u n d :
T h e r es h o u l db e 4 V o r m o r e
P o o r g r o u n d ( G 4 0 1 ,G 4 0 2 )
Faulty ignition key switch
An open in the wire
Shortin the wire
Un d e ra l l c o n d i t i o n s
C h e c kf o r c o n t i n u i t yb e r w e e . l F e
a u d i o u n i t 1 6 Pc o n n e c t o rl - o 3 l e r m i n a l a n d p o w e r d o o r l o c kc o n t r o l
u n i t 1 2 Pc o n n e c t o rN o . 6 l e r m r n a l :
T h e r e s h o u l d b e c o n t i n ut y
An open in the wire
C e i l i n gl i g h t s w i t c h i n
"middle position"
C o n n e c tt o g r o u n d :
T h e c e i l i n gl i g h r s h o u l dc o m e o n .
B l o w nN o . 4 3( 7 . 5A ) f u s ei n t h e
under-hoodIuse/relaybox
B l o w nc e i l i n gl i g h tb u l b
F a ul t y c e i l i n gl i g h t
A n o p e ni n t h e w i r e
Each door open, one at
a time
C h e c kt o r v o l t a g et o g r o u n d :
T h e r es h o u l db e ' l V o r l e s s .
. Faulty door switch
. An open in the wire
Un d e ra l l c o n d i t i o n s
Connectto groundl
H o r ns h o u l ds o u n d .
. Blown No. 52 ('15A) fuse in the
under-hoodfuse/relaybox
. Faulty horn
. F a u l t yh o r n r e l a y
. A n o p e ni n t h e w i r e
YEL/RED
lgnition switch ON
B6
815
B1
B3
BLK,/YE
L
8LK
BLU/RED
BLUlt/EL
B8
LT GRN/
BLK
814
LT GRN/
RED
Br6
. B l o w n N o . 4 7 ( 7 . 5A ) t u s e i n t h e
u n d e r h o o d f u s e ,r ie l a y b o x
. An open n the w re
LJndea
r llconditions
WHT/BLU
A5
Possible cause if result is not obtained
GRY
Blown No. 28 , I0 A) fuse in the
underdashfuse.elaybox
An open " :ne n re
'.1 - 5 A' iuse n the
B o$. \.
, , ^ o e ' a a s _ ' - s e r e l a yb o x
A_ ooe^ ' :ne wrre
the B connectoronly to the audio unit.
Reconnect
Cavity
B9
l-l
Wire
GRN/ORN
8 1 0 GRNAr'r'HT
Test condition
Test: Desiredresult
Driver'sdoor lock
s w i t c hi n U N L O C K
Checkfor voltageto ground:
T h e r es h o u l db e 1 V o r l e s s .
Driver's door lock
switch in LOCK
Check for voltage to grou nd:
There should be 4 V or more.
Driver'sdoor lock
switchin UNLOCK
Check for voltage to ground:
There should be 4 V or more.
Driver's door lock
switch in LOCK
Check lor voltage to ground:
There should be I V or less.
PossiblecauseiI result is not obtained
.
.
.
.
P o o rg r o u n d1 G 5 5 1 )
Faultydriver'sdoor lockswitch
An open in the wire
S h o r ti n t h e w i r e
.
.
.
.
P o o rg r o u n d ( G 5 5 1 )
Faulty driver's door lock switch
An open in the wire
Shon in the wire
23-263
Power Door Locks
Audio Unit lKeylessReceiver
CircuitlTerminals('96- 98 modelsl
16PCONNECTOR
Wire
Cavity
BLU/RED
LT GRN
Trunklatchswitch
Ft2
BLU/YEL
Unlock(Driver'sdoor)
B4
BLU
LT BLU
B6
L
BLK/YE
*81
B8
B9
ORN
Removethe inner handle(seesection20).
2.
D i s c o n n e ctth e 3 P c o n n e c t o rf r o m t h e d o o r l o c k
switch.
lgnition key switch
Checkfor continuitybetweenthe terminalsin each
switchpositionaccordingto the table.
Valetswitch
Security{lN)
No. 14 (7.5A) fuse
Security(D2)
LT GRN/BLK C e i l i n gl i g h t
GRN/ORN Unlock(All doors)
810
*811
GRNA/VHT Lock(OutPutl
*812
WHT/BLK Security(D0)
YEL/BLU Security(D'l)
+B13
1.
Destination
B1
*82
*85
Driver'sDoor LockSwitch Test
\
Terminal
1
Position
LOCK
UNLOCK
8 1 4 LT GRN/RED Door switch
Ground (G401,G402)
B15
BLK
GRY
norn
*: For securitysystem(option)
23-264
DRIVER'S
DOOR
LOCK
swtTcH
3
o- ----o
OFF
BLU/WHT LEDO
o to
2
o
----o
Driver'sDoor LockActuatorTest
l
1.
Removethe driver'sdoor panel(seesection20).
2.
the 4Pconnectorfrom the actuator.
Disconnect
DoorLodr ActuatorTest
Passenger's
1.
Removethe passenger'sdoo. pa^e see sect o'
201.
2.
the 2P connectorfrom lhq aclualor
Disconnect
NOTE:The front passenger'sdoor lock actualor,s
shown;the left rear and right rear door lock act{,a
tors are similar.
J
of
Terminalside
maleterminals
Terminalsideol maleterminals
3.
Checkfor continuitybetweenthe terminalsin each
knobswitchpositionaccordingto the table.
Terminal
\
F""lti*
- lll
3.
o
LOCK
UNLOCK
4.
\
Checkactuatoroperationby connectlngpower ano
ground accordinglo the table. To preventdamage
to the actuator,apply batteryvoltageonly momentarilY.
Terminal
-ll
Fo"JJ'-lrlon';"
1
LOCK
@
Checkactuatoroperationby conneclrngpower and
ground accordingto the table To preventdamage
to the actuator,apply baneryvoltageonly momentarily.
Terminal
\
,
2
LOCK
O
@
UNLOCK
O
o
Position
4.
lf the actuatorIailsto work properly,replaceit.
o
UNLOCK
l-l
5.
lf the actuatorfailsto work properly.replaceit
23-265
Power Door Locks
TransmitterTest
NOTE:
. lf the doors unlock or lock with the transmitter,but
r oesnot comeon, the
t h e L E Do n t h e t r a n s m i t t e d
LEDis faulty;replacethe transmitter.
. lf any door is open, you cannot lock or unlock the
door with the transmitter.
. lf you unlockedthe doorswith thetransmitter,but do
n o t o p e n a n y o f t h e d o o r s w i t h i n 3 0 s e c o n d s t, h e
doors relockautomatically.
. The doors do not lock or unlockwith the transmitter
if the ignitionkey is insertedin the ignitionswitch.
1.
Usinga keylessentrychecker(07MAJ- SP003001:
. Placethe transmitteron the keylessentry checker, and pressthe transmitterbutton.
- lf the indicatorlight does not come on, check
for:
- a dead or low batterv
- Faultytransmitter
- lf the ray indicatorlight comes on, the transmitteris OK.
ENTRY
CHECKER
KEYLESS
INDICATORLIGHT
TRANSMITTER
NOTE: After a transmitter battery has been
replaced,aim the transmitterat the receiver,and
pressthe transmitterbuttonsix times,
Confirm you can hear the sound of the door lock
actuatorswhen vou pressthe si)dhtime.
23-266
TransmitterProgramming('96- 98 models)
)
Storing TransmitterCodes
.
.
.
The codes of up to four transmitterscan be stored in the control unit. {lf a {ifth code is stored,the code which was
storedtirst will be erased.)
Whenthe systementersthe registrationmode,all previouslysloredcodeswill be erased.
The systemleavesthe registrationmode and returnsto the normalmode if you
- turn the valetswirchOFF,or
- t u r nt h e i g n i t i o ns w i t c hO F F o
,r
- do not pressthe transmitterbuttonfor more than 10 seconds
Procedure:
NOTE:lt is importantto maintainthe time limits betweensteps
Insertthe ignitionkey into the
ignitionswatch.
T u r n t h e i g n i t ; o ns w i t c hO N
flr).
VALETSWITCH
Within 10seconds,go to steP3.
3. Press and hold the valet switch
for at least tive seconds.
(You will hearthe sound of the
a c t u a t o r st u r n a n gt o U N L O C K . )
NOTE:lf the tuner is turned ON, it will
go off and come on againwhen the registrationprocedureis completed-
go to step4.
Within10seconds.
AUDIOUNIT
4. Pressone of the transmitter
buttons,
(Youwill hearthe soundof the
actuators
turningto UNLOCK.i
N O T E : l f y o u w a n t t o r e g i s t e rt h e c o d e s
of more than one transmitter, repeat step
4 within 10 secondswith the next trans'
mitter.
TRANSMTITTER
l-l
NOTE:After storingits code,makesure
t h e t r a n s m i t t e rw o r k s p r o p e r l yb Y
repeatedlypressingone ot its buttons.
(The system starts to work when You
pressany transmitterbuttonsix times-)
23-267
Power Door Locks
('99- 00 modelsl
TransmitterProgramming
Storing transmitter codes;
The codes of up to three transmitterscan be read into
t h e k e y l e s sr e c e i v e ru n i t m e m o r y .( l f a f o u r t h c o d e i s
stored,the codewhich was inputfirst will be erased.)
N O T E : l t i s i m p o r t a n tt o m a i n t a i nt h e t i m e l i m i t s
betweenthe steps.
'1. Turn the ignitionswitchON (ll).
2. Within1 to 4 sec.,pushthe transmitterlockor unlock
buttonwith the transmitter
aimedat the vehicle.
3. Within I to 4 sec.,turn the ignitionswitchOFF.
4. Within 1 to 4 sec.,turn the ignitionswitchON 1ll).
5 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r
u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
6. Within 1 to 4 sec.,turn the ignitionswitchOFF.
7. Within4 sec.,turn the ignitionswitchON (ll).
8 . W i t h i n 1 t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r
u n l o c kb u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
9 . Within 1 to 4 sec.,turn the ignitionswitchOFF.
'10.
W i t h i n4 s e c . t, u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 1 . W i t h i n ' 1t o 4 s e c . , p u s h t h e t r a n s m i t t e rl o c k o r
u n l o c k b u t t o n w i t h t h e t r a n s m i t t e ra i m e d a t t h e
vehicle.
1 2 . Confirm you can hear the sound of the door lock
acIuarors.
W i t h i n 8 s e c . ,a i m t h e t r a n s m i t t e r s( u p t o t h r e e )
whose codesyou want to storeat the receiver,and
pressthe transmitterlockor unlockbuttons.
C o n t i r mt h a t y o u c a n h e a rt h e s o u n d o f t h e d o o r
lockactuatorsaftereachtransmittercode is stored.
1 4 . Turn the ignitionswitchOFF,and pull out the key.
Confirmproperoperationwith the new code(s).
23-268
)
SupplementalRestraintSystem(SRSI
...........24'2
SpeciafTools...
Component/Wiring Locations
......24-3
fndex ................
24-5
................
Description
......."
24'6
Circuit Diagram
Precautions/Procedures
24-7
GenerafPrecautions...............,,,,,,,..
Airbag Handlingand Storage .........24-7
24-8
SRSUnit Precautions......................
InspectionAfter Deployment ........'24-8
.......24'9
WiringPrecautions...................
BackprobingSpring-loadedLock
.......,24-9
Connectors
Spring-loadedLock Connectol ....,,.24-10
Spring-loadedLockConnectorwith
24-10
Built-inShortContact.................
Disconnectingthe Airbag
.....'24'11
Connector(sl
Steering-relatedPrecautions...,.,.,,.24'12
Troubleshooting
2+13
Seff -diagnostic Proctdurcs .............
2+13
Readingthe DTC ..............................
24-15
Erasingthe DTCMcnrory ................
Troubleshooting h.ttnitt.nt
..............24-15
Failures
24-16
....................
SRSU n it ldcntificrtion
Diagnostic Troublc Code (DTC)
24-17
Chart- '96 - 97 Models..."'.".......
Diagnostic Trouble Code (DTCI
'$ - 00 Models '.........""'24'19
ChartSRS lndicaror Light Wire
...'.,24-25
connections
........,,,,.24-26
Ffowcharts
Airbag
...'.'...24-67
Repfacemant
.................24'70
Disposaf
Cable Reel
Repfacement
SRSUnh
Repfacement
.........24'72
..'......24'76
l-l
-
+
sRs
SpecialTools
Ref,No,
o-,
an*r
@
o
/a*,
I
Tool Number
07HAz- SG00500
0 7 P A Z0 0 1 0 1 0 0
0 7 s A z- T B 4 0 1 1 A
0ITAZ- SZ5011A
07TAZ- 001020A
Description
DeploymentTool
SCSServiceConnector
SRSInflatorSimulator
SRSSimulatorLeadC
Backprobe
Adapter,17 mm
* 1r Includedin SRSTool Set 07N4M- SM5000B
*2: Usewith the stackingpatchcordsfrom T/N 07SM
o
4-2
1
1
I
1
2
001000A,BackprobeSet.
6\
o
t,
Oty
I
PageReterence
2 41 0
24-14
24-42
24-42
24-30
Component/WiringLocations
Airbag
Index:With FrontPassenger's
)
LIGHT(ln the gaugeassemblvl
SRSINDICATOR
Troubleshooting,
Page24 13
Gaugeassembly,section23
To HORNSWITCH
CABLEREEL
Replacemenl
page2!-t 2
To DRIVER'SAIRBAG
t
DASHBOARDWIREHARNESS
to SRSINDICATOBLIGHTin
GAUGEASSEMBLY
5P CONNECTOB
DBIVER'SAIRBAG
Beplacement,
page24-61
page24 70
Disposal,
AIBBAG
FRONTPASSENGER'S
Replacement,
Page24_67
Disposal,
Page24 70
SRSMAIN HARNESS
to CABI-ERE€L
2P CONNECTOR
SERVICECHECK
{2PI
CONNECTOR
IBRN,BLK]
SRSMAIN HARNESS
to FRONTPASSENGER'S
AIRBAG
2P CONNECTOB
SRSMAIN
to UNOER-OASH
BOX
FUSE/RELAY
2P CONNECTOR
t,
SRSMAIN HARNESS
to SRSUNIT
r8P CONNECTOR
SBSMAIN HARNESS
to MAIN
WIREHARNESS
3P CONNECTOR
MEMORYERASESIGNAL
(MES)CONNECTOR
I2P)
[GRY,GRYIor IGRN.GRNI
MAIN WIREHARNESS
to DASHBOARDWIREHARNESS
24PCONNECTOR
SRSUNIT
(lncludingsafingsensor
and imPactsensorl
ReplacementPage24 76
2+3
Gomponent/WiringLocations
Index:Without FrontPassenger's
Airbag(someCanadaModelsl
SRSINDICATOR
LIGHT(ln the gaugeassembly)
Troubleshooting,
page24-13
Gaugeassembly,section23
To HORNSWITCH
To CRUISECONTROL
SET/RESUMESWITCH
oo/
\oo
To DRIVER,SAIRBAG
DASHBOARDWIREHARNESS
to SRSINDICATORLIGHTin
GAUGEASSEMBLY
5P CONNECTOR
DRIVER'SAIRSAG
Replacement,
page 24-67
page24-70
Disposal,
SERVICECHECK
CONNECTOR
{2P}
IB8N,BLKI
SRSMAIN HARNESS
SRSMAIN
to UNDER-DASH
FUSE/RELAYBOX
2P CONNECTOR
SRSUNIT
{lncludingsafingsensor
and impactsensor)
Replacement.
page24,76
SRSMAIN HARNESS
to SRSUNIT
18PCONNECTOR
DUMMY RESISTOB
SRSMAIN HARNESS MEMORYERASESIGNAL
(MES)CONNECTON
(2P'
to MAIN
WIRE
IGRY,GRYIo. IGRN,GRNI
HARNESS
3P CONNECTOR
MAIN WIREHARNESS
to DASHBOARDWIREHARNESS
24PCONNECTOR
24-4
SRSUNIT
GROUNO
Description
)
help protectthe driverland
The sRS is a safetydevicewhich,when used in coniunctionwith the seatbelt, is designedto
unit {includingsafing
front passenger)in a frontal impactexceedinga certainset limit. The systemconsistsof the sRS
(and
passenger's
airbag)
front
sensorand impactsensor),the cablereel,the driver'sairbag
FRONTPASSENGEB'S
AIRAAG
DRIVER'SAIRBAG
CABLEREEL
SRSUNtT
Operation
ignitesthe inflatorcharge(s)lf
necessary,
The main circuitin the SRSunit sensesand judgesthe force of impactand, if
and the back-uppower clrcult
regulator
voltage
the
impact,
due to the
batteryvoltageis too low or power is disconnected
will keepvoltageat a constantlevel.
resoectivelv
t
For the SRSto operate:
(1) The impactsensormust activate.and sendelectricsignalsto the mlcroprocessor'
must computethe signals'and must sendsignalsto the airbaginflator(s)'
(2) The microprocessor
and deploythe airbag(s)'
ignite
must
{3) The inflator(s)
_"-_-l
r3B!#h
!..
I
i
I
ffi,*
Self-diagnosisSystem
(ll),the SRSindicatorlight comes
circuitis built into the SRSunit;when the ignitionswitchis turned ON
A self-diagnosis
normally
is
operating
on and goesoff afteraboutsix secondsif the system
driving,it indicatesan abnormallf the liglt does not come on, or does not go off aftersix seconds,or if it comeson while
ity in the system.The systemmust be inspectedand repairedas soon as possible
l,
passeson the inforthe memorywill storethe causeof the malfunctlon,and the data link circuit
For betterserviceability,
PGM TeslerconHonda
with
the
read
(DLC).
can
be
intormation
This
link
connector
mationfrom the memoryto the data
nectedto the DLC(16P).
24-5
Circuit Diagram
IGNITION
SWITCH
UNDER-HOOD
FUSE/RELAY
8OX
WHT/8LI(
+WHT
SBSINDICATOR
CIRCUIT
{lnthe gaugeassembly)
Brake
systsm
light
passenger's
airbag
DRIVER'S
AIRBAG
INFLATOR
lt - - - - l l
II
PGM_FI
DUMMY I
I
BESISTOR
tll
10
16
GRY
(GRN)
14
17
r
13
t5
I
t'7
:
24-6
18
3{VBl
8
GRY
{GRN)
LT8LU
V
7(VAl
9
GRY
IGNN)
I
G40t
G402
6
SRSUNIT
I
BRN
t
.-l\./
BRN
l
.-r\./
DATALINK
ECM/PCM SERVICE
CONNECTOR
CHECK
{DLC)
CONNECTOR
{r6P)
t
l
la rl
MEMORY
ERASE
SIGNAT
IMES)
CONNECTOR
I2P)
SRSUNITTERMINALS
G801
Teminalsideoi thal€terminals
4''
Procedures
Precautions/
GeneralPrecautions
)
r Carefullyinspectany SRS part beforeyou install it Do
not install any part that shows signs of being dropped
or improperlyhandled'suchas dents,cracksor deformation:
- Airbags
- Cablereel
- S R Su n i t
Airbag Handlingand Storage
Do not try to disassemblethe airbag assembly. lt has no
s e r v i c e a b l ep a r t s O n c e a n a i r b a g h a s b e e n o p e r a t e d
(deployed). it cannot be repaired or reused'
For temporary storage of the airbag assembly during service. oleaseobserve the following precauttons:
store the .emoved airbag assemblv with the pad sur) irbag
face uo The driver's(and front passenger'sa
(see
c o n n e c t o ' ' s ' - a s { h a v e )a b u i l t . i n s h o r t c o n t a c t
page 2a-l 1
.
:
-""dd.r6t
| ..r
dtatltt-,tl
force lo c.usa 3a.ix!
r-+r-a k imninncrlv slorcd lace down,
could propel the unit whh enough
intury
Use only a digital multimeterto checkthe system lf
it's not a Honda multimeter,make sure its output ls
1OmA (0.01A) or lesswhen switchedto the smallest
value in the ohmmeterrange.A testerwith a higher
outputcould damagethe airbagcircuitor causeaccidentaldeploymentand possibleinjury'
-
I Do not install used SRS parts from anothervehicle
When makingSRSrepairs,useonly new pans'
AIRBAGCONNECTORS
(Withbuilt in shon contact)
) E x c e p tw h e n p e r f o r m i n ge l e c t r i c ailn s p e c t i o n s '
poslalwaysdisconnectboth the negativecableand
three
least
at
wait
and
battery,
the
tive cable from
minutesbeforebeginningwork
r R e p l a c e m e not f t h e c o m b i n a t i o nl i g h t a n d w i p e r /
w a s h e rs w i t c h e sa n d c r u i s ec o n t r o l s w i t c hc a n b e
donewithout removingthe steeringwheel:
switchreplace
Combinalionlightand wiper/washer
ment,seesection23
- Cruisecontrolsevresumeswitch replacement'see
section23.
-
l,
.
Wheneverthe ignition switch is ON {ll), or has been
turnedOFFfor lessthan three minutes'be carefulnot
to bump the SRSunit; the airbag(s)could accidentall y d e p l o ya n dc a u s ed a m a g eo r i n j u r y '
.
) eenactivated'
W h e n e v e rt h e a i r b a g { s )h a s ( h a v e b
unit.
replacethe SRS
.
Store the removedairbagassemblyon a secureflat
surfaceaway from any high heat source{exceeding
and free of any oil' grease,detergentor
212"FI1OO"CJ
water.
CAUTION: lmproper handling or storage can intern'lJy
damagethe airbag assembly,making it inoperativo
lf you suspect the airbag assembly has been dam€cd'
inslall a new unit. and relsr lo the Deployment/DisPG'l
olocedulesfor disposingol the damaged airbag
2+7
Precautions/Procedu
res
SRSUnit Precautions
Takeextracarewhen paintingor doing body work in
the areabelow the dashboard.Avoid directexDosure
o f t h e S R S u n i t o r w i r i n gt o h e a tg u n s ,w e l d i n g .o r
sprayang
equipment.
D i s c o n n e ctth e a i r b a gc o n n e c t o r ( sb) e f o r ed i s c o n nectingSRSharnessconnectors(seepage24-1|1J.
After any degreeof frontal body damage,or after a
collisionwithout airbagdeployment,inspectthe SRS
unit for physicaldamage.lf it is dented.cracked,or
deformed,replaceit.
Be surethe SRSunit is installedsecurely.
Do not disassemble
the SRSunit.
Store the SRS unit in a cool (lessthan about 104.F/
40"C)and dry (lessthan 80% humidity,no moisture)
place.Do not spill water or oil on the SRS unit, and
keepit awayfrom dust.
During installationor replacement,be carefulnot to
bump (impactwrench,hammer,etc.)the areaaround
the SRSunit. The airbag(s)could accidentally
deptoy
and causedamageor injury.
24-8
InspectionAfter Deployment
A f t e r a c o l l i s i o n l n w h i c h t h e a i r b a g ( s )w a s ( w e r e )
deployed,replacethe SRSunit,and inspectthe following:
1.
Inspectall the SRSwire harnesses.Replace.don,t
repair,any damagedharnesses.
2.
Inspectthe cablereelfor heatdamage.lf thereis any
damage,replacethe cablereel.
3.
A f t e r t h e v e h i c l ei s c o m p l e t e l yr e p a i r e dt,u r n t h e
ignitionswitch on. lf the SRS indicatorlight comes
on for aboutsix secondsand then goes off. the SRS
systemis OK. lf the indicatorlight does not function
properly,go to SRSTroubleshooting.
Wiring Precautions
)
.
Neverattemptto modify,spliceor repairSRSwiring'
NOTE:SRSwiring can be identifiedby specialyellow
outer Protectivecovering.
BackprobingSpring'loaded Lock
Gonnectors
.
When checkingvoltageor resistanceon this type of
to removelne
connectorthe flrst time, it is necessary
wire side.
probes
from
the
insert
tester
to
retainer
NOTE: lt is not necessaryto reinstallthe removed
retainer;the terminalswi I stay lockedin the connector housrng.
8e sureto installthe harnesswiresso that they are not
with otherparts.
oinchedor interfering
RETAINER
* Discardafterremoval.
t
To removethe retainer,insert a flat tip screwdriver
betweenconnectorbody and retainer,and carefully
pry out the retainer.
NOTE:Takecarenot to breakthe connector.
FLATTIP
SCBEWDRIVER
M a k e s u r e a l l S R Sg r o u n d l o c a t i o n sa r e c l e a na n d
groundsare securelyfastenedfor optimum metal-tometalcontact.Poorgroundingcan causeintermittent
problemsthat are difficultto diagnose.
a,
RETAINER
24-9
Precautions/Procedures
Spring-loadedLockConnector
Some SRS system connectors have a spring-loaded lock.
Spring-loadedLockConnectorwith
Built-inShort Contact
Disconnecting
To releasethe lock, pull the spring-loaded sleeve toward
the stop while holding the opposite half of the connecror.
Then pull the connector halves apart.
T h e d r i v e r ' sa j r b a g( a n df r o n t p a s s e n g e r , a
s )i r b a gh a s
( h a v e )a s p r i n g - l o a d e dl o c k c o n n e c t o rw i t h a b u i l r - i n
short contact.When this connectoris disconnected,
the
p o w e rt e r m i n a la n d t h e g r o u n dt e r m i n a li n t h e a i r b a a
connectorare automatically
shoned.
N O T E :B e s u r e t o p u l l o n t h e s l e e v e a n d n o t o n t h e
connectorhalf.
Connectorhalves disconnected:
SPRING-LOADEO
SLEEVE
GROUNDTERMINAL
Do not pull on this
half of the connector.
Connecting
1.
Hold the pawl-sideconnectorhalf, and presson the
backof the sleeve-side
connectorhalf in the direction
s h o w n .A s t h e t w o c o n n e c t o rh a l v e sa r e p r e s s e d
together,the sleeveis pushedbackby the pawl.
SHORTCONTACT
NOTE:Do not touch the sleeve.
CABLEREELCONNECTOR
Conneqtorhalves connected:
GROUNDTERMINAL
Whenthe connectorhalvesarecompletelyconnected,
the pawl is released,and the spring-loadedsleeve
locksthe connector.
SPRING.LOADED
SLEEVE
24-10
the AirbagConnector(sl
Disconnecting
)
th€ negative battery
To prevent sccidental 8irbag deployment, turn th€ ignition switch oFF. disconncct
!@@
"nd *"it thr"e minutes b€fore disconnoctingany sRS conn'ctors'
ffi,
(C' D)'
the SRSmain harness(A)from the SRSunit' disconnectboth airbags
. Beforedisconnecting
.Beforedisconnectingthecab|ereel2Pconnector(B),disconnectthedriver,sairbag2Pconnector(c).
'1. Disconnectthe negativebatterycable,and wait at
leastthree minutes.
t
2.
the airbagconnector(sl.
Disconnect
F ont PasEanga/3Side:
.
Removethe glove box.then disconnectthe front passenger'sairbag2P connectorand SRS main harness
2P connector.
Driver's Side:
.
Removethe accesspanel from the steeringwheel'
then disconnectthe driver'sairbag2P connectorand
cablereel2Pconnector.
FRONTPASSENGER'S
AIRBAG
2P CONNECTOR
CABTTREEL
2?
CONNECTOR
AOCESSPANEL
a,
24-11
res
Precautions/Procedu
Precautions
Steering-related
Stesring Wheel and CableReolAlignment
St€€rin9 Column Removal
NOTE:To avoid misalignmentof the steeringwheel on
reassembly,make sure the wheels are turned straight
aheadbeforeremovingthe steeringwheel.
CAUTION:
. Eefore removing thg stggring column. disconnectthe
connsstor bqtween the cable r€el and th€ SRS msin
harness.
. lf the stoering column is going to be romoved without dismounting th6 stoering wheel, lock the steering by turning the ignition key to o-LOCKposition, or
remove the key trom the ignition switch so that the
steering wheel will not turn.
NOTE:
W h e n t h e a i r b a ga n d c a b l e r e e l a r e d i s c o n n e c t e d ,
don't reconnectthe battery cable. lf the battery is
reconnected
and the ignitionswitch is turned ON (ll),
the SRSunit will storethis as an open in the driver's
airbaginflator,and the SRS indicatorlight will come
on.
For disconnectingthe spring-loadedlock type connector, refer to page24-'10.
Rotatethe cablereelclockwiseuntil it stops.
Then rotate it counterclockwise{approximatelytwo and
a half turns) until the arrow mark on the cablereel label
pointsstraightup.
SRSMAINHARNESS
2PCONNECTOR
Do not replacethe originalsteeringwheelwith any other
design becauseit will make it impossibleto properly
installthe airbag(only use genuineHondareplacement
parts).
After reassembly,confirm the wheels are still turned
straightaheadand that the steeringwheel spokeangle
is correct.lf minor spokeangleadjustmentis necessary,
do so only by adjustingthe tie-rods,not by removing
and repositioning
the steeringwheel.
24-12
:
r
Troubleshooting
Procedures
Self-diagnostic
functionof the SRSsystemallowsit to locatethe causesof systemproblemsand to storethis informa'
The self-diagnostic
this datacan be retrievedvia a data link circuit
tion in memory.For easiertroubleshooting,
I
l
. When you turn the ignitionswitchON (ll),the SRSindicatorwill come on. ll it goes off aftersix seconds.the systemis
n o r m al .
turns
. lf there is an abnormality,the systemlocatesand definesthe problem,storesthis informationin memory,and
off or if the batis
turned
switch
ignition
when
the
memory
even
in
the
remain
will
The
data
light
on.
the sRS indicator
tery is disconnected.
(2P),and turn the ignitionswitchoN (ll),
o when you connectthe scs serviceconnectorto the servicecheckconnector
thesRsindicator|ightwi||indicatethediagnostictroub|ecode(DTC)bythenumberofb|inks.
for this code'
. After readingand recordingthe DTC.proceedwith the troubleshooting
Precauiions
.Useon|yadigita|mU|timetertocheckthesystem'|fit,snotaHondamu|timeter,makesureitsoutputisl0mA(0.
or|esswhenSwitchedtothesma||estva|ueintheohmmeterrange,AtesterwithahigheroUtpUtcouldd
airbagcircuitor causeaccidentalairbagdeploymentand possibleinjury'
be carefulnottobumpthe
r when-everthe ignitionswitchis oN (ll).or has beenturnedoFF for lessthanthree minutes,
injuries
or
damage
cause
and
deploy
accidentally
could
airbags
SRSunit;the
airbag
(and the front passenger's
. Beforeyou ,"n1ou"th" SRS main harness,disconnectthe driver'sairbagconnector
.
.
)
t
connector).
low, measuringvalLleswon t be
Makesure the batteryis sufficientlycharged{seesection23}.lf the batteryis dead or
correct.
and do not connectthe terminals
Do not touch a testerprobeto the terminalsin the sRS unit or harnessconnectors,
with a jumperwire. Useonly the backprobeset or the specialtools'
locktype connectors,referto page24-9'
For backprobingspring-loaded
Readingthe DTC
when the SRSindicatorlight is on, readthe DTCusingone of thesemethods:
A.
follow the tester'sprompts lf the tester
Connectthe HondaPGM Testerto the 16PData Link Connector{DLC),and
indicatesnoDTc,DTcg-1orDTc9-2,doub|e-checkbyjumpingtheservicecheckconnectorandwatchingt
indicatorlight (seenext Page)
HONDAPGMTESTER
l,
Il6PI
DATA LINKCONNECTOR
24-13
Troubleshooting
B. The SRSindicatorlight can also indicatethe DTCby the numberof blinkswhen the SCSserviceconnectoris connected to the servicecheckconnector(2P).
rl
J
1. Turn the ignitionswitchOFF,and wait for ten seconds.Then connectthe SCSserviceconnectorto the servicecheck
connector(2P).lf you do not wait ten seconds,the SRSunit will not be completelyresetand will not outputDTCS.
SERVICECHECK
CONNECTOR
{2PI
IGRY,GRYIor IGRN,cRN]
SCSSERVICECONNECTOR
07PAZ- (m10100
Turn the ignitionswitchON (ll).The SRSindicatorlight comeson for aboutsix secondsand goesoff. Then it will indi,
cate the DTC:
- The DTCconsistsof a main code and a sub-code.
- Includingthe most recentproblem,up to threedifferentmalfunctionscan be indicated.
- In caseof a continuousfailure,the DTCwill be indicatedrepeatedly(seeexample1 below).
- In caseof an intermittent
failure,the SRSindicatorlightwill indicatethe DTCone time,then it will stayon (seeexample2 below).
lf both a continuousand an intermittentfailureoccur,both DTCSwill be indicatedas continuousfailures.
- In casethe systemis normal(no DTC),the SRSindicatorlightwill stayon (seeexample3).
Readthe DTC.
Turn the ignitionswitch OFF,and wait for ten seconds.Then disconnectthe SCSserviceconnectorfrom the service
checkconnector(2P).
2.
3.
4.
Examplesof DTCIndications:
1.
Continuousfallure,SRSIndicatorLightisl
l.-zs
-
Main @de
r
- -
DTC21
Mosrraenr probtsm
- l F M.in code ir)
r
Sub.code (2)
DTCI2
-'l
F
M a r nc o d e ( 1 1
--l
F
S u b c o d et 1 t
DTCl1
Thnd.most recenl
Intermittentfailure,SRSlndicatorLight is:
2.
Lrghr srays on rn ca* ol
DTC5l
N ormal (no failure),SRSIndicator Light is:
3.
ON
No OTC,system is norhal, rhe
sutb chek __.1
penod
24-14
J
Erasingthe DTCMemory
)
T o e r a s et h e D T C ( s f)r o m t h e S R S u n i t , u s e a H o n d a
P G M T e s t e r( s e et h e H o n d a P G M T e s t e rS R Sv e h i c l e
SystemSupplement)or the followingprocedure
1.
2.
Makesurethe ignitionswitchis OFF
Connectthe SCSserviceconnectorto the MES connector(2P).Do not usea jumperwlre.
TroubleshootingIntermittent
Failures
lf therewas a malfunction,but it doesn'trecur,it will be
storedin the memory as an intermittentfailure,and the
S R Si n d i c a t olri g h tc o m e so n .
Afte. checkingthe DTC,troubleshoot as lollows:
1.
.!--J
MEMORYERASE
I2PI
SIGNAL(MESICONNECTOR
IGRY,GRYIor [GRN,GRNI
t
]P,
&
SCSSERVICECONNECTOR
o?PAZ- 0010100
Turnthe ignitionswitchON (ll).
The SRSindicatorlight comeson for about six seconds and goes off. Removethe SCSserviceconnector from the MESconnector(2P)within four seconds
afterthe SRSindicatorlightwent off.
The SRSindicatorlight comeson again.Reconnect
the SCS service connectorto the lvlESconnector
(2P)within the four secondsafterthe SRSindicator
l i g h tc o m e so n .
The SRS indicatorlight goes off. Removethe SCS
s e r v i c ec o n n e c t o rf r o m t h e M E S c o n n e c t o r( 2 P )
within four seconds.
7 . The SRSindicatorlight indicatesthat the memoryis
erasedby blinkingtwo times.
8. Turn the ignition switch OFF,and wait for ten seconos.
"Readingthe DTC"}.
Readrhe DTC{see
E r a s et h e D T C m e m o r y ( s e e
Memory").
" E r a s i n gt h e D T C
3 . With the shifi leverin neutral,turn the ignitionswitch
O N ( l l ) ,a n d l e i t h e e n g i n ei d l e .
4.
The SRSindicatorlight comeson for about six seconds and goesoff.
l * F
ON
--
t
-l
l
takea test
Shakethe wire harnessand the connector,
quick braking,cornering),
drive (quickacceleration,
and turn the steeringwheel fully left and right,and
hold it there for five lo ten secondsto find the cause
failure.
of the intermittent
l f t h e p r o b l e mr e c u r s t, h e S R Si n d i c a t o rl i g h t w i l l
stayon.
-q
6a.c f'-
:q
Problemrecurs,light stayson
SRSindictlor
lighi
MES
conncclot
tcaminals
6.
CONNECTED
failure,the syslf vou can't duplicatethe intermittent
tem is OK at thistime.
DISCONI{ECTED
O,
24-15
Troubleshooting
SRSUnit ldentification
+: On '98 - 00 models,the troubleshootingproceduresare differentfor eachtype
of SRSunit. ldentifvthe SRSunit in the
vehicleusingthe chartbelow,then follow the properflowchanin the followingpages.
'98 - 00 Model SRS units
MAKER
NEC
KEIHIN
SIEMENS
IDENTIFICATION
MARK*
M1
Remark
Driver'sairbagonly
M1
Driver's& Passenger's
airbags
M2
Driver's& Passenger's
airbags
M3
Driver's& Passenger's
airbags
'96 - 97 Model SRSunits
MAKER
NEC
PARTSNUMBER
77960-S04-C81
Remark
Driver'sairbagonly
77960-S04-N81
Driver's& Passenger's
airbags
TAKATA
77960-S04-N82
Driver's& Passenger's
airbags
SIEMENS
77960-S02-A81
Driver's & Passenger'sairbags,
'97 Model
only
LABELIIDENTIFICATION
MARK)
lr
24-16
DiagnosticTroubleCode(DTG)Chart-'96 - 97 Models
l
SRSindicator light
doesn'tcome on
DTC
none
(doesn't
c o m eo n )
none *4
(doesn't
go off)
1-1
Possiblecause
FaultySRSindicatorlightcircuit
Sae page
Troubleshooting
24-26
FaultySRSindicatorlight circuit,internal
failureof SRSunit,faultySRSpowersupply.
24-29
Openin the driver'sairbaginflator
24-42
in the driver'saarbag
lncreasedresistance
inflator
Troubleshooting
24-42
l-3
Shortto anotherwire in the driver'sairbag
inflatoror decreasedresistance
24-44
1-4
Shortto Dowerin the driver'sairbaginflator
24-46
1-5
Shortto ground in the driver'sairbaginflator
24-48
2-1
airbag:
With front passenger's
airbaginflator
Open in the passenger's
airbag:
Withoutfront Passenger's
ODenin the dummy resistor
24-50
24-54
airbag:
With front passenger's
airbag
in the passenger's
Increasedresistance
inflator
airbag:
Withoutfront Passenger's
in the dummy resistor
lncreasedresistance
24,50
24-54
comeson
t
a,
Correctiv6action
2-3
airbag:
With front passenger's
Shon to anotherwire in the passenger's
airbaginflatoror decreasedresistance
airbag:
Withouttront passenger's
Shortto anotherwire in the dummy resistor
or decreasedresistance
2-4
airbag:
With front passenger's
airbag
Shortto power in the passenger's
inJlator
airbag:
Withoutfront Passenger's
Shortto power in the dummy resistor
24-54
24-60
airbag:
With front passenger's
aarbag
Shortto groundin the passenger's
inflator
without front passenger'sairbag:
Shortto ground in the dummy resistor
24-56
24-61
Troubleshooting
24-52
24-59
(cont'd)
24-17
Troubleshooting
Diagnostic
TroubleCode(DTCIGhart-'96 - 97 Models(cont'd)
Possiblgcause
53
Cortestiveaction
I Internalfailureof the SRSunit
S R Su n i t
replacement
lnternalfailureof the SRSunit
SRSunit
replacement
Internalfailureof the SRSunit
Internalfailureof the SRSunit
S R Su n i t
replacement
Internalfailure
of the SRSunitortwo failuresat a
time
8-6*3
J
Internalfailure
ofthe SRSunit
Internalfailureof the SRSunit
FaultySRSpowersupply(VBline)
SRSunit replacement
code (SRSunit must not
be usedany longe.)
NOTE:
* l: In caseof an intermittentfailureDTCg-1,it meanstherewas an internal
failureof the SRSunit or a faultv SRSindica
tor light circuit.Do the troubleshooting
for intermittentfailures(seepage24-15).
*2: lt both DTC9-2and DTC5-1are indicated,do the troubleshooting
for DTCg-2.
*3: Apply to the '97 modelcoupeHX and DX.
*4: DTCcannotbe readwith a HondaPGMTester;checkby jumping
the SCSserviceconnector.
24-18
.
)
TroubleCode(DTC)Chart-'98 - 00 Models
Diagnostic
NECSRSUnit
SRS indicator light
doesn'tcome on
DTC
none
(doesn't
c o m eo n )
none*3
(doesn't
go off)
Possiblecause
Troubleshooting
24-26
FaultySRSindicatorlight circuit,internal
fallureof SRSunit,faultySRSpowersupply
( V Bl i n e )
Troubleshooting
24-34
Troubleshooting
24-39
Open in the driver'sairbaginflator
24 42
in the driver'sairbag
Increasedresistance
inflator
24-42
Shortto anotherwire in the driver'sairbag
inflator or decreasedresistance
Troubleshooting
24-44
't-4
Shortto power in the driver'sairbaginflator
24-46
t-5
Shortto groundin the driver'sairbaginflator
24-48
With front passenger's
airbag:
Open in the passenger's
airbaginflator
Withoutfront passenger's
airbag:
Open in the dummv resistor
airbag:
With front passenger's
airbag
in the passenger's
Increasedresistance
inflator
airbag:
Withoutfront passenger's
in the dummy resistor
Increasedresistance
I r
comes on
with front passenger's
airbag:
Shortto anotherwire in the passenger's
airbaginflatoror decreasedresistance
Withoutfront passenger's
airbag:
Shortto anotherwire in the dummy resistor
or decreasedresistance
2-4
l,
Seepage
F a u l t yS R Si n d i c a t olri g h tc i r c u i t
No DTC*3
( l i sh t
comeson FaultySRSpower supply(VA linel
afterselfdiagnosis)
l-1
Correstiveaction
24-50
24-54
24-50
24-58
Troubleshooting
24-52
24,59
airbag:
With front passenger's
airbag
Shortto power in the passenger's
inflator
Withoutfront passenger's
airbag:
Shon to power in the dummy resistor
24-54
24-60
With front passenger's
airbag:
airbag
Shortto groundin the passenger's
inflator
airbag:
Withoutfront passenger's
Shortto groundin the dummy resistor
24-56
24-61
(cont'd)
24-19
Troubleshooting
DiagnosticTroubleCode(DTC)Chart-'98 - 00 Models{cont'dl
SRSindicator light
DTC
5-1
Possiblecause
CorrectiYeaction
See page
lnternalfailureof the SRSunit
SRSunit
replacemenl
24-76
lnternalfailureof the SRSunit
SRSunit
replacement
24-76
lnternalfailureof the SRSunit
SRSunit
replacement
24-76
lnternalfailureof the SRSunit
SRSunit
reptacement
24-76
Internalfailureof the SRSunit or two failures
at a trme
Troubleshooting
24-62
g _ 1 * r* 3
lnternalfailureof the SRSunit
SRSunit
replacement
24-76
9-2+2 *3
lnternalfailureof the SRSunit
5-4
6-1
6-2
o-5
6-4
7-1
comeson
7-3
8-1
8-2
8-6
10-1
SRSairbagsdeployed(SRSunit must be
reDlaced)
5l|5 Untr
replacement
SRSunit
replacement
24-76
24-76
NOTE:
* 1: In caseof an intermittentfailureDTC9-1,it meanstherewas an internalfailureof the SRSunit or a faulty SRSindicafor intermittentfailures(page24-'15).
tor light circuit.Do the troubleshooting
*2: In caseof an intermittentfailureDTC9-2,it meanstherewas an internalfailureof the power supply{VB line).Do the
troubleshooting
for intermiftentfailures.
*3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.
\
24-20
) r
KEIHINSRS Unit
SRSindicator light
doesn'tcome on
DTC
none
(doesn't
come on)
none*3
(doesn't
go offl
comeson
Correctiveastion
See page
FaultySRSindicatorlight circuit
Troubleshooting
24-26
FaultysRs indicatorlight circuit,internal
failureof SRSunit,faultySRSpower supply
{VB line)
Troubleshooting
24-34
Possiblecau3e
Open in the driver'sairbaginflator
24-42
1-2
in the driver'sairbag
Increasedresistance
inflator
24-42
1-3
Shortto anotherwire in the driver'sairbag
inflatoror decreasedresistance
1-4
Shortto power in the driver'sairbaginflator
24-46
1-5
Shortto ground in the driver'sairbaginflator
24-44
2-1
Open in the passenger's airbag inflator
24-50
airbag
Increasedresistancein the passenger's
inflator
24-50
Shortto anotherwire in the passenger's
airbaginflatoror decreasedresistance
l , . l
I
2-4
Troubleshooting
Troubleshooting
24-44
24-52
airbag
Shortto power in the passenger's
inflator
24-54
airbag
Shortto ground in the passenger's
inflator
24-56
(cont'd)
24-21
Troubleshooting
DiagnosticTroubleCode(DTCIGhart-'98 - 00 Models(cont'd)
SRS indicator light
DTC
5-2
5 3
Possiblecause
Corective action
Seo page
lnternalfailureof the SRSunit
SRSunit
replacement
24-76
Internalfailureof the SRSunit
SRSunit
replacement
24-16
Internalfailureof the SRSunit
SRSunit
reptacement
24-76
Internalfailureof the SRSunit
S R Su n i t
replacement
24-76
Internalfailureof the SRSunit
SRSunit
replacement
24-76
Internalfailureof the SBS unit
SRSunit
reptacemenr
24-76
SRSairbagsdeployed(SRSunit must be
reDlaced)
SRSunit
replacement
24-76
5 4
6-1
6-2
_
64
comeson
n
8l
8S
9 _ 1 * *r 3
10-1
NOTE:
*l: In caseof an intermittentfailureDTC9-1.it meansthere was an internalfailureof the SRSunit or a faultv SRSindicator light circuit.Do the troubleshooting
for intermiftentfailures(pa9e24-15).
*2: In caseof an intermittentfailureDTC9-2, it meansthere was an internalfailureof the power supply(VB line).Do
the
troubleshooting
for intermittentfailures.
*3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.
24-22
) r
SIEMENSSRSUnit
SRSindicator light
doesn'tcome on
DTC
none
(doesn't
c o m eo n )
T r o ub l e s h o o t i n g
24-26
none*3
(doesn't
go ofl)
FaultySRSindicatorlight circuit,internal
failureof SRSunit,faultySRSpowersupply
{VB line)
Troubleshooting
24-34
1-1
in the driver's
Openor increasedresistance
airbaginflator
1-3
Shortto anotherwire in the driver'sairbag
inflatoror decreasedresistance
1-4
Shortto power in the driver'sairbaginflator
24-46
Shon to ground in the driver'sairbaginflator
Openor increasedresistancein the passengers
airbaginflator
24 48
2-1
2-3
,-.
l)
See page
FaulWSRSindicatorlight circuit
comeson
l - J
Corregtiveastion
Possiblecause
24,42
Troubleshooting
24-50
Shortto anotherwire in the passenger's
airbaginflatoror decreasedresistance
2-4
airbag
Shortto power in the passenger's
inflator
2-5
airbag
Shortto ground in the passenger's
inflator
24-44
24-52
Troubleshooting
24-54
24-56
^
t
(cont,d)
24-23
d
Troubleshooting
TroubleCode(DTG)Chart-'98 - 00 Models(cont'dl
Diagnostic
SRSindicator light
DTC
5-4
6-3
6-4
comeson
Possiblecause
Corective action
See page
lnternalfailureof the SRSunit
SRSunit
repracemenl
24-76
lnternalfailureof the SRSunit
SRSunit
reptacemenr
24-76
Internalfailureof the SRSunit
SRSunit
replacement
24-76
lnternalfailureot the SRSunit
S R Su n i t
replacement
24-76
Internalfailureof the SRSunit
S R Su n i t
replacement
24-16
lnternalfailureof the SRSunit
SRSunit
repracemenl
24-76
SRSairbagsdeployed(SRSunit must be
.eplaced)
SRSunit
reptacemenl
24-76
8-1
8-2
8-6
g _ 1 **rr
10-1
NOTE:
*'l: In caseof an intermittentfailureDTC9-1.it meansthere was an internalfailureof the SRSunit or a faulty SRSindicator light circuit.Do the troubleshooting
for intermiftentfailu.es(page24-15).
*2: In caseot an intermittentfailureDTC9-2. it meansthere was an internalfailureof the power supply(VB line).Do the
troubleshooting
for intermiftent failures.
*3: DTCcannotbe readwith a HondaPGMTester;checkby jumpingthe SCSserviceconnector.
24-24
a,
SRSIndicatorLightWireConnections
SRSIndicatorLight Power Circuit
DASHBOARDWIRE HARNESS
C508 -+
To UNDER-DASH
BOX FUSE/RELAY
20PCONNECTOR
To GAUGEASSEMBLY
C41 1, C412 : Terminalsido of mdlo t6rminals
C501, C5O2,C508, C801. C802, C807 : Wi.6 sidcof fomalot.rminals
SRS Indicato. Light Control Circuit
To SRSUNIT
a t
t
I
MAIN WIBE HARNESS
SRSMAIN HARNESS
GRY
BLU
c411
To GAUGEASSEMBLY
O I
C501
C508
C801
C807
2oP CONNECTOR
: DASHBOARDWIRE
HARNESS
: DASHBOARDwlRE HARNESS5P CONNECTOR
2P CONNECTOR
: SRSMAIN HARNESS
: SRSMAIN HARNESS18P CONNECTOR
C802
C412
C41 1
C502
: SRSMAIN HARNESS3P CONNECTOR
3P CONNECTOR
: MAINWIREHARNESS
: MAIN WIREHARNESS24P CONNECTOR
: DASHBOARDWIRE HARNESS24P CONNECTOR
24-25
Troubleshooting
TheSRSIndicatorLight Doesn'tComeOn
CAUTION: Whonever ths ignition switch is ON {ll}, or
has been turned OFF tor less than three minutes. be
careful not to bump the SRS unit; the airbagls)could
accidentallydeploy .nd caus6damage or iniuri€s.
Checktho pow€r supply (fuse):
Turnthe ignitionswitchON (ll),and checkwhetherthe other
indicatorlightscomeon (brakesystem,etc.).
Oo the other indicator liohts como on?
YES
NO
Check th6 fuso:
C h e c k t h e N o . 2 5 { 7 . 5 A ) f u s e i n t h e u n d e r - d a s ht u s e / r e l a y
b"t
ls th6 tu36 OK?
YES
NO
))
Checkthe bulb:
Replacethe No. 25 (7.5A) fuse, and checkthat the
SRSindicatorlightcomeson.
Doosthe SRSindicator liqhl come on7
No
I YES
END
Checktho wire harns b€twecn fus6 and gauge aasambly:
Checkfor an open in the wire harnessbetweenluse
No. 25 {7.5A) and the gaugeassembly,and repair.Check
thatthe SRSindicatorlightcomeson.
Doo. tho SRSindic.tor light como on?
I
I
yEs
No
END
Checktho SRSindicator light bulb:
1. Turnthe ignitionswitchOFF.
2. Removethe gaugeassembly.
3. Checkfor blownSRSindicatorlight butb.
ls the SRSindicator light bulb OK?
YES
NO
Ch.ck the SnS indicator liglrt circuit:
Replacethe bulb, and reconnectthe gauge assembly
connectors.
Thenturn the ignitionswitchON {ll}.
Ooesth6 SRSindicato. llght come on?
I YEs
No
:ND
lAl To page 24-27
24-26
lB'Jfo page24-27
No. 25 (7.5Al FUSE
)
Frompage24-26
(A)
Frompage24-26
(B)
DASHBOARDWIREHARNESS
5P CONNECTOR
check the sRs indicator light circuit:
1. Disconnectthe dashboardwire harness5P connector
from the gaugeassembly.
2. Connecta voltmeterbetweenthe No. 1 terminal(+) of
the 5Pconnectorand ground.
3. T!rn the ignitionswitchON 1ll),and meas!revoltage.
ls there 8.5 V or loss lor six seconds atter the ignition
swilch has beenturned ON {lll?
YES
NO
Faulty SRS indicator light circuit in the gauge e$embly;
replace the SRS printed circuit boa.d in tho gauge
ass€mblY.
I t
Checkthe wire harnessotthe SRSindicator light circuil {1):
'1. Turnthe ignitionswitchOFF.
2. Disconnectthe main wire harness24P connectorfrom
the dashboardwire harness.
3. Connecta voltmeterbetweenthe No. 5 terminal {+) of
the mainwire harness24Pconnectorand 9round
4. Turnthe ignitionON (ll),and measurevoltage.
ls thore 8.5 V or lcss tor tix second3.Itor the ignition
switch has b6en turned ON lll)?
YES
MAIN WIREHARNESS
2,rPCONNECTOR
NO
Short to oower in the BLU wire ol the dashboald wiro
harness;rgpaii the ham€ss.
WIRE
DASHAOARD
HARNESS2irP
CONNECTOR
To page 24-28
ar
c411
(cont'd)
24-27
Troubleshooting
TheSRSIndicatorLight Doesn'tComeOn (cont'dl
Frcm page24.21
MAIN WIREI{ARNESS
3P CONNECTOR
Ch6cktho wire h6rn6s of tho SRSindicator light circuir (21:
1. Turnthe ignitionswitchOFF.
2. Disconnect
the SRSmain harness3P connectorfrom the
mainwire harness,
3. Connecta voltmeterbetweenthe No. 1 terminal(+) of
the SRSmain harness3P connectorand ground.
4. Turnthe ignitionswitchON (ll),and measur€voltage.
13thore 8.5 V or less for 3ir sacond3aftgr tho ignition
switch h.3 b.en turned ON llllT
YES
NO
Short to power in tho BLU wi.e of lhe m.in wiro hrnroas;
r€orir tho ham6as.
SRSMAIN I{ARNESS
3P CONNECTOR
c802
SRSUNIT
Chockthe wi.e harnessotthe SRSindicatorci.cuit l3l:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe banery negativecable. th6n the positive
cable,and wait three minutes.
3. Disconnectthe driver's(and front passenger's)airbagconnector{s}(seopage24-11).
4. Disconnectthe SRS main harness18Pconnectortrom
5. Connecta voltmeterbetwo€nthe No. 6lerminal {+} of
the SRSmain harness18Pconnectorand ground.
6. Turn the ignitionswitchON (ll),and measurevollagg.There
shouldbe 0.5V or less.
SRSMAIN HARNESS
18PCONNECTOR
ls voltago as specified?
SRS MAIN HARNESS1APCONNECTOR
YES
NO
Faultv SRSunh; roplic. the unit l!€e paqo 2+76).
Shoft to Dowar in tha BLU wire ot tho SRS mein h.rn.r3:
reobce the hrlne3s,
24-2a
)
TheSRSlndicatorLightDoesn'tGo Off -'96 - 97 Models
CAUTION: Wheneverthe ignition switch is ON (ll), or has been turned OFFfor less than three minutes, be careful not to
deployand causedamageor iniuries
bump the SRSunit; the airbag{slcould accidentally
Try to reproducelhe SRSindicator light:
1. Erasethe DTCmemory(seepage24'15).
2. Turnthe ignitionswitchOFF,and waitfor ten seconds.
3- Turnthe ignitionswitchON {ll),andcheckthatthe SRSindi
catorlight comeson for aboutsix secondsand goesoff
Doesthe SRSindicEtorlight stay on?
NO
[*
Intermittent lailure, system is OK at this time. See
TroubloshootingInt6rmittent Failureson page 24'15
Ch€ckthe No. 13 {15A} and No. 23 (10A) fuses:
1. Turnthe ignitionswitchOFF.
2 . C h e c kf o r b l o w nN o . 1 3 ( 1 5A ) a n d N o . 2 3( 1 0A ) f u s e si n
box.
the underdashfuse/relay
Are the fuses OK?
vEs
No
Replacethe luses, and erasethe memory
1. Replace
the fuses.
2. Connectthe SCSserviceconnectorto the MES con
nector.
3. Erasethe DTCmemory(seepage24 15).
the SCS
switchOFF,then disconnect
4. Turn the ignitaon
serviceconnectorfrom the MESconnector.
5. Turnthe ignitionswitchON (ll).
Doesthe sRS indicato, tigt t go or "ne. "ii--JJl
l.J
-
I YEs
1
No. 't3 {15Al FUSE
SRS UNIT
NO
END
i
Conlirm the DTC,and continue troubl6shootilg.
Checkfor an open in the SRSmain harness{VA linell
'1. Tu.nthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe driver's (and front passenger's)airbag
(seepage24 11).
connectorls)
'18Pconnectorfrom
4. Disconnectthe SBS main harness
the sRS unir.
the batterypositivecable,then reconnectthe
5, Reconnect
negativecable.
6. Connecta voltmeterbetweenthe No. 7 tetminal (+) of
the SRSmain harness18Pconnectorand ground.
7. Turnthe ignitionswitchon.
SBSMAIN HARNESS18PCONNECTOR
b there battery voltageT
YES
NO
(A)
To page24 30
I I
Open in the SRS main harnessIVA line); replacethe SRS
main harness.
(cont'd)
24-29
Troubleshooting
The SRSIndicatorLight Doesn'tGo Off -'96 - 97 Models(cont'd)
Frcm page 24-29
(A)
SRSUNIT
SRSMAIN HARNESS
18PCONNECTOR
Checkthe SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo.
6 and No.7 with a iumDerwire and
FeultySRSunit or poor cont.ct !tth. SRSftain hsmeis
18Pconnector;ch6ckthe conncctor,
lf the connectoris OK, rcpl.c. tho SRSunh.
To page24-31
07TAZ- 001020A
JUMPERWIRE
Wiresideot femaleterminals
24-30
DASHBOARDWINEHARNESS
)
Frompage24'30
(B)
Checkth. SBSindicatot circuit:
1. Turnthe ignitionswitchOFF.
2. Removothe gaugeassembly.
NoTE: Do n;t disconnectthe dashboardwire harness5P
connsctorlrom the gaugeassembly
3. Turnthe ignitionswitchON (ll).
4. Connectth€ dashboardwire harness5P connectorterminalsNo. 1 and No.5with a jumperwiro.
Doo3th. SRSindicstor light go offf
Fautty SRS indicltot light citouit in th. grugc a$cmbly;
rcpl.ce the SRS ptint.d cilcuit boaJd in thc gtugs
mcsog
A#
I Btu
lYEt
lUUpeA Wtng
Wire side of fomale
terminals
WIREHARNESS
OASHBOARD
5P CONNECTOF
I t
Ch.ck tor a ihort to glound in th. SRS IndioltoJ light cir'
cuit:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe dashboardwire harness5P connector
from the gaugeassemblY
3. Checkresistancebetweenthe No. 1 terminal of the dash
boardwire harness5P connectorand ground.Thereshould
b€ 1 MOor more.
Ch.ck to. an opon in tho SnS indic.tor light circuh:
of the SRS
1. Ch6ck resistanc€between the No 6 terminal
'l
msin harness18Pconnectorand No. terminalot the
dashboardwire harness5P connector;there should be
Wiresideol female
tetmtnals
SRS MAIN HARNESS
lAP CONNECTOR
Wire sideot femaleterminals
(D)
To page 24'33
or
To page 24-33
DASHBOARDWIREHARNESS
5P CONNECTOR
(cont'd)
24-31
Troubleshooting
TheSRSIndicatorLightDoesn'tGo Off -'96 - 97 Models(cont'dl
Frompage24-31
MAIN WIREHARNESS
Ch6ckfor a shon lo ground in tho m.in wire harness:
1. Disconnectthe dashboardwire harness24P connector
from the mainwire harness,
2. Checkresistance
betweenthe No. 5 terminalof the main
wire harness24Pconnectorand ground.Thereshouldbe
1 M0 or more.
Short to ground in the dashboard wire harness; repair
the dashbo..d wire harnoss.
HARNESS
Checkfor a short to ground in the SRSmain h..ness:
1. Disconnect
the SRSmain harness3P connectorfrom the
mainwire harness,
2. Checkresistance
betweenthe No. 1 terminalof the SRS
main harness3P connectorand ground.Thereshorrldbe
1 fu,|0or more.
ls the resistanceas specifisd?
Short to ground in the main wire harnoas;r€pair the
main wire harness.
SRSMAIN HARNESS
3P CONNECTOR
Wire side oI female
terminals
\
24-32
)
DASHBOARDWIBEHARNESS
5P CONNECTOR
Frompage24-31
(Dl
Checklho SRSindicator Gircuitinput voliage:
1. Reconnectthe SRS main harness18Pconnectorlo the
SRSunit.
(+) of
2. Connecta voltmeterbetweenthe No. 1 terminal
ground
and
connector
5P
the dashboard
3. Turnthe ignitionswitchON (ll),and measure
ls there 8.5 V or more six secondsafter lhe ignilion switch
has beenturned ON (lll?
The Droblem h.s disappe.red due to disconnectingantl
connecting the connectors. Be sure all lerminals mako
oood contact, and recheck the syslem lsoe
iroubleshooting Intermittent Failure3on page 2{-151'
Poor contact at the SRSmain h.rn6s 18Pconnector;ch'ck
lI the problem k still present, replacethe SRS main har'
Wiresideof temale
termtnars
Frompage24-31
(El
l r
SRS MAIN HARNESS
18P CONNECTOR
Checkfor an open in the dashboatdwir€ harness:
1. Disconnectthe dashboardwire harness24P connector
from the mainwire harness.
betweenthe No. 6 terminalof the SRS
2. Checkresistance
main harness18Pconnectorand No 5 terminalof the
m a i n w i r e h a r n e s s2 4 P c o n n e c t o r ;t h e r e s h o u l d b e
0 - 1 . 00 .
MAINWIREHARNESS Terminalsideot maletermlnals
24P CONNECTOR
Ooen in tha BLU wire ot the dashboard wire harness;
the dashboardwiie harness.
SRS MAII{ HARI{ESS
laP CONI{ECTOR
Checkfor an open in the main wire harness:
the SRSmain harness3P connectorfrom the
1. Disconnect
mainwire harness.
betweenthe No 6 terminalof the SRS
2. Checkresistance
main harness18Pconnectorand No 1 terminalof the
thereshouldbe 0 - 1 0 o
SRSmainharness3P connector;
ls the resistanceas sp€cilied?
SRS MAIN HARNESS
3P CONNECTOR
. L
ODen in the BLU wire of the main wire hamess; tepair
the main wire harness.
Ooen in the SRS main harness;replacelhe SRS main har
24-33
Troubleshooting
TheSRSIndicatorLight Doesn'tGo Off -'98 - 00 Models
CAUTION: Whenever the ignition switch is ON {ll}, or
has b66n turned OFF for less than three minutes, be
careful not to bump the SRS unit; the airbags coutd
accidentallydeploy and causedamage or iniuries.
Try to reproducethe SRSindic.tor light:
1. Erasethe DTCmemory(seepage24-15).
2. Turn the ignitionswitchON (lt),and checkthat the SRS
indicatorlight comeson for aboutsix secondsand ooes
ol1.
Intormittentlailulo, systomis OK atthistime. SooTrouble
l. o.mittgnl Failuroson paqe24-15.
Checkthe No. 23 (10 Alfuse:
1. Turnthe ignitionswitchOFF.
2. Checkfor blown No. 23 (10 A) tuse in the under,dash
fuse/relaybox.
Replaceihe fus€, and 6.asethe momory
1. Replace
the No. 23 110A) fuse.
2. Erasethe DTCmemory(seepage24,15).
3. Turnthe ignitionswitchON (ll).
No. 23 {10 Al FUSE
FUSE/RELAY
BOX
Doos the SRS indicator light go off after 3ix second3?
Checktor an open in the SRSmsin harness{VB lincl:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait tor threeminutes.
2. Disconnectthe driver's (and front passenger,s)
airbag
(seepage24-11).
connector(s)
3. Disconnectthe SRS main harness18p connectorIrom
the sRs unit.
4. Reconnectthe battery positive cable, then reconnectthe
negativecable.
5. Connecta voltmeterbetweenthe No. 3 terminal (+) of
the SRSmain harness18Pconnectorano qrouno.
6. Turnthe ignitionswitchON {ll).
SRSMAIN HARNESS18P CONNECTOR
(A)
To page 24-35
24-34
)
From page 24-34
(A)
SRSMAIN HARNESS
Chockiho SRSunit:
Connectthe SRSmain harness18PconnectorterminalsNo'
6 and No.3 with a jumperwire and backprobe
Doostho SRSindicator light go off?
Faulw SRSunit or poot co tact at the SRSftain htmes!
18Pconnoctor;chackthe connagtot.
ll tha connoctorb OK roplacalho SRSunit'
SRSMAIN HARNESSI8P CONNECTOR
oid tu3e No. 23 t10 A) blow?
JUMPEBWIRE
(B)
To page24-36
1 )
Chcck for e short to ground in th. SRS indicator lighi circuh:
1. Turnthe ignitionswitchOFF
2. Disconneitthe dashboardwire harness5P connector
from the gaugeassembly.
3. Checkres-ista;cebetweenthe No l terminai ofth€dashboard wire harness5P connectorand ground There
'1
shouldbe M0 or more.
Wiresidgof lemaleterminals
DASHBOARDWIREHARNESS
5P CONNECTOR
ic)
To page 21'31
gtug'
Short to glound in th. gaugs aslomblY; .6plac' th'
DASHBOARDWIREHARNESS
5P CONNECTOR
c508
t of lemale
o!
(cont'd)
24-35
Troubleshooting
The SRS Indicator Light Doesn't Go Off - '98 - 00 Models (cont,dl
Frompage24 35 DASHBOAEDWIREHARNESS
1B)
Check the SRS indicetor circuit:
1. Turn the ignition switch OFF.
2. Bemove the gauge assembly, Do not dlsconnectthe
dashboard wire harness 5P connector from the gauge
assemoly.
3. Turn the ignition switch ON (ll)
4. Connect the dashboard wire harness5P connector terminals No. 1 and No. 5 with a jumper wire.
Doesthe SRSindicator light go om
YES
NO
Faulty SRS indicator light circuit in the 9au96 assembly;
replace the SRS printed circuit board in the gauge
essembly.
Checkfor an open in the SRSindicator light circuit:
r. rurn rne rqnrtonswrtchut-t-.
2 . D i s c o n n e ct h
t e d a s h b o a r dw i r e h a r n e s s5 p c o n n e c t o r
from the gaugeassembly.
3. Checkresistance
betweenthe No. 6 terminalof the SBS
main harness18Pconnectorand No. I terminalof the
dashboardwire harness5P connector;there should be
0 1 . 00 .
ls the resistanceas soecified?
YES
OASHBOARDWIRE HAR'{ESS
5P CONNECTOR
llTf;rv;1c508
.1#
I Bru
lYEr
JUMpERWIRE
Wire sideof female
rerminats
SRSMAIN HARi{ESS
I8P CONNECTOR
c807
NO
Wire sideof femaleterminals
(D)
To page24 38
24-36
(E)
To page24-38
DASHBOARDWIREHARNESS
5P CONNECTOR
)
From page 24-35
(c)
MAIN WIREHARNESS24PCONNECTOR
Checklor a 3hort to glound in tho main wira harno$:
1. Disconnectthe dashboardwire harness24P connector
from the mainwire harness.
betweenthe No 5 terminalofthedash2, Checkresistance
board wire harness24P connectorsnd ground There
shouldbe 1 M0 or more
Short to giound in tha dalhbo!]d wir! ha]n'$; t'plil
lho darhborrd wira hrrnos!.
WIRE
DASHBOARD
HARNESS24PCONNECTOR
DASHEOARDWIREHARNESS
24P CONNECTOR
BLU
Wke side oI female
terminals
l )
MAIN WIBEHARNESS
3P CONNECTOR
Chockfor ! shon to ground in tho SRSmain herness:
the SRSmain harness3P connectorfrom the
1. Disconnect
mainwire harness.
2. Checkresistancobotween the No. 1 terminal of the SRS
main harness3P connectorand ground, There shor,lldbe
3P CONNECTOR
Short to ground in tha main wir6 hainoss; r'Prir the
SRSMAIN HARNESS
3P CONNECTOR
Short to ground in thc SRS main harn6s; leplac' th' SRS
l1'
(cont'd)
24-37
Troubleshooting
The SRS Indicator Light Doesn't Go Off -'98
- 00 Models (cont'dl
Frompage24 36
(D)
DASHBOARDWIREHARNESS
Checkthe SRSindicetor circuit input voltage:
1. Reconnect
the SRS main harnessl8P connectorto the
SRSunit.
2. Connecta voltmeterbetweenthe No. 1 terminal(+) of
the dashboard5Pconnectorand ground.
3 . T u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,w a i t f o r s i x s e c o n d s ,
then measurevoltage,
ls th€re 8.5 V or more?
YES
NO
The problem has disapp€areddue to di3connectingand
conneding the connectors. Be su.e all te.minals make
good contact, and recheckthe system {see T.oubleshooting Inte.miftent Failureson page 24-15).
Poor contact et the SRS main harnass18p connactoricheck
the connector,
. ll the connector is OK, substitute a known-good SRSunit,
and recheck.
' It the problem is still present, replacethe SRS main haF
ness.
DASHBOARDWIRE HARNESS
5P CONNECTOR
c508
Frompage24-36
Checkfor an open in the dashboardwir6 harness:
1. Disconnectthe main wire harness24P connectorfrom
the dashboardwire harness.
2. Checkresistance
betweenthe No. 6 terminalof the SRS
mainharness18Pconnector
and No.5 terminalof the main
wireharness
24Pconnector;
thereshouldbe 0 - 1.00.
ls the resistanceas 3pecitied?
YES
SRSMAIN HARNESS
18PCONNECTOR
c807
NO
c41 l
Open in the BLU wire ot the dashboardwire harness;
repair the dashboardwire harness.
Checktor an open in the main wire haanoss:
1. Disconnect
the SRSmain harness3P connectorfrom the
main wire harness.
2. Checkresistance
betweenthe No. 6 termanalof the SRS
mainharness18Pconnector
and No. 1 terminalof the SRS
main harness
3Pconnector;
theresho!ld be O- l.O0.
ls the resistancea! specified?
YES
Open in the SFS main hrrness; replacethe SRS main harness.
\
SRSMAIN HARNESS
18PCONNECTOR
NO
Open in the BLU wire of the m.in wire ha.ness: .eoair
the main wire harness.
24-38
Terminalsideof malelerminals
cao2
SRS MAIN HARNESS
3P CONNECTOR
No DTC-'98 - 00 Models
CAUTION:Wheneverthe ignition switch is ON (ll), or
has been turned OFF for less than three minuies. be
careful not to bump the SRS unil; the airbags could
accidentallydeploy and causedamageor iniuries
Checkthe tuse:
CheckIor blown No 13 {15 A) fuse in the underdash fuse/
(A)To page24'40
Beplacethe fuse.Turnthe ignitionswitchON (lll, and check
that lhe tusedoesn'tblow
The oroblem has disappeared.Test'drivethc vehicleand
s6e Troubleahoodng lntermittent Failureson pago 2&15
No. 13 {15A) FUSE
. J
Check for short to ground betweon the under-dash fuse/
relav box end the SRS unil
1 . T L r r nt h e i g n i t i o n s w i t c h O F F
2, Disconnect the battery negative cable, then drsconnect
the positivecable,and wait for three minutes'
3. Disconnect the driver's {and front passenger's airbag)
c o n n e c t o r { s ){ s e e P a g e 2 4 _ 1 1 )
4. Disconnect the SRS main harness 18P connector irom
5 . C h e c k r e s i s t a n c eb e t w e e n t h e N o 7 t e r m i n a l o f t h e S R S
m a i n h a r n e s s 1 8 Pc o n n e c t o r a n d g r o u n d
There should be 1 M0 or more
sRs MAIN HARNESS
FauftySRSuniu replacethe SRSunii (seepage 21-761'
O1'
(8)
To page24 40
(cont'd)
24-39
Troubleshooting
No DTG-'98 - 00 Models(cont'dl
trom page24 39
(Bi
Checkfor short to ground in iho SRSmain ha.no$:
1. Disconnect
the SRSmain harness2P connectorfrom the
fuse/relay
under-dash
box.
2. Checkresistance
betweenthe No. 7 terminalof the SFS
main harness18Pconnectorand ground.Thereshould
be 1.0MO or more.
ls lha r6i3tlnce
as sp.cilied?
YES
NO
Short to ground in the und..-d.sh tu3a/r.lay box;
roplacethe undsr-dlrh tu!6/rahy box.
Short to ground in fho SRS main harness;rsplecc the SRS
main htrnors.
SRSMAIN HARNESS
2P CONNECTOB
FUSE/RELAY
BOX
SRSMAIN HARTESS
18PCONNECTOR
c807
(A)Frompage24 39
Wir€ side ot fsmale
terminals
Checklor an open in the SRSmain harn€ls:
1- Turntho ignitionswitchOFF.
2. Disconnectthe bafterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe driver's (and front passenger's)
airbag
(seepage24-11).
connector(sl
4. Disconnectthe SBS main harness18Pconnectortrom
the sRs unit.
5. Reconnect
the batterypositivecable,then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 7 terminalol the
SFS main harness18Pconnectorand qro!nd.
7. Turnthe ignitionswitchON (ll),and measure
Poor contact rt the SRS main harness 18P conn.ctor:
chockth€ connectoi.
. ll th. connector is OK, iubstitute a known-good SRS
unit, and recheck.
. lf tho pioblem is still pres6nt. replace the SRS mlin
haanos3.
To page24.41
24-40
SRS MAIN HAR ESS
lAP CONNECTOR
c807
)
Frompage24-40
Checkfor an open in the SRSmain harn6s:
1. Turnthe ignitionswitchOFF.
the SRSmain harness2P connectorfrom the
2. Disconnect
under-dashfuse/relaybox
betweenthe No. 1 terminalol the SRS
3. Checkresistance
main harness2P connectorand No. 7 terminal of the
SRSmain harness18Pconnector.
T h e r e s h o u l d b e0 5 O
ls the resistancees specitied?
YES
NO
Poor contact at the SRS main hatness2P connector;
checkthe connector. It the connector i3 OK, substitute a known-good und€rdash fuse/relav box, and recheck.
.ll the Droblemi5 still pres€nt,replacelhe SRS main
harness.
BOX
FUSE/RELAY
SRSMAIN HARNESS
18PCONNECTOR
c807
Open in the SRS main hsrness; leplaco the SRS main harness.
)
Wire side of female
terminals
SRSMAIN HARNESS
2P CONNECTOR
lrt
24-41
Troubleshooting
DTC1-1and DTG1-2
CAUTION:Wheneverthe ignition switch is ON 0l), or
has been turned OFF for le33 than three minutes, be
careful not to bump the SRS unit; the airbagls) could
accidentallydeploy and causedamage or inluries.
DRIVER'SAIRBAG
Try to reproduc€the SRSindicator light:
1. Erasethe DTCmemorylseepage24,'15).
2. Turnthe ignitionswitchON {ll),andcheckthatthe SRSindicatorlight comeson lor aboutsix secondsand goesoff.
Doesthe SRSindicator liqht 3tav on?
REEL
Intermittent lailure. system is OK at this time. So€Tlouble
Intermittent Failur6 on Deqe24-15.
2P CONNECTOR
AZ - SZ5011A
Checkfor en open in th€ driver's airbag inllator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnectthe
positivecable,and wait for three minutes.
3. Disconnectthe driver'sairbag2P connectorfrom the cable
reel 2P connector.
CAUTION:Do not disconnectthe pa9,!eng6.,s
ailbag connector.
4. Connectthe specialtool {2 0)to the cablereel2P connec,
tor.
5. Reconnectthe battery positive cable, then reconnectthe
negativecable,
6. Erasethe DTCmemory{seepage24 15}.
7. Readthe DTC{seepaqe24-13).
ls OTC1-1 or DTC1-2 indicatod?
07sAz-TB{0t1A
t2 0 JACKT
-
Open or incroas€dresistanc€in the driver's ai.bag inoator; r€place the d ve/s airbag lse6 pege 24€?).
SRSMAIN HARNESS
Checkfor an opgn in the cabl6 reel:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnect
the specialtool {2 O) from the cable reel 2p
connector,
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SRSmain harness.
4. Connectthe specialtool {2 0} to the SRS main harness
2P connector,
{cont,
CABLE
REEL
2PCONNECTOR
07TAz- SZ5011A
To page 24-43
(2 0 JACK)
24-42
l !
)
From page 24-42
Checkfor an opgn in the cabl6 reel (cont'd):
5. Reconnectthe battery positive cable,then roconnectthe
negativecable.
6. ErasetheDTCmemory(seepage24 15i
7. Readthe DTC(seepage24-13).
l. DTC1-l or DTC1-2 indicrt.d?
Opan or incraGad rcsbtanca in tha crbla raal; rapllca
1 J
Chccklor .n oDcn in th. SBS mtin harne$i
1. Disconn€ctthe battery negative cabl€, then disconnect
the positivecable,and wait tor threeminutes
2, Disconnectthe lront passgnger'sairbag connoctorfrom
the SRSmain harness(with front pssseng€r'sairbag).
3. Disconnectthe SRS main harn€ss18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool {2 0)
from the SRSmain harness2P connector.
4. Checkresistancebetlveonterminals No. 1 and No 13 ot
the SRSmain harness18Pconnector.
Thereshouldbe approx.2.0- 3.0O.
Poor contact rt tha SRS main harna*t 18P connactor;
chack tho clnnactot,
. It th. conn.ctol b OK. tubttitut. a known-good SRS
unit. end rcchock.
.lf the problem is still prcsent, replace tho SRS main
harnoss.
Ooen or incr6asadr.si3tlnca in tha SRS mlin hatnaar;
lfr
24-43
Troubleshooting
DTC1-3
CAUTION:Wheneverthe ignition switch is ON {lll, or
has been turned OFF lor less than thrEe minutes, be
caroful not to bump the SRS unit; the airbag(s)could
accidenlallydeploy and causedamage 01 iniuries.
DRIVER'SAIRBAG
ASSEMALY
TrVto reproducethe SRSindicator light:
1. Erasethe DTCmemory(seepage24-15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi
catorlight comeson for aboutsix secondsand goesoff.
Doesthe SRSindicalor light stav on?
YES
NO
Intermittent lailure. system is OK ai this tim€. Se€Troubl€shooting Intermittent Failureson page 24-15.
REEL
2P CONNECTOR
AZ - SZ5011A
Checktor a short lo another wire in the drivo.'s eirbrg in{la1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2P connector,
CAUTION:Do not disconnectthe passenger'sairb.g
connector,
4. Connectthe specialtool (2 0)to the cablereel2P connec
tor,
5. Reconnectthe baftery positive cable, then reconnectthe
negativecable,
6. Erasethe DTCmemory(seepage24 15).
7. Readthe DTC(seepage24-13).
ls DTC1-3 indicated?
YES
07saz- TB4011A
{20 JACK)
NO
Shon in the driver's airbag intlator; replacethe driver's airbag {seepage 24-67}.
SRSMAIN HARNESS
CABLE
REEL
2P CONNECTOR
Check lor a short in the ceble reel:
1. Disconnect the battery negative cable, then disconnect
the positivecable,and wait for three minutes.
2. Disconnectthe special tool (2 O) from the cable reel 2p
07TAZ- SZ5011A
3. Remove the dashboard lower cover, and disconnect the
cable reel 2P connector from the SRS marn naroess.
4. Connect the special tool (2 O) to the SRS main harness
2P coonector.
{cont,di
fo page24-45
07sAz- TBr011A
t2 0 JACKI
24-44
)
Ftom page 24-44
Check for a shon in the cable reel lcont'dl:
5 , R e c o n n e c tt h e b a t t e r v D o s i t i v e c a b l e , t h e n r e c o n n e c t t h e
n e g a t i v ec a b l e .
6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 ) .
7. Readthe DTClseepage24'13).
Short in the cable reel; replacethe cable reel (see
page 21-721.
SRSUNIT
I J
Ch€cktor a shon in the SRSmain harness:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe front passenger'sairbag connectorfrom
airbag).
the SRSmain harness(withfront passenger's
3. Disconnectthe SRS main harness18Pconnectortrom
the SRS unit. Do not disconnectthe specialtool (2 0)
from the SRSmain harness2Pconnector.
4. Checkresistance
betweenterminalsNo. 1 and No. 13 of
'18P
the SRSmain harness connector.
Thereshouldbe aDorox.2.0- 3.00.
SRSunit; replacelhe SRSunit lsee ptge 21-
Short in the SRS m.in ha.ness; roplace the SRS mein hal-
o1|
24-45
Troubleshooting
DTC1-4
!
CAUTION:Wheneverths ignition 3wiich is ON {lll, or
has boen turned OFF tor loss than three minutes, bs
caroful not to bump the SRS unit; the airbagls) could
accidoDtallydeploy and causedamage or iniulies.
DRIVER'SAIRBAG
Try to roproduc. the SRSindic.lor lightr
1. Erasethe DTCmemory(seepage24-15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlightcomeson tor aboutsix secondsand goesoff.
Ooes th6 SRS indicltor liqht stey on?
YES
NO
Intermitid{ failure, 3y3tem b OK at this time. S€e Troubloshooting Intormittont Failursson pago24.15.
CABLEREEL
2P CONNECTOR
Checkfor a 3hort to powo. in the d.iver's .irbag inflator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe bafterynegativecable,then disconnect
the positivecable,and wait for three minut6s.
3. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2P connector.
CAUTION: Do not disconnoct the parsengcr'r airbag
connactoa.
4. Connectthe SRSserviceconnector(2 O)to the cablereel
2P connector.
5. Reconnect
the batterypositivecable,then reconnectthe
negativecable.
6. ErasetheDTCmemory(seepage24-15).
7. Readth6 DTC{seopage24-13},
ls OTC1-4 indic.tedT
YES
07SAZ- TB,()11A
(2 0 JACKI
NO
Short to pow.r in the driver'i rirbrg inilrtor; r€pl.co
the driver'! airbag l!e. paga 24-67).
SRSMAIN HABNESS
CABLE
REEL
2PCONNECTOR
Checkfor a ahort to Dow€r in tha crblo.eet:
1. Disconnectthe batterynegativecabl€,then disconnect
the positivecable,and wait for threemrnur€s.
2. Disconnect
the specialtool (2 O) trom the cable reel 2P
cononector.
3. Bemovethe dashboardlower cover,and disconnectthe
cablereel2P connectortrom th€ SRSmain harness.
4. Connectthe specialtool 120) to the SRSmain harness
(cont'd)
2P connector.
07TAZ- Szsol'lA
fo page 24-47
t2 0 JACK)
24-46
)
Frompage24-46
Chockfor a short to power in the cabls roel lcont'dl:
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemorylseepage24-15).
7. Readthe DTC(seepa1e24-131.
b DTC1-4 indicat€d?
YES
NO
Short to power in tho cable reel; roplac. tho cable reel
lsee Dase24-721.
SRSUNIT
I J
Chockfor e short to powot in the SRSmain hornoas:
1.Disconnectthe batterynogativecable,then disconnect
the positivecable,and wait for threeminutes.
airbagconnectorlrom
the front passenger's
2- Disconnect
the SRSmain harness(with front passenger'sairbag).
3. Removethe specialtool (2 0) trom the SRSmain harn€ss
2P connector.
/t.Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
5. Reconn6ctthe battery positive cable,then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 1 {+i terminalof
the SRSmain harness18Pconnectorand body ground.
7. Turn the ignilion switch ON lll), and measurevoltage
Thereshouldbe 0.5V or less.
8.Turnthe ignitionswitchOFF.
9. Connecta voltmeter between the No. 13 (+) torminal ol
the SRSmain harness18Pconnector8nd body ground.
lO.Turn the ignition switch ON (ll), and measurevoltage
Thereshouldbe 0.5V or less.
Aro voltrges a3 specified?
YES
NO
FauftvSRSunh; roplacctho SRSunh {soepago 2+761'
Short to power in the SRS main h.rness; .eplace rhe SRS
main harness.
a0
24-47
Troubleshooting
DTC1-5
J
CAUTION:Wheneverthe ignition switch is ON {ll). or
has been turned OFF for less than three minutes, be
caretul not to bump ths SRS unit; the airbag(slcould
accidentallydeploy and causedamage or iniuries.
DRIVER'SAIRBAG
2P CONNECTOR
DRIVER'SAIRBAG
ASSEMBLY
Try to rep.oducethe SRSindicator light:
1. ErasetheDTCmemorv(Seepage24'15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi
catorlight comeson tor aboutsix secondsand goesoff.
Ooes the SRS indicator light stay onl
YES
NO
REEL
Intermittentlailure,systemis OK at this time. SeeTroubleshooting lntormittent Failure3on page 24-15.
2P CONNECTOR
AZ - SZ5011A
Check for a short to ground in lh€ driver's airbag inllator:
1. Turn the ignition switch OFF.
2. Disconnect the battery negative cable, then disconnect
the positivecable,and wait for three rninutes.
3. Disconnect the driver's airbag 2P connector from the
cable reel 2P connector.
CAUTION: Do not disconnect tho p.ssenger's airbag
connectoa.
4. Connectthe specialtool (2 0)to the cable reel 2P connec
tor.
5 . R e c o n n e c tt h e b a t l e r y p o s i t i v e c a b l e , t h e n r e c o n n e c t t h e
negativecable6 . E r a s et h e D T C m e m o r y ( s e e p a g e 2 4 - 1 5 ) .
7 . R e a dt h e D T C ( s e e p a g e 2 4 - 1 3 1 .
I
07sAz- TB40't1A
(2 0 JACK)
ls OTC1-5 indicatedT
YES
NO
Short to ground in the drive/s airbeg inflator; r€pl.ce the
driver's.iib.g (see page 24d1.
SRSMAIN HARNESS
2P CONNECTOR
CABLE
REEL
2PCONNECTOR
Checklor a short to ground in the csble reer:
l. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnect
the specialtool {2 (}) from the cable reel 2P
3. Removethe dashboardlower cover,and disconnectthe
cablereel2P connectorfrom the SRSmain harness.
4. Connectthe Specialtool {2 0} to the SRS main harness
2P connector(cont'd).
07TAZ- SZ5011A
To page 24-49
{2 0 JACK)
24-44
. I
)
Frompage24-48
Checkfor a ahort to ground in th. cabl. r.el (cont'd):
5. Reconnectthe battery positive cable, then reconnectthe
nagativ€cable.
6. Erasethe DTCmemory(seepage24-15).
7. Readthe DTC(seepage24-13).
b DTC1-5 indicli.d?
YES
NO
Short to ground in tho crblc rocl; rophce the crble roel
k c orsa 2+721.
T J
Chockfor e short to ground in tha SRSmain harneas:
1. Disconnectthe batterynegativecable,then disconnoct
the positivecable,and wait lor three minutes.
2. Disconnectthe tront passenger'sairbag 2P connector
from the SRS main harnsss {with front passeng€r's
airbag).
3 Romovethe specialtool(2 0)trom th6 SRSmain harness
2P connoctor,
4. Ch€ckresistancebetween the No. 1 terminal of the SRS
main harness18Pconnectorand ground.and betwgen
connecthe No. 13terminalofthe SRSmain harness'l8P
tor and grouncl.
Thereshouldbo I Mo or more,
la tha raidrnc!
SRSUN]T
.3 rDccified?
YES
NO
Flulv SRSunit rcpl.c. th. SRSunit {r€e prg.2+161,
Shon to ground in th. SRS m.in h.rno$; r.pl.ce tho SRS
main harnaas.
Ir,
24-49
Troubleshooting
DTC2-1and DTC2-2- With FrontPassenger's
Airbag
I
CAUTION: Whenever the ignition switch is ON (ll), or
has been turned OFF for less than thr€e minutes, be
careful not to bump th€ SRS unit; the airbags could
accid€ntallydeploy and causedamage 01 iniuries.
Try to reproducethe SRSindicator light:
1. Erasethe DTCmemory(seepage24-15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlight comeson for aboutsix secondsand goesoff.
Doesthe SRSindicator liqht stay on?
YES
NO
FRONTPASSENGER'S
AIRBAG2P CONNECTOB
Int€rmitl€nl failure, sFtem is OK at thb time. Soe Troubleshooting Intermittent Failureson page 24-15.
Checktor an open in the pmi€nger's airbag inflator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then discohnect
the positivecable,and wait tor threemanutes3, Disconnect
the front passenger's
airbagconnectorlrom
the SRSmain harness{seepage24.1...
4. Connectthe specialtool (2 0) to the SRS main harness
2P connector,
CAUTION: Do not disconnectthe driver's airbag connectot,
5. Reconnectthe battery positive cable, then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24-'!5).
7. Readthe DTC(seepage24-13).
ls DTC2-l or DTC2-2 indicated?
YES
MAIN HARNESS
- sz50r1A
NO
07sAz- TB4011A
{2 0 JACK}
Opon or increasedrosistancein the pa$enger's airbag
inflator; replacetho pass€nqor'sairbaq lsee paEJe2a$71.
Io page24-51
o1
24-50
Frompage21 50
Checkfor an open in the SRSmain ha.ness:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threemrnrrtes
2. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2Pconnector(seepage24 11)
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRS unit. Do not disconnectthe specialtool (2 0)
fromthe SRSmainharness2P connector'
betweenthe No. 10terminaland No. 14
4- Checkresistance
terminalof the SRSmain harness18Pconnector'There
shouldbe apProx2 0 3.00
ls the resislanceas specified?
YES
SRSUNIT
NO
Poor contact at the SRS m.in harness 18P connector;
checkthe connector'
. ll the connector is OK, substituto a known_goodSRS
unh. and rccheck,
.lf the probl€m is still present, replace th€ SRS main
narness,
SRSMAIN
18PCONNECTOR
. J
Ooen or incretsed resistancein the SRS m.in harness;
replac6the harness.
l 0
24-51
Troubleshooting
DTC2-3- With FrontPassenger's
Airbag
Whaneverihe ignhion switch is ON lll), or
CAUTIONT
has been turnod OFF lor le33 than threo minutes. be
careful not to bump lhe SRS unit; ths airbags could
accidontallydeploy lnd causedamage or inluries.
Try to reproducetho SRSindicator light:
1. Erasethe DTCmemory (seepage24 15).
2. Turnthe ignitionswitchON 1ll),andcheckthatthe SRSindi,
catorlight comeson for aboutsix secondsand goesoff.
Doe3the SnS indicator light 3t.y on?
YES
NO
Intermittort tailura, 3y3tem b OK at this time. S€e Troubleshooting Intormittent Failuroson page 24-15.
FRONTPASSENGER'S
AIRBAG2P CONNECTOR
Checktor a 3hort io another wire or dec.oasodrelirtanct in
th6 passonger'sairbag inflato.:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the Dositivecable,and wait for threeminutes.
3. Disconnectthe tront passenger'sairbag 2P connector
from the SFS main harness(seepage24-11).
4. Connectthe specialtool (2 O) to the SRS main harness
2P connector.
CAUTION:Do not disconn€ctth6 driver's airbag connector.
5. Reconnectthe baftery positivecable, then .econnecttho
negativecable.
6. Erasethe DTCmemory{seepage24-15).
7. Readthe DTC(seepage24 13).
l. DTC2.3 indicated?
YES
- szsorla
NO
Short io another wiao or d€creasedrcsi3tanc6in the prs3enger's airbag intlator; repl.ce the passong.r's .irbag
lsee page 2467).
{2 0 JACK)
To page 24-53
24-52
l
)
Frcm page 24-52
Checktor a short to another wira or docroasedtesistancoin
th€ SRSmain hamess:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait tor threemanutes.
2. Disconnectthe driver's airbag 2P connectorfrom the
cable reel 2P connector.
3. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit. Do not disconnectthe specialtool (2 0) Irom
the SRSmain harness2P connector.
betweenthe No. 10terminaland No. 14
4. Checkrosistance
terminalof the SRSmain harness18Pconnoctor.There
shouldbe approx.2.0- 3.0f).
SRSMAIN HARNESS
18PCONNECTOR
) J
Itt
24-53
Troubleshooting
DTC2-4- With FrontPassenger's
Airbag
J
CAUTION:Wheneverthe ignition switch is ON lll), or
has been turnod OFF for less than throa minutes, be
car.Iul not to bump the SRS unit; the airbags could
accidentally
deployand causedamageor iniuries.
Try to r€producethe SRSindicalor light:
1. Erasethe DTCmemory(seepage24 15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindi
catorlightcomeson Ior aboutsix secondsand goesoff.
Doesthe SRSindicator light stay on?
YES
NO
lDtermittenl failure, syltom b OK at this tima. S€eTrouble.
shooting Int€rmittent Failuroson page 24-15.
Checklor a short to pow6r in the passenger'sairbag intlator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
3. Disconnectthe front passenger'sairbag 2P connector
from the SRSmain harnesslseepage2/t 11).
4. Connectthe specialtool (2 O) to the SRS main harness
2P connector.
CAUTION: Do not disconnectthe driver's airbag connector.
5, Reconnect
the batteryposit;vecable,then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24-15).
7. Beadthe DTC(seepage24-13).
ls OTC2-4 indicatod?
YES
NO
MAIN HARNESS
AZ - SZ5011A
Short to power in the passenger'sairbag inflator; replace
tho passenger'sairbag lsee page 24-67)
To page24 55
24-54
07sAz- TB4011A
120 JACKI
)
Ftom page 24-54
Checklor e short to power in lhe SRSmain harness:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait Ior threeminutes.
2. Disconnectthe driver's airbag 2P connectorlrom the
cablereel2P connector.
3. Disconnectthe SRS main harness18Pconnectortrom
the sRs unit.
4. Removethe specialtool (2 o) from the SRSmain harness
2P connector,
5. Reconnectthe baftery positive cable,then reconnectthe
negativecable.
6. Connecta voltmeterbetweenthe No. 10 (+) terminalof
SRSmain harness18Pconnectorand ground.
7. Turn the ignitionswitch ON lll), and measurevoltage
Thereshouldbe 0.5V or less.
L Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18Pconnectorand ground,and
measurevoltage.Thereshouldbe 0.5V or less.
SRS UNIT
A16 voltages as specified?
YES
NO
FauftvSRSunit; repl.ce the SRSunil (seeptge 24-761
1 J
Shon to power in th. SRS main harness;roplace the SRS
main hanes3,
Itt
24-55
Troubleshooting
DTC2-5- With FrontPassenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0l). or
has b€6n turned OFF tor loss than three minutes. be
careful not to bump tho SRS unit; th€ airbags could
accidentallydeploy and causedamage or injuriss.
T.y lo reproducethe SRSindicator light:
1. Erasethe DTCmemory(seepage24,15).
2. Turnthe ignitionswitchON l), and checkthatthe SRSindicatorlight comeson for aboutsix secondsand ooesoff.
Intermiftem f.ilure, ty3tom ir OK at this timo. See TroubleIniermittent Failuro3on paqe24-15.
FRONTPASSENGER'S
AIRBAG2P CONNECTOR
Check to. a short to g.ound in the passenger,sai.bag inflator:
1. Turnthe ignitionswitchOFF.
2. Disconnectthe batterynegativecable,then disconnect
the poshivecable,and wail for threeminutes.
3. Disconnectthe fronl passenger,sairbag 2p conneclor
lrom the SRSmain harness{seepage24 l t ).
4. Conneclthe specialtool (2 0) to the SRS main harness
2P connector,
CAUTION: Do not disconnectthe drivor,sairbag connec_
tor.
5. Reconnect
the batterypositivecable,then reconnectthe
negativecable.
6. Erasethe DTCmemory(seepage24 15).
7. Readthe DTC {seepage 24-13).
tl
MAIN HARNESS
AZ - SZ50114
Short to ground in the p8,s€nger,sai.bag infleto.; replaoe
rhe passenger'sairbag ls€opage24{7).
To page 24-57
07sM - TB4011A
{2 0 JACK)
o!
24-56
I
)
From page 24-56
Checklor a short to ground in tha SRSmain haino$:
1. Disconnectth€ batterynegativecable.then disconnect
the positivecable,and wait for threeminutes
2. Disconnectthe driver's airbag 2P connectorfrom the
cable reel 2P connector'
3. Disconnectthe SRS main harness18Pconnectorfrom
the sRS unit.
4. Removethe specialtool (2 0) from the SRSmain harness
2P connector,
5. Checkresistanceb€tweenthe No. 10 terminal ol the SRS
main harness18Pconnectorand ground,and between
the No. 14terminalot the SRSmain harnoss18Pconnec
or more'
tor and ground.Thereshouldbe 1 N/10
k tho rod.tanco .3 3pocified?
YES
SRSUNlT
SRSMAIN HARNESS
18PCONNECTOR
NO
FaultySRSunit; topl.co the SRSunit (seopage 24-761'
Short to giound in the SRS msin hamets; replaccth€ SBS
main harno33.
O l,t
24-57
Troubleshooting
DTC2-1and DTC2-2- WathoutFrontPassenger's
Airbag
I
CAUTION:Wheneverthe ignition switch is ON {lll. or
has been turned OFF tor less than three minutes, be
caretul not to bump the SRS unit; the aidag could accidentallydeployand caussdamageor iniuries.
Try to reproduc€the SRSindicator light:
1. Erasethe DTCmemory{seepage24-15r.
2. Turnthe ignitionswitchON (ll),andcheckthattheSRSindi
catorlight comeson lor aboutsix secondsand ooesoff.
Ooesthe SRSindicalor light stay on?
SRSUNIT
Intermittent failu.e, system is OK at this time. Se€ TroubleIntermifient Failuieson paqe24-15.
OUMMY RESISTOR
Check for an open oa increasedresistance in the dummv
teslstot:
1. Turnthe ignitionswitchOFF.
2. Removethe dummy resistorfrom the SRSmain harness
2P connector,
3. Checkthe resistance
betweenthe A and B terminalsof
the dummy resistor.Thereshouldbe 1.5- 2.50.
resistoa.
Checklor an open or incre.sed resisiancein the SRS main
harness:
'1. Disconnect
the batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver's airbag 2P connectorfrom the
cablereel2Pconnectorlseepage24 t t).
3. Disconnectthe SRS main harnesst8p connectorfrom
the SBSunit.
4. Connectthe dummy resistorto the SRSmain harness2p
connector.
5. Checkresistance
betweenthe No- 1Oterminaland No. 14
terminalof the SRSmain harness18p connector.There
shouldbe aDorox.1.5- 2.50.
SRSMAIN HARNESS
18PCONNECTOR
ls the resistance es speciti€d?
YES
Poor contact ar the SRS main hahess 18p connector;
checkthe connector.
. lf the connector is OK. substitute a known-good SRS
unit, and recheck.
. lf the problem is still present. repbce the SRS main
narness.
Open or increasedresi3tanc6in tho SRS main harness;
24-5A
\
O U
)
Airbag
DTC2-3- Without FrontPassenger's
CAUTION:Wheneverthe ignition switch is ON (lll, ot
has been turned OFF for less than three minutes, be
careful not to bump thc SRS unit; the ailbag could accidentallydeployand causedamageor iniuries.
Try to reproducethe SRSindicator light:
1. Erasethe DTCmemorytseepage24 15).
2. Turnthe ignitionswitchON (ll),andcheckthatthe SRSindicatorlight comeson for aboutsix secondsand goesoff
Doesthe SRSindicator light staYon?
SRSUNIT
lntermittent failure, system is OK ai this time See
Int€rmittont Failureson page 2/a'15
Ch6ckfor a Short to another wile or decreasedresistancein
the dummy resistor:
switchOFF.
1. Turnthe ignitaon
2. Removethe dummy resistorfrom the SRSmain harness
2Pconnector.
betweenthe A and B terminalsof
3. Checkthe resistance
the dummy resistor.Thereshouldbe 1-5- 2.5O.
ls the resistanceas specifiod?
I J
DUMMY RESISTOR
SRSMAIN HARNESS
2P CONNECTOR
A
B
ifti
Checkfor a short to another wile or decrea36dr6istance in
the SRSmain harness:
1. Disconnectthe batterynegativecable,then d'sconnect
the positivecable, and wait for threem inutes
2 . D i s c o n n e ct th e d r i v e r ' sa i r b a g2 P c o n n e c t o frr o m t h e
cablereel2Pconnector(seepage24-l l)
3. Disconnectthe SRS main harness18Pconnectorfrom
the sRs unit.
NOTE:Do not connectthe dummy resistorto the SRS
main harness2Pconnector.
betweenthe No lO terrninalandNo lil
4. Checkresistance
terminalof the SRSmain harness18Pconnector'There
shouldbe 1 M0 or more.
|T'
ti^i
DUMMY
RESISTOR
SRSUNIT
ls the resistanceas
YES
SRSMAIN HARNESS
18PCONNECTOR
FauflySRSunit; replacetho SRSunit l3ee page2+761'
att
Short to another wiro or decreasedresistancein the SFS
main harness;replacethe SRSmain harne3s.
24-59
Troubleshooting
DTC2-4- Without FrontPassenger's
Airbag
CAUTION: Whenever the ignition switch is ON 0l). or
has been turned OFF for lsss lhan three minutes. be
caretul not bump the SRS unit; the airbag could accidentally doploy and causodamageor iniuries.
Try to r€produc€tho SRSindic.to. light:
1. Erasethe DTCmemory (seepage24,15).
2. Turnthe ignitionswitchON (ll),and checkthat the SRSindicatorlight comeson for aboutsix secondsand go€soff.
Do€rthe SRS indicrtor light stay on?
rEs
NO
lntormitteit t ilur., iyst m b OK at thb tim6. Sle Trouble
shooling Intdmitt.nt Frilu.os on pag6 2+lS.
Checkfor a short to power in the SRSmain h.rna3s:
1. Disconnectthe bafterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Dlsconnectthe driver's airbag 2p connectorfrom the
cablereel2P connector(seepage24,11).
3. Dlsconnectthe SRS main harnessl8p connectortrom
the SRSunit.
4. Beconnectthe battory positiv€ cable, then reconnectthe
negativecable.
5. Connecta voltmeter between the No. lO (+) terminal of
the SFS main hsrness18Pconnectorand qround.
6. Turn the ignition switch ON {ll), and me-asure
voltage.
Thereshouldbe 0.5V or less.
7. Connecta voltmeterbetweenthe No. 14 (+) terminalof
the SRS main harness18Pconnoctorand ground,and
measurevoltage.Thereshouldbe 0.5V or less.
A.e voltage. .3 spocifi.d?
YES
NO
F.ulty SRSuniC .epla"" tl,. SnS unn l""" p"g" 2+7O:_l
Short to pow.r in tha SRS mlin harnc$ or tho dummy
r*istor; chocklor contact bctwcen th. dummy r6ai3to. rnd
rnother wiro. lf there is no contrct, rcphcc the SRS msin
hame3s.
24-60
SBS UNIT
SRSMAIN
18PCONNECTOR
)
Airbag
DTC2-5- Without FrontPassenger's
ol
CAUTTON:Wheneverthe ignition switch is ON lll)'
be
minutes'
three
than
for
less
has been turnsd OFF
acci'
careful not to bump the SBS unit; the airbag could
iniuries'
or
damage
Gause
and
deploY
dentally
Tru to .oproducethe SRSindic'tor light:
1 ErasetheDTCmemory{seepage24 15)'
SRSindiz. irin tfie ignitions.itch ON (ll),and checkthat the
goes
otf
and
seconOs
six
for
about
on
iatoi ligiricomes
on7
stay
light
Doesthe SRSindic.tor
|
NO
YES
Troubl'tn---t",-in"m l"itrt", "v"tem is oK at thb lim' seo
3hooling Intormitt6nt Failureson pago 2+15'
SRSUNIT
ffih",n"""'
I J
disconnect
i. oi""onn""t ttte u"tt"ry negativecable'then
the Dositivedable, and wait lor th ree mrnutes' {from
the
z. 6i"J-"""a tt'" driver's airbag 2P connector
(see
page
24_11)'
2P
connector
reel
cable
from
s. b]""onn""t,f'" SFS main harness18Pconnector
the SRSunit.
betweenNo lo terminal of the sRS
L di"lfi""i"on."
connectorand ground and between
18P
main harness
iie t'lo.t a terminatof the SRSmain harn€ss18Pconnector and ground Thereshouldbe 1 Mo or more'
SRSMAIN HARNESS
18PCONNECTOR
I
I btheresistanceasso444g14._ ._
YES
NO
-Faulty
sRs unit;,epltcethe sRs unit (seepage2+761'
dummY
6lort to sround in tho sRS main harness or the
i""i"toi; "-ft""* fot "ont.ct bdtwo€n the dumTI Iesbt9r.and
h6i'
li"r"J.
n irt"t" is no contact.r6pl'co the sRs mtin
ness,
ott
24-61
Troubleshooting
DTC8-6
CAUTION: Whonover the ignition switch is ON lll), or
has been turned OFF for less than thro€ minutes, be
careful not to bump th6 SRS unit; the airbags could
accidentallydeploy and causedamage or iniuries.
Besidesindicatingan abnormalityin the SRS unit, DTC
8-6 may also indicatethat two problemsequivalentto
DTC1-l and 2-4, 1-4 and 2-1,ot 1-4and 2-4 occurredat
the sametime. Proceedin the ordershown below.
Checkth. SRSmain harn6$:
1. Disconnectthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes.
2. Disconnectthe driver's airbag (and front passenger,s
airbag)connector(s){see page21-111.
3. Disconnectthe SRS main harness18Pconnectorfrom
rhe sRS unit.
4. Reconnectthe battery positive cable, then reconnectthe
negativecable.
5. Turnthe ignitionswitchON (ll).
6, Connecta voltmeterand measurevoltagebotweenthe
No. 10 terminalof the SRSmain harness1BPconnector
and ground,and betlveenthe No. l{ terminaland qround.
Th6reshould be aoDrox.0 - 0.5 V.
Aro voltages as spacified?
YES
SRS MAIN HARNESS
18PCONNECTOR
NO
Sho.t to power in tho SRS mrin hamoss; rsplace th6 SRS
main haanac3.
\
Chacl the SRSmain hrrne*s and the cabl. reel:
Connect a voltmeter and measure voltage between the
No. 1 terminalof the SRS main harness18p connector
a n d g r o u n d , a n d b e t w e e nt h e N o . 1 3 t e r m i n a l a n d
ground.Thereshouldbe approx.0 - 0.5V.
Are voltageso3 specilied?
YES
NO
SRSunit; replacethe SRSunit lse6 page 2+76).
To page24-63(A)
o1
24-62
)
,
Frompage24'62(A)
Checkthe cable reel:
1. Turnthe ignitionswitchOFF
2. Disconneitthe cable reel 2P connectorfrom the SRS
maln harness,
3. Turnthe ignitionswitchON {ll}
4. Connecta voltmeterand measurevoltagebetweenthe
No. 1 terminalof the SRS main harness18Pconnector
a n d g r o u n d , a n d b e t w e e nt h e N o 1 3 t e r m i n a l a n d
ground.Thereshouldbe approx.0 - 0.5V'
Are vohtg6 as specifi"dT-
YES
NO
Short to powor in the cabto reel; replace thg cable rool
(seepage 24'721.
Short to powet in the SRS main h.rness; replace the SRS
main harness.
I J
t,
24-63
Troubleshooting
DTC9-2
CAUTION: Whenever the ignition switch is ON 0l), of
has been turned OFF lor lass than three minutes, be
carefulnot to bump the SRS unit; the airbag(s)could
accidentallydeploy lnd caqsedamageor iniuries.
Checkthe tu.c:
1. Turnthe ignitionswitchOFF.
2. Checkfor blown No. 23 (10 A) fuse in the under,dash
fuse/relaybox.
(A)To page24-65
Replace
the tuse.Turnthe ignitionswitchON lll) , and check
that the fusedoesn'tblow.
Th6 problem hs3 disappe.rod,TGt-dJiv€ the vehicloand
3eeTroublerhootingIntermiftcnt Failuro3on paqo2l-15.
No. 23 lr0 Al FUSE
FUSE/RELAY
BOX
!
SRSMAIN HARNESS
18PCONNECTOR
SRS UN'T
Check tol short to ground betwe.n tho unde.-da3h fus./
r.ley box and the SRSunit.
1. Turnthe ignitionswitchOFF.
2. Disconnectthe bafterynegativecable,then disconnect
the positivecable, and waittorthreeminutes.
3. Disconnectthe driver's (and front passenger,s)
airbag
(seepage24-11).
connector(s)
4. Disconnectthe SRS main harness1gp connectorfrom
the sRs unit.
5. Checkresistancebetweenthe No. 3 terminal of the SRS
marnharness18Pconnectorand ground,
Thereshouldbe 1 MO or more.
SRSMAIN HARNESS18PCONNECTOR
FeuftySRSunh; rcphce the SRSunit lsee pag.2+761.
Otf
To page24-65
24-64
I
)
(B) from page 24-64
Checktor ahort to ground in the SRSmain harn$s:
the SRSmain harness2P connectorfrom the
1. Disconnect
box.
fuse/relaY
under-dash
betweenthe No. 3 terminalof the SRS
2. Checkresistance
main harness18Pconnectorand ground Thereshould
be 1.0M0 or more.
ls the re3istancea3 specified? -
YES
Short to giound in tho undot-drlh lut'/rol'y
replace the undel-da3h fusgtgEl!9l--------.-
NO
box;
Short to ground in tho SRS m.in harn$s; roplecothe SRS
main harness.
BOX
FUSE/BELAY
(AlFrom page24'64
Chcckfor an op€n in th6 SRSmain harness:
1. Turnthe ignitionswitchOFF.
2. Disconne;tthe batterynegativecable,then disconnect
the positivecable,and wait for threeminutes'
3. Disconnecttho driver's (and front passenger's)airbag
connector(seePage24'11).
4. Disconnectthe SRS main harness18Pconnectorfrom
the SRSunit
5. Reconnectthe battery positive cable, then reconnectthe
neoativecable.
6. Co-nnecta voltmeter betlveen the No 3 terminal ol the
SFS main harness18Pconnectorand ground'
switchON (ll),and m€asure
7. Turnthe
SRSMAIN HARNESS
18PCONNECTOR
Poor contact at the SRS main harnoss 18P connoctor;
checklho connoctor.
. ll the connector k OK, sub3titute r known'good SRS
unh. and recheck
. lf the problom is slill present, lepl.ce the SRS main
o0
To page 24-66
(cont'd)
24-65
Troubleshooting
DTC9-2 (cont'dl
Frompage24-65
Chocktor an open in th€ SRSmain hern€ss:
1. Turnthe ignitionswitchOFF.
2- Disconnect
the SRSrnainharness2p connectorlrom the
under-dash
fuse/relay
box.
3- Checkresistance
betweenthe No. 2 terminalof the SRS
main harness2P conneciorand No. 3 terminal of the
SFS main harness18Pconnector_
Thereshouldbe 0 0.50
Poor contact at the SRS main ha.ness2p connector;
checkthe connecto..
. lf the connectoris Ol(, sub3titute a known-good underdash tuse/r€laybox, and recheck.
'lt tho problem is still present,replecethe SRS
main
SRSMAIN
Open in the SBS main harness;replacethe SRS main har_
ness,
SRSMAIN HARNESS
18PCONNECTOR
\
SRS MAIN HARNESS
2P CONNECTOR
o!
24-66
I
Airbag
)
Replacement
After a collisionin which the airbagswere deployed'the
airbagassembliesand the SRSunit must be replaced'
Front Passengel'sSide:
Disconnectthe 2P connectorbetweenthe front passenger'sairbagand SRSmain harness'
.
Store a removed airbag with the pad sur'
!!!@
airbag is improperly stored face down'
rr
trt"
iFup.
with
a c c i d e n t a ld e p l o y m e n t c o u l d p r o p e l t h e u n i t
enough force to causeserious iniury'
NOTE:When disconnected,the airbagconnectoris
shorted.
FRONTPASSENGER'S
automaticallY
AIRBAG
2P CONNECTOR
CAUTION:
. Always disconnsct lhe airbag conn€ctor(s)when the
harnessis disconnected.
. Do not disassembleor tamper with the ailbag'
NOTE:
. Do not installusedSRSpartsfrom anothervehicle'
When repairing,useonly new SRSparts'
Do
o Carefullyinspectthe airbag beforeyou install it
b
e
i
ng
o
I
s
i
g
n
s
n o t i n s i a l la n a i r b a gt h a t s h o w s
cracks
dents'
as
such
handled,
droppedor improperly
or deformation.
1.
Disconnectthe batterynegativecable'then disconnectthe positivecablefrom the battery'and wait at
leastthree minutes
2.
the airbagconnector(s):
Disconnect
SRSMAIN HARNESS
Driver's Side:
.
3.
Removethe accesspanel from the steeringwheel'
drivthen disconneclthe 2P connectorbetlveenthe
er's airbagand cablereel
ls
NOTE:When disconnected,the airbag connector
shorted
automaticallY
Bemovethe airbag(s):
Driver's Side:
.
bit' then
Removethe two Torx bolts usinga Torx T30
removethe driver'sairbag
ORIVER'S
AIRBAG
oo
TORXBOLTS
Use a Torx T30 bit
DRIVEE'SAIRBAG
2P CONNECTOR
(cont'd)
24-67
Airbag
(cont'd)
Replacement
Front Passenger'sSide:
CAUTION: B€ sure to inslall the SRSwiring so that it is
not pinched or interforirg with other parts.
.
Removethe three mounting nuts from the bracket,
then removethe harngssclip.
. Liftthe front passenger's
airbagout of the dashboard
by coveringthe lid and dashboardwith a cloth, and
prying carefullywith a flat-tip screwdflver.
4.
Installthenew airbag(s):
Driver's Side: Placethe driver,s airbag into the steering
wheel,and secureit with new Torx botrs.
TORXBOLTS
9.EN.m(1,0kgf.m,7.2tbtftl
Replace.
NOTE: The lid of the airbag has pawls on its side
which attachit to the dashboard.
DRIVER'SAIRBAG
Front Pass€ngar'sSide:
.
.
P l a c et h e f r o n t p a s s e n g e r , a
s i r b a gi n t o t h e d a s h board.
Tightenthe front passenger,s
airbagmountingnuts.
ANAAG MOUNTINGNUTS
9.8 N.m 11.0kgf.m, 7.2lbf.frl
Replace.
24-6a
)
5,
the airbagconnector(s)'
Reconnect
Front Passengor'sSide:
a Attachthe airbagconnectorto the connectorholder'
then reinstalltheglovebox.
Driver's Side:
a Connectthe driver'sairbag2P connectorto the cable
reel2Pconnector,then installthe acc€sspanelon the
steeringwheel
AIRBAG
FRONTPASSENGER'S
DRIVER'SAIRBAG
2P CONNECTOR
6.
the
Connect the battery positive cable, then connect
negativecable.
7.
After installingthe airbag,confirm Proper sYstem
operatlon:
. Turn the ignition switch ON (ll);the SRS indicat o r l i g h t s h o u l dcome on for about six seconds
and then go off
a Makesure both horn buttonswork
oo
24-69
Airbag
Disposal
Beforescrappingany airbags(includingthose in a whole
vehicleto be scrapped),
the airbagsmust be deployed.lf
the vehicleis still within the warrantyperiod,beforeyou
deploythe airbags,the HondaDistrictServiceManager
must give approvaland/orspecialinstructions.
Onlvafter
the airbagshave beendeployed(as the resultof vehicle
collision,for example),canthey be scrapped.
lf the airbagsappear intact (not deployed).treat them
with extremecaution.
Followthis p.ocedure:
Front Passenger'sAirbag:
4.
Removethe glove box, then disconnectthe 2p connector between the lront passenger,sairbag and
SRSmain harness.
FRONT
PASSENGER'S
AIREAG
2PCONNECTOB
Deployingthe Airbags: In.vehiclo
NOTE:lf an SRS vehicleis to be entirelyscrapped,its
airbagsshouldbe deployedwhile still in the vehicle.The
airbagsshould not be consideredas salvageableparts
and shouldneverbe installedin anotherveh;cle.
c o n f i r m t h s t o a c h a i r b a g a s s e m b t yi s
!@
securelymounted; otharwiso. sev€re personal iniury
could result lrom deployment.
1.
Disconnectthe bafterynegativecable,then discon_
nectthe positivecable.
2.
Confirmthat the specialtool is functioningproperly
by followingthe checkprocedureon the tool label
or on page 24-'l'l.
SRSMAINHARNESS
Cut off the airbag connector,strip the ends of the
airbagwires,and connectthe deploymenttool alli_
gator clips to the airbag.placethe deploymenttool
at leastthirty feet (10 meters)awayfrom the airbag.
Driver's Airbag:
3.
DRIVER'S
AIRBAG
a !
FRONTPASSENGER'S
AIRBAG
Removethe accesspanel,then disconnectthe 2p
connectorbetweenthe driver,sairbagand the cable
reet.
DRIVER'S
AIRBAG
2P CONNECTOR
ALLIGA
CLIPS
(Yellow)
ALLIGATOR
CLIPS
{Yellowl
At loast
thiny toet
(10 metorsl
BATTERY
24-70
. U
E)
I
Doployingth6 Airbag: Out-of-vehicle
Connecta 12 volt batteryto the tool:
.
.
7.
lf the green light on the tool comes on, the aarbag ignitercircuitis defectiveand cannotdeploy
t h e a i r b a g .G o t o D a m a g e dA i r b a g S p e c i a l
Procedure.
lf the red light on the tool comeson, the airbagis
readyto be deployed.
N O T E :l f a n i n t a c t a i r b a g h a s b e e n r e m o v e df r o m a
scrappedvehicle.or has been found defectiveor dama g e d d u r i n g t r a n s i t ,s t o r a g eo r s e r v i c e ,i t s h o u l d b e
deployedas follows:
Po3ition the airbag laca up, outdoors on
@
flat ground at lsast thirty f€€t (t0 ml from any obstacles
or people.
P u s h t h e t o o l ' s d e p l o y m e n ts w i t c h . T h e a i r b a g
should deploY(deploymentis both highly audible
and visible;a loud noise and rapid inflationof the
bag,followedby slow deflation).
lf the airbagsdeploy and the green light on the
tool comeson. continuewith this procedure.
. l{ an airbag doesn't deploy,yet the green light
comes ON, its igniter is defective.Go to DamagedAirbagSpecialProcedure.
.
During doployment, the airbag sssom'
!!@
bly can become hot enough to buln you. Wait thir'
ty minutes aftsr deployment belore touching tho
assembly.
Disposeof the completeairbag assembly.No part
of it can be reused.Placeit in a sturdy plasticbag,
and sealit securelY,
1.
Confirmthat the specialtool is tunctioningproperly
by followingthe checkprocedureon this pageor on
the tool label.
2.
Follow steps5, 6, 7, and I of the in-vehicledeploymenl Drocequre.
DamagedAirbag SpacialProcedure
CAUTION:
. Wear a fsce shield and gloves when handling a
deployed airbag.
. Wash your hands and rinse them well with
wat6r after handling. deployedairbag.
r an airb.g cannot be deployed, it should
!@
iiiTi-treatcd as normal scrap; il should still be considsrsd a potontially oxplosive device that can cau3o sstious iniury.
1.
lf installedin a vehicle,lollow the removal procedure on page24-67.
2.
In all cases.makea shortcircuitby twistingtogether
the two airbaginflatorwires.
AIRAAG
Packagethe airbag in exactlythe same packaging
part camein.
that the new replacement
" D A M A G E DA I R B A G
4 . M a r k t h e o u t s i d eo f t h e b o x
get confusedwith
not
it
does
so
NOT DEPLOYED"
your Partsstock.
5. Contactyour Honda District ServiceManager for
how and whereto returnit for disposal.
3.
DeploymentTool: CheckProcedur€
t('
1.
Connectthe yellow clips to both switch protector
handleson the tool; connectthe tool to a battery.
2.
Pushthe operationswitch:green meansthe tool is
OK: red meansthe tool is faulty
3.
the batteryand the yellowclips.
Disconnect
24-71
GableReel
Replacement
store a .emove airbag assambly with the
!@@
pad surtace up. lf the airbag is improperly stored face
down, accidentaldeploymont could propel the unit with
enough force to causesorious iniury.
Makesurethe wheelsare alignedstraightahead.
4.
Removethe driver'sdashboardlowercover.
TORXEOLTS
Use a Torx T30 bit.
CAUTION:
. Alwsys disconnectthe airbag connoctor(s)when ih€
harnessis disconngcted.
. Do not disassembleor tamper with the airbag.
N O T E :C a r e f u l l yi n s p e c tt h e a i r b a ga s s e m b l yb e f o r e
installingit. Do not installan airbagthat shows signsof
being dropped or improperly handled.such as dents,
cracksor deformation.
l.
Disconnectthe batterynegativecable.then disconnectthe positivecablefrom the battery,and wait at
leastthree minutes.
Removethe accesspanelfrom the steeringwheel,
then disconnectthe 2P connectorbetweenthe driver's airbagand cablereel.
NOTE:When disconnected,
the airbagconnectoris
automaticallyshorted.
DRIVER'S
AIRBAG
DRIVEB'S
DASHBOARD
LOWERCOVER
5.
Removethe two Torx bolts from the steering wheel,
and disconnectthe horn connector.Then remove
the driver'sairbag.
\
or
24-72
)
\
the connectorsfrom the horn and cruise
Disconnect
controlsevresumeswitches,then removethe steering wheel nut.
6.
8. Removethe columncovers.
CONTROL
CRUISE
SET/RESUME
SWITCHCONNECTOR
STEERING
NUT
HORNCONNECTOR
CABLEREEL
2P CONNECYOR
)
7.
Remove the steerlng wheel using a steering wheel
pulrer.
Disconnectthe 3P connector betweenthe main wire
8nd the 2P conharnessand cablereelsub-harness,
nectorbetweenthe cablereel and SRSmain harness'
CABLEREEL
CONNECTOR
HOLOER
WHEELPULLEF
STEERING
{Commerciallv_available)
) U
SRSMAIN HARNESS
2P CONNECTON
CABLEREELSUB
HARNESS
3P CONNECTOR
10. Removethe cablereelfrom the column
{cont'd}
24,73
--/
CableReel
Replacement(cont'd)
NOTE:
. B e f o r ei n s t a l l i n gt h e s t e e r i n gw h e e l ,t h e f r o n t
wheelsshouldbe alignedstraightahead.
. Be sure to installthe harnesswires so that they
are not pinchedor interferingwith other parts.
. A f t e r r e a s s e m b l yc.o n f i r mt h a t t h e w h e e l sa r e
still turned straightaheadand that the steering
wheel spokeangle is correct(roadtest).lf minor
spokeangleadjustmentis necessary,
do so only
by adjustingthe tie-rods,not by removing and
repositioning
the steeringwheel.
1 1 . S e t t h e c a n c e ls l e e v es o t h a t t h e p r o j e c t i o n sa r e
a l i g n e dv e n i c a l l y .
Installthe steeringcolumncovers.
1 4 . lf necessary,centerthe cable reel. {New replacement
cablereelscome centered.)Do this by first rotatingthe
cable reel clockwiseuntil it stops.Then rotatett coun
(approximately
terclockwise
two and a halfturns)until
the arrow markon the cablereellabelpointsstraight
up.
ARROWMARK
PROJECTIONS
12. Carefullyinstallthe cable reel on the steeringcol
umn shaft. Then connectthe 3p connectorto the
cablereel sub-harness,
and connectthe 2p connector to the SRSmain harness.
. 24-74
15. lnstall the sleering wheel, then connect the horn
conneclor and cruise control sevresume switch con
neclor.
CRUISECONTROL
STEERING
WHEEL
SET/RESUM€
16. Installthe steeringwheel nut, and connectthe horn
c o n n e c t o tr o t h e s t e e r i n gw h e e l .T h e n i n s t a l lt h e
driver'sairbag.
TORXSOLTS
9.8N m 11.0kgf m, 7.2lbtftl
Replace.
Use a Torx T30 bit.
18. Reconnectthe driver's airbag 2P connectorto the
c a b l e r e e l 2 P c o n n e c t o ra. n d r e i n s t a l tl h e a c c e s s
panelon the steeringwheel.
19. Reconnect
the batterypositivecable,then the negative cable.
DRIVEB'S
AIRBAG
20. After installingthe cable reel,confirm propersystem operation:
Turn the ignitionswitch ON (ll);the SRS indicator light should come on for about six seconds
and then go off.
a Makesureboth horn buttonswork.
a M a k e s u r e t h e h e a d l i g h ta n d w i p e r s w i t c h e s
, n d m a k es u r et h ec r u i s ec o n
G o f o r a t e s td r i v e a
trol switcheswork.
WHEELNUT
STEERING
50 N.m 15.0kgf.m,36lblft)
Replace.
I
DRIVER'S
2P CONNECTOB
HORNCONNECTOB
1 7 . Attachthe cablereel2Pand 3P connectorto the conn e c t o rh o l d e r .T h e n i n s t a l lt h e d r i v e r ' sd a s h b o a r d
lowercover.
)U
DRIVER'SDASHBOARDLOWERCOVER
24-75
SRSUnit
Replacement
CAUTION:
. Betore disconnoqting lny pErt of the SRS wire halness,disconnectth9 airbag conn"ctorlsl.
. During installltion or teplacemsnt. do not bump
(impact w.cnch, hamm€r stc.l the area noar tho SRS
unit.
3.
Removethe right sidecoverfrom the SRSunit.
SRS UNTT
NOTE:
o Do not damagethe SRSunit terminalsor connectors.
. Do not disassemblethe SRS unit; it has no serviceableparts,
. Storethe SRSunit in a clean,dry a.ea,
. Do not use any SRSunit which has be€nsubjectedto
water or showssignsof beingdroppedor improperly
handled.such8s dents,cracksor deformation.
1.
Disconnectthe bstterynegativecable.then disconnectthe positivecablefrom the battery,and wait at
leastthree minutes.
2.
Disconnect
the airbagconnector{s}:
TOBX
BOLTS
Ugea Torx
T30bit.
NOTE:When disconnected,
the airbagconnectoris
automatically
shorted,
RIGHTSIOE
COVER
Driver's Side:
. Removethe accesspanel from the steeringwheel.
then disconnectthe 2P connectorbetweenthe driv_
er's airbagand cablereel(seepage24-11).
Removethe left side cover from the SRSunit,then
d i s c o n n e ctth e S R S m a i n h a r n e s sl g p c o n n e c t o r
from the SBS unit.
Front Passenge/sSide:
. Disconnectthe 2P connectorbetweenthe tront oas_
senger'sairbagand SRSmain harness(seepage 2411).
SRSUNIT
5.
24-76
Removethe four Torx boltsfrom the SRSunit,then
pull out the SRSunit from the driver,sside,
o\
6.
Installthe new SRSunit.
N O T E : D o n o t r e u s ea t o r x b o l t t h a t h a s r e d
threads.Replacethe bolt with a new one.
9 . Reconnectthe driver's aibag 2P connectorto the
c a b l e r e e l 2 P c o n n e c t o rt,h e n r e i n s t a ltl h e a c c e s s
panelon the steeringwheel.
1 0 . Reconnectthe tront passenger'sairbag connector
to the SRSmain harness.
1 1 . Reconnect
the batterypositivecable,then the nega
tive cable.
' t 2 . After installingthe SRSunit,confirmpropersystem
operation:Turn the ignitionswitchON (ll);the SRS
indicatorlight shouldcome on for aboutsix seconds
andthen go oif.
TORXBOLTS
9.8 N.m 11.0kgf.m, 7.2 lbf.ft)
U3e . Torx T30 bit.
SRSMAIN HARNESS
)
TORXBOLTS
9.8N.ml'1.0kg{.m,7.2lbf.ft}
Usea TorxT30bit.
7.
Connectthe SRSmain harnessl8P connectorto the
SRSuniu push it into posjtionuntil it clicks.
8.
I n s t a l lt h e S R S u n i t c o v e r s( r i 9 h t a n d l e f t ) .M a k e
surethe coverssnaptogetherin the middle.
)(l
24-77
.-
Contents
Howto UseThisManual I
(seeCircuitIndex)
CircuitSchematics
Fuse/Relaylnformation
6
Ground-to-Componentslndex
6-6
ComponentLocationPhotooraohs
201
Conriector
Views 202
CircuitIndex
Accessorypowersocket 155
Airconditioner
Air
delivery
'96198
61
'99-'00models
models 61-2
Blower
controls
'96198
60
'99100models
models 60-1
Compressor
controls 62
Fans 63
Anti-lockbrakesystem(ABS) 44
A/Tgearpositionindicator
CVT 89
All exceptCVT 89-1
Automatic
transmission
controls
All '96-'98modelsexceptCVTandGX 39
'99100
All
modelsexceptCVT 39-8
All
GX
models
39-8
'96-'98CVT 39-4
'99100cw 39-12
Back-uplights
CoupeandSedan 110
Hatchbackl'10-1
Brakelights
All
Coupesand'96-'98
Sedans 110-15
'99-'00
Sedans 110-16
Hatchback110-17
Brake
systemindicatorlight
'96198
7'1
'99100models
models 71-1
Ceilinglight 114-3
Chargingsystem 22
fan 63
Condenser
Console
lights 114
Cruisecontrol 34
Dashlights 114
Daytime
running
lights 110-13
gauge 81-1
Enginecoolant
temperature
Foglights 110-10
Frontparkinglights 110-2
Fuelgauge 81-1
Fuse/relay
box
Under-dash 6
Under-hood 6-4
Underhood
ABS 6-3
Gauges 81
Grounddistribution14
Ground-to-Componentslndex
6-6
Hazardwarning
lights
'99100
All
except
Sedans 110-6
'99100
Sedans 110-8
Headlights110-12
Headlightswitch 100
Heater- SeeAirConditioner
Horn
'96197models 40
'98model 40-1
'99100models 40-2
lgnition
keyreminder 73
lgnition
system
'96198
modelsexceptDl685 20
All
All'99100modelsexceptD16Y5withMn 2O-2
All
D1685engines 20-2
'99-'00
D 16Y5withM/T 20
lndicators 80
Integrated
controlunit 70
lnterlocksystem
CVT 138
'All
9 6except'96J98
1 9 8 C V T1 3 8
-1
platelights
License
'96-'98
All
Coupesand
Sedans I l0-3
'99100
Sedans 110-4
Hatchback110-5
Lowfuelindicator
light 74
Moonrool
'96197models |22
'98-'00models 122-1
Odometer 81
indicator
light 80-3
Oilpressure
Powerdistribution
Batteryto ignitionswitch,fuses,andrelays 1 0
Fusesto relaysandcomponents10-2
Powerdoorlocks
modelswithoutkeyless
All
entry 130
'96-'98
modelswithkeyless
entry 130-2
'99100modelswithkeyless
entry 130-12
Powermirrors
Without
detogger 141
Withdefogger '141-2
Powerwindows 120
Programmed
fuelinjection
system(PGNr-Fl)
All'96-98
models
except
D1685 23
All'99-'00modelsexceptD16Y5
withM/TandD1685 24
All
D1685engines 25
'99100
D16Y5withM/T 23
Radiatorfan 63
Rear
windowdefogger
'96-,98
64
'99100models
models 64-1
Seatbeltreminder 73
system
Security
'96.'98
USAHX,LX,EX 133
'96-'98Canada
EX,Si 133
'99TOO
HX,LX,EX,DX.VSi 133-4
'99100USA
CanadaEX,Si 133-4
AllCX andDX models 133-8
Speedometer81
Startingsystem
A./T(AllexceptDl685) 21
A"/r(D16Bs) 21-1
Manualtransmission
21-2
Slereosoundsystem 150
rastraintsystem(SRS) 47
Supplemental
Tachometer 81
Tailliqhts
Sedans 110-3
Allboupes
and'96-'98
'99100Sedans
110-4
Hatchback110-5
Trunklight 114-3
Turnsignallights
All
except'99100
Sedans 110-6
'99-'00
Sedans 110-8
Vehiclespeedsensor(VSS) 33
Wiper/washer
Front 91
Rear 92
HowToUseThisManual
The nextfew pagesdescribehowthismanualis organized.
Theyalso
explainwhatkindof information
the manualcontains,
whatthat
problems.
informalion
means,andhowto useit to troubleshoot
electrical
Circuitschematics
breakthe entireelectrical
systemintoindividual
systems,likethe LowFuellndicator
Lighton the nelitpage.
Onlyelectrical
components
thatworktogetherareshowntogether,
so you won'tbe distractedby unrelatedwires.
Explanations
of the abbreviations
and svmbolsusedin the schematics
beginon page[Fl. You'llneedto knowwhattheymeanbeforeyou canuse
a schematiceffectively.
HowToUseThisManual
oa
CircuitSchematics
Eachschematic
represents
onecircult.A
circuit'swiresandcomponents
arearranged
to showcurrentflow,frompowerat the top of
the page,to ground,at the bottom.
SharedCircuits
Othercircuitsmaysharepoweror ground
terminals
or wiringwiththe circuitshown.A
wirethatconnectsonecircuitto another,for
example,is cut shortand hasan arrowhead
at the endof it pointingin the directionof
currentflow.Nelitto the anowheadis the
nameo{ thecircuilor comoonent
which
sharesthatwiring.Toquicklycheckshared
wiring,checkthe operation
of a component
it
works,you know
serves.lf thatcomponent
the sharedwiringis OK.
"HOT"labeltells you when
the ignitionswitchsupplies
powerto the fuse.
\
UNDER.
DASH
FUSE/
SeePowerDistribution, . RELAY
i t
I BOX
I t----t
oaqetO-3.
L*--:--------J
2 Y C723
Junctionconnectorhasone ol
morebus bars in it; eachconnactg
YELI Pao'o'8
- ""
to two or morewire terminala.
I
i t
. a
l l u " :^: , {
l
,
c725
vlEUt/75
-> ? t
SeePower
Distribution,
page10-3.
SoeIndicators I ASSEMBLY
LOWFUEL
INDICATOF
LIGHT r-l
:-------J
Symbols
A completedescription
of schematic
symbolsbeginson page| 8
Brokenwiremeans
EI
A
"'"'I
L?*?l?,-
Splice ---------)
i
/
Artowheadmeans
wire connectsto
anothercircuit;
it ooints in direction
of currentflow.
Connectors
All in-lineandfuseboxconnectors
are
(C725,C416,etc.).
numbered
t _
connectors
arenotnumbered
Component
I
by the nameof the
butareidentiJied
component.
lf a componenl
hasmorethan
eachconnector
is assigned
oneconnector,
a letter(A,B, C, etc.).Belowmostconnector
L --Cavity number; ----->
numbers
namesare
'
andcomDonent
Jiili'iJi!--'
PHOTOandVIEWnumbers.
ThePHOTO shoin on pageS .
numberrefersto a Dhotoin the backof the
bookthatshowslhe conneclor'slocationon
thecar.TheVIEWnumberrefersto an
7
Male
illustration
in the backof the bookthat
GBN/FEO
terminal
showstheconnector
face,wirecolors,
cavitynumbers,
andotherdetails.
connector
Theconnector
cavitynumbering
sequence
TheImletor
beginsat the top leftcorneroJthe connector
as seenfromeitherof theviewooints
shown
on pageffl . Disregard
anynumbers
moldedintotheconnector
housino.
Wires
Wiresare identilied
by the abbreviated
namesof theircolors;the secondcolorrsthe
colorof the stripe.Wiresarealsoidentified
by
theirlocationin a connector.
The number'2"
nextto the maleandfemalewireterminalsat
meansthoseterminals
C416,for example,
join in cavity2 of connector
C416.
Arrowwith note rErng
othercircuilsconnccth€re.
Connectornumber;
indexbeginson
page203.
"o'r"/
PHOTO
52 <-
\
FUEL
TANK
UNIT
O rrlL
I
I
BrK
I
:
c301
ptioro 21
PowerDistributionSchematics
PowerDistribution
schematics
showhowpoweris suppliedfromthe positivebatteryterminalto
variouscircuitsin thecar.Referto the PowerDistribution
sectionto geta moredetailedpicture
of howpoweris suppliedto thecircuityou'reworkingon.
FromBatteryto lgnitionSwitch,Fuses,andRelays
Individual
circuitschematics
beginwitha fuse.Thefirsthalfof PowerDistribution,
however,
"upstream"
showsthewiring
betweenthe batteryandthefuses.
i BATTERY CYLINDER
BLOCK
t
t
I
II
L.lt
I
-
J
l
l
",-*f ]fo,o
i.Jr;-t
I| t ! -
STARTER
Pase21
!
t FUSE31
I
f
iL_i***'"
i
*
"rn*i
I
ilr------
L-------J
!
r
----------------Y-?-
l
r
rusesoI ruseasI rusega| ' ,s. ,aI =u.- srl FUSE
ruse/I4
aai
ruseqr
47 I' ruse
FUSEso
sri ruse
5{' I' ruse
FUSE51'
FUSEia
' FUSE
52
powEF
\
powrn
Bc, \F,.n
.;,cren \ ooon \coounc \ cor,r. \sun noor\
\tcsw
\ FUsE
w'NDowf50a
t3f*f5#
{*
.i1-;.*"1liT""fi3f*
fffi'*"f'*
fS?'*
f5# fffi*"
f'* fs?'*
OOOB
T101
4
34
GAN
ALK
f102
l
l
l
l
ALTERNATOR
Page22
\COOLING
"";%,,
Y rtr,'.9l' -%,t",,
vtEw47
I
w-
\SUN
BOOF \ FOWER
SeePowerDastribution,
pages10,10and
10'10and10-11.
!
vH-,alr.lt -
' I ---il 9,1?t.urr, 'rrr.,
i I
l--4F--?-
a
I
r(op-B)
FUSE5
t i!?'.,,?""
t::=.
A/C CLUICH
(FNHEATED
SEAD
204
.{Noru3€d)
J$ifl#ii
FUSE6
ECU
204
Jtocl
-I
l ty::.1----.- Ii
FUSE8
DF POWEF SEAT
204
}3fo**."".o'
t-L- - -L- - -:rJ:e'-- -Ei s+s-r -.Fl-J-Jrr.-.
C901 C921
{Not
PHorozz OPTION
Used)
v/EW22 CONNECTOB
page10-2.
SeePowerDistnbution,
YEL
c330
7
c901
vlEw22
't PowER
I uon-I Wlt{DOW
i. racrsit RELAY
P^da 1t
L-J
P;dr1ii-
a
CON.
- - -L - - -. ... Ji - -.J.- - -e-- -l. - - -La - J- - - I - - -
1
i-f,
r--
\
FUSE4
FADIO
104
FUSE3
FUSE12
CONOENSEFFAN RELAY
COOLING FAN RELAY
FUSE19
(BUltNrrG
LIGHT)
R/C MIRROF
I
I
I
\
\
ToFuses17,18,21,
and24,for details,
seePowerWindows
page120.
I
I
I
See Power Distribution,pages 10-4and 10-5.
HowToUseThisManual
oa
PowerDistributionSchematics(cont'd)
FromFusesto Relaysand Components
showsthewiring"FromFusesto Relaysand
Thesecondhalfof PowerDistribution
by showingwhichcircuitsshareluses.lf
Thiscanspeedyourtroubleshooting
Components."
circuitandanothercircuitsharea fuse,checka
showsthalan inoperative
PowerDistribution
to
you
knowthefuseis goodandpoweris available
lf
it
works,
the
other
circuit.
in
component
circuit.
the inoDerative
I
i *. to
i ru..'.'
l *
\
){nuo$rouc}rr)
}g*"""'
}tS
\
I
UNDER.
DASH
FUSE/
RELAY
BOX
I tusttt
tt
}ff***,
I
,
'f,"c;93,.:
' f,t'ffi
lv'Ew6o !
1,.",
l
N
:
'
-- ----\&-------ir
*_lu*'.
l
' ,.,'li"
'rll$vryglu
'"rr'
:
"'':r.,
]:l. ,'
,:ti. .:1,,.,
18 g C442
04
i ".o,*",I
^.o,r.u
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t
,
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11"""
'71ffi"
--t**,-
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l*'-
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i "l9*',g
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nEDisLu
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. ED,w' (
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121
i
,.L
t
t
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DAYTIME
RUNNING
LIGHTS
CONTROL
UNIT
paoe1to-j2
1so
PHdTo
vtEw65
- - - ' C a n a d a' _ _ _
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:
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:
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.
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12 .L e
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POWER
SEAT
CONTROL
UNIT
Paoe143-2
PHdro
t2.
wEw110
t
t
l
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ALTENNATOR
Paoe22
PHdro 29
l
t
l
l
L------J
STEREOAMPLIFIER
Paoe150-3
PHdfo 1s3
vtEw 106
(cont'd)
GroundDistribution
Schematics
ThissampleGroundDistribution
schematic
showsall of the components
thatsharetwo
groundpoints.
TCS
FRONT
RIGHT
CONTROL
PASSENGER'SREARDOOR
FRONT
UNIT
ASHTRAY
PASSENGER'SSEATBELT
Page35
LIGHT
SEATHEATER SWITCH
Page145
P a g e1 1 4
Page147
t
t
9 Y
l
l
B
t
t
l
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'T-'
2 9
I -
t
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r
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u
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G601
c611
HowToUseThisManual
ComponentLocations
or connector
is locatedon thecar,lookup itsphotonumberin the
To seewherea component
Location
sectionin the backof the book.The photowillalsotellyouthecolorof
Component
the connector,
andhowmanycavitiesit has.
I
I
3
r -
|
1 GAUGE
r - 1 cRUtsE
! !fi':* a
| I_S-9_EIBLY
l t ' ' " " '
r I
To see where
connectorsand parts
are located,look up
their photos in the
Component
Locationsection.
1 POWERTRAIN
UNrr
I CONTROL
i[i9#r,
ground,or
nameor a connector,
lf thereis no photonumberbelowor besidea component
in
Index
terminalnumber,lookup thatnameor number the Connector-to-Harness thatbegins
has,whereit'slocated,
andwhat
on page203.Thechartlistshowmanycavitiesa connector
harness,
andthe
the
location
on
the
to.
The
related
illustration
shows
connector's
it connects
harnessrouting.
and Wke HarnessRouling
Connactorldontlticallon
Drlvors Sea!wne Harn€ss
Lefts'd.Hrc hatu$ 1c2611
Lofts'd. src hamass1c262)
F6ar up.dow^n.morykisor
l
DFIVEF'S
POWER
SEATWIAE
HAFNESS
It a connectoron a
schematichas no
photonumber,look it
up in the Connector
ldentilicationchart
and relatedillustration.
203
E
c712
c7t6
\ c702
c701
203.1
oo
ConnectorViews
cavities,lookup itsviewnumberin the Connector
of a connector's
Toseethe configuration
whereit
Viewsectionin the backof the book.Eachviewincludesthecolorof the connector,
to.
is located,andwhatit connects
Viewsto helplocatethe propercavitywhenyou needto probea
Usethe Connector
hasmorethanonewireof the same
helpfulif theconnector
lt canbe especially
connector.
cotor.
circuits
in separate
viewscanalsobe usedto helpdiagnosemultiplesymptoms
Connector
sharedby thosecircuits.Here's
whichcouldbe causedby a singleproblemin a connector
how:
for thatcircuit.
and lookup the schematic
1. Pickoneof the multiplesymptoms
(includepage
in thatschematic
2. Makea listof allthe in-lineandfuseboxconnectors
numbers).
on yourlistto seeil circuits
Viewsection,lookup eachconnector
3. Then,in the Connector
lf
they
do, inspectthatconnector
runthroughoneof them.
relatedto the othersymptoms
for the oroblem.
wiperdon'twork.Listall
andthewindshield
Theblower,rearwindowdefogger,
Example:
in the blowercontrolscircuitandthencheckthe Connector
in-lineandfuseboxconnectors
(sample
findthatC324is commonto the rearwindowdefogger
below).
You
Viewsection
circuit,so you inspectC324andfindthe problem,bentterminals.
circuitandwiper/washer
ConnectorViews (cont'd)
21. C324
Brown
Behindleftkickpanel
- Connectsleftenginecompartry'ent
wireharnessto
mainwireharness
ll,ll,
5
1 . WHT(Blowercontrols)
2 . YEUBLU(Rearwindow
defogger)
(Starting)
BLK,ryVHT
BLU/YEL
(Wiper/washe0
6
7
5 . 8LU (Wiper/washed
6 . BLfiEL (lgnition)
(ABS)
7 . WHT/BLU
HowToUseThisManual
Symbols
Wire Color Abbreviations
The followingabbreviationsare used to
identifywire colorsin the circuitschematics:
BLK....
BLU....
BRN....
GRN....
GRY....
L T B L U.
LTGRN.
ORN....
P N K. . . .
P U R. . . .
R E D. . . .
WHT...
Y E L. . . .
.........b|ack
. . . . . . . . b. l u e
,......b
. rown
. . . . . . . .g r e e n
. . . . . . , . .g r a y
.....lightbtue
....lightgreen
. . . . . . .o r a n g e
. . . . . . . , .p. i n k
. . . . . . . .p u r p l e
. . . . . . . . . .r e d
.........white
. . . . . . . .y e l l o w
A brokenlinemeansthispartof thecircuit
is notshown;referto the circuitlistedfor
the complete
schematic.
oo
"ral
-.1
SeeGround
Distribution,
page141.
o
I
Whereseparatewires
join,onlythespliceis
shown;for detailson
theadditional
wiring,
referto thecircuits
listed.
G101
UNDEROASH
FUSE/
RELAY
BOX
ili::i
Wires
A wavylineat the endof
a wiremeanslhe wireis brokenby the bindingof
the bookor by a "choice"
bracketbutcontinues
on
the nextpage.
8LK
Cruise
Control, € aaa
Indrcalors
Gauges,
a.
!
YEUsLK
T
tl
Wirechoicesfor optionsor
different
modelsarelabeled
andshownwitha "choice"
bracketlikethis.
Wireinsulation
can be
onecolor,or onecolor
withanothercolorstripe.
(Thesecondcoloris
thestripe.)
Thiscircuitcontinues
on
page.
(The
another
arrow
showsdirection
o{ current
flow.)Totollowthe RED/
BLKwirein thisexample,
youwouldturnto page23-5
andlookfor the "2"anow.
{[
+##l:i""l
Manual
lransmission
ryil;::,
Thismeansthe branchof the
wireconnects
to another
circuit.ThearrowDointsto the
nameof the circuitbranch
wherethewirecontinues.
""^l
Nameof Circuit
""'
.""1"""1".'0
Thisbrokenlinemeans
bothterminals
arein
connector
C134.
I
:-l
- "C"
Connectors
The cavities(and wire terminals)in each
connectorare numberedstarting from the
trom
upperleft,lookingat the maleterminals
the terminalside (or lookingat the female
f romthewireside.Bothviewsarein
lerminals
the same directionso the numbersare the
even
same.)All actualcavitiesarenumbered,
in them.
if theyhaveno wireterminals
WlreSlde
ot
TerminalSlde
ol
MaleTsrminals
Femalg Trrmlnala
Thissymbolrepresents
onebusinsidethecaoof a
A \
iunctionconnector.
connectorcap
lr"ctb.
\
containsseveralbuses,but \
that
onlytheoneaffecting
The
ciriuitwillbeshown.
|
A
c103
--f
f
!!*!"*F"#fi5';,H
I
wiresto
Remaining
the samebusare
represented
by a
brokenline.
SeeGauges
t
t
l
l
Splices
The connectorcavitynumberis listednextto
The
eachterminalon the circuitschematic.
shownbelowis #6.
cavity/terminal
Cavlty/
Termlnsl6
Solicesareshownas a dot.Theirlocation
andthe numberof wiresmayvary
on the harnessmanufacturer.
depending
*-I
I
",.-"*
*"1
*-l*-l*-l*"1 *-l
a---a---a--- a--- o
-a
Components
A solidborderlinemeansthe
is shown.
entirecomponent
t_J
Terminal
Thismeanstheconnector
connectsdirectlyto the
componenr.
{
T
_A
Thismeanstheconnector
to a lead(pigtail)
connects
wireddirectlyto the
component.
A brokenborderlineindicales
l
thatonlypartof the component l
is shown.
Thenameof the
componentappearsnext
to its upperrightcorner
followedby notesabout
itsfunction.
l
l
BRAXE
swtTcH
Closed wilh
pedaldepressed.
HowToUseThisManual
oo
Symbols
"G"
Ground -
Switches
Thissymbolmeansthe endol
the wireis attached(grounded)
to thecarframeor to a metal \
partconnected
to theframe. \i
Theseswitchesmove
together;
the brokenstraight
linebetweenthemmeansthe,
are mechanically
connected.
ffi
Othertypesof switches
are
controlled
by a coilor a solid
statecircuit.Unlessotherwise
noted.all switches
areshown
(rest)
position,
in theirnormal
with poweroff.
ffi
I
I
oro,|
-t'
Eachwireground(G)it --/
for reference.
numbered
Thisgroundsymbol(dot
the
and3 lines)overlapping
meansthe housing
component
is grounded
of the component
to the carframeor to a metal
partconnected
to theframe.
Thissymbolrepresents
the bus insidea ground
connector.
Thedots
I
Solid-state
;"r"LI I I
i:l*,':1,'^:*,:"
connectto.
terminals
Thegroundsymbol(largedot)
is theconnection
betweenthe
part
busandmetal(grounded)
of the car.
- "T"
Terminals
Each"T"lerminal(ringtype)
for reference
is numbered
and
location.
A "T"terminalis
securedwitha screwor bolt.
Shielding
Thisrepresents
RFI
(RadioFrequency
Interference)
shielding
arounda wire.The
is always
shielding
to ground.
connected
Fuses
Thismeanspoweris supplied
whentheignition
switchis in ON (ll).
\t,,,,
T
Currentrating
Diodes
A rectifier
diodeworkslikea one
wayvalve.lt allowscurrentto
llowonlyin thedirection
of the
arrow.
f--l;j-i",..
I
A Zenerdiodeblocksreverse
justlike
currentat normalvoltages
a rectifier
diode.At highvoltages.
however,
a Zenerdiodeallows
currentto flowin reverse
oo
Troubleshooting
Five-Step
L VerifyThe Complaint
in the problem
Turnon allthecomponents
circuillo checktheaccuracyof the customer
Do notbegin
Notethe symptoms.
complaint.
or testinguntilyou have
disassembly
narrowed
downthe problemarea.
2. AnalyzeThe Schematic
for the problem
Lookup theschematic
howthecircuitis
circuit.Determine
to workby tracingthe current
supposed
pathslromthe powersourcethroughthe
to ground.Also,trace
circuitcomponents
circuitsthatsharewiringwiththe problem
circuit.The namesof circuitsthatsharethe
samefuse,ground,or switch,andso on,are
referredto in eachcircuitschematic.Try to
operateanysharedcircuitsyou didn'tcheck
in step1. lt the sharedcircuitswork,the
sharedwiringis OK,andthe causemustbe
in thewiringusedonlyby the problem
circuit.lf severalcircuitsfailat the same
time,thefuseor groundis a likelycause.
andyour
Basedon thesymptoms
of the circuit'soperation,
understanding
identifyoneor morepossiblecauses.
3. lsolateThe ProblemBy TestingThe Circuit
Makecircuitteststo checkthe diagnosis
you madein step2. Keepin mindthata
is the keyto
logical,simpleprocedure
Test
efficient
troubleshooting. for the most
likelycauseof failurefirst.Tryto maketests
at pointsthatareeasilyaccessible.
TestEquipment
devices.
Mostcircuitsincludesolid-state
Testthevoltagesin thesecircuitsonlywith
or higherimpedance
digital
a 1o-megaohm
mUltimeter.
Neverusea test lightor analog
meteron circuitsthatcontainsolid-state
to the devicesmayresult.
devices.Damage
Test Light and DVOM
devices,usea
On circuitswithoutsolid-state
A
testlightto checkfor voltage. testlightis
madeup of a 12voltbulbwitha pairof leads
one lead,touchthe
Aftergrounding
attached.
otherleadto variouspointsalongthecircuit
wherevoltageshouldbe present.The bulb
willgo on if thereis voltageat the pointbeing
tested.lf you needto knowhowmuch
voltageis present,usea digital
(DVOM).
volVohmmeter
Self-PoweredTest Light and DVOM
testlightto checkfor
Usea self-powered
is
Thistool madeup of a lightbulb,
continuity.
battery,and tlvo leads.To test it, touchthe
the lightshouldgo on.
leadstogether:
testlightonlyon an
Usea self-powered
the
circuit.First,disconnect
unoowered
battery,or removethe fusethat feedsthe
circuityou areworkingon. Selecttwo points
in the circuitbelweenwhichyouwantto
Conneclone leadof the
checkcontinuity.
testlightto eachpoint.lf there
self-powered
the testlight'scircuitwillbe
is continuity,
andthe lightwillgo on.
completed,
4. Fix The Problem
Oncethe specificproblemis identified,
makethe repair.Be sureto usepropertools
andsafeprocedures.
5. MakeSureThe CircuitWorks
in the repaired
Turnon all components
circuitin all modesto makesureyou've
fixedthe entireproblem.ll the problemwas
a blownfuse,be sureto testall of the
circuitson thatfuse.Makesureno new
problems
turnup andtheoriginalproblem
not
recur.
does
TESTLIGHT
SELF-POWERED
lf, in addition,you need lo know exacW hc'.
much resistancethere is betweentwo oo'^=
(DVOM)
use a digitalvolUohmmeter
acdrt'Cn
t1
HowToUseThisManual
TestEquipment(cont'd)
In the"OHMS"range,the DVOMwillmeasure
resistancebetweentwo pointsalonga circuit.
Lowresistancemeansgoodcontinuity.
Diodesand solid-statedevicesin a circuitcan
makea DVOMgivea falsereading.
Tocheck
a reading,reversethe leads,andtakea
secondreading.lf the readingsdiffer,the
componentis affectinglhe measurement.
JumperWire
Usea jumperwireto bypassan opencircuit.
A iumperwireis madeup ot an in-linefuse
holderconnectedto a set of test leads.lt
shouldhavea five amoerefuse.Never
connecta jumperwireacrossa shortcircuit.
Thedirectbatteryshortwillblowthefuse.
Troubleshooting
Precautions
BeforeTroubleshooting
oa
1. Checkthe mainfuseandthefusebox.
2. Checkthe batteryfor damage,stateof
charge,andcleanandtightconnections.
CAUTION:
. Donot quick-charge
a batteryunlers
the batterygroundcablehasbeen
disconnected,
or you will damagethe
alternatordiodes.
. Do not attemptto cranktheenginewlth
the groundcabledisconnected
or you
will severelydamagethewiring.
WhileYou'reWorking
1. Makesureconnectors
areclean,andhave
no looseterminals
or receptacles.
2. Makesurelhatconnectors
withoutwire
(silicone)
sealsarepackedwithdielectric
grease.PartNumber:08798-9001
.
Packwllh dlelectrlc(sillcons)greass
Short Finder (Short Circuit Locater)
Shortfindersare availableto localeshortsto
ground.Theshorttindercreatesa pulsing
magnetic
fieldin the shortedcircuitwhlchyou
can followto the locationof the short.lts use
is explained
on page15.
pushit untilit
Whenconnecting
a connector,
"clicks"intoplace.
Do not pull on the wires when
disconnectinga connector.Pull
only on the connectorhouslngs.
SHORT FINDER
To ordei any test equipmentshownabove,
contactyour localtool supplier.Fora list of
suppliers
andtoolnumbers,referto Honda
Required
SpecialToolsand Equipment
ServiceBulletin.
Most circuits Includesolid-state
devlces.Testthe voltagesIn these
circuits only with a lo-megaohmor
higher impedancedigital multlm6ter.
Neveruse a test light or analogmeter
on chcuits that contain solld-state
devices.Damageto the devices
may result.
oo
Tests
Troubleshooting
Testingfor Voltage
Testingfor Continuity
Whentestingfor voltageat a connector
withoutwireseals,youdo nothaveto
seoarate
thetwo halvesof the connector.
fromthe back.
Instead,probethe connector
Alwayscheckbothsidesof the connector
andbentterminals
becausedirty,corroded,
(noelectrical
contact=
cancauseproblems
an open).
at a connector
Whentestingfor continuity
you
withoutwireseals, do nothaveto
thetwo halvesof the connector.
separate
Jromthe back.
lnstead.Drobethe connector
Alwayscheckbothsidesof the connector
becausedirty,conoded,andbentterminals
contacl=
cancauseproblems(noelectrical
an open).
1. Connectoneleadof thetestlightto a
knowngoodground,or,if you'reusinga
(DVOM),placeit in
digitalvoltohmmeter
DCvoltsrange,and
the appropriate
connectits negativeleadto ground.
the negativecablefromthecar
1. Disconnect
you're
usinga DVOM,placeit in
battery.lf
"OHMS"
range.
the lowest
test
2. Connectone leadof a self-powered
part
of the
lightor DVOMto oneendof the
circuitvouwantlo test.
connecthere
[fl5tst-t
and light should
IJJ
\"
I
comeon.
------{
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6m""*soLENo,D
here I { lll
connect
I
I
3#Ji8iL,*
lj!!J
.t.
Connecttheotherleadof the testlightor
DVOMto the pointyouwantto check.
lf thetestlightglows,thereis voltage
present.lf you'reusinga DVOM,notethe
voltagereading.lt shouldbe withinone
batteryvoltage.
voltof measured
A lossof morethanonevoltindicates
a problem.
A
Connectthe otherleadto the otherend.
testlightglows,thereis
lf the self-powered
lf you'reusinga DVOM,a low
continuity.
readingor no reading(zero),means
goodcontinuity.
NOTE:Alwaysusea DVOMon high
A testlightmaynot
circuits.
impedance
glow(evenwithbafteryvoltagepresent).
r3
HowToUseThisManual
Troubleshooting
Tests
Testingfor VoltageDrop
Testinglor a Shortwith a TestLight or DVOM
Wires,connectors,
andswitchesaredesigned
to conductcurrentwilha minimumlossof
voltage.A voltagedropof morethanonevolt
indicates
a Droblem.
1. Removethe blownfuseanddisconnect
the load.
'1.Placethe digitalvolVohmmeter
(DVOM)in
the appropriate
DCvoltsrange.Connect
the positiveleadto the endof the wire
(orto theconnector
or switch)closestto
the bafterv.
2. Connecta test lightor digital\roltr'ohmmeter
(DVOM),switchedto the appropnareDC
voltsrange,acrossthe tuselerminalsto
makesurevoltageis present.Youmight
haveto turnthe ignitionswitchto ON:
checkthe schematic
to see.
TESTLIGHT
ol
DVOM
<-
s80RT TO
GFOUNO
Disconnecl lhe
load here.
3''
Connectthe negativeleadto the other
endof the wire(orthe othersideof the
connector
or switch).
Turnon the components
in the circuit.
The DVOMwillshowthedifference
in voltagebetweenthetwo points.A
difference,
or drop,of morethanone
voltindicates
a oroblem.Checkthe
circuitfor loose,dirty,or bentterminals.
ffito.'"o'o
.t.
Beginning
nearthelusebox,wigglethe
harness.
Continue
thisat convenient
ooints
aboutsix inchesapartwhilewatchingthe
testlightor DVOM.
Wherethetestlightgoesoff,or the DVOM
voltagedropsto zero,thereis a shortto
groundin thewiringnearthatpoint.
NOTE:Alwaysusea DVOMon high
impedance
circuits.
A testlightmaynot
glow(evenwith batteryvoltagepresent).
co
Testingfor a Short with a Sell-Powered
Test Light or DVOM
Testingtor a Short with a Short Circuit
Locator (Short Finder)
1. Removethe blownfuseanddisconnect
the batteryand load.
1. Removethe blownfuse.Leavethe
batteryconnected.
test
2. Connectone leadof a self-powered
(DVOM)
lightor digitalvolUohmmeter
(switchedto the lowest"OHMS"range)to
thefuseterminalon the loadside.
2. Connectthe shortfinderacrossthe battery
sideof
andthe load(component)
terminals
thefuseterminal.
SATTERY
Dlsconnectthe batlery.
FUSE
BOX
Removethe fuse.
<-
ssoRrro
ciouNo
FUSE
BOX
SHORT
FINOER
SELF.
POWERED
TESTLIGHT
o1
DVOM
Dlsconnectthe
load here.
.)"'
r| SOLENOID
I swtrcH
Kl"
Connectthe otherleadto a known
goodground.
nearthefusebox,wigglethe
4. Beginning
thisat convenient
harness.Continue
pointsaboutsix inchesapartwhile
watchingthetestlightor DVOM.
testlightgoeson or
5 . lf the self-powered
a lowreadingor no
displays
DVOM
the
(zero),
is a shortto ground
there
reading
in thewiringnearthatPoint.
-.T.1
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PULSING
MAGNETIC
FIELD
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- G601(Hatchback)
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NOTE:Wiresshownwithoutcolorcodesare black.
LEFT
REAR
TURN
LEFT
SIGNAL TAIL
LIGHT
LIGHT
Page110-7 Page110-5
LEFT
ERAKE
LEFT
LIGHT/
TAILLIGHT BACK.UP
Pages110-5 LIGHT
a n d1 1 0 - 1 7 Page110-1
(
)
RIGHT
REAR
TUNN
FIGHT
SIGNAL TAIL
LIGHT
LIGHT
Page110-7Page110-5
RIGHT
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LIGHTi
TAIL
LIGHT
Pages110-5
a n d1 1 0 - 1 7
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LICENSE LICENSE
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PLATE
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Page110-5Page110-5
RIGHT
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Page110-l
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G601
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PHO|O 132
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CONDENSER
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Page47
Page
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PHO|OT0
vtEw 51
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c753
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G751
GFY(r9)
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!.
G801
14-13
lgnitionSystem
-
All '96-'98ModelsexceptDl685; '99-'00Dl6Y5 with M/T
NOTE:ForServiceCheckConnector
details,seepage23-3.
@
rDc
CKP
sensor
input
sensor
Inpur
(IDCP)
POWERTRAIN
or ENGINE
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MODULE
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CYP
sensor
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98-00 modets
I
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ground
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ground
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ground
POWERTRAIN
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-
All Dl685 engines;All '99-'00Modelsexcept Dl6Y5 with M/T
NOTE:ForServiceCheckConnector
details,
seepage24-4(exceptD1685)or 25-4(D1685).
STEERING
LOCK
POWERTRAIN
sii.s*- | (Pcn'orEcM)
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20-3
StartingSystem
- AutomaticTransmission
(All exceptDl685)
.133-7,
or 133-12
NOTE:Forcarsequippedwithoptionalsecuritysystem,seeSecuritySystem,page133-3,
for startingsystemcircuitschomatic.
WHT/BLK
c3s2
PHO|O I
vlEw 27
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page10. a
'10 c433
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SeePower
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Page'10.
SeePGlr-Fl,
page25.
STARTER
BATTERY
21-1
StartingSystem
- ManualTransmission
NOTE:Forcarsequippedwithoptionalsecuritysystem,seeSecurity
System,page133-3,or 133-7,or 133-12
for startingsystemcircuitschematic.
WHT/BLK
c3s2
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vtEw 27
r.------T-------------=;-*^:-lsrEERtNG
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pag610.
FUSE15
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Fuelpump
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ABS,
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page14-5.
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page14.
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MODULE
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HO2SinBt
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E*o,*.
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UNDER.
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39
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23-11
PGM-FI(All '9G'98ModelsexceptD16B5;'99 D16Y5with MiT)
- D16Y5Engine
23-12
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L TG R Nw t t r
13
- g c401
,F"| "."":.tun't
[!l",,,
It
I
I
i
+ F,'"%*
(sO2sHTc)
,
ir.
tt
!
i
.E------
Secondary
HO2S
heater
control
*'--
(PCS)
EVAPpufge
control
solenoid
valvecontrol
(vSV)
EVAPcontrol
canistervenl
shutvalve
control
Yi',,,u,
----
L2WBS)
POWER.
EVAPbypass ! TRAINor
solenoid
I ENGINE
valvecontrol I CONTROL
MODULE
----J
| (PCMor
ECM)
vtEW70
24-11
(D1685)
FuelInjectionSystem(PGM-F|)
Programmed
(N),
in PARK(P)or NEUTRAL
NOTE:Fuse31 is HOTwithlgnitionSwitchin START(lll)andA'/TGearSelector
seeStarting
System,page21-1.
@
ii6iir-
- -TFU'E;--- - - gI3'5"
I
p--',b"
!['.iF{,
ffi:|EHF?
i'[-------------'[&T:1,
iI
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7.54
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| --+
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--
ffii;l'i;
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"",""[*=
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I
J
I
A
T
|.-------
25
HI
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ll
I
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oBon
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arsl
t
page
canver|
rrsl
er-u
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t
- - - - - - -- - -;s,nl- -ffi'J-.'"-;t--7;,i----&;----i-,"ffifi
input
input
Oac*rjp
I
I
I
N
t T /IlU
GFNYEI
r vv
'rT#
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!
I
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t
l
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I
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A
,,..!.
a24
'-^-*'!
PowER-
f,mihHin.
{
I (PCM)
lif''?;"
FromB
FromA on
facingpage.
v
I
WHT/REO
c401
WHT/BED
WHT/FED
WIIT/BED
a
*"rr"a^ |
,L-:l'il
mm1:2
FUEL
INJECTOR
RELAY
FUELPRESSURE
REGULATOR
SHUT.OFF
SOLENOID
VALVE
PHOTO 135
r-
vlEw73
W}ITIRED
r
arr<
S€sGround
Dietribution.
LJ*
IT ;.;.il,
*'"J'.
|
'
m
'
mm,t ,iJ,-,
m'ill"'"-"'
c150
:
c4o'l
PHO|O147
a
vtEW72
-"----.<
- -J
"u"T.l,
*
fu*gr
PorYgr
Ground Grouft
v'
a -
i{
fl[J2)
(rNJ3]
it.;:;t"'-
INJECTOR
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MODULE
0NJ4]
Ground
I-J
Ground
;:[
BFN/BLK
I
I
I
SeeGround
oistribtnbn,
I
8LXI
""'7lw;8"'"
;.;..{
:il
c.t 16
(Terminals'l-7)
SeeG.ound
Dislribution,
pag€14-3.
Distribr;tion,
pags r{-6.
ti
:
BFN/
BLK
!
y'o,J
PHOIO 86
clot
Y
!-'
G101
2s-1
PGM-FI(D1685)(cont'd)
I
t
I
!rurr
| "'f8;i
I
I
h.
I
(
ct20
vtEw29
DISTRIBUTOR
PHO|O 44
TDC/
IGNITION
CONTBOL
MOOULE
Se3Ground
Distrilutbn,
page14-3.
I
I
:nl
I
c|(P/
CYP
0cM)
Y
!
!
!
__.!,",,0
{ti'o'i""'"
it-{ "i1lg,*
|
I .""u.*o
c9 A
!'I
I
I
I
-,'il"i -*-*i -.?'ii - - - - - -ri**i -''!
Sensor Saflsor
ground ground
L------
25-2
C30
S€nsor
ground
Sansor
ground
| 3l"J:uel
POWERTRAIN
CONTROL
! MODULE
(PCM)
!
l t
b;,.i,,
I
I
) ur"lro
Ground
(tcz)
Ground Grornd
(PG1j
(PO2)
Rsier€nce
voltaoe
Ncto
Map
ssnBor
input
(MAP}
S€nsor
ground
(SGr)
POWERTRAIN
CONTROL
MODULE
(ECM)
Sewica
chock
cottn6ct0r
fioul
' (scs)
PHO|O 86
vtEw 70
ic------
a20Y
B22
82
(Ierminals8.14)
vtEv\/39
S€€Ground
Dlsr.ihJtion,
pags14-5.
S€eGround
Distribution,
p8g€14-2.
II
Ses Grolnd
F
PHOTO 33
3rr;rs'
-F
___l
:
G4/l2
PHQTO 125
(cont'd)
25-3
PGM-FI(D1685) (cont'd)
(
UNDERHOOD
FUSE/
RELAY
BOX
uYt%%,
WHT/REO vr6wJ,
I
aaz 4
wxlnro I
8 Y C352
ll Proro8
S€EPowsr
Bistribution,
pag€10-10.
,""'o"n I u'* "
ll wwcnr
Se3Powet
Distribution,
pags 1&13-
.4
*"r,o"., ll
sI
I
DATA LINK
coNNECTOR (DLC)
qA
l'?!-1
BRAKESWTTCH
| Closedwithbrake
| /
!-l-ij 9;'3,1ff'**""
'T
"*'-.1,
See ABS,
i
ll
ci t 3 11
tlofo t
'EW5!
vtEw
59
F------
(x.irie
oata
inpuv
output
:
I
-----gl-
VIEC
vafue
contol
812I'
GFN,^YEL
i
I
!
I
I
F':t;"
o"n,,,.f,
r{r *."
Il-i-JJlll!,[.fi"'"
25-4
\ : (
Pt9q
Brako
switch
input
WEC
prossure
switchinpllt
PSP
switch
inpui
;ry---T
(wU)
\
lPSPSvv)
flffiii':Y-2E
"l
t
--l
I
I
\
a
"*|
---J
I
I
POWERSTEERING
(PSP)
PRESSURE
swtTcH
SeeGround
Distribution,
pag€ 1+2.
t__________L
@
----t
UNDER.
2s
t FUSE
I p.4:!
) Iff" sesPower| ;"Eiii
I
|
IL--*----il--l-J
tF,%.,
l------+
3l'i:?'J:"
'oY F;%.
YELI v/Ew
55
---
- - - - - - - - - -;f
f
I
Y
c+ lv'rwto
r--'1r-:-----'l
seePower
!
pass10'6
Disiribution,
See
Fans
I
G U N|
see
I
I
I
ComDressor
Conliols
|
BLKnEo
I
*o I
o,.1.
I
o',,l
GAUGE
l"?i*,"..
f*
,\
! f,s";"ty"tt
vtEwTl
|
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see!y'c
B L U V H|T
I
I
see
Startrnq
System
'-iminatstz'zo1
Charorno
Syste-m
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"".11-lro,..
I
I
-ruil
|
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,r---U,a"i---strF-*-*"r"tr8*i-#%,.----;w;,---lne
[it^'"
\
tan control
\
r
i
i
rL------
control
'[g3l
I
l27Y
BLU,FEo
I
Y
See Vehicle
SpeedSensor
(vss)
Atternaror
FR
i"R8!,
c23
ll,
t
Input
-._
AJc
rsquest
VSS
BtUw}rI
I
ciutchreiaycontrol
l
I
Y
See A,/C
Compressor
contiot
",gl,1o
"ur
l
w8rRED
I
I
Y
Atternator
controt
"'11'%,
--------J
| (pCM)
|l. puoroea
iir*.
I
I
"rX
wxronr
l
I
I
Y
-'-d
3i:,""I"'n'"n
(cont'd)
25-5
I
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PGM-FI(D1685) (cont'd)
EGR
vdvo
EGR In
valvs s€mor nd*6nc6
voltac€
contol inDln
inDut volt|ce
: control
I G.€GF} GGf,q N@a
L------87
c28
Fueria (
pres$uro
i.snsor
inout
inbut
.(PFoJ
lP
inDul
s€{tlor input
s8fi8of
fiPg'
t
h.tsllank tenF,
ingJl
sonsolifix,
ssnsof
fiFO)
------J
\
II
;
,
c150
PHOTO112
j
C'ro1
PHO|O sl
c575
vtEw7i
EXHAUST
GASRECIR.
CULATION
(EGR)VALVE
and LIFT
SENSOR
THROTTLE
POSrT|0N
CIP)
SENSOR
PHOfO 36
FUELTANK
PRESSURE
SENSOn
FUEL
TA}IK
TEMPEB.
ATURE
SENSOR
H
"""r":x
PHOTO116
(
1 Y
o
GRI{/BLK
4
c575
GNN/BLK
c401
GNN/gLK
2
PHOfO 57
vtEw 40
cls0
GRN/BL(
n"*r"a^[
'r
cai/BLXll
creA
r--?
POWERTBAIN
lsJiH,I CONTROL
MOOULE
I groundI (PCM)
I
25-6
I
J
PHOfO 86
a
-.t
POWERTRAIN
lcoNTRoL
\.
. -,.^-I llglllTP-.
.
sensor_rnpul
;
nFa
I
rL------
I MODULE
Fuel
p{sssure
sansor
input
sensor
input
(PF2)
.s€nsor i;ir*,o
input
:
GcD
i|An
I
--------J
c13I'
c14Y
c26
From
facing
page.
v
!
FUEL
TEMPERATURE
SENSOR
_l
ENGINE
COOLANT
TEMPERATURE
INTAKE
AIR
TEMPERATURE
SENSOR
SENSOR
flltur'ffi
(rAr)
(Ecr)
From
nen
page.
v
i
GFN/BLKlI
i
EG-f
,{J
c't 15
(ferminals&14)
vtEw38
(cont'd)
25-7
PGM-FI(Dl685) (cont'd)
\ ' (
i
Primary
HO2S
Secondary
Input
(PHO25)
(PHozst
(sHo?sr
input
L-------
J,
POWERTRAIN T
CONTROL
MODULE
(PcM)
I
I
S€s Power
Distribution,
p6gs1&5.
PHO|O A6
vlEW 70
UNDERDASH
FUSE/
RELAY
BOX
PHOTO 58
J,
i'tj I
Lti-'!
! !
SeeGround
Distuibution,
pago14-2.
t "l
G101
PHOfO 33
c't23
:li
1
SeaPower
Dislibution,
pag€'1G5.
c125
(
BLK
SECONDARY
HEATED
OXYGEN
SENSOR
(HO2S)
PRIMARY
HEATED
OXYGEN
SENSOR
(HO2S)
BLK
c123
2
c125
GFN/
ALK
HOzS'
n€ater
conlrol
25-8
HO2S
hgater
control
POWERTRAIN
CONTROLMODULE
(PcM)
I
VehicleSpeedSensor(VSS)
\ . (
il';;---l
I
\
ALTENNATOA
UNDER-DASH
FUSE/RELAY
BOX
I PHO|O 5a
I I""::,",,",
!
Lr_f1l_i
9#":1"
".*,1,[
CRUISE
vtEw69
12
EtuwHr|
! so""oo!iio',6T""f
iffii
!
!
!;i#:*!
l;i"i;'!
L---J
B11 Y
TRANS.
MtsstoN
I v"ni"t" CONTROL
I v"ni"pI CONTROL
UNIT
l:g9qd
l:p"gd I MODULE
iineilt i vtEw43
I'T$, I FCM)
[il
iiTs'l,
l'ffi, D . ^ . . 1 *
L J
il[
I
[
!y:ll*!Bb'^i1?'J.'
lr*J iipEr',r"
l;6';irtE
liib-r,ro,ecu1
I
[
( - C 1 8 )Y
vtLNTo
SeePowerDistribution,
page10-5.
(
"""-'
Y'
Oerminats1.t-13)
vlEw52
lgnitjon
Vohiele
speeo
ouptn
VEHICLE
SPEED
SENSOR
(VSS)
PHATA 35
Ground
= '96-98: AllmodelsexceptD1685
'99
00: D 16Y5 w th Lr/T
= '96-'98:All models
'99-'00:D16Y5
with M/I D1685
33
.i
a
- Howthe GircuitWorks
Withthe ignitionswitchin ON (ll) or START(lll),
batteryvoltageis suppliedthroughfuse15 and
the BLI(WHTand BLK/YELwireto the vehicle
speedsensor(VSS).Thesensoris groundedby
the BLKwireto G101. Thespeedometer
and
othercontrolunitsin the circuitsupplyabout5
wire.Thevehiclesoeed
voltsto the BLU/WHT
groundsthe
(VSS)
intermittently
sensor
generates
BLUMHTwirewhich
a pulsedsignal
in it. Thenumberof pulsesperminute
increases/decreasos
withthe soeedof the car.
Reterto th€ ServiceManual(Section23, Electrical)
procedures.
tor specifictostsor troubleshooting
33-1
CruiseControl
(
FUSE
i4
I
t
i
P*",
f tlfl*t.,s""
DistribulDn,
|
(CBUISECO{TAOL)
\
a
UNDER.DASH
FUSE/RELAY
BOX
H
L--g----r9101_
".,."11[ftT:{.
See
Dash and
Console
Lights
"-T[_
! i,*f+*l
f:L[
CRUISE
CONTROL
MAIN
swtTcH
"oN"
It{otcAToR
\fa
See
Dashand
Console
Lights
Openwith
brakepedal
depressed.f--
I
LrcRNI
I
Ir
,.L-----
r#e
i--l
L-------
34
'r
"""I
*"1
I
t
---3-l
-ffi$r------(
l
--------J
* = '96-'97models
*' = GXmodels
;iil;------'l
onl|,
ATO9IT
l5a
506 Po\r€r
Dislrhulbn,
pagelot3.
UNDER-HOOD
FUSE/RELAY
BOX
----li----J
i
c352
8
PHOTO8
WHT/GFN
,r:ill
ilifl'?H]"*,--
,rllI
g**.
---!
",f,*,,":l
CABLE
S€s
llorns
-----J
I REEL
I
I
I
STEERING
WHEEL
?
I
I
l r
I
BRAKE
.
Closedwith
brak€pedal
deprcssed,
Rlroma/
Accel
Sultch
swtTcH
PHOTO 68
3
ItK
2
gu{
r-r------
1 CABLE
IREEL
I
3ll'
CNU|sE
CONTNOL
SETngSUtE
swlTcH
| \
I
"+f--a=={
--.'*""*-[
\rnfig*,',,"1o,,
","*"
*-'*:'!
|s.triL!fl8;lp,*,;,,LT.FN,FEDI
o"n.t""t I
L-
A
..^at
J
,,^"1,
c430
(s6-'s7moders
i)J[
Br?kp
swilch
fr^
intut
\
I
- -
(sl g -o9"95]I-( e6-e7moders
lll
Sevdecel
signalinput
cRUlsE
---:--l
Resuma/
t Ctitrf-nlOr_
acc€lsignal
i uNif
inp,n
| p#ib *
13
lvtEw
(cont'd)
34-1
CruiseControl(conrd)
\ta
- --
;lG;r-usEz5
J,T"r"r,E;oAit
tusEiRELAY
IiF" 3g;g;; f,%,,
-------' page.tG6.
I
L:4---:---J
SeeDash
and Console
;I
Ss€ po$/er
Distribution,
page10-6.
wEw56
-r+
GAUGE
I ASSEMBLY
CRUI6E
CONTROL
rNrxcaTon
UGHT
\1
E3
BL|(
I
----*-
I
I
J
E2Y
""t===j
I
t-ffiI
c0f 0r
I
Se€GroundDistribution,
pag61+7.
c411
PHOTO 60
RED/BLU
= G401
I
I
10
('96197models9)
'Cruigecontrol'
indlcatorlight codrol
Cruisecontrol
actuatorqontol
I
Gro{nd
('96198 models 8)
o
11
ENN/ELX
aFt/Bu(
2
aLu
6nNAVST
c202
4
BBT{
4
BRt{lv}tT
3
PHOfO23
VIEW1
c203
PHOTO18
CRUISE
CONTROL
ACTUATOR
Se€GroundOistribution,
page1+4.
l'
34-2
G202
""r1
i -
'99100
016Y7/D16Y8with A"/T -
POWERTRAIN
Cruise CONTROL
conrol MODULE
sgnal
(PcM)
i8s)i
|
\
-
-
iil
-
;
-
i
-
-
*
-
-
-
'
'
Cruise
control
signaloutput
.
l
c
= '96-'98:All models
'99100: D16Y5with M/T,01685
R
U
|
s
E
I CONTROL
|oNir
I PHATO55
I
.--------;----
13
' vtEw
vehiclespeedinput
oisengageinput
---J
SeeVehicle
Sensor
rySS)
"{
CLUTCH
swtTcH
Open with
clutch pedal
oepresseo.
,--r-s=-.
A/T GEAR
POSITION
swtTcH
L- ----
SeeGrolnd
Dlslribution,
page14-6.
I
Y
l
l
L__l
#
:
x
ALU,ryVHT
O-a
See Gfound
Digtribution,
page 14-5.
I
3
ct30
Cferminals
11.13)
PHATO E3
vlEw 52
VEHICLE
lI:::1"I SPEED
SENSOR
I output I
(vss)
J
G401
34-3
GruiseControl(cont'd)
- Howthe CircuitWorks
Thecruisecontrolsystemusesmechanical
and
electrical
devicesto maintain
thecar'ssDeedat a
settingselectedby the driver.
SystemDescription
Thecruisecontrolunitreceives
command
signals
fromthecrursecontrolmainswitchandthecruise
controlSeVResume
switch.Withthe ignition
switch
provided
(ll)
(lll),
in ON or START voltageis
to the
cruisecontrolmainswitchthroughfuse14.When
youpushtheswitchto ON,poweris provided
to the
cruisecontrolunitandthe brakeswitch.
The cruisecontrolunitreceivesinformation
about
operating
conditions
fromthebrakeswitch,the
vehiclespeedsensor(VSS),andtheclutchswitch
(manual
transmission)
or theA,/Tgearposition
transmission).
Thecruisecontrol
switch(automatic
unitthensendssignalsto thecruisecontrolactuator
whichregulates
thethrottleposition
to maintain
the
selected
speed.Theconlrolunitcompares
the
actualspeedof thecarto theselected
speed.The
controlunitthenusesthe resultof thatcomoarison
to openor closethethrottle.
(
Youcan cancelthe cruisecontrolsystemby
turningthe mainswitchoff. Thisremovespowerto
thecontrolunitanderasesthesetspeedfrom
memory.lf the systemis disengaged
temporarily
by the brakeswitch,or clutchswitch,andthe car's
speedis stillabove25 mph,pressthe resume
switch:thecarwillautomatically
returnto the
previously
setspeed.
For gradualacceleration
withoutpressingthe
pedal,pushthe RESUME
accelerator
switchand
holdit there.Thiswillsendan "acceleration"
signal
to the controlunit.Whenyou releasethe switch,the
systemwill be reprogrammed
for the newspeed.To
slowthe car down.oushthe SETswitchin and hold
it there.Thissendsa "deceleration"
signalto the
controlunit,causingthe car to coast.Whenthe
desiredspeedis reached,releasethe SETswitch.
This reprograms
the systemtor the newspeed.
Referto the ServiceManual(Section23, Electrical)
procedures.
tor specifictestsor troubleshooting
(
The brakeswitchreleasesthe system'scontrolof
the throttleat the instantyou presson the brake
pedal.Theswitchsendsa signalto thecontrolunit
by removingpowerfromthe normallyclosedbrake
powerat the
input(GRYwire),andproviding
(GRN/vVHT
normally
openbrakeinput
wire).The
controlunitresponds
by allowing
thethrottle
to
close.The clutchswitchor the A,/Tgearposition
switchsendsa "disengage"
signalto thecontrolunit
that alsoallowsthe throttleto close.
The cruisecontrolsystemwillset and automatically
maintain
anyspeedabove25 mph(40km/h).Toset
it, makesurethemainswitchis on andtheswitch
indicator
is on.Then,afterreaching
thedesired
speed,presstheSETswitch.Thissendsa "set"
signalto thecruisecontrolunitwhich,in turn,
controlsthe cruisecontrolactuatorto maintainthe
setspeed.
Whenyoupushthe SETswitchandthecruise
controlsystemis on,the"cruisecontrol"
ON
indicator
lightsup.
a
34-4
A/T Controls(All '96-'98ModelsexceptCW and GX)
r.(
UNDER"HOOD
r5A
see power
I FUSE/RELAY
I BOX
I
--li$"i':,--i
L-.At----8 Y 93^s_1'"'".u
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vshicle
slc€€d
inp{
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I inpg!
inpr.,t
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speedsenior
input
forsotenoid
DrivenDultev
speed iens6r
input
S€condaw
-speed
gearshaft
s€nsorinput
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iil
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t
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See Power
Distribution,
page10-2.
iT;;*-l
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UNDER.OASH
FUSE/RELAY
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1rGP2)
-
I TRAIN
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MODULE
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\
controlsolonoids
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\
t
( H L CL S - ) T H L C L S + )( S C L S - ) ( S C L S ' I i S H L S I
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GRN
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lruffil
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..
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rLG2r
PHO|O 86
I
cl16
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8-14)
BLK
CVT
TRANS.
MISSION
SOLENOID
vlEW39
SeeGround
Distribution,
page14-2.
BRN/BLK
BRN/
BLK
SHtF'
CONTNOL
LINEAR
SOLENOID
(cont'd)
39-13
A/T Controls('99-'00CVT)(cont'd)
\)a
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10 Y c50t
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i-=1ffifiI"'""'3**",
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ii
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ground
lmr
sansof
input
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86
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A9
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12
c410
c131
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GAUGE
ASSEMBLY
PHO|O67
vtEw71
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kldlcrtor
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Il
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I
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,
,I
I
i
fsn$t';
c410
vtEw35
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POStTtON
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1
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a-<
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|
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*o" to-t
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39-15
Horn
- '96-'97
Models
UNDER.
HOOD
FUSE/
RELAY
BOX
c353
PHOTOs
SeePower
Oistribution,
pag610-13.
""^T.!,HORN
RELAY
PHA|O 58
6 g c411
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60
a,
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:i :i-I:::--l
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TUNER
RAOIO
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c214
1
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vtEw21
PHO|O 73
VEW 5A
| | vtEw68
WHT/qRN
VHT/qRN
pre-wired--Vehicles
lor accessory
securitysystem
c430
BLU
I
1
Sse Cruise
Control
-------
J
GBY
-
-.!
HORN
l
STEERING
WHEEL
h
:
40
c4o1
PHQ|A 57
- '98
Model
FUSE52
I
I
I
floFft,
sroPtT
154
I Y C3s2
S€oPowsl
Disfibdion,
page1013.
""',o"nI il?lo,'
wHT/cFN
U
@.
THI
UNDER.
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FUSE/
RELAY
BOX
:t
c353
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RELAY
o
GFY
87
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;
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l
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ELU
I
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- '99-'00
Models
UNDER.
HOOD
FUSE/
RELAY
BOX
FUSE52
HORI,
SfOP LT
t5a
HORN
RELAY
---------^1
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i
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,
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KEYLESS
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coNTRoL
UNIT
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c214
v|EW21
with
Kevless
Entry
PHOIO 134
vtEw 75
Vehiclespre-wiredfor
accessorysecuritysystem
GRY
c430
ELU
PHOTO 65
.l
I
a
\
I
SeeCruise
Control
I
I
I
I
CABLE
REEL
GRY
STEERING
WHEEL
HORN
a!m" niffil"
40-2
.,1
,
Anti-LockBrakeSystem(ABS)
UNDER.HOOD
H'.'""
ii[*:'*"
1
c357
PHOTO 4
GFN
10
BEO
c359
PHO|O 6
Grqlnd 2
{GX!2)
l"l Fi* :l :l
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I-J
.-L----i il
T
44
PHOIO 125
UNDER-HOOD
r------1
ABSFUSE/
FUSE61
RELAYBOX
PUIiP
olon
c356
night
Reer
ABS
Soloroid
(ln)
Right
Rear
ABS
Solenold
(Out)
i-.t_____l
Lett
Front
ABS
Solenoid
(od)
FUSE63
MTN
CHECK
7.54
3
*fitr
c357 2
YEURED
c356
A19
\
RightrearABS
solenoidcontrol
\
i
/
&------
comm6n
LeftftontABS
solenoidcontrot
(PMR)
(MCK)
Pump
Motor
motdr
;i;
loni of
^
Service.check
connectorinput
11.I
BRN
"Tl
'Tl
I
trrt
sRS.ATcontrols
SERVICE
CHECK
CONNECTOR
I
t-!
---_____J
See GrOUnd
vttt 63
LTBLU
vccvnv
DATALINK
CONNECTOR
(DLC)
PHA|A 125
':
1
c360
ABS
PUMP
MOTOR
pHOrOso
Pll'lo.,jpn. p y:l:!:1
'--=-Ea;
I
i
aBscoNrRor_lrNr
*L_T'=Llj:t
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I
I!
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l
DLC
inpuvoltput
A14
r
rr eru
check
I
See Ground
*---==4oi
PHOfO,/
44-1
Anti-LockBrakeSystem(ABS)(cont'd)
(
.I UNDER-
!'-r;us?;---l H5BE"FUSE16
iA DEF
ilrryilrfi#ftilHri
'tr
lEtsY SeePower
:ar Distribution,
page10-8.
L-g------J
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I
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vlEW50
page 1G6.
I
pHoro5d
c501
vlEW55
SeePowerDistribution,
page1S6.
se€Power
Distribution,
10-13'
Page
YEL
D5
GAUGE
ASSEMBLY
.tr
.I BRAKE
r -N-
|
| swrrcH
\
igr:*
AAS INDICATOR
LIG}IT
usA
a'KBLU
o"ntr"r
Carsda
!
It
I
'96-97
mooels
D3
Dl
ftff^"n"o''''ot
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i".,
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".1
",I
mI
T1*l
{FLo)
i
seecroundDistributiofl,
iffit
'
n
:
iot
{FL1)
B23Y
i
(FBo)
B8Y
I
{FF1)
B21lf
i
(Rr"o)
B6Y
^*ry*l:-------l
8Bi"o.
ir .UH|T
iicib et
vlEw63
Sg____gT]-__g,l-j
BlsY
(
G401
1lo2)
lgnition2 '
used) ; 4ts5lnolcalor
l i g hct o n l r o l
Speedsensoranputs r - - - - j .
t,"LTfflo",
Input
Blolf
!
B4X
B17f
o"",'..
o""l .,",-ul u.,"..1
I
r| | r | t I t , l l , l
"on"
't---'+----"[. I --fo f!'?'%,'
ll ll
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ti
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lU]flqtfl
lt;Tt?f
lt"F"Ti?l
I
lt5T8?lI
l"#tgl I
44-2
(
- Howthe CircuitWorks
The anti-lockbrakesystem(ABS)preventslocking
of thewheelsas a resultof heavybrakingand/or
poorlraction.A vehiclewithlockedwheelscannot
be steered.The anti-lockbrakesystemcontrolsthe
thedriverto
application
of thebrakes,allowing
maintain
controlof thesteering.
theantilockbrake
Underanti-lock
conditions,
system(ABS)modulatesthe pressureof the brake
tluidto eachbrakecaliper.Thissystemis a four
at eachcaliperis
channelsystem:thepressure
of the pressureal any
controlledindependently
othercaliper.Whenevera wheelis likelyto lock
theanti-lock
brakesystem
dunngbraking,
at thatwheel.When
modulates
thebrakeoressure
is reduced
to the pointwhere
the brakepressure
of wheellocking,
thereis no longeranypossibility
braking
thesystemreturnsto theconventional
systemmodeof operation.
Batteryvoltageis appliedat all timesthroughfuse
switch
63 to theABScontrolunit.Whenthe ignition
to the
is in ON (ll),batteryvoltageis supplied
controlunitthroughfuse16.Thecontrolunitis case
grounded.Inputsare receivedfromthe brakeswitch
andthe individualwheelsensorslocatedat each
wheel.TheABScontrolunitusestheseinputsto
unit.Thesolenoids
solenoid
controlthe modulator
pressure
appliedto each
adjustthehydraulic
calioer.
function.
TheABScontrolunithasa self-diagnosis
fault,
it
turns
on the
unit
detects
a
Whenthecontrol
"ABS"indicator
brake
theanti-lock
anddisables
braking
system.lf thefaultis notin theconventional
to operatenormally
system,the brakeswillcontinue
feature.
butwithouttheanti-lock
'19,
Referto the ServiceManual(Section
testsor
for specific
Anti-Lock
BrakeSystem)
procedures.
troubleshooting
44-3
Supplemental
Restraint
System(SRS)
(
UNDER-DASH
FUSE/RELAY
FUSE23 BOX
(sRs)
FUSE13
FUELPUUP
FBA UMT)
15A
SeePower
Distibution,
page10-2.
c801
PHOTO 58
PHO|O 111
G F Y0 7 )
or GFN
{18)
. To avoid accidentaldeploymentand possible
iniury alwaysdisconnectthe driver'sairbagand
f rontpassenger's
airbagconnectors(automatically
shorted)beforeworkingnearany SRSwiring.
. CAUTION:
Wheneverthe ignitionswitchis ON (tt),
or hasbeenturnedOFFfor lessthanthreeminutes,
be caretulnot to bump the SRS unit; the airbags
could accidentallydeploy and cause damageor
SRSMEMORY
ERASE
(MES)CONNECTOR iniuries.
STGNAL
G A Y ( 2 1 )o r G R N
GFN
GFY O4)
or GRN
lgnition
Input
(VA)
lgnition
input
(VB)
Driver's
cont.ol
SRS
UNIT
SRSindicator
lighlcontrol
MESconnectorinput
rffi{{_ilil
;
Passenger's
ai|bagconlrol
t
,
prc..
rnpuv
Ourpul
Service
check
connector
Inpu
t-----Passengefs
:
airbagcontrol
;
, /+rr
;
,
Ground
I pir-r
14
GRY
(5)or
GFN
GRY
GFY
0)
t2l
GFN
GFN
i ffi
ir:r*::"."
ffirtu!-T:l
2
ALK
J(ii
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i""'"1*"o,"'.1''
'"'Jl
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SERVTCE
(DLC) CHECK
CoNNECTOR
piarasa
CONNECTOR
,J:
vtEw48
H!=";=_J
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shortcontact)
L_________J
47
|
-
FCqOt
PHO|A
57
PHOIO 125
a
UNDER.DASH
FUSE/RELAY
BOX
FUSE25
PHO|O5E
IIEIEB
754
S88 Fowor
I
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ASSEMBLY
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PHOfO 57
47-1
BlowerControls
'96-'98Models
@
UNDER.DASH
FUSE/RELAY
BOX
UNDER.
HOOD
FUSE/
RELAY
BOX
PHOTO 5A
BLOWEF
noToR
BELAY
PEOfO I
(
BLU/
YEL
1 l
BLU/
HEATER FAN
SWITCH
SeeGror
Ground
Dbtribution,
Dbtributi
page
14-5.
oaqg14.
ar<
L
-
60
II
_l
c402
6
1
BLK
BLK
BLK
calr
See
L/c
Compressor
Controls
- '99-'00Models
i-F;;t
iGi'i'-----'l
UNDER.HOOD
FUSE/RELAY
BOX
BEATEA
,'/C RE|AY
7.5A
L-t'::-i
"d[ft?"l'
L-*----::--J
FUSE55
HEAIER
t/toToR
UNDER.
HOOO
FUSE/
RELAY
BOX
".*1.[F*ft"
n
BLU
UNDERDASH
FUSE/
SeePower
RELAY
Dist.ibution, BOX
page10"9.
PHOTO 58
I
I
-".. i c.u,
--';-lP;!o;i:
$
---------J
Se€Powsr
Dl8tdbution,
pago1O11.
l
3ffJ?il3'o'"o'o*'on
,f
ALOWEF
moToR
REIAY
-f-***;;Iru
PHOTOI
l1
:::::: - ---r-- -- J
L__f_---_-_
BLIV
YEI
BIU
g€ePowsr
Dlslribution,
pag€lGg,
t!.-
---:-----.l
------------a--E
za
'r
BLowER
l-'n
I A lm-o-roC'
Ir
eaoz
PHoro12s
I( MrlProraE3
I Y I
-
=----GG-a
".","i-l'
Ea
JI
1
lgnition
Blower I
t Battory
input
molor i
i (brckup)
t
,,o*",
ffJtt'
' 'Jback I
I
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Power
motor
i
highrelay transislor
!
Ls::s1gl-tt:---J
A6
813
alK
OFN/
WHT
HEATER I"-'FI
CONTROLI
|
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wr'vzo
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POWER
rAlHStStOn
| pHoro
13e
I
I
6
BLOWER
MOTOR
TIIGH
RELAY
PHO|O 83
|
lJ J I
BLK
2
c440
BIK
SeeGround
Oistribution,
page'14-5.
"l
G402
Se€Ground
Si:lf:::'>-1
G402
60-1
Air Delivery
a
- '96-'98Models
I
:
\
I FUSEiRELAY
H€AITN
! f I9"",'
i
UNOER-DASH
17
t FUSE
f
:
seePowsr !
BOX
PHOTA 58
otsaibution, i
LJ----':g':'--.i
9
C420
BLx,yEL
Y
ELK/'(EL PHora363
I
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er.x,ter-[
SgEPorvst
DistrtbLditr,
pags I S9.
".*..";:.it#?.9.,,
RECIRCULATION
CONTROL
MOTOR
PHO|O A2
SeeDashand
ConsoleUghts
c723
GBN/IVHT
12
r
I
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I
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PHOTO138
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13
S6€IVC
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61
I
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MOTOR
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YEUBEO
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YEUBED
138
HEATER
CONTROL
PANEL
8
I
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t
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it
Venl
Swltch
lleat
Swltch
\
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c723
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S9eGround
Distribution,
page14-5.
h
-_l
G402
61-1
Air Delivery
a
- '99-'00Models
- -{-;;;
-
r--T----.I
i|
,ry:i.l?
i
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UNDER-HOOD ;
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I
I
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U page1o-9.
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MODE
CONTROL
MOTOR
RECIRCULATION
CONTROL
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PHOTO139
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Htr
Ttr
=tr
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*tr
T Ti
Ttr
lgnition Mod€ Mode
Battery
(backup) input
detrost h€av
delrost
Air
Sensor mix
grgund cool
Ground
Mode L4ode
heat
heav
venl
Air
mix
hot
Mode
vent
Air mix
5Y
poientia,
reTgrano9rnrrul
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motor
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13
BFN
SeeGround
Distribution,
page14-5.
I
61-2
R€circulato Fresh
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WHT I
ONN
c723
F ash/
Roclre
Swftch
AIR MIXTURE
CONTROL
MOTOR
I
So€Roar I
Windolv :
Delogger
Reclrc.
SeeRear
Window
Oetogger
Y
t t
L__l
--tGo3,
vtEw76
I
AFN
SLK
CONTROL
PANEL
Recirc
Recirc S$,itch
Swilcfi
switch
tED
LED
common mput
control common - J
;;-;
J'J - - - J-JL
i5:- -
c9 Y cl1
812
a
L-------
oatLEo
---J
HEATER
PUSH
swtTcHEs
(
- Howthe CircuitWorks
'96198Models
'99J00 Models
The air deliverysystemdirectsthe flowof air used
systems.
by the heaterandair conditioner
The heatercontrolpanelreceivesbatteryvoltageat
all timesthroughfuse47. Withthe ignitionswitchin
ON (ll), voltageis suppliedto the heatercontrol
panelthroughfuse17.Thecontrolpanelis
groundedat G402.
The heatercontrolpanelcontrolsthe air delivery
motors,and suppliesa 5 VDC reterencevoltageto
the air mixturecontrolmotor.
The air mixtureand modecontrolmotorseach
receiveinputstromthe heatercontrolpanel.The air
mix motorregulatesthe mixtureof coldand hot air
doot
by varyingthe positionof the heater-evaporator
ModeSelection
Modeselectionis controlledby the modeswitches
in the heatercontrolpanelandthe modecontrol
motor.Whenyouselecta specificmode,voltageis
appliedthroughthedimmingcircuitto the LED,
whichcomeson, indicatingthe modeselected.
Groundis orovidedto the modecontrolmotor
thoughthat modeswitch.The motorthen runsuntil
the air controldoorreachesthe properposition.
Fresh/Recirculation
56lection
button,a
Whenyou pressthe freshor recirculation
groundsignalis sentfromthe heatercontrolpanel
controlmotor.The motorthen
to the recirculation
doorreachesthe proper
runsuntilthe recirculation
position.Batteryvoltageis alsoappliedthroughthe
LED,andthe
dimmingcircuitto thecorresponding
LEDcomeson.
Referto the ServiceManual(Section21, Heater)for
proc€dures.
specitictestsor troubleshooting
The modecontrolmotorcontrolsthe directionand
volumeof outletair.The air flowcan be directedto
the dashboardventsor the cornervents.
Boththe air mixturecontrolmolorand modecontrol
motorare groundedby the h€alercontrolpanel.
The recirculation
controlmotorreceivesbattery
swilchis
voltagethroughfuso17whentheignition
of thefresh/recirc
theposition
in ON (ll).lt regulates
door,and is controlledby two positioninputsfrom
"Fresh").
the heatercontrolpanel("Recirc"and
Referto the ServiceManual(Section21, Heater)tor
procedures.
specifictestsor troubleshooting
61-3
A/CCompressor
Controls
\ a
- AllModels
@
f-T-*-'.T'---lH53.',EPA?' i-l-------
i iflH* !F,?r",,
| tsBi":J;"#il
!
|
|
oaoe1o-9. !
L_J1_j:_-_j
***
e Y c42o
ifi"l'
f
seepower
^
UNDER-HOOD
FUSE/RELAY
BOX
ia f6F"'.i:.",",
T
I
!
I
H
i
!
I
|
SeePower
Distriburion.
pase
1o-1.
&c
COMPRESSOR
CLUTCH
RELAY
-
Y
PHOfO 10
l
-t---------J
c353
: POWERTRATN
I or ENGINE
!
,acc,
! arn.^-^,o..^,
i.,ii.r| fi3$18.
! iii"i-iiii"v
A/Crequest
(pCMor ECM)
I
!
I
(ACSJ
L------J
a pHOrOa6
v t E w7 0
cc5)
M7
a
REO
c2'14
BEO
1
vtEW21
c209
RED
c752
ct31
BLU/RED
?
BLU/FEO
2
BLU/FEO
:"1'!i'------;
COMPRESSOR
THERMAL
PROTECTOR
a='e6-'s8:
except
D1685
'99100:A||moders
Fi:rz,
vtEw21
ir'iio ,"
D16Y5with l\illT
'* = 96-'98:All models
99. 00: Dt6y5 wth t\4/t Dl6Bb
atc
c1
PRESSURE
swtTcH
".,n""t
1(
"
".r-".rf,"tA%
A,/C
COMPRESSOR
CLUTCH
"."-:,fi
tfr,]4.
v
To facing page ('96''98 models)
or page62'2 ( 99-'00models).
62
!
(on bracket)
- '96-'98Models
FromC214on
facingpage.
UNDER.
HOOD
FUSE/
RELAY
BOX
v
"**il'ifr"e;
S€eFwvof
Distrih$on,
pags10'11.
INDICATOR
----1
HEATER
co TROL
PANEL
D i m m i n- o
I Clrcult
L------J
SeeAit
Delivery
'l ctte
I
lrc
I
I
I
10
HEATER
FAN
swtTcH
62-1
AiC CompressorGontrols(cont'd)
- '99-'00Models
(
Frompage62.
vI
.I
UNDER.
I HOOD
i FUSE/
I RELAY
*"-ilii.,"r,
ihtli
I Box
I
J
UNDER.HOOD
FUSE/RELAY
BOX
SegPow6r
Distrlbutiofl,
pag€'lGl1-
c353
4
PHO|O 8
BLUAVHT
15
6LUAVHT
a,/c
THERMOSTAT
Olt below
3 " C( 3 7 " F ) .
l[,,*
"'""
".j:[ru*,,ry
';.!,
"..;X
(
THERMISTOR
B11A
A8A
r - - : = -A/C
-II
Switch
common
l'lC
switch
LgD
codrol
,c,/c
switch
itput
cl
GBN
ORN
t/c
Swltch
S€eAir
Delivefy,
Rear
Window
Dslogg6f
B€ttery
(backup)
Switch
IED
cormon
c5
{;[
B ' I O| '
lgnition
input
request
vtEW57
Grouod
BIK
SeeAir
D€livery,
Rgar
Window
D€foggar
r,/c
HEATER
PUSH
swrTcHEs
SeeGround
Dist.ibdion,
page1,1-5.
Ot'l
lndicatof
Y
I
=ffi;
PHOfO 125
62-2
HEATER
I CONTROL
: PANEL
(
- Howthe CircuitWorks
Batteryvoltageis suppliedthroughtuse56 to the
A,/Ccompressor
clutchr€laycontactsat all times.
Withthe ignition
switchin ON (ll),vollageis applied
to the coilof the A,/Ccompressor
clutchrelay
throughfuse 17.Whenyou pushthe A,/Cswitch
ON,andthe heaterfan switchis in position| , 2, 3,
or 4, a "ground"
inputis provided
to the engine
controlmodule(ECM)or powertrain
controlmodule
(PCM)throughthe l'lC thermostatandthe l'lC
pressureswitch.
TheA,/Ccompressor
clutchrelayis groundedby the
enginecontrolmodule(ECM)or powertraincontrol
module(PCM).Whenenergized,
theA'lC
compressor
clutchrelayallowsbatteryvoltageto
turnon the A,/CcomDressor
clutch.
TheA,/CON indicatorlightcomeson whenthe A,/C
systemis requested.
A,/CThermostat
The A'lCthermostatis locatedon the evaoorator
housing.The A,/Cthermostatturnsoff the A,/C
at the
compressor
clutchif the temperature
goesbelow3'C (37'F).Thisprevents
evaporator
fromfreezingon the evaporatorfins
condensation
theairdeliveryintothepassenger
andblocking
compartment.
Theblowermotorwillkeeprunning
whenthe sensorturnsoff the comDressor.
A,/CPressureSwitch
The fuC oressureswitchis locatedin the condenser
is in a high
outletlinewhererefrigerant
pressureliquidstate.The switch
temperature/high
willsenseabnormally
highor lowpressure,
and
ground,
This
removes
openthecircuit.
andthe
compressor
willstoprunning.
ThermalProtectot
Thethermalprotector,locatedon the A,/C
compressor,
opensandturnsthe compressor
off if it
senseshightemperature.
Oncethecompressor
will
cools,theswitchwillcloseandthecompressor
beginrunningagain.
Referto the ServiceManual(Section22,
AirConditioning)
for specific
testsor
procedures.
troubleshooting
62-3
Fans
- AllModels
\,1
|
cof{oENs€R
FAN
RELAY
Prtofo10
Se€I'i C
Compre€sor
Cont ols
c352
1
ALKAED
f
uY 9,;%,.
cFN vIEw5e
"'
;
Y:.
\ra
BLKaEo
";::-:.."-!
I
T
---::Y
""'I h!ii'in","
'is.2o) :
:
I :
spliced
together
insteadof in
thejunction
connectoron
Dl6Y5models
l;l:'l?'* i
I i,o''ur,ff;,
II r---,; |JBEI
:;
I control
|
I
I
du.
,I
c753
1
BLU/BLK
CONDENSER
FAN
MOTOR
ALK
2
c753
BLK
:L--J
'
'
'
:
I
I
H
:I
:
PoWERTRAIN
or
E N G I NC
E O N T R O L'
MODULE
(PCMoTECM)
:
PHAfO 86
wEw 7a
ENGINE
COOLANT
TEMPERATURE
swtrcH
l l q A- - - - .
c211
BLL
PHO|O 33
?
RADIATOR
FAN
MOTOR
I
BLK
t1 - '96.f98:
models
'99-'00:All
016Y5withM/I 01685
'99-'00:
"2 =
Allmodelsexcept
D16Y5
withM/Tand01685
Ses Grolnd
Gro!nd
Diskibution,
page
14.
oaqe14.
i:
"'*1F J T
_l
I
I
Se€Ground
Ostribution,
Pago14.4"
PHOTO11
BLK
1
c211
ELK
'Glot
*
63
czsr
33
123lCVIl
*
czor
a
- '96-'98Models
i-ITy::.;--l
il;;
il-;;.;l
UiB!'*
i-T ig;Eili--l Liff" tS^*
From Under-hood
Fromunder,hood
;
rac,nspaee
|
(
HEATEB
liEF;
i$f"
I i?r*'
i llH**"",
1"1 seepower
' iL8ry-s:d-J
i-r-g-.'I.-
Fuse/Relay
Boxon
I
U l S I r l O U I r O nI , e l l o ' O 5 8 L l v - - - -
H
L-I----q,ryli"--Jr'i
L-L---q'i.'g;-.1wxreru
9
V
".,*"'l
|
I vr'wi."
X ,cgr,g
""
SeoPow€r
Disaibution,
page10n1.
::::ll6iirf{ffi.",".,
--- --'''lB;,zfz
"f
"$r*,,,,
Jl[1__::.fif-o
*iiiFr-B:er.#:r
" r**"
+asero€
:'j'd",.,
-1-'
Gll".-11yorror"-:'L
r------,F-
UNDER.
HOOD
FUSE/
RELAY
! BOX
[
A/C ON
INOICATOR
L -----
HEATER
CONTROL
PANEL
-J
SeeAk
Delivery
Gate
tc
I
L---rr--
---
- -J
IF-F;Ia,ic
Swltch
,!r---*l
h
...
,----------J
-:{l-lit't;;
L€:_jftH+z
"*f
,""n,ouno
___-i*-]
63-1
Fans (cont'd)
rla
- '99-'00Models
iTm,il-l5;i;T
iln"lgg1
*-"'
L_t]stE"_i*-o*
!-J-___i
"W"u'
".*L[F*f,l"' -*,".'"[ftT,;.'
I
I
SsePower
',-.',
.-..
?+
3s;iT:3:'
S€€Pow€r
I
?'4
3ff:?f?l:
::--
;+
OEE
I
I
{***,Pase*11
Dbfibution,
pacp10.9.
It
a,/c
THERMOSTAT
Offbelow
3'C (37"F).
2
Y
^..._-_I
*-*"!
2oV c723
l
t
tI
L
- -_-\Tgr?;u
'l
I I rHERMrsroR
lt |
q/
t
r l
I
I
2 39 - - - - - - - - - - - - - - 2 ,
f,
l
ar-x,ver|
t
l
I
t
I
c723
,2tr prtoroz!3a
t
n
tn*t,".u I
I
orl
---riliii"--
---rF------
"tol
(backup)
inplt
requ€si
i
HEATER
CONTROL
PANEL
I vlEw76
Switch"
common
L-----
N
r,/c
svritcn
LED
control
switch
input
c
Swikh
LED
cofrrnon
l
I
Ground
_ _.i
A6
BLK
A/C
Swlbh
S€eAlt
Deliv€ry,
Baar
Window
D€loggpr
63-2
SeeAir
Dslivery,
n6ar
Window
Delogoor
a/c
ON
lrdlcalqr
HEATER
PUSH
swtTcHEs
SeeGround
Distribution,
pag€1+5.
I
;-a; J
rfa
- Howthe CircuitWorks
RadiatorFan
Voltageis providedat all timesto the radiatorfan
relay(contacts)throughfuse57. Withthe ignition
swilchin ON (ll),voltageis provided
to thecoilof
therelaythroughluse 17.
The radiatortan relaycan be groundedthrough
switchor the
eitherthe enginecoolanttemperature
enginecontrolmodule(ECM)or powertraincontrol
module(PCM).
The enginecoolanttemperature
switchgrounds
(coil)
radiator
fan
relay
when
the engine
the
coolanttemperature
exceeds199'F (83'C).The
switchopenswhencoolanltemperature
decreases
3'- 8'C.
CondenserFan
Voltageis providedat all timesto the condenserfan
relay(contacts)throughfuse56. Withthe ignition
switchin ON (ll), voltageis providedto the coilof
the relaythroughfuse17.WhenyoupushtheA'lC
switchandputtheheaterfanswitchin 1, 2,3, o( 4
position,the ly'C thermostatcomeson, the
condenserfan relayenergizes,andthe condenser
fanmotorruns.
A,/CThermostat
is locatedon the evaporator
TheA,/Cthermostat
housing.TheA,/Cthermostat
tumsoff the A/C
clutchif the temperature
at the
compressor
goesbelow3'C (37'F).Thisprevents
evaporator
fromfreezingon the evaporator
fins
condensation
andblockingthe air deliveryintothe passenger
goesbelow3'C
lf the temperature
compartment.
groundwillbe
(37"F)tumingoff the Ay'Cthermostat,
fan relay.Thiswill
removedfromthe condenser
deenergize
the relayand removevoltagefromthe
fan motorcausingthefan to stoprunning.
condenser
Reterto the ServiceManual(Section23, Eleckical)
procedures.
for specifictestsor troubleshooting
63-3
RearWindowDefogger
- '96-'98Models
il
l1c
SeeDashand
ConsoleLights
UNDER-DASH r - F - - - - 1
I FUSE/RELAY
FR DEF R€LAY
7_54
c501
@
.I
FUSE16
FEO/
BL|<
\rl
ff":;;1il,l"'3|""
3"C3jgl-i
i-f:"'*rul
!._L:___J
UNDER-HOOD
FUSE/RELAY
BOX
c351
vtEw55
vtEw34
REAR
wtNDow
DEFOGGER
SWITCH
rf
ll-,--:L::
See Dash and
Console Lights
S€eGround
Distribution,
page14-7.
NEAH
wtNDow
DEFOGGER
RELAY
UNOERDASH
FUSE/
RELAY
BOX
P|1oTO59
L--------
-------J
'1"[ FzT;4co,pe
ano
seoanu
Hatchback
t*''
"._,".trf
T^
"'-f
Y
I
I
a rr(
t___
64
I
fl[lfEex,"
t
SeeGround
Distribution,
page14-7.
:
g"x%,0,
".^,"i'uI
' * 9,g%,,,
eu,eul
G401
|.Tl
IiIDEFoGGER
II "
*-l
seecround
Distnbutron,
Pase14-10
"r- |
I
* coor
PHA|O 1A2
nean
I .5 | WTNDOW
I
I
^--.
PHOra1AA
- '99-'00Models
t@
r
I
I
HEJT'EFAIC RETAY See Power
7JA
0istribution,
pag€1&9.
".*:.f
L
PHOfO 58
I
t sl*t-' '"o'o'
L-*----J
3 Y C3s1
J
c420
UNDER-HOOD
IFUsE/RELAY
r-r---1
| ( #tt*
UNDER-DASH
FUSE/RELAY
BOX
FUSE'7
vtEw53
!
Ss6 Pows Dist bution,
pag€10-9.
HEATER
CONTROL
PANEL
"T.I
lgnitioninpd
I
I
I
LED
gontrol
Swiich
Slitoh
Groulld co{Y}rnon inM
A6
c9
ALX
BLK
c12
YEL
gl",,ry'_l
c6
c1
A7
PUR
ORN
BLU/
YEL
r'
R€aI
Wlndow
Dcrogger
Sultch
S9a€round
Distr&dbn,
P.go 1it-7.
RearwinoowI
dofogger I
Snitch
LED
common
-
21
Se€Air ;
D6livory
BLU/
YEL
BLU/
YEL
Deliv€ry
---J
HEATERPUSHSWITCHES
L-------
c723
PHO|O 138
c440
ON
Indlcitor
56€ Air
I. G,rc2
wlIT/GFI{
4
(GX10)
BLU/
YEL
PHO|O81
vtEw45
c411
PHOTO 60
vtEw60
PHOTO63
vtEw53
vtEwss 5
8
SeeGound
Distdbltion,
page14-7.
I
I
I
I
UNDEN.DASH
FUSE/RELAY
BOX
c420
c501
PHO|O 5e
I
I
I
I
I
NEAB
wlNooly
DEFOGGEN
F€I.AY
Prrolo 59
cssl
vtEw47
Halchback
"*1[ftTi.:-wtNDow
cotL
ANTENNA
{cx'l)
T 9,*%,,
[93ff''n'*'
",-"",-,
1
t o REAR
!.'IFI
".":il
lll
82
ALK
*r
H
DEFOGGER
:
eY
G401
PHOIO 57
DEFoGGER
-.1
wtNDow
t_
I wrNDow
arr<
BEAR
I
",
V F,9"oB
erxialul
I
*-r" *"r'
I J
Sre Ground
DFtrtbditm,
pago1+7.
".-i."tr
ftTi",,'
t
* csoz
!
G601
S€9Grolnd
Distribtdion,
pag€1+ 10
ffiff$Ee
I
I
*
cttr
PHOfO 10A
64-1
RearWindowDefogger
- Howthe CircuitWorks
'96198Models
I
Voltageis appliedat alllimesthroughtuse50 to the
rearwindowdetoggerrelay(contacts).
Withthe
ignition
switchin ON (ll),voltageis appliedthrough
tuse16to the rearwindowdefogger
switch.
Whenyou turnthe switchON,voltageis appliedto
thedefogger
timercircuit.Thetimercircuitsupplies
voltageto the rearwindowdefoggerrelay(coil).The
relayenergizesand suppliesvoltageto the rear
windowdefogger.The defoggergridthenheatsthe
rearwindowto removeany condensation
fromthe
glass.
The defoggertimercircuitwillautomatically
turn off
the rearwindowdefoggerafterabout25 minutes.
Referto the ServiceManual(Section23, Electrical)
procedures.
for specifictestsor troubleshooting
'99100Models
Voltageis appliedat all timesthroughfuse50 to the
rearwindowdeloggerrelay(contacts).
Withlhe
ignition
switchin ON (ll),voltageis appliedthrough
fuse16to the heatercontroloanel.
Whenyouturnthe rearwindowdefoggerswitch
ON,a signalis sentto lhe defoggertimercircuit
built-into
the heatercontroloanel.Thetimercircuit
suppliesvoltageto the rearwindowdefoggerrelay
(coil).The relayenergizesand suppliesvoltageto
the rearwindowdefogger.The defoggergridthen
heatsthe rearwindowto removeanv condensation
fromthe glass.
a
Thedefoggertimercircuitwill automatically
turnotf
the rearwindowdefoggerafterabout25 minutes.
Referto the SeryiceManual(Section23, Electrical)
procedures.
for specificteslsor troubleshooting
a
64-2
Integrated
ControlUnit
NOTE:Fuse31 is hotwithlgnitionSwitchin START(lll)andclutchpedaldepressed
or A,/TGearSelector
in
(N),seeStarting
PARK(P)or NEUTRAL
System,page21,21-1,ot 21-2.
t@
i'l-;;,-lH8B'r*
| \ rrmn1gn I FUSEI
i f t*"
LJr____J
u'lftf,%,
vtEw3a
SeeBrake
System
lndicator
ig8f"
PHOT7
O
S
wHr/FED
|
li^hl
3fl3,n'"n
sYsteh
wHr,FED I
!t
<--=-
,r"r,".0
|
|
FUSE 3I
staaTEa
SIGI{AT
7AA
S€s Siarling
Syslsm,pago21,
21-1.or 21'2.
SEsBrake
System
lndicetor
Light
,n"r,".u
I
.l B*?r:""
,.!,.*,
Ssa
ClharSrrE I
Systom I
I
I
I
I
A6
\
\
\
\
\
\
EogGound
Distlbution,
page l,l-7.
I
L------
--r-r..r'
3
c420
PHO|O 63
vtEw 53
FED/BLU
See
Ceiling
Light
SeeSeatBelt
andlgnition
KeyRemind€rs
/
I
I
I
I
I
SeeWiper,ryVasher
@
I
.1
-
t
t
I
SeaPower
Distfibution,
I
I
1
pag€10-5.
iz
FUSE15
FUSE30
ALTEi}IATOR
sP 8S$80n
l|lslFl,|tEl{l
uotfT3
?.54
FR \I/IP€g
Fi WASTIEF
204
7'5A
soe Headtight sss Power
Distibution,
Switch,
-
A8
UNDERDASH
FUSE/
RELAY
BOX
FUSE26
page100-t. pags1G7.
fo
INTEGRATED
CONTNOL
UNIT
\
vEw af
\
\
Ught8.ON
nemhder
Circrti
\
Combin€d
l,Ylper/
Warhot
Cireuit
lfllsnl|liter
Wip6r Relay
Circuit
\
\
t
I
,
I
I
I
a-------
*I "'r
I
I
I
I
-----[---t----""r,".*I ".u-"rl
t t
\--
See WiperMasher
70-1
BrakeSystemIndicatorLight
- '96-'98Models
NOTE:Fuse31 is hotwith lgnitionSwitchin START(lll) and clutchpedaldepressedor A,/Tgearselectorin
(N),seeStarting
PARK(P)or NEUTRAL
System,page21, 21-1,or 21-2.
FUS€ 31
atAirEn
8Gl{tt
7.all
UNDERDASH
FUSE/
RELAY
BOX
FUSE25
s." Ponr"t
ffR
S€oStarlingSysl6m,
pag621,2l-1,or el-2,
Distribulion,
page10-6.
rry
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PHOTO60
vtEw55
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Dlstribution,
page1G6.
;?l
---.I
GAUGE
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$os Indicators
i',i!i,I2'
(slt--95.:l-_i
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Froiit sz
- '99-'00Models
NOTE:Fuse31 isJtotwith lgnitionSwitchin START(lll) and clutchpedaldepressedor A,,/T
gearselectorin
PARK(P)or NEUTRAL
(N),seeStarting
System,page21,2i-1, ot 21-2.
--Iil;--------l
Fr,lrs
3i
s""po*"r
) 9ff"
"-
3m"
-\,
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pasezr.zi-t.'or'ztlz.
cot{TRoL
UNIT
ftoa 64
vEwa7
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Bulb
chek
outp$
Brake
Bulb
Chsck
Cheuh
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l BOX
|
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-:--' --
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o""'"T|
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S€6Ground
Distribution,
pago14-7.
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c551
PHO|O 6i
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PHOfA 63
(r;'
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PHO|O 63
Used)
14
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FED/GFN
I c419
:
18Jl iE?'8'
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Sss Gfound
Distribution.
pag€147.
T
Y
t t
L_l
.'-4o.'
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| | lP9l_-
:
1 Y Cs51
".o'o""! iffl1oru"
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PARKTNG
,
I BRAKESWITCH
I
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ennxerluro
I LEVELSWITCH
| /_,?lfJ",ii"."gl'.-
w::::"
"'-1"::::
! 3:"'lll"*l
".-l I
lIdft"f[]r'"r'"
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+
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----j
:
G40l
PHOIO 57
71-1
BrakeSystemIndicatorLight(cont'd)
- Howthe CircuitWorks
The brakesystemindicatorlightcomeson to alert
the driverthatthe parkingbrakeis applied,or that
the brakefluidlevelis low.lt alsocomeson as a
bulbtestwhentheengineis cranked.
a
ParkingBrake
Withtheignition
switchin ON (ll)or START(lll),
voltageis appliedthroughfuse25 to the brake
systemlight.Whenyou applythe parkingbrake,the
switchclosesand providesa groundfor the light.
Thelightthencomeson to remindyouthatthe
parkingbrakeis applied.
Brake Fluid Level
switchin ON (ll) or START(lll),
Withthe ignition
voltageis appliedthroughfuse25 to the brake
systemlight.lf the brakefluidlevelis low,the brake
fluidlevelswitchcloses,providinggroundto the
circuit.The brakesystemlightthencomeson,
thed verto a lowbrakefluidlevelin the
alerting
brakemastercylinder.(Checkbrakepadwear
beforeyou addfluid).
Bulb Check
Withtheignition
switchin START(lll)andclutch
pedaldepressedor A'lTgearselectorin PARK(P)
(N),voltageis appliedthroughfuse31
or NEUTRAL
to the brakebulbcheckcircuit.The brakebulb
currentto flowthrough
checkcircuitcloses,allowing
the brakesystemlightand bulbcheckcircuitto
ground.The brakesystemlightthencomeson to
testthe bulb.
Referto the ServiceManual(Section23, Electrical)
procedures.
for specifictestsor troubleshooting
71-2
\fa
SeatBeltand lgnitionKeyReminders
--f*.?*-j
UNDEF-HOOD
FUSE/RELAY
BOX
--LryJ
',J,trni:
UFIEN
?,irA
S6s Pow€f
Distribrtion,
pe961&10.
.4
UNDER.DASH
FUSE/RELAY
BOX
FUS€ 25
PHOfO 58
Ss€Power
Distribution,
Fag61G6.
r:f ftir
+
(Termlnals17-20)
t
vlEw 56
YEI
S€€Pow€t
Distibliion,
pag€10"6.
r--xr------
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Beepero0tpul
Ssar
Door f€y
b6h
swiich sr'/itch switcfl
Inpu inpul
Inpur inpd
input
Inpr',t
il-----*=f,f-----J
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PHO|O 57
73
PHoros6
:
G4ol
Howthe CircuitWorks
Seat Belt Warning
Withthe ignitionswitchin ON (ll) or START(lll),
batteryvoltageis appliedto the seatbeltreminder
light.Whentheseatbeltis notbuckled,
the seat
beltreminder/key-on
beepercircuitin the
integrated
controlunitsensesgroundthroughthe
closedseatbeltswitch.Theseatbeltreminderlight
comeson andstayson,andthe beeperbeepsfor
6 seconds.
The reminder
lightandbeeperwillstop
whentheseatbeltis buckledor thetimercircuit
deactivatesthem.
lgnitionKeyWarning
Batteryvoltageis suppliedat all timesto the seat
beltreminder/key-on
beepercircuitin the
integrated
controlunit.Whenyouturnon the
ignitionkeyswitchthe integrated
controlunit
sensesground.lf youopenthedriver'sdoor,the
doorswitchcloses,causingthebeeperto sound
untilthe dooris closed.
Referto the ServiceManual(Section23, Electrical)
procedures.
for specitic
testsor troubleshootrng
73-1
LowFuelIndicatorLight
\rl
't UNDER.DASH
I FUSE/RELAY
BOX
I
I
I
PHOTO 58
J
pag6 106.
,
-ls,T,*-*:lligff*,
l',;l:'l?,'
or*+*i
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c503
9FN/GBN
PHO|O 61
15
vlEw3s
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PHO|O A5
BLU/FEO vtEw59
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Than|tlrlor
So€
qauges
L-----J
PowERTRAtN
I i$grtor I MoD]LE(pcM)
I
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- ----J
SaeGround
Distribution,
pa$ 14-9.
74
A3A
!'-{ilril}-1
Lowtuel
I CONTROL
S'
i18l7"*
Howthe GircuitWorks
All ExceptGX
Do not smoke while working on the fuel system.
Keepopen flame awaytrom the work area.Drain
fuel only into an approvedcontainer.
A thermistor
is mounted
in thefueltankunit.When
thethermistor
is cool,itsresistance
is veryhigh.
Whenthethermistor's
temperature
increases,
its
resistancedecreases.Fuelin the fueltanktransters
heatawaylromthe thermistorfastenoughto keepit
coolso the thermistor'sresistancestayshighand
lhe lowfuelindicator
lightdoesnotcomeon.When
thefuelleveldropsbelowthethermistor,
the
thermistor's
temoerature
increases.
Withoutthefuel
to coolit, the thermistor'sresislancedecreases,
allowing
currentto llowthroughthelowfuel
indicator
lightandthethermistor
to ground,andthe
lowfuelindicator
lightcomeson.
Referto theServiceManual(Section
23, Electrical)
procedures.
for specifictestsor troubleshooting
GX
ThePCMturnson the lowfuelindicator
lightwhen
thefuellevelis low.ThePCMwillalsoblinkthe
indicatorlightwhena problemis detectedby the
fueltankpressure
sensoror thefueltank
temperature
sensor.
Referto the ServiceManualGXSupplement
(Section
11, FuelandEmissions)
for specific
tests
procedures.
or troubleshooting
74-1
Indicators
! a
UNDER-DASH
FUSE/RELAY
BOX
PlloTO 58
Dim
input
Grolnd
lgnition
lndicatof
contlol
'1
3in""li"?''""
,
"i*l?""
""""*l'
"*o""tr
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INOICATOR
LIGIIT
see Gauges
----J
GAUGE
ASSEMBLY
BLU/NED
=[
See
S€ ABS
SeesRs
==:
PHOIO 67
vlEw 71
=
I
1
c507
(Termlnals1.6)
vlEw56
S€e(Ground
Grouft Distribtltion,
page
4-7.
e, 114-7.
l____l
-
G4o1
PHOIO 57
(cont'd)
80-1
Indicators(cont'd)
.I
UNDER-DASH
IFUSE/RELAY
FUSE2s
I
I
I
I
! F,gI".,
UETER
7.54
SeePower
Distribution,I
page10€. I
J
't0 t
YEL
S€ePow€rDistribution,
page10-6.
YEL
I
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-7
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Fuellndicator
Light
---J
B3Y
"*,*" i
SeeBrake
System
Inbicator
'.,
t
""'"'* "*-i
!-
pre_w
reo
so.
savenricres
ror
(oPrroN)
F"EIi,6HiJttr"
""""";:"J;
!H;fi;"";Jt"'
accessory
securrtv
svstem
rc;1rg
ii|ot$,,
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- _- i_l ll__-_-_---v-' _- E" r\ sl !' -; _-r -_' -_ -_ -_ -_ -_-_-_-_-- -_ ii
o Zl
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A C503
Paoro
PsOrOo'
6t
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_-l _ 'l' :-Y'" ': -: y : ,,, _"""'^
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BLU
i,
SYSTEM
_..._.._ q SECURTW
BLU'BLK .. ELueLx
IllI ".u"."
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nourpcrrip
-4 BLU/8!K 9
'9900 vehicles pre-wiredfor
?-(:
,
I
c401
pHOfO 57
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accessorysecuritysystem
P H O f O1 J 6
vlEW58
Coupeand Sedan
"ar,"a^
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""'"'-lt
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Gx)
,:*'* ""dan
80-2
BLU/BLK v/Er,!
e
Jf
"arr"a*l
TRUNKLATCH
SWITCH
Closedwith
trunkopen.
3rr<
'96197 models
'98-'00models
"'"'"i{
"^'
qF*til'-""
4r*liT;--'""
""'-it:':
* = Male-Female
terminalsreversed
for'99-'00models
".* |
Bi?fi,,ri"li
Page14"12'
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BellR€minder
PNKI
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LEVEL
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ENGINE
OIL
PRESSURE
l
o
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SaeGrourd
I
,9c215 g:"Jifll' ;
t
l
Y
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swrTcH
Closedwith
lowoil pressure.
l/
i
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!-
PHOfO 19
:
Gauges
;;;;6;;#'t----lllgi'
i i-r-;
ffiffig'i ^i,i'llt"#,*'
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ifr{li,l[i
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SPEEDOMElER
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82
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Nsst,
oaoe
S€€Ground
Oistribution,
page1+7.
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L__j;,#39'n.',
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GAUGE
ASSEMBLY
f
l-*
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COOLANT
TEiTPERATNE
GAI'GE
\
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FUEL
GAUGE
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YEUGFN I
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Gxmod€t
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GXmodel
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YEUGFN
I
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OFN/BLU
F*H4''
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Fuer
lll,l5
vlEw35
OFN/BLU
OFN
tf
c410
A4
c131
vtEw59
.I POWERTRAIN
*!--* il?:+:ifl!r+i-''
!fi8tsllP.
331ffi
!i;E-i/'i
14ii11"t:'f""'
#."o,".
r --=
l--JvtEwzo
81-1
Gauges(cont'd)
- Howthe GircuitWorks
Whenthe ignition
switchis in ON (ll)or START(lll),
batteryvoltageis suppliedthroughfuse25 to the
gaugesin thegaugeassembly.
Speedometerand Odometer
Theodometerand soeedometer
drivecircuits
receivepulsesfromthe vehiclespeedsensor
(VSS).Thepulserateincreases
as thecar
accelerates.
The frequencyand durationof these
inputpulsesare measuredand displayedby the
speedometer,
odometerandtripmeter.
Tachometer
Thetachometerdrivecircuitreceivespulsesfrom
theignition
controlmodule(lCM)in thedistributor
assemblyor the ECM/PCM.The solid-state
lachometer
thendisplays
thesepulsesas engine
speed.Foreach200pulsesperminutefromthe
ignition
controlmodul€(lCM)or the ECM/PCM,
the
tachometer
displays100RPM.
EngineCoolantTemperatureGauge
gaugehastwo
The enginecoolanttemperature
intersecting
coilswoundarounda permanent
magnetrotor.Voltageappliedto the coils,through
fuse25, generatesa magneticlield.The magnetic
field,controlledby the coolanttemperature
sending
unit,causesthe rotorto rotateand the gauge
needleto move.As the resistancein the sending
unitvaries,currentthroughthe gaugecoils
changes.The gaugeneedlemovestowardthe coil
withthe strongestmagneticfield.
The6nginecoolanttemperature
sendingunit's
resistancevariesfromabout137ohmsat low
enginetemperature
to between3H6 ohmsat high
(radiatorfan running).
temperature
Referto the ServiceManual(Section23, Electrical)
procedures.
for specific
testsor troubleshooting
(
Fuel Gauge(All except cX)
Thefuelgaugehastwointersecting
coilswound
arounda permanentmagnetrotor.Voltageapplied
to thecoils,throughtuse25,generates
a magnetic
field.Themagnetic
field,controlled
by thefuel
gaugesendingunit,causesthe rotorto rotateand
thegaugeneedleto move.As the resislance
in the
sendingunitvaries,currentthroughthegaugecoils
changes.
Thegaugeneedlemovestowardthecoil
withthestrongest
magnetic
field.
Thefuelgaugesendingunit'sresistance
varies
fromabout2-5ohmsat full,to about110ohmsat
empty.Whenyou turnthe ignitionswitchoff,the
gaugeremainsat the lastreadinguntilyou turnthe
ignition
switchto ON (ll)or START(lll)again,
Referto theServiceManual(Section
23, Electrical)
procedures.
forspecific
testsor troubleshooting
FuelGauge(GX)
Thefuelgaugehastwointersecting
coilswound
arounda permanentmagnetrotor.Voltageapplied
to the coils,throughfuse25, generatesa magnetic
field.Themagnetic
field,controlled
by the PCM,
causesthe rotorto rotateandthe gaugeneedleto
move.The PCMcalculatesthe gasquantityin the
fueltankby usingthefuelpressure
valuedetected
by thetueltankpressure
sensorandthefuel
temperature
valuedetectedby the fueltank
temperaluresensor,andoutputsthe signalto the
gaugeassembly.
The gaugeneedlemovestoward
thecoilwiththestrongest
magnetic
field.
Whenyouturnthe ignitionswitchoff, the gauge
remains
at the lastreadinguntilyouturnthe ignition
switchto ON (ll)or START(lll)again.Whenthe
PCMdetectsa malfunction
withthe fuelpressureor
gas
temperature,
or detectsa
leak,the PCM
reduces
thefuelmeterto 0.
Referto theServiceManualGX Supplement
(Section
11, FuelandEmissions)
forspecific
tests
procedures.
or troubleshooting
a
a
81-2
A/T GearPositionIndicator
-cw
@
r
\
UNDER-DASH
FUSE/RELAY
BOX
SEEA,TT
Controls,
PGM.FI
;l
I
SeeDashand
Lights
Console
YEL
A
l
FED I
A1
"Ttr
SeeA/T
Controls
Y
l
t
FED/BLKI
t
l
A/T Gcar
Poiltlo{|
Indlc{or
t----Y--A.t3
TI
-;-----;++
;+
t -l-rl :I
I
BLKBLU
7
{
GAUGE
ASSEMBLY
\
a
c410
vtEw35
BLK/BLU
a
eui [S
BruI
See
lnterlock
System
BLKBLU
12
GRNA!/HT
ar
l
a
BLK
aLu
I
SeeA,/T
Controls
c433
A/T
GEAR
POStTtON
swrTcH
Sec Ground
Distribution,
pag€1+7.
Y
I
L__l
+
:
89
I
G401
\
a
a
- AllexceptCW
@E
rT---'I I FU3E25
UNDER.DASH
I FUSE/RELAY
I l-----+ pags1G6.
L.*--------J
I
i. ia m* **J.e:1-iF,?T,'
S€eA,/T
Controls
;:I
llIftr;1'
SeeDashand
ConsoleLights
.-a---{ csoT
SeeA"|T
Controls
+ r
'..[--[Eq"Ti**,,
."r'*"*",iFI
-
o' I
BEO I
105'
Pag€
AJA
I
AED/BLXI
AZ t
T
:I GAUGE
I ASSEMBLY
i'l;l:,tr?,'
a
ru
L:+ -1
_J-(y'g,--
t----g--
A11
A13
BLVBLU
f#**
BlVBIU
a
Bu( lF
BLU
I
See
lnterlock
System
I
I
I
I
I
I
I
I
I
a Ir
I-i
"."i?
BLX/BLU
Ga rryvST
A/T
GEAR
POSTTTON
SWITCH
S€eCruiseConbol
ALK
1
c433
BLK
vtEw11
SeeGmund
DistrihJtion,
page1+5.
: S€eGfound
I Disribution,
-
paga r.l- /.
L__i
=
G401
A/T GearPositionIndicator(conrd)
- Howthe CircuitWorks
Withtheignition
switchin ON (ll) or START(lll),
voltageis appliedto the A,/Tgearpositionindicator.
The A,/Tgearpositionswitchprovidesa groundfor
eachposition.
As an inputis grounded,
itsindicator
lightcomeson. lf youselectR,for example,
ground
willbe provided
to the inputof theA,/Tgearposition
indicato(andthe R indicator
willcomeon.
Withtheheadlight
switchin PARKor HEAD,voltage
is appliedto the RED/BLK
wireterminal.
This
panelillumination
changes
the indicator
fromfixed
to controlled
by thedashlightsdimmerinput
throughthe REDwire.
Whenthe powertrain(allexcept'96-'98CVT)or
('96198CVT)controlmodule(PCMor
transmission
TCM)detectsan abnormalityin the automatic
transmission
controlsystem,or whenyou request
diagnostic
troublecodesthroughtheservicecheck
connector,
the PCMor TCMwill makethe D4 (D for
lightblink.
CVT)indicator
Referto theServiceManual(Section14,
AutomaticTransmission)
for specifictestsor
procedures.
troubleshooting
\ia
89-2
FrontWiperMasher
I
I
a
Fi WIPER
fi YYAEIIER
c423
vtEw3
A4
I
I
I
t
t
91
\
I
l
\a
-----1
,.
UNDER-
l DASH
FUSE/
RELAY
BOX
I F
PHOTO 58
3--------4
WINDSHIELD
WIPERMOTOR
wEw5a
GFN/ELK
4
-".ir--;;;;
"i]5
.i.5^t
"{
Distribution,
r---':G-'---r
: c4ol
PHOTO57
Wlndshlrld
Wipor/
Warhar
Swltch
oFF (
ot
s€e
cround our
r
I
",.u,".*l
i
t
i
I
I
l----l
'"""""--:--
r
|
--.J---,
r
'
,r___f
a
BTA
t
|l
---------J
3l'#ltgl *-l I
!
t
tll
Inr Lo,
-a- -4. I
:
J
!
a |
-'tEt165
F#1.,---------;
B2
-__?F___?_rt
______
l
A5
|NTE_
1INTE.
r 1ao6Ttn
wioer--"-'
contrcit
\r t\\ (f\""-|lizlff,ll;'-
\
'"Y;Isil
aLU'wH
ntdmiitant/ha.k
/ l Intermittenvoark
\1
coMBrN\ill?H
Park
H.t
tr'Psr
Input
ffiI
cround
J.
'n"*-li3$H'o'
| i $$p
rs"'tilgnition
l litrlY,
ll
Inlerminanlwipsr RolayCircuit
i
91-1
FrontWiperMasher(cont'd)
- Howthe CircuitWorks
Whenthe ignition
switchis in ON (ll)or START(lll),
batteryvoltageis appliedto lhe combination
wiper
switch.andthe windshieldwiDermotor.
Low Speed
Whenyou turnthe wiperswitchto LO,the wiper
motor'slowspeedwindingis groundedthroughthe
BLUwireandthe LO speedcontactsof the wip€r
switchat G401,and the wipersrunat low speed.
ParUOfl
Whenyouturnthe wiperswitchOFF,the integrated
controlunit(PARKinput)grounds
thewipermotor
throughthe BLUMHTwire.Thecamswitchon the
motorsignalsthe integratedcontrolunitthatthe
wipersarein the PARKposition;
thecontrolunit
ground
from
thenremoves
the motor,and the
wipersstopin the PARKposition.
High Speed
Whenthewiperswitchis in Hl,thehighspeed
windings
wipermotorare
of thewindshield
grounded
throughthe BLUIrELwireandthe Hl
contactsof the wiperswitchat G401,and the
wipersrunat highspeed.
Intermittent
Whenthe wiperswitchis in lNT,batteryvoltageis
appliedthroughthe YEUBLUwireto the integrated
controlunit(lntermittent
wiperON input).The
integratedcontrolunit(lnt€rmittenvPark
Wiper
Control)groundsthe low speedwindingsof the
wipermotorand the wipersmakea singlesweep
everyfew seconds(SeeLowSpeedabove).When
thewiperretumsto the PARKposition,
thepark
switchappliesbatteryvoltagethroughthe
BLUMHTwireto the integratedcontrolunit(PARK
input),andthewipersstopin the PARKposition.
Mist
Whenyoupullthewiperswitchdownto MIST
position,
the highspeedwindings
ot thewipermotor
throughthe BLU^/ELwireandthe
aregrounded
closedcontactsot the mistswitchat G401,and the
wipersmakeonepassacrossthewindshield
at high
speed.The ParUOfffunctionthentakesoverand
the wipersstopin the PARKposition.
91-2
Washel
Whenyou pullthe wiperswitchtowardyouto turn
on the washerswitch,batteryvollageis appliedto
the washermotor.The motorpumpsfluidontothe
windshield
untilyoureleasethe lever;on '98r99
models,the integratedcontrolunit(windshield
washerON input)s€nsespowerat the WHT/BLK
wireterminaland runsthe wiperswheneverthe
washermotorruns.
Referlo the ServiceManual(Seclion23, Electrical)
procedures.
for specifictestsor troubleshooting
'l'
RearWiperMasher
F
I
I
I
I
FUSE3
'1 = '96-'98 models
(RRWPEN
Rn waaHERl
1 r
c423
8
PHOfO 58
vtEw3
GFN
4
{ . 1 :6 )
*' = Male - Female
terminalsreversed
'99-'00
lor
models
c551
PHOTO 63
c562**
PHOTO101
GRN
c607
GRN
Lf GRN/BLK
PHO|O 112
4
1
c767
6
PHOTO 126
LI GRN/BLK
Gf,N/BLK
LT GRN/ELK
c607
PHOTO112
vtEw I
REAR
wtNoow
WIPER
MOTOR
GRIi
3
LT GFN
4
LT GRN
ge€ Qround
Distdbr{ion,
page1+'12.
vlEw9
c562 ri
( t 1 :1 3 )
vtEw42
BLX
>-ra
c40'l
t
LT GAN
t
( . 1 r1 4 )
".-
LTGFN
4
( * 1 :3 )
c767
2
c607
I
cs62*
vlEW42
lrcFN/BlK
G761
a
132
lPhofo
'98100oodsls)
B (C427\
t:
!l
3
c401
('1:2)
iL
BLU
s (c427'l
6
GFN/BLK
4
9i:;"*
GFN/BIK
vlEw 30
1
c205
Lr.RN/BLX
LT GFN/BLK
FEO
REAR
wtNDow
WASHER
MOTOR
BLK
c205
S€eGound
Dietrlbution,
paget4"6.
BLK
So€Ground
Distribution,
page14-4.
--f
I
I
L__l
+
:
92
G40l
a
HeadlightSwitch
(
UNOER-OASH
FUSEiRELAY
BOX
i-t-;;l
1 J lff*n"'
PHOTO58
Sse Power
Disiribution,
page10-12-
L-.J----J
H
*itn12
nrrl'?;Ii
i
ffif'illi!
I
UNDER-HOOD
FUSE/RELAY
BOX
'SeePower
' Distribution,
: Page10-12.
L-----J
HI
-- )
Headlight
Swltch
ot[*o1-
HEADPAnK
ot.
-]
panx
I
COMBINATION
LIGHT
swtTcH
"roo a]ot.
IPAnK
a
{
FUSE22
FUSS2t
FUSE4
L H/I
LOIY SEAfl
t0a
F H/L
LOW EgAtl
R TIIL
HIG|{ AEAM
t0A
UNDER-DASH
FUSE/RELAY
BOX
____:== _ _,_.
l_-.__
1-sr*r"
i
t
:
vtEw53
".0-", i
i
".o".uI
I
l
l
--'l
l
i ".ou.,
t
i
t
i
l
l
r
i
l
i
2
--u{.sao,l,.i
neourrr nroerul'/Ftr'o
I
:---,
,.|,___ui
il--Tll''%i'sr"' ii
- -I DAYTIME
UNNING
IRLIGHTS
II! RESTSTOR
'- Paqe
110-13
it@4li**"""li;
100
s-i5-r
i
.
! a
UNDER.DASH
FUSE/RELAY
BOX
PHOTO 58
I
I
I
I
I
I
I
r--1
l ?EqnATEO
I uohtsI co rRoL
; OFI I UNIT
FIJSEl0
FUSE32
tpE SE UGfiTS
tan r|{rs
! input! im?,t
7,54
To Under-dash
Fus€/Rglay8ox
on n6xl pag€.
-J---------rt--15Y C501
c4r9
PHOfO 6i
----J
c927
OPTION
CONNECTOR
PHOTO 62
nEo/
ALK
* = '96-'98models
REO/
EIK
14
RED/BLK
c507
(Ierminals
11n6)
, FED/
vtEw56
C't40
PHOTO El
REO/
ALK
1
c723
"-"'['**,.1
*1[ _[*[,*,
f12)
r--1
|
|
:
PHOfO 138
;-r
| i i
|
:
|
|
A"rrGEAR !
------J
p$i+bd'i
EEil'J",3333fi".'
Page114
PANEL
Eli"ira
Page114
pHOfO 71
PHO|O 1i7 (g9'@l
wEtt/ 41
v/Ew761ee-oo)
PHoro
6,
VIEW71
i l
ll
|
I
I
I
t : t
l : l
t ; t
I t
I l. Ll- - J I
t
l
l
L--J
; L--J
' CRUISE OASH LIGHT
HAZARD , REAR
WARNING.
WINDOW
:CONTROL
BRIGHTNESS
(96-'98models)SwITcH . DEFoGGER;MAIN
CONTROLLER
Page114.1
Page114-1;SWITCH ' SWITCH Page114-1
pHOfO 73
, P a g e 1 1 4 -'1P a g o 1 1 4 - 1
v t E3v 2/
L--J
ilB?o'?u"."
V|EW6A
ot
irril?.rJll
Page114-1
PHOfO 13/
vtEw 74
(cont'd)
100-1
HeadlightSwitch (cont'd)
-.I
RomUderdash
Fur€/Bslay
8oxor
prevrous
prge.
-
-
-ri-Y
'-
c421
ll PHoro63
50
neoialxI u/EW
---'f
c2o1
ri"Je'tl
i"'oYizt i: iI
13 Y C5s1
ll esoro6J
v'Edu7
BEDelfi
i
Hatchback
Coupeand Sedan
l,
!'--'l
Itlt5i:^- :
I
i
L--J
, ll
UNDER.DASH
FUSE/RELAY
BOX
".o,".*l
l3pfif.l-"o."-i
pe6161ja
,
=,a,e.Fema,e
terminalsreversed
ll
: tr__________Y::_____:
9
('99100models18)
for '99-'00models
c562.
vtEw42
FED/BLK
1
(cruise3)
c202
c604
PNO|O23
ytEw 1
5
c605
wEwa
FEO/BLK
".,"-[TI
"ao,"a* |
I
\
I
LEFT
BRAKE
LIGHT/
TAILLIGHT
Page110-5
LEFT
TAILLIGHT
Page110-5
RIGHT
TAILLIGHT
Page110-5
/---l
\---t
RIGHT
BRAKE
LIGHT/
TAILLIGHT
Page110-5
ro.",. ?,I
,rUrOO
r-\
\_,
\;,,
LEFT FRONT
PARKING/
TURN
SIGNAL
LIGHT
Page110-2
100-2
RIGHTFRONT
PARKING/
TURNSIGNAL
LIGHT
P a g e1 l 0 - 2
LEFT
LICENSE
PLATE
LIGHT
Page! 10-5
RIGHT
LICENSE
PLATE
LIGHT
Page110-5
I
t=Male-Female
terminalsreversed
for'99-'00
models
FED/ALX
I
c562 r
(GX6)
vlEw42
('96-'98Sedans except GX 14)
('99100models except GX 18)
FED/BLX
FED/BIX
FED/BLX
All
Exc€pt
'99'00
Sedang
\
All
except
'99'00
S€dans
'99100
Sgdans
FED/ALK
'99'00
godans
REO/ALK
All
exc€pt
'99"'00
Sedans
'99r00
Sedans
"'*.jx".*:tr ""'r{"*^*
All
except
'99r00
Sedans
'99-'00
Sodans
t
"ao,"a"
I
ql
\
LEFT
INNER
TAILLIGHT
Page110-4
RIGHT
INNER
TAILLIGHT
Page110-4
LEFT
BRAKE
LIGHT/
OUTER
TAILLIGHT
Page110-4
c613
c617
c604
FEO/B!K
RED/BLX
\
LEFTINNER
BRAKE
LIGHT/
TAILLIGHT
Page110-3
RIGHTINNER
BRAKE
LIGHT/
TAILLIGHT
Page110-3
c605
'l)
Sedans
\
)
3
FED/BLK
FED/
ELK
(99-'00
Sedans1)
/
RIGHT
BRAKE
LIGHT/
OUTER
TAILLIGHT
Page110-4
LEFT
LICENSE
PLATE
LIGHT
Page110-3
or 110-4
RIGHT
LICENSE
PLATE
LIGHT
Page110-3
or 110-4
LEFT
OUTER
BRAKE
LIGHT/
TAILLIGHT
Pag€110-3
/
RIGHT
OUTER
BRAKE
LIGHT/
TAILLIGHT
Page110-3
Back-UpLights
- CoupeandSedan
!, (
*=Male-Female
reversed
terminals
for '99100models
T
I
FUSE19
I
EACKUF UGH'S
754
UNDER.DASH
FUSE/RELAY
BOX
PHOfO 58
x
:c,- - - - - J
10
c419
YEURED
A/T exceptCW
YEUNEO
15
('99-'00except D16Y56)
c'13't
vlEw59
'lrry
:+f't::
YEL
c124
2
PHOTO31
PHOrO 150(Si)
GRN/BLK
BACK-UP
LIGHTSWITCH
Closedwith
transmission
in reverse.
GFN/BLK
tl
l y! -*i
14
('99100except016Y518)
|
PHO|O75r (SD
""",":lt
:t
;;-'i-
15015)
PHOTO
vtEw59
CRN/BL(
.I A/T GEAR
|
| ?osllrgN
i l"-3.^'
i "j!*{b.
a.
Af
cl24
GRN/BIX
D
3 ^ C433
yeL a VIEW41
a"s#[c#
i*'o*
';".;t---'i
aplF--1
o
* "",0::","
u't' o'
! (
o"n,".-*
[
l2ot| #:;",,
t gg-oomooers
All
oxcept
'9$'oo
Sodans
,rrr:eS;f""t"-!#
I ;; t
"*^*f,
'99-'00
S€dan$
GFN/BLK
l
""::in;;'
ffi,*,,. T
o
@FLRI''
@i[TJ+."
"*r
2
>-rO
RIGHT
BACK.UP
LIGHT
@
2
SeeGround
Distribution,
pags1i1.1t.
II
a
".-
|
!
G601
I
!
\
G601
PHO|O 102IAX)
110
(
I
Hatchback
tr@
UNDER-DASH
FUSE/RELAY
BOX
YEVRED
15
c13t
PHOTOA5
('99-'00D16Y76)
YEL
YEUREO
vlEw59
c433
c'|24
YEI
vtEW41
GRN/BLK
POSTTTON
BACK"UP
LIGHTSWITCH
Closedwith
transmtsston
in revetse.
I
I rl*--?
GFN/BLK
1
c124
L
GRN/BLK
14
c131
(99-'00D16Y718) PHOfO 85
GBN/ALK
swrTcH
,5i*
-;;1---'
i
o I co..
vtEw59
12
('99100models16)
c401
GFN/BLK
c552 r
4
('99-'00models19)
*=irale-Female
terminals
reversed
tor '99' 00 models
PHOTO101
vlEW 42
GFN/BLK
o
G
""",Jfi
fiT,,3,*
@i[T,'+'"
-*1
orr<
BLK
ALK
I
c604
@|,LHI"'
--l
s€ecround
t-Ti"...
i'""#'T?!:
"l9t*,,,
I
lJJ"''"'
I
.! c6ol
110-1
LicenseLights,ParkingLights,and Taillights
- Coupe,Sedan,and Hatchback
UNDER.HOOO
I I rusecs I FUSE/RELAY
BOX
Li5:_i
"^1,1fr!;?'
g€oPow€r
Dlstrbutiofl,
page101?.
arr*
HI
B1
-- - Y - - - '--:gsg-l
:t!
FED/GFNll
- - -.
: -i::-|
neoionlr lf C422
I PHorc58
7 A, vtEwt6
-)'
56€.Hsadlqht
FUsEsr
lYi-"'l;-.
DaO€
- 10$1.
ru9c ltz
uclrlaEtlclllS
ta{- uotfls
7.lla
c927
oPTfoN
3totur['JY3;tttu
ropnor.rt
(oPrroN)
c;A
Ptloro 56
:]%
pre'wired
tor
vehicres
ceucssu'Yir
cLlEssv'v .evu"rt
JtJre"'
UNDER.DASH
I FUSE/RELAY
BOX
I
13 Y Cssl
63
I ltlglo
-" "'
clNl.rEcroR
I
FEoiEL(
t
II
AED/ELX
FED/8LK
1
(withcruise3)
|
v
RED/BLI(
ToDaoe110-3 '96(AliC6upes
98 Sedans),
and
or page110-4( 99-00 Sedans),
or page110-5(Halchback)
GAN/YEI
/-1M\
fb
d
\Y,Z
LEFTFRONT
I PARKTNGIuRN
slcNALLlcHr
c202
r -'!
wiiri
| xtYess
|
II
I Entry
KEYLESS '
DOOR
LOCK
:
CONTROL;
UNIT
RIGHTFRONT
PARKING/TURN
SIGNALLIGHT
'I
seeGround
"* |
3$l''Tll
I
l.?'J
!- czoz
PHOfa 19
110-2
I
'99100
moqels
L.-r
- All Coupesand'96-'98Sedans
\
Frompage110-2.
*=Male-Female
terminalsreversed
for'99-'00
models
s"o"n"
"*cept
491!]
1'so'sa
('99-'00
modelsexceptGX l8)
RED/BLK
c605
2 ^
2 ^
LEFT
LICENSE
PLATE
LIGHT
SeeGround
Oistribution,
page14-10.
RIGHT
LICENSE
PLATE
LIGHT
@ @
RIGHT
OUTER
BRAKE
LIGHT/
TAILLIGHT
".,,*-fJr
c613
PHOTO115
See Brake
SeeBrake
Lights
:rd
r:d
ALK
Y
BLK
ryI
V
l-
erxI
AlK
c613
LEFT
OUTER
BRAKE
LIGHT/
TAIL.
LIGHT
SeoGround
Distribution,
page14-10.
erx I
o -l
*.-*L=t
RIGHT
INNER
BRAKE
LIGHT/
TAILLIGHT
INNER
BRAKE
LIGHT/
TAILLIGHT
SeeGround
Di6tribution,
page1410.
c604
c517
1
BLK
C60s
4
BLK
4
c604
BLK
Se€Ground
Distribution,
page14-10.
I
.-
G60l
110-3
LicenseLights,ParkingLights,and Taillights(cont'd)
- '99-'00Sedans
Frompage110-2.
FEO/BLK
18
(GX5)
c562
vtEw42
REO/BLK
SeeBrake
Lights
CBtl^lvl{t
1 l
1 l
LEFT
LICENSE
PLATE
LIGHT
3
RIGHT
LICENSE
PLATE
LIGHT
RIGHT
BRAKE
LIGHT/
OUTER
TAILLIGHT
@
@
zY
zY
2 ^
2A
@
LEFT
INNER
TAILLIGHT
rY
110-4
@
rY
RIGHT
INNEB
TAILLIGHT
LEFT
BRAKE
LIGHT/
OUTER
TAIL.
LIGHT
- Hatchback
\
*=l\4ale-Female
terminalsreversed
lor'99-'00
models
('99r00
FEO/ALK
REO/BLI(
c604
RED/BI-K
See
Brake
Lights
FED/BLK
c607
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5
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RED/BLX
RED/BLK
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itI
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Dislribution,
pags 14-12,
c605
PHOTO118
vlEwa
Y
I
2
c608
I
G601
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I F"al,,,
PHoro132
-1
:
(98100 modets)
110-5
TurnSignaland HazardWarningLights
- All except'99-'00
Sedans
TUHII
SIGNAU
HAZARD
REI-AV
?nofog
UNDER.
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FUSE/
BELAY
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c411
15
PHOTO 60
vlEw 60
:n-
c501
See Ground
D$tribution,
page l4-7.
vtEw5!
55
u
Isee Dash
L
Lights
T
*x ll
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tBl
GAN/OFN
PHOfO 57
I
_1
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@iJ8l$,o" @tSS'* i
3""",n",,
IH
TH
Indicators
L-------i
82
II ffi"ufi:I'oo
ALK
SeeGroundDistribution,
wge 14-7.
I
t
t
l
L___l
#
:
G401
PHOfO 5/
110-6
-l
?EEi *,.:ffi
----J
\
*=l\4ale-Female
terminalsreversed
for'99-'00
models
COMBINATION
LIGHT
Tum
Signal
Switch
l
From Splice or
facing page.
vi
cnrineo csor
I
c423
" l"P'li'
\
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q
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vtEw30
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i
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l
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I TURNSIGNAL
uorr
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erx I
I
Distnbution,
pages
p a y 6 !14-10
, , - , v >-rO
>-ra
and14-12.
I
ar-<
and
1+12
"'iI
3:"":ix'5:
I
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I
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c2o2
!t- PHOTO
19
"I
I ."n.
2
aLK
c6ol
4- PHA|A
1A2
PHOIO 173 (Halchback)
110-7
TurnSignaland HazardWarningLights
- '99-'00Sedans
@
i-f;.;l
iL J)Li- -r- J-
3 Y c352
H33'""
i Bl oEx t F f
PHoro
7
vlEw27
tun
SIGIITJ
TOAZARD
R€I.AY
psaloI
""k
S€eGroundDisldbution,
pag€l4-7.
c411
PHOfO @
vlEw 60
S€€Ground
Distih.dion,
pag€ 14-7.
I UNDER.
I DASH
: FUSE/
I RELAY
I BOX
i PHO|O 58
--------J
c501
vtEw55
PHO|O 57
HAZARD
WARNING
swtTcH
vtEw32
'--{
ToUnderdash
Box
Fuse/Relay
on thispage.
GAUGE
ASSEMBLY
See
Gauggs,
lndicato.s
L-----
s2
ALK
II ff;f#looo
S€eg.ound Dist$bution,
pag€t4-7,
lL___ll
+
:
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PHOfO 57
110-8
\
COMBINATION
LIGHT
Tum
Signal
swrTcH
Swltctl
ytEW64
A2
From Splice on
facing page.
v
GRN/FED
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60
I
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g:"',gn*l
144
Pase
t
I
V?'t
+ 9ao-1
110-9
Fog Lights
_ Vehiclespre'wired
for accessory
securitysystem
SECURITY
SYSTEM
CONNECTOR
(oPT|ON)
c403
a
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li[?i,i'*'
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I
I
See Headlights'
(Canada)
FOGLIGHT
IN-LINEFUSE
k-j'/,-d
u
lvtEw
!7
gee Ground
Distribution,
pag€144.
- - - - . OptionalFogLightSwitchHarness
LIGHT
SWITCH '
oFF a-a
oN
FOGLIGHTON
INDICATOR
c408
PHOTO66
- - _ _ - - t
c201
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::-*frt*,
ii
c207
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\
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i
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|
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:BOX
I I 3oa
I pHoroT
LJ----J
I Y C3s2
ulEY:?-- - wHrl PYo-rg8-
Vehiclespre-wired
- - - for accessory
securitysystem
5 f|
SECURIrySYSTEM
CONNECTOR
(oPTloN)
- - canada
WHT
C419
P H Q | O 6 3v t E W 4 s
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COMBINATION
LIGHT
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Swlich
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t
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swrTcH
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----J
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Swirch,
oao6100.
- Canada -
FUSE21
F i/t
IOW AEAM
FUSE4
B H/L
HIGll BEAM
UNDER.
DASH
FUSE/
RELAY
BOX
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RIGHT
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--g------J
1IIGH
lLr
-
:
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PHOTO57
110-12
See Ground
Distdbution,
page 14-4.
SoeGround
Distribution,
page14-4.
\
- Canada
--
f
3 A
r'
I
I
I
16
Pdoto\i
vttw.rs
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r
FUSE
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ra
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SeeBrake
System
IndicatorLight
l
cnvneo
I
asl
Brakesysiem
indicatorlight
control
lgnition
Ughis-on Sattery
npur
Hoadl8hicornrol
b'rak8input
Ground
vtEw66
B1
\
DAYTIME
RUNNING
LIGHTS
CONTROL
UNIT
BED/GRN
OAYTIME
RUNNING
LIGHTS
RESISTOR
H
PARKING
BRAKE
swtTcH
Closedwith
parkingbrake
applied.
\
S€eGround
Dlstribution,
page 1,1-6.
I
Y
L
_-J
+
:
G401
PHOTO57
110-13
Headlights (cont'd)
- Howthe CircuitWorks
Low Beams
Withthe headlight
switchin HEADandthedimmer
switchin LO,currenttlowsthroughthe headlight
switch.fuse21. fuse22.andthelowbeam
tilaments
to ground,andthelowbeamscomeon.
HighBeams
Withtheheadlight
switchin HEADandthedimmer
switchin Hl,currentflowsthroughthe headlight
switch,dimmerswitch,fuses4, 5, andthehigh
beamfilaments
to ground,andthehighbeams
comeon.
Currentalsollowsthroughthe highbeamindicator
lightto ground.The highbeamindicator
comeson
to remindthedriverthatthe highbeamsareon.
Flash-to-Pass
Theflashfeatureworkswiththe headlight
switchin
youmove
(low
PARK,
or
HEAD
When
OFF,
beams).
theflash-to-pass
switchto ON,currentflows
throughthe switch,fuses4 and5, andthehigh
to ground,andthehighbeams
beamfilaments
flash.Thehighbeamindicator
alsoflashesduring
theflashoperation.
Theflashfunctionhasno effect
if thehighbeamsarealreadyon
DaytimeRunningLights(Canada)
Whenyouturnthe ignition
to ON (ll) withthe
parkingbrakereleased,
thedaytimerunninglights
controlunitsupplies
batteryvoltageat the
WHT/RED
wire.Thisvoltageis appliedto thehigh
throughthedaytimerunninglights
beamheadlights
resistor.
Eachhighbeamheadlight
receives
less
thanbatteryvoltagecausingthemto comeon at
reducedbrightness.
lf theparkingbrakeis set,a groundsignalis applied
to thedaytimerunninglightscontrolunitat the
RED/GRN
wire.lf theparkingbrakeis setwhenyou
firstturnthe ignition
switchto ON (ll),thehighbeam
headlights
willremainoff untilyoureleasethe
parkingbrake.Oncethe highbeamheadlights
are
on,settingtheparkingbrakewillnotturnthemofi.
Whenlowor highbeamoperation
is requested,
batteryvoltagefromthe headlight
switchis applied
to thedaytimerunninglightcontrolunitviathe RED
wire.Thedaytimerunninglightscontrolunitthen
turnsofftheheadlights.
110-14
Referto theServiceManual(Section
23,Electrical)
procedures.
forspecific
testsor lroubleshootrng
tl
BrakeLights
- All Coupesand'96-'98Sedans
?-------
i
iI
t t!::o
)t SrTIr
154
UNDER-HOOD
geePower
Distribution,
i FUSE/RELAY
BOX
i
L--E-]-p3n:"'1--.:
8 Y C3s2
*nrlo." i[o"'r?,
I
*"r,o"n
SeePower
Distribution,
page1013.
o----a
wHr/GFN
i
WithCruiseControl
t
WithoutCruiseControl
,r"r,o*[
*"r,n*[
1 BRAKE
SWTTCH
r t
BNAKESWITCH
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pedaldepressed.
l-'rt
l4J
LQlt'*'*t'**"
o""*,1,
n""n",.tr
PHOTO 68
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rt
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I
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*=Male-Female
reversed
terminals
for '99-'00models
PHO|O 125
GFN/II/HT
13
('99100modelsexceptGX 17)
GFN^^/HT
2
('99-'00models except GX 10)
GFNMHT
vtEw
54
c401
c563
(C562'99100modelsexceptGX)*
V|EW42
GFN,ryVHT
Without
optionalspoiler
GAN/
with
optionalspoilar
GFN/
BLK
\ a
+ 9,6,91o,",
110-15
BrakeLights
- '99100Sedans
'_-._-_:---t-u!E az
xonn,
UNDER.HOOD
I FUSE/RELAY
ErreE/oErAv
I
I
oaoe tG13.
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I
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I
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Sso Power
Distrlbdlon,
aToPrr
t6a
|
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L--:t------------J
Se€ Power
Oigtribution,
pags1G13.
WithoutCruis€Contd
BRAKESWITCH
Closedwithbrake
pedaldepressed.
PHOTO 8
o"na",
I
--f
!--
o""-",
PGI\,4-FI
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(fermtnals
1'l-'14)
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PagelGl2
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51
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ir
models)
t 3ml
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CONTBOLLER
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.l
REAR
;
I wrNDow.,
: DEFOG.
I GER
:
I swrrcH ,
I
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page1.{-7.
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iHorost
G401
P4ofo57
114-1
CeilingLight,TrunkLight,and Spotlights
LT GRN/ALK
'96.98USA:CX,DX
'96.[98Canada:All
'96-'98USA:
LX,EX,and HX
'98:GX
'99100:All
exceptDX
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i
t
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LT
GRN/
RED
REo
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LT GRN/FEO
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Door Locks
LT GFN/
irruotL-T
: i " i i y@ o
----
-----
* = '99-'00modelsexceptcX
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q;,{"i};}',,Hgt:$
6
pHoro96
114-2
-
door o
Sedan -
--azt
LEFT
REAR
DOOR
swtTcH
Closedwith
dooropen.
IT GRN/fiED
n
RIGHT
;
REAR
DOOR
SWITCH :
Closed with ;
door open. ,
\,f
r=Male-Female
terminalsaeversed
for'99-'00
models
DASH
FUSE/
RELAY
BOX
Se€Pow€r
Disfibution,
pag61o-t0.
ftTll,'
-",,".'"f
Hatchback I
\ , ,
A
sxcept
'9$'98
Sedan
wiliout
Moonroof
c407
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'95-'98
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lt
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trunkopen.
c407
LT GAN/EIK or lT GRN/RED
"il
(v/Fw2 98r0o mod€rs)
SeoGround
Distdbution,
pagst+10
ot 1+1'l.
\
P H o t o5 8
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+
PHOTO 102
114-3
PowerWindows
- Driver'sDoorand FrontPassengerDoor
--
l'l-'G'-.i**oo* I i',I3.',8J39"
FUSE 24
i ) lo1*"
{s/n nElav)
,
i f,?T"
L-9------J
'rF,*%,
Se€Powef
Distribution,
page106.
'ry'
*rtier-u
|
6I i[ff'3"
PowER !
I
wtNDow
RELAY
PHOfO 6S
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Distribution,
page14-7.
c42O
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Switch
POWER
wtNDow
Contrsl
Unlt
MASTER
swtTcrl
PHATO 88
vlEw 36
I
I
I
(SedanA4)
8
(SedanA5)
REO/^YEL
1
FEDor aEO/BLU
(SedanA7)
4
(SedanA6)
12
ALU
RED/BLU
c633
YELo. REo/YEL
LTBLUoTBLU
DRIVER'S
wlNDow
MOTOR
BLK
4
c633
ALK
SeeGround
Distribution,
page14-7.
I
.---+<
-
I
G401
PHOIA 57
1 20
I
SeeGroundDistibution,
page14€.
G551
\
7and8
on Jollowing
p490.
t
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GNN/BLK
1
GRN/ALK
vtEw22
c557
PHOIO 93
vtEw 62
1
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-
UP
FRONT
PASSENGER'S
wtNDow
swtTcH
C}FF
c653
FRONT
PASSENGER'S
wtNDow
MOTOR
BLU/YEL
Motorhasa sell-resefting
circuitbreaker.
7
(SedanAl)
lwrNDow
I MASTER
swrTcH
: PHO|O
88
I
J6
lvtEw
Frod PasSengsr'a
Swich
I
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RearSwilches
:
-,:l--J
----.,:,1":l
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Distribution'
I
"'-!r+J
(cont'd)
120-1
Power Windows (cont'd)
- RearDoors
BEDAV}IT
BEDAI/IIT
c5?r
PtlQTO 99
VIEW6
LEFT
REAR
wtNDow
MOTOR
LEFT
REAR
wtNDow
swtTcH
tp
DOWiI
Motorhasa seltresening
circuitbreaker
2
YEUGBN
c571
1
PHOTO 99
-GRN,^/EL
z
qR|i
FEOAIVHT
11
10
c556
il
GRN,^TEL
GFN
A14
93
vtEw61
At6
POWER
wlNDow
MASTEB
SWITCH
vtEw36
Lai RraarSfiici
|
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-siq-r"a{::l=-.i
3s"qni'
"-l-'J
120-2
Oisuibdion,
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-
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-
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r uHr
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vtEw22
c570
PHOfO 99
RIGHT
REAR
wtNDow
MOTOR
BLUMHT I
or REO
"ru"ao I 2
orYEL
wtNDow
SWITCH
neo,tea 4
c672
\ , ,
RIGHT
REAR
nED/BLU
orowt{
Motorhasa
self-resetiing
circurtbreaker.
ofF
UP
YEI
I
YEL
A9
POWER
wtNDow
MASTER
SWITCH
vtEw36
f',
120-3
PowerWindows (contd)
- Howthe CircuitWorks
CAUTION:
Youcould iniureyour arms,hands,or
you
fingersif
unintentionally
switchthe driver's
window to "automaticdown" while working in
that door with the power on. Disconnectthe
window switch conneclot or the batterywhen
working in the driver's door.
SystemDescription
Theoperation
of the powerwindowsis controlled
by
the mainswitchin the powerwindowmasterswitch.
Whenthe mainswitchis in OFF,onlythe driver'sdoor
windowcanbe openedor closed.Withthe main
switchON,all windowscanbe ooenedor closed
eitherby swtchesin the masterpanel,or swttchesin
thedoors.Thedriver'swindowswitchalsohasan
automatic
downmodewhichis tumedon by pushing
theswitchdownto its secondoosition.
The powerwindowsare drivenby reversiblemotors.
Eachmotoris protect€dby a built-incircuitbreaker.
lf thewindowswitchis heldon too long(withthe
windowobstructed,
or afterthewindowis fullyup or
down),thecircuitbreakeropensthecircuit.The
circuitbreakerresetsautomaticallv
as it cools.
Driver'sWindow
Withthe ignitionswitchin ON,voltageis providedto
the coilof the powerwindowrelaythroughfus€24.
Thecontactsof the powerwindowrelayclose,and
voltageis appliedto the driver'sswitch.Whenyou
pushthe powerwindowmasterswitchto UP,voltage
is appliedto the driver'swindowmotor.(Themotor's
groundpathis backthroughthe masterpower
windowswitch.)The driver'swindowmotorthen
drivesthe windowup.Whenyoupushthe switchto
DOWN,voltageis appliedin the oppositedirection
andthe motordrivesthe windowdown.
Automatic Down(Driver'sWindow)
Withthe ignitionswitchin ON or START,voltageis
appliedto the coil of the powerwindowrelay.The
contactsof the powerwindowrelaycloseand
voltageis appliedlo the powerwindowmaster
switch.Whenyoupushthedriveasswitchto the
AUTODOWNposition,
voltageis appliedthrough
thedriver'sswitchto thedriver'swindowmotor.The
pulsesat thepulserinputwhile
controlunitreceives
the motoris running.
Whenthewindowis fully
down,themotorstops,andpulsesareno longer
generated
by thepulser.Thisis sensedby the
controlunitat thepulserinput,andvoltageis no
longerappliedto the driver'swindowmotor.
120-4
PassengerWindows
Withthe ignitionswitchin ON,voltageis appliedto
the coilof the powerwindowrelaythroughfuse24.
The contactsof the powerwindowrelaythenclose,
applyingvoltageto the individualwindowswitches
and the powerwindowmasterswitch.Withthe
masterpanelmainswitchON,thepassenger
windowscan be ooeratedfromthe individual
windowswitchesor fromtho masterpanelswitches.
Whenyou pushthe frontpassengsr's
window
switchto UP,voltageis appliedto the f ront
passenger's
windowmotor.(Themotoris grounded
throughthe contactsin the frontpassenger's
windowswitchandthe oowerwindowmaster
switch.)The windowmovesup as longas you hold
the switchin the UP position.lf you pushthe switch
to DOWN,voltageis appliedin th€ opposite
directionto the frontpassenger's
windowmotor,and
the windowmovssdownas longas you holdthe
switchin the DOWNDosition.
Thewindowswitches
in the otherdoorsoperatesimilarly.
Whenyou pushthe frontpassenger's
switchin the
masterpanelto UP,voltageis appliedthroughthe
frontpassenger's
windowswitchcontactsto the
frontpassengefswindowmotor.(Themotoris
groundedthroughthe contactsin the front
passenger's
windowswitchandthe powerwindow
masterswitch.)The windowmovesup as longas
youholdtheswitchin the UP position.
lf youpush
the switchto DOWN,voltageis appliedin the
oppositedirectionto lhe frontpassenger's
window
motor,and the windowmovesdownas longas you
holdthe switchin the DOWNposition.The other
passenger
windowswitches
in themasterpanel
operatesimilarly.
Referto the ServiceManual(Section23, Electrical)
procedures.
for specifictestsor troubleshooting
Moonroof
'96-'97Models
@
---1
UNDER.DASH
IFUSE/RELAY
FUSE24
(PAVAELAY}
(slF FEraY)
i-tffil**l
ii3-.',BJi9g"
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liffio,
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See Power
Dr$nouton.
Page10-12.
B lii:;?"u'
l.-F'I
UNDER.DASH
! | | ruserneuv
GFN/OFN
I | | ""B-gt..
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L-*..J
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MOONROOF
OPEN
RELAY
vtEw15
GFN/BED
To A on this
page.
vtEw13
MOONROOF
MOTOR
GFN/FEO
2 veL
c717
PHOTO107
1
TILT/
CLOSE
swtTcH
OPEN/
CLOSE
swtTcH
2
c7't8
BLU
2
MOONROOF
OPEN
crosE
TILT
S€eGround
Distributiofl,
page14-7.
122
MOONROOF
CLOSE
RELAY
swtTcH
'98-'00Models
\
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---1
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UNDER.DASH
ffi**'iF,?T",
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PHOfOs8
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pag€t&12.
UTIDER.DASH
FUSE/RELAY
BOX
PHOTO 58
4
-a
-
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_iu
s
MOONROOF
OPEN
RELAY
MOONROOF
closE
RELAY
PHO|O 51
vtEw13
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Tospliceon
tnrspage.
c717
c718
TILT/
CLOSE
swficH
OPEN/
CLOSE
swrTcH
2
c7t8
9LU
MOONROOF
o*ir
lltl
CLOAE
swtrcH
Sa€Grolx|d
Distribution,
pag€1+7-
122-1
Moonroof (cont'd)
- Howthe CircuitWorks
MoonroofOpen
MoonrootClosefrom the Tilt Position
Whenyou pushthe moonroofswitchto the OPEN
position,
the moonroof
openswitchappliesground
"open"relaythroughtheYELwire.
to the moonroof
The moonroof"open"relayappliesbatteryvoltage
motorthroughthe GRN/RED
wire.
to themoonroof
"close"relaysupplies
groundto the
Themoonroof
moonroofmotorthroughits normallyclosedrelay
conlacls.Whenthe moonroofmovesout of the fully
thetilvclose
switchmovesto the
closedoosition.
theopen/close
switchmovesto the
OPENposition;
OPENoosition.
Whenyou pushthe moonroofswitchto the CLOSE
posilion,the moonroof"open"switchappliesground
to the moonroof"close"relaythroughthe YEURED
wire,open/close
switchand moonroof"open"relay.
"open"
The moonroof
relayappliesbatteryvoltageto
the moonroofmotorthroughthe GRN/REDwire.The
moonroof"close"relaysuppliesgroundto the
moonroofmotorthroughits normallyclosedrelay
contacts.Whenthe moonroofis fullyclosed,the
tilvcloseswitchmovesto the closedoositionandthe
open/close
switchmovesto the CLOSEDposition.
Referto the ServiceManual(Section23, Electrical)
procedures.
for specifictestsor troubleshooting
MoonroolTilt
Whenyoupushthe moonroof
switchto theTILT
position,
the moonroot
tiltswitchappliesgroundto
"close"
relaythroughthe BLUwire,
themoonroof
tilvclose
switchand REDwire.Themoonroof
"close"relayappliesbatteryvoltageto the
GRNffEL wireto the moonroofmotor.The
"open"relaysupplies
groundto the
moonroof
moonroofmotorthroughits normallyclosedrelay
is in thetiltoosition,
Whenthe moonroof
contacts.
the trlvcloseswitchmovesto the TILTEDposition;
the open/closeswitchmovesto the TILTED
Dosition.
MoonroofClosetrom the Open Position
Whenyou pushthe moonroofswitchto the CLOSE
"close"switchappliesground
position,
the moonroof
"close"
relaythroughtheYEURED
to themoonroof
The
wire,tilvclose
switchandGRN/RED.wire.
moonroof"close"relayappliesbatteryvoltageto the
motor.The
GRNI/ELwireto the moonroof
"open"
ground
relaysuppfies
to the
moonroof
closedrelay
moonroof
motorthroughits normally
is fullyclosed,the
Whenthe moonroof
contacts.
the
tilvclose
switchmovesto theclosedposition;
switchmovesto theCLOSEDposition.
open/close
122-2
PowerDoorLocks
- All ModelsWithoutKeylessEntry
FUSE/RELAY
i--r?Grs;-'iUNDER.HOOD
BOX
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PHO|Q93
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.
PASSENGER'S'
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wHT/
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WHT/
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c664
WHT/BEO
,
c634
c664
LEFTREAR
DOORLOCK
ACTUATOR
DRIVER'S
4
DOOR
LOCK
ACTUATOR
BLK
WHT/FEO
PHO|A 92
4
BLU/
vlEW6
I YEL/
WHT/RED
DOOR
KEY
DooRLocKi
ACTUATOR,
WHT/FED
FED
c571
BLK
I
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130-1
PowerDoorLocks
- '96-'98ModelsWithKeylessEntry
I
(NotUsed)
c562
(Ssdan5)
See
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dooropen.
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unlockinput
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WHT/REO
vtEw61
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input
WHI/REO
cs56
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input
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[-:I
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ALUAViIT
Unlock/lock
output
POWER
DOOR
LOCK
CONTROL
UNIT
c556
BLU/NED
PHOfO93
vtEw 61
DOOR
KEY
4
c634
BLUAVHT
DRIVER'S
DOORLOCK
swlTcH
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VIEW6
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anput
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c664
PHA|A9S
i
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FRONT
PASSENGER'S
DOORLOCK
ACTUATOR
n"r,n"n
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vtEw62
PHO|O95
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c557
locx
YEURED
92
DRIVER'S
DOOR
LOCK
ACTUATOR
DOOR
LOCK
KNOB
WHT/FED
IBLK
22
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BLK
c556
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vtEw61
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3'i#i:T:'
130-3
Power Door Locks (cont'd)
- Howthe CircuitWorks
KeylessEntrySystem
the powerdoor
Thekeylessdoorlockscombine
keyJob
transmitter.
The keyless
lockswitha remote
part
The
keyless
of the radio.
receiverunitis
directinputsf romthe ignition
receiver
unitreceives
passenger
doorswitches,and an
keyswitch,the
inputtromthe driver'sdoorswitchthrough
indirect
the integratedcontrolunit.
PowerDoor Locks (With or Wlthout Keyless)
The powerdoorlocksystemis madeup of the
oowerdoorlockcontrolunit.driver'sdoorlock
switch,and individualdoorlockactuators.The
powerdoorlocksare controlledby the driver'sdoor
lockswitchand the driver'sdoorlockactuator
switch.
Transmitter(With KeylessEntry)
Thetransmittersendscodedradiowavesignalsto
the keylessreceiverunitwhenone ot its buttonsis
pressed.Eachtransmitterhasa uniquecodethat
mustbe 'laught"to the keylessreceiverunitbefore
it can operatethe doorlocksor any otherlunction.
to operate
can be programmed
Up to 4 transmitters
locks.
the keylessdoor
Door Locking (With or without KeylessEntry)
Whenyou pushthe driver'sdoorlockswitchto the
groundis appliedto the GBN/IVHT
lockposition,
wireto the oowerdoorlockcontrolunit.The control
unitthenappliesbatteryvoltageto the WHT/RED
wireandgroundto theYEUREDwire.The
passengerdoorlockactuatorsthenactivateto lock
doorlocks.
thecorresponding
Whenyou lockthe driver'sdoorwiththe keyor door
locked,andthedriver's
lockknob,it is mechanically
doorlockactuatorswitchappliesgroundto the
oowerdoorlockcontrolunit.The controlunitthen
appliesbatteryvoltageto the WHT/REDwireand
groundto the YEUREDwire,activatingthe
passengerdoorlockactuatorswhichlockthe doors.
Dool Locking with Transmitter
Whenyoupressthe LOCKbuttonon the remote
transmitter,
the powerdoorlockcontrolunitapplies
batteryvoltageto the WHT/REDwireandgroundto
doorlock
the YEUREDwire.The passenger
thenactivateandlockthe doors.A ground
actuators
slgnalis alsoappliedto the BLU/REDwireto lock
the driver'sdoor.lf anydooris open,youcannotlock
it usingthe remotetransmitter.
130-4
Door Unlocking(With or Without KeylessEntry)
Whenyoupushthedriver'spowerdoorlockswitch
groundis appliedto the
to the unlockposition,
GRN/ORNwireto the powerdoorlockcontrolunit.
The controlunitthenappliesbatteryvoltageto the
wiresandgroundto the
YEUREDandBLU/RED
The
WHT/REDwire.
doorlockactuatorsthen
activateto unlockthe doors.
Whenyouunlockthedriver'sdoorwiththekeyor
the
unlocked;
thedoorlockknob,it is mechanically
otherdoorsdo not unlock.
Door Unlocking(WithTransmltter)
Whenyou pressthe UNLOCKbuttonon lhe remote
transmitteronce.the powerdoorlockcontrolunit
appliesbatteryvoltageto the WHT/REDwireand
groundto the BLU/REDwireto unlockthe driver's
door.Whenyou pressthe UNLOCKbuttontwice,
the controlunitthenappliesgroundto the YEURED
wiresto activatethe passengerdoorlocks.lf youdo
notopena doorwithin30 secondsafterunlocking
the doors
the doorswiththe transmitter,
relock.
automatically
TransmltterProgramming
switchON (ll).
1. Turntheignition
buttonon the
2. Pressand holdthe Valet-Disarm
(between
andthe
the
AM/FM
button
radio
programming
CD/TAPEbutton)to enterthe
mode.(Continueto holdthe buttonduringthe
procedure,
willbe cancelled.)
or programming
Checkthatthe powerdoorlockscycleto confirm
mode.
thatyou'rein the programming
"UNLOCK'
"LOCK'
buttonon the
or
3. Pressthe
power
doorlocks
transmitter.
Checkthatthe
cycleto confirmthatthe codewasaccepted.
4. Pressthe"LOCK"or "UNLOCK"buttonon each
(Youcan program
of the remainingtransmitters.
per
vehicle.)
up to fourtransmitters
havebeen
5. Afterall the transmitters
programmed,
buttonto
releaselhe Valet-Disarm
mode.
exitthe programming
BeepOn/OftFeature
'I. Pressand holdthe LOCKandOPTIONbuttons
on the transmitter.
LED:
2. Watchthe transmitter's
Oneflash:Beeoactivated.
Twotlashes:Beeodeactivated.
KeylessReceiverUnit Troubleshooting
lf a faultykeylessreceiverunithasone of the symptomsbelow,turnto the pagelistedand followthe
procedure.lf the symptomseemsrelatedto an inputproblem,or is notcovered
appropriate
troubleshooting
procedures,
by the troubleshooting
do the InputTestson page130-6. Referto the circuitschematicon pages
130-2and 130-3as needed.
SymptomIndex
KeylessEntryDoesNotWorkIn Any Mode
Page130-8
CeilingLightDoesNotComeOn WhenTheDoorsAre Unlocked
WithTheTransmitter
....
Page130-9
DoorsDo Not UnlockOr LockWithThe Transmitter. . . .
"Beeo"FeatureOn
HornDoesNotSoundWithThe Transmitter
Page130-1
0
Page130-11
Page130-11
.1,
H o r nD o e sN o tS t o pS o u n d i n.g. . . . . .
Page130-11
Input Tests
Page130-6
Power Door Locks (cont'd)
KeylessReceiverUnitInputTest
fromtheaudiounit.
disconnected
withA (Main)andB (Keyless)
testsarepertormed
Thefollowing
Wire
Color
Terminal
No.
TestConditlon
Test: DesiredRasult
Checkfor vollageto ground:
Thereshouldbs battery
voltage.
4
WHT/BLU Underallconditions
5
YEURED lgnitionswitchACC(l) Th€reshouldbe battery
Checklor voltageto ground:
Terminal
No.
voltage.
Wire
Color
TestCondiiion
lgnitionkeyinserted
intothe ignitionkey
switch
BLU/RED
lgnitionkey r€moved
key
tromtheignition
switch
3
BLUI/EL Underallconditions
6
BLK/YEL lgnition
switchON (ll)
8
LTGRN/
BLK
Ceiljnglightswitchin
"middleposition"
14
LT GRN/
RED
Eachdooroponed,
oneat a time
tc
BLK
Underallconditions
16
GRY
Underallconditions
130-6
Test:DesiredResult
Checkfor voltageto ground:
Thereshouldbs 1 V or less.
Checklor voltageto ground:
Thereshouldbe 4 V or more.
PossibleCauseit resull is not obtained
BlownNo.47 (7.5A)tusein the
under-hood
fuss/relaybox
o An openin the wire
a BlownNo.28 (10A)fuseinthe
box
underdashfusg/relay
a An openin the wire
a
PossibleCauseif rssult i3 not obtalned
a
a
a
a
Checkfor continuitybetween
the audiounit16Pconnector
No-3 terminalandpowerdoor I
lockcontrolunit12Pconnsctor
No.6 terminal:Thereshould
be continuity.
.
Checkfor voltageto ground:
Thersshouldbe battery
vollage.
.
Poorground(G401,G402)
Faultyignitionkeyswitch
An openin the wire
Shortin the wire
An openin thewire
BlownNo.14 (7.5A)fusein the
fuse/relay
box
under-dash
An openin thewire
a BlownNo.43 (7.5A)fusein the
undsr-hood
fuse/relaybox
to ground:Theceiling a Blownceilinglightbulb
Connect
lightshouldcomeon.
a Faulty
ceilinglight
o An openin thewire
to ground: a Faultydoorswitch
Checkfor continuity
Thereshouldbe continuity.
a An openin lhe wire
to ground: a Poorground(G401,G402)
Checkfor continuity
Thereshouldb€ continuity.
a An openin thewire
. BlownNo.52(15A)fusein the
under-hood
tuse/relaybox
Conn€ctto ground:
. Faultyhorn
Hornshouldsound.
. Faultyhornrelay
. An openin thewire
\
Thefollowing
testsareperformed
withA (Main)reconnected
to theaudiounit.
B
Terminal
No.
9
10
Wire
Color
GRN/ORN
GRN/vvHT
TestCondilion
Test:DesiredResult
Driver's
doorlock
switchin UNLOCK
Check tor voltage to ground:
Thereshouldbe l V or less.
Driverdoorlock
switchin LOCK
Checkfor voltageto ground:
Thereshouldbe 4 V or more.
Driver's
doorlock
switchin UNLOCK
Checkforvoltage
to ground:
Thereshouldbe 4 V or more.
Driver'sdoorlock
switchin LOCK
Checkfor voltageto ground:
Thereshouldbe 1 V or less.
PossibleCauseit result is not obtained
o
.
.
.
Poorground(G551)
Faultydriver'sdoorlockswitch
An openin thewire
Shortinthewire
r
.
o
o
Poorground(G551)
Faultydriver'sdoorlockswitch
An openinthewire
Shortin the wire
\
\
130-7
Power Door Locks (cont'd)
KeylessEntryDoesNotWorkIn Any
Mode
verifythatallthe
NOTE:Beforebeginning,
programmed
to the vehicle.
transmitters
are
1. Doesthe radioworkproperly?
Yes- Go to step9.
No - Go to the neldstep.
NOTE:Forsteos2 - 8. referto the schematicdiagramforthe StereoSoundSystemon page150.
fusebox)and
2. Arefuses28 (inthe under-dash
fusebox)OK?
fuse47 (intheunder-hood
Yes- Go to step4.
No - Replacethe blownfuse,thengo to the
nen steo.
3. Doesthefuseblowagain?
Yes- Locateand repairthe short.
No- Retestthesystem.
withtheoptional
security
4. ls thevehicleequipped
system?
Yes- Go to the nextsteP.
No - Go to steD6.
5. Doesthe keylessentryworkcorrectlywhenthe
securitycontrolunitconnectoris disconnected?
Yes- Faultysecuritysystem,go to security
systemforfurthertroubleshooting.
No - Go to thenextstep.
6. ls therebatteryvoltageat terminal4 of the radio
(A)?
mainharnessconnector
=
A
Yes- Go to the nen step.
No - Locatethe openin the wiringbetween
tuse47 andthe radio.
7 . ls therebatteryvoltageat terminal5 of the radio
(A),whenthe ignition
mainharness
connector
(l)
switchis in theACC or ON (ll) position?
Yes- Go to the nextstep.
No - Locatethe openin the wiringbetween
fuse28 andthe radio.
130-8
fromterminal14of theradio
8. ls therecontinuity
mainharnessconnector(A) to ground?
Yes- Replacethe radio.
No - Repairthe openin the wiringbetweenthe
radioandtheground(G501).
Does
the
transmitterLEDcomeon whenanyot
9.
the buttonsare oressed?
Yes- Go to steo 12.
No - Go to the nextsteo.
'10.lsthetransmitterbatteryinstalledwiththe
positivesidefacingup?
Yes- Ensurethatthe batterycontacttabsare
repositioned,
then replacethe battery.
Removethe keyfromthe ignition,then
closethe doorsand trunk.Pressthe
six times,
LOCKbuttonon the transmitter
thengo to the nextstep.
No - Ensurethatthe bafterycontacttabsare
thenreinstallthe batlery
repositioned,
correctly.Thenreprogramthe transmitter
and retestit. Usethe procedureon page
programming.
130-4for transmitter
LEDcomeon whenanyof
11. Doesthetransmitter
the buttonsare oressed?
Yes- Go to the nextstep.
and programit by
No - Replacethe transmitter
on page130-4.
usingtheprocedure
in all modes?
12.Does
thesystemworkproperly
Yes Finished.
Thesystemis OK.
No - Go to the nextsteD.
\,1
\lr
13. Recheck
witha knowngoodtransmitler
reprogrammed
to thevehicle.Doesthesystem
workproperly
in all modes?
Yes- Replacethe transmitter
and programit by
usingthe procedure
on page130-4.
No - ReDlace
the radio.
CeilingLightDoesNotComeOnWhen
TheDoorsAre UnlockedWithThe
Transmitter
NOTE:Thevehiclemusthavea tactoryradioinstalled.
1. ls theceilinglightswitchin thecenterposition?
Yes- Go to the nexl steo.
No - Reposition
theceilinglightswitchand
retest.
2. Doestheceilinglightcomeon withtheceiling
lightswitchin theON position?
Yes- Go to the nextstep.
No - Repairtheceilinglightcircuit.
3. Doesthetransmitter
LEDcomeon whenanvof
the buttonsare oressed?
Yes- Go to the nextstep.
No - Checkthe transmitterbattery,then retest.
lf theceilinglightstilldoesnotwork,go to
the nextsteD.
4. Recheckwitha knowngoodtransmitter
reprogrammed
to thevehicle.Doesthesystem
workproperly
in all modes?
Yes- Replacethe transmitter
and programit by
procedure
page
usingthe
on
130-4.
No - Goto the ne)dsteo.
(B)
5. Withthekeylessentryharnessconnector
jumper
wire
disconnected
fromthe radio.runa
f romterminal
8 to ground.
Doestheceilinglightcomeon?
Yes- Replacethe radio.
No - Repairtheopenin the keylessentry
8
harnessconnector
{B)terminal
(LTGRN/BLK)
wire.
\
130-9
Power Door Locks (contd)
DoorsDo Not UnlockOr LockWith
TheTransmitter
1. Do thedoor'sunlockandlockwhenusinqthe
driver'sdoorlockswitch?
Yes- Go to the nextstep.
No - Repairthepowerdoorlocksystem.
LEDcomeon whenanvof
2. Doesthetransmitter
are
the buttons oressed?
Yes- Go to the nextsteo.
No - Checkthe transmitterbattery,thenretest.
It lhe doorsstilldo notunlockor lockwith
the transmitte(go to the nextstep.
Recheckwitha knowngoodtransmitter
to the vehicle.Doesthe system
reprogrammed
in all modes.
workproperly
Yes- Replaceand programthe transmitter,
thenretest.Usethe procedureon page
programming.
130-4for transmitter
No- Gotothenextstep.
I of the keyless
Runa jumperwirefromterminal
(B)
ground.
to
entryharnessconnector
5. Runa jumperwirefromterminal10ol the
(B)to ground.
keylessentryharness
connector
Do the doorslock?
ves - Go to ttie nextsteo.
No - Repairtheopenin theterminal10
(GRN/vVHT)
wire.
Doesthe voltageat terminal1 of the keyless
entryharnessconnector(B) changefrombattery
voltagewhenthe key is not in the ignition,to
lessthan1 voltwhenthekeyis in the ignition?
Dothedoorsunlock?
Yes- Go to the nextsteD.
No - Repairtheopenin theterminal9
(GRN/ORN)
wire.
Yes- Go to the nextstep.
switchor repairthe
No - Replace
theignition
wire.
terminal1 (BLU/RED)
damaged
keyless
7. Doesthe voltageat terminal14 of the
entryharnessconnector(B) changefrombattery
voltagewhenallthedoorsareclosed,to less
than 1 voltwhenany dooris opened?
Yes- Replacethe radio.
No - Repairtheopenin theterminal14
(LTGRN/RED)
wire.
130-10
HornDoesNotSoundIn ThePanic
"Beep"
ModeOr WithTheTransmitter
FeatureOn
a
NOTE:The transmitterhasa BeepOn/Offfeature.
Referto page130-4for howto tumthe beepon or
off.
1. Doesthehornsoundwhenthe HORNbuttonis
oressed?
Yes- Go to the nextsteD.
No - Repairthehorncircuit.
2. Doesthe transmittorLEDcomeon whenanyof
the buttonsare pressed?
Yes- Go to the nextstep.
No - Checkthe transmitterbatterythenretest.
ll the beepfeaturestilldoesnotwork,go
to the nextsteo.
3. Recheckwitha knowngoodtransmitter
to the vehicle.Doesthe system
reprogrammed
workproperlyin all modes?
Yes- Replaceand programthe transmitter,
then retest.Usethe procedureon page
programming.
130-4for transmitter
No Go to thenextstep.
4. Withthe keylessentryharnessconnector(B)
wire
fromthe radio,runa.iumper
disconnected
f romterminal16to ground.
HornDoesNotStopSounding
security
withtheoptional
1. ls thevehicleequipped
system?
Yes- Go to the nextstep.
No - Go to step3.
Do€sthe hornstopsoundingwhenthe security
controlunitconnectoris disconnected?
Yes- Replacethe securitycontrolunit.
No- Go to thenextstep.
Doesthe hornstopsoundingwhenthe keyless
entryharnessconnector(B) is disconnected?
Yes- Reolacethe radio.
No - Reoairthe homcircuit.
Doesthehornsound?
Yes- Reglacethe radio.
No - Repairtheopenin theterminal16 (GRY)
wire.
\
130-11
PowerDoorLocks
- '99-'00Modelswith KeylessEntry
@
i-f?G;.-----l
UNDERDASH
FUSE/
RELAY
BOX
i ?f*""t:::",i
L-,H-i{*q-J
8 Y C419
vtEW49
See
HOrns
15
Horn
control
Door
open
input
Grgund
K€y
switch
Inpul
'12
17
ALK
Y
I
F--.--.r-
I
G401
z sEcuglw
!r.lFN'
REO
SYSTEM
'14
GRN
130-12
t5
=2
tsb'*nii'cro*
c447 (oPTroN)
vtEw5a
See Headlight
Switch
c447
vlEw58
a,o"nt"ao 1l (Not
LT GFN/RED
See lgnition
Key Reminder
UNDERDASH
FUSE/
RELAY
BOX
GFN
I
ALU/f,EO
LT GRN/
FED
a9
Lighls
tlash
control
3
LT GFN/RED
SeeGround
Distribution,
pageI +6,
lgnltion
input
C415
PHora
6a
ALU/IVITT
VlEtt\/
14
STEERING
LOCK
PHO|O 71
lgntlion Kay
SYrftch
Closedwith key
in ignition.
UNDER.
HOOO
FUSE/
RELAY
BOX
f*-.l'il
I
I
9
WIIT/GRN
I
TryJ
c351
c57o
,
5
PHOfO 99
V\EW5
'
YEL/BED
c6?4
:
1
PHOfAgs
vlEW31
YEI/BEO
,
c557
vlEw62
c654
YEUFED
FRONT
PASSENGER'S
DOORLOCK
ACTUATOR
aaa
".u".o
!
!t
I
c674
+
PHoro
95
c570
',;f,tr?"n
SeePower
Distribution,
page1S12.
WHT/FED
i
z
i wrvneo
,
a
c654
c557
l-1"1/1.9
. vtEw62
't8
UnlocKlock
outpul
Unloclvlock
otttput
Battsrv
'
ingJt
Unbck
Input
Look
input
Lock
input
Unlock/lock
output
KEYLESS
DOOR
LOCK
CONTROL
UNIT
9
BLUAVHT
GRN/OBN
WHT/FED
1
GBN/ONN
BLU/FED
't5
19
GRN/OFN
(?
fff
LJ-T->J
wrccr I
mc.
***
[J
DOOR
LOCK
KNOB
c634
4
PHOfa 92
;;;
oTYEL
DRIVER'S
oooR
LOCK
ACTUATOR
BLK
WHT/REO
c634
"iI-.
\
c556
vlEw61
aLU/'$/HT BLU/BED
ALUMHT
DRIVER'S
DOOR
LOCK
swtTcH
12
PHO|A 92
BLK
.
l:
cssr
130-13
Power Door Locks (conrd)
- Howthe CircuitWorks
KeylessEntrySystem
Thekeylessdoorlockscombine
the powerdoor
lockswitha remotekey-fobtransmitter.
The keyless
doorlockcontrolunitreceives
directinputsfromthe
ignition
keyswitch,the passenger
doorswitches,
inDutfromthedriver'sdoorswitch
andan indirect
throughthe integrated
controlunit.
PowerDoor Locks
The powerdoorlocksystemrs madeup ot the
keylessdoorlockcontrolunit,driver'sdoorlock
switch,andindividual
doorlockactuators.
The
powerdoorlocksarecontrolled
by thedriver'sdoor
lockswitchand the driver'sdoorlockactuator
switch.
Transmittel
The transmitter
sendscodedradiowavesignalsto
the keylessdoorlockconlrolunitwhenoneof its
Eachtransmitter
buttonsis pressed.
hasa unique
codethat mustbe 'laught"to the conlrolunitbefore
it canoperatethedoorlocksor anyotherfunction.
Up to 4 transmitters
can be programmed
to operate
thekeylessdoorlocks.
DoorLocking
Whenyoupushthedriveasdoorlockswitchto the
groundis appliedto theGRNMHT
lockposition,
wireto the keylessdoorlockcontrolunit.The
controlunitthenappliesbatteryvoltageto the
WHT/RED
wireandgroundto theYEUREDwire.
The passengerdoorlockactuatorsthenactivateto
lockthecorresponding
doorlocks.
Whenyoulockthednver'sdoorwiththekeyor door
lockknob,it is mechanically
locked,andthedriver's
doorlockactuator
switchappliesgroundto the
oowerdoorlockcontrolunit.Thecontrolunitthen
appliesbatteryvoltageto theWHT/RED
wireand
groundto theYEUREDwire,activating
the
passenger
doorlockactuators
whichlockthedoors.
Door Lockingwith Transmitter
Whenyou pressthe LOCKbuttonon the remote
transmitter,
the keylessdoorlockcontrolunilapplies
batteryvoltageto the WHT/REDwireand groundto
the YEUREDwire.The passenger
doorlock
actuatorsthenactivateand lockthe doors.A ground
signalis alsoapplied
to the BLU/RED
wireto lock
the driver'sdoor.lf anydooris open,youcannotlock
it usingthe remotetransmitter.
DoorUnlocking
Whenyoupushthedriver'spowerdoorlockswitch
groundis appliedto the
to the unlockposition,
wireto the keylessdoorlockcontrolunil.
GRN/ORN
Thecontrolunitthenappliesbatteryvoltageto the
YEUREOandBLU/RED
wiresandoroundto the
130-14
WHT/REDwire.Thedoorlockactuatorsthen
activate
to unlockthedoors.
Whenyouunlockthedriver'sdoorwiththe keyor
thedoorlockknob,it is mechanically
the
unlocked;
otherdoorsdo notunlock.
DoorUnlockingwith Transmitter
WhenyoupresstheUNLOCKbuttonon the remote
transmitter
once,thekeylessdoorlockcontrolunit
appliesbatteryvoltageto the WHT/REDwireand
groundto the BLU/RED
wireto unlockthedriver's
door.Whenyou pressthe UNLOCKbuttontwice,
thecontrolunitthenappliesgroundto theYEURED
wireslo activatethe passengerdoorlocks.lf youdo
notopena doorwithin30 seconds
afterunlocking
the doorswiththe transmitter,
the doors
automatically
relock.
TransmitterProgramming
. Entering
theprogramming
modecancelsall
learnedtransmitter
codes,so noneof the
previouslyprogrammed
transmitters
willwork.
Youmustreprogramall the transmitters
once
you'rein theprogramming
mode.
. To keepthe systemfromexitingthe
programming
mode,complete
eachstepwithin5
seconds
of theprevious
step,andprogram
the
transmitters
within10 secondsof eachother.
'1. Turnthe ignition
switchON (ll).
"LOCK"
2. Pressthe
or "UNLOCK"
buttonon one
(A non-programmed
of thetransmitters.
transmitter
canbe usedforthisstep.)
3. Turnthe ignition
switchOFF(0).
4. Repeatsteps1, 2, and3 twomoretimeswith
thetransmitter
usedin step2.
5. Turntheignition
switchON (ll).
"LOCK"
6. Pressthe
or "UNLOCK"
buttonon the
sametransmitter.
Checkthatthe powerdoor
lockscycleto confirmthatyou'rein the
programmrng
mooe.
"LOCK"
7. Pressthe
or "UNLOCK"
buttonon each
(Youcanprogramup to four
lransmitter.
pervehicle.)
lransmitters
Checkthatthepower
doorlockscycleafteryou pusheachtransmitter
button,contirmingthatthe systemhasaccepted
thetransmitter's
code.
BeepOn/OffFeature
1. Pressandholdthe LOCKandOPTIONbuttons
on thetransmitter.
2. Watchthetransmitter's
LED:
Oneflash:BeeDactivated.
Twoflashes:Beepdeactivated.
KeylessReceiverUnit Troubleshooting
lf a faultykeylessdoorlockcontrolunithasone of the symptomsbelow,turnto the pagelistedandtollowthe
procedure.lf the symptomseemsrelatodto an inputproblem,or is not covered
troubleshooting
appropriate
procedures,
on
by thetroubleshooting
do the InputTestson page130-16.Referto thecircuitschematic
pages130-12and130-13as needed.
SymptomIndex
KeylessEntryDoesNotWorkIn Any Mode
CeilingLightDoesNotComeOn WhenTheDoorsAreUnlocked
....
WithTheTransmitter
Page130-17
Page130-18
Page130-1
I
DoorsDo Not UnlockOr LockWithThe Transmitter. .
'Beep"
Feature
On ......... Page130-19
HornDoesNotSoundWithTheTransmitter
\
HornDoesNotSoundInThe PanicMode ..
. .i.n. .g. . . . . . . . . .
HornDoN
e so t S t o p S o u n d
Page130-19
Page130-19
Input Tests
Page130-16
.
130-15
Power Door Locks (cont'd)
KeylessDoor Lock Control Unit Input Test
Thefollowingtestsare performedwiththe keylessdoorlockcontrolunitconnectordisconnected.
Wire
Color
Terminal
No.
Test Condition
Test: Desir€dResult
PossibleCauseif result ls not obtain€d
BlownNo.43 (7.5A)luse in the
under-hood
tuse/relaybox
Connectto ground:Theceiling o Blownceilinglightbulb
lightshouldcomeon.
a Faulty
ceilinglight
a An openin the wire
a
1
LT GRN/
BLK
3
lgnitionkeyinserted
intothe ignitionkey
switch
BLU/RED
lgnitionkeyremoved
lromthe ignitionkey
switch
BLfiEt
b
Ceilinglightswitchin
"middleposition"
lgnition
switchON (ll)
switchin
REO/BLK Headlight
PARK OTHEAD
LT GRN/
RED
Eachdooropened,
oneat a time
GRY
Underall conditions
BLK
Underallconditions
15
130-16
Ch€cklor voltageto ground:
Thereshouldbe I V or less.
Checkfor voltageto ground:
Thereshouldbe 4 V or more.
Checklor voltageto ground:
Thereshouldbe battery
voltage.
Checkfor voltageto ground:
Thereshouldbe battery
voltage.
Poorground(G401,G402)
Faultyignitionkeyswitch
An openin the wire
o Shortin the wire
a
a
a
.
.
a
a
o
BlownNo.14 (7.54)fusein the
under-dash
fuse/relaybox
An openin thewire
Blown No. 32 (7.5A)luse in the
under-dashfuse/relaybox
A faulty headlightswitch
An open in the wire
Checklor continuity
to ground: o Faultydoorswitch
Thereshouldbe continuitv.
o An openin the wire
. BlownNo.52 (154)fusein the
under-hood
fuse/relaybox
Connectto ground:
. Faultyhorn
Hornshouldsound.
. Faultyhornrelay
o An openin the wire
Checklor continuity
to ground: a Poorground(G401, G402)
Thereshouldbe continuity.
a An openin the wire
rl,
KeylessEntryDoesNot Workln Any
Mode
verifythatallthe
NOTE:Beforebeginning,
transmitters
are programmed
to the vehicle.
withtheoptional
1. ls thevehicleequipped
security
system?
Yes- Go to the nextsteD.
No - Go to step3.
2. Doeslhe keylessentryworkcorrectlywhenthe
is disconnected?
security
controlunitconnector
Yes Faultysecuritysystem,go to security
systemfor f urtherlroubleshooting.
No - Go to the nextsteo.
3. Doesthe transmitterLEDcomeon whenanvof
the buttonsare pressed?
Yes- Go to step6.
No - Go to the nextstep.
4. ls the transmitter
batteryinstalledwiththe
positive
sidefacingup?
Doesthe transmitterLEDcomeon whenanvof
the buttonsare oressed?
Yes- Go to the nextsteo.
No - Replacethe transmitter
and programit by
on page130-14.
usingthe procedure
Doesthe systemworkproperlyin all modes?
Thesystemis OK.
Yes- Finished.
No - Go to the nextstep.
7. Recheckwitha knowngoodtransmitter
to thevehicle.Doesthesystem
reprogrammed
workproperly
in all modes?
Yes- Replacethe transmitterand programit by
on page130-14.
usingthe procedure
Replacethe keylessdoorlockcontrolunit.
No
\r;
Yes- Ensurethatthe batterycontacttabsare
repositioned,
then replacethe battery.
Removethe keytromthe ignition,then
closethe doorsandtrunk.Pressthe
LOCKbuttonon the transmittersix times,
thengo to the nextstep.
No - Ensurethatthe batterycontacttabsare
repositioned,
then reinstallthe battery
correctly.Thenreprogramthe transmitter
and retestit. Usethe procedureon page
programming.
130-14 fortransmitter
\ r
130-17
Power Door Locks (cont'd)
CeilingLightDoesNotComeOnWhen
TheDoorsAre UnlockedWithThe
Transmitter
1. ls theceilinglightswitchin thecenterposition?
Yes- Go to the nextsteD.
No - Reposition
theceilinglightswitchand
relesI.
2. Doestheceilinglightcomeon withtheceiling
lightswitchin theON position?
Yes- Go to the nextsteo.
No - Repautheceilinglightcircuit.
LEDcomeon whenanvof
3. Doesthetransmitter
the buttonsare oressed?
Yes- Go to the nextstep.
No - Checkthe transmitterbattery,then retest.
lf theceilinglightstilldoesnotwork,go to
the nextstep.
4. Recheckwitha knowngoodtransmitter
reprogrammed
to the vehicle.Doesthe system
in all modes?
workproperly
Yes- Replacethe transmitterand programit by
on page130-14.
usingthe procedure
No - Go to the nextstep.
5. Withthe keylessdoorlockcontrolunitconnector
runa jumperwirefromterminal1
disconnected,
to ground.
DoorsDo NotUnlockOr LockWith
TheTransmitter
1. Dothedoor'sunlockandlockwhenusingthe
drivefsdoorlockswitch?
Yes- Go to the nextsteo.
No - Repairthepowerdoorlocksystem.
LEDcomeon whenanvof
2. Doesthetransmitter
the buttonsare oressed?
Yes- Go to the nextsteo.
No - Checkthe transmitterbatlery,thenretest.
lf thedoorsstilldo notunlockor lockwith
go to the nextstep.
the transmitter,
3. Recheckwitha knowngoodtransmitter
reprogrammed
to the vehicle.Doesthe system
properly
work
in all modes.
Yes- Replaceand programthe transmitter,
then retest.Usethe procedureon page
programming.
130-14 fortransmitter
No - Go to the nextsteo.
4. Doesthe voltageat terminal3 of the keyless
doorlockcontrolunitconnectorchangefrom
batteryvoltagewhenthe keyis not in the
ignition,
to lessthan1 voltwhenthekeyis in
the ignition?
Doestheceilinglightcomeon?
Yes- Replacethe keylessdoorlockcontrol
un[.
No - Repairtheopenin theterminalI
(LTGRN/BLK)
wire.
Yes- Go to the nextstep.
No - Replacethe ignitionswitchor repairthe
wire.
terminal
3 (BLU/RED)
damaged
5. Doesthe voltageat terminal12 of the keyless
doorlockcontrolunitconnectorchangefrom
batteryvoltagewhenall the doorsareclosed,to
lessthan I voltwhenanydooris opened?
Replacethe keylessdoorlockcontrolunit.
Reoairtheooenin theterminal12
(LTGRN/RED)
wire.
130-18
HornDoesNotSoundIn ThePanic
ModeOr WithTheTransmitter"Beep"
FeatureOn
NOTE:The transmitterhasa BeepOn/Otttoature.
Referto page130-14for howlo turnthe be€pon or
off.
1. Doesthehornsoundwhonthe HORNbuttonis
oressed?
Yes- Go to the nextstep.
No - Repairthehorncircuit.
2. Doesthe transmitterLEDcomeon whenany of
the buttonsare Dressed?
Yes- Go to the nextsteP.
battery,thenretest.
No - Checkthe transmitter
lf the beepfeaturestilldoesnotwork,go
to the nextsteo.
3. Recheckwitha knowngoodtransmitter
to the vehicle.Doesthe system
reprogrammed
properly
in all modes?
work
Yes- Replaceand programthe transmitter,
thenretest.Usethe procadureon pag€
programming.
130-14 fortransmitter
No - Go to the neLtsiep.
4. Withthe keylessdoorlockcontrolunitconnector
runa iumperwirefromterminal
disconnected,
15to ground.
HornDoesNotStopSounding
1. ls the vehicleequippedwiththe optionalsecurity
system?
Yes- Go to the nextstep.
No - Go to steD3.
Doesthe hornstopsoundingwhenthe security
controlunitconnoctoris disconnected?
Yes- Replacethe sEcuritycontrolunit.
No - Go to the nsxtstep.
Doesthe hornstopsoundingwhenthe keyless
doorlockcontrolunitconnectoris disconnected?
Yes- Replacethe keylessdoorlockcontrolunit.
No - ReDairthe horncircuit.
Doesthe hornsound?
Yes- Replacethe keylessdoorlockcontrolunit.
No - Repairtheopenin th€terminal15 (GRY)
wire.
\lr
130.19
SecuritySystem
- '96-'98USA:HX, LX, EX;'96-'98Canada:
EX.Si
UNDERHOOD
FUSE/
RELAY
BOX
@ @
UNDER.
DASH
FUSE/
RELAY
I I C5s1 ! BOX
FUSE3
*'^'*'
,";;;i[ftT"fi'
",-f
,..1
.-"*luuu'
I
I
t"'1,",*
'lffi;?'- 1 ,i!r13" u".al
--Jt--J
C423
Dfstnoulon.fuO
yEL
wnr I
_::;=ffi
f::T;J
-Tl[3,*,,,*-"""
HORN
RELAY
|
|
l
%;1
i'"---i[
PHA|O 129 (9A nodel)
{'96-97models3)
I
:
'98model
(Not
il il
Horn
control
Baitery
tgnition
I
'96-97models
\
I
lgnition
key
I i*iiirr inilt
8LU/
FED
eround
L------
--------tiY
-----J
I
;t,t
fon:*,
,-l_""_
i l-flb'fitg"#
i".e"er;; |
-8LUFEo
-l-s-f----
1
vlEw21
ll
a.
BLUaED
= --
I
e.r,".o ll
, Ag::l^.
GAN
HORN
aLuneo Ill v,rwoo-'gr-u.neo
v,rw DU BLU/BEo
O -(
eruneoll
' + c4is
sersarr
R,
See
Seat Belt
and tgnitionKey
Reminders
.,u*i,l( il,?l?.uo
r-{---;:E[t-:--.rsrEERrNG
sTEERTNG
lgnltionKsy
'I
Swftch
I LOCK
I PHoroz1
*.1
Closed with
c201
vlEw30
ll-Ukevinisnition l
:r:["_-----r ilrff,i$t
J!@i---;""i
I
ilr,tlp:
! o"n"'o''
".*l
]t ____
_______i_______I
133
---'------l
POWERDOORLOCK ;
CONTROL
UNIT ,
---- Canada
';;;1;
------J-i
.r
Driver
door
unlock
inpd
'F":;!-_--",*tIi
input
| :
juj_.r,
lpr,_j
L______jg:_l=,_______
UNDE'
i 'I 11'.1'.11
::
\ H E A D I I O r i T 'lSBi'"
!:t
Lock
Unlock
--'I
I r1--
{
t--
L j,-
--
lPHo'o7
-J
: -9lT1u.r^
_r_f9_.-u:
!**
""""I
o*u*u'
*",*"[T*Fi
.",1
i
"ll-_-_il
-".11
,* t-J--'-----'-hff
I
k;i
18f ia-eii,
't
|semooeriir
f,
" t " ; t l o " n , o "trn |
"""*",|ft"t'i f
sEcuRrwLED,,
L--J---------J",0.
L______d
| | -liffi*
,i,Hfil_[l!,ffisH
i ,of.--sL--d,---t--------cl-+-'dl
, i *t
t : LED control
ooor
door
Drtusr's
uavgrs
Drivgr'sdoor
unloc* outpul
untocx
Unlock
untock
:
'r
Va
a rrEs
t
\\I vvatst
:;
,
'
$vitch
; s,vitch
f iinqrt
narr
:
84 |,
;I
I Vabt
s Y---^a---.;f
Lrgn'
ugnt
Light
flash
iI
".""""
!
I
U
'
q._"u_n'r
Ii sEcuRlw
--:"ll'i- -'; iontrot
13'*"
- ----' ' lI9c9o,Nt r R
RooL!L
outrut
---:i"-1i3y.-TTiii- --11-F-o-:y-"1
--" -' - ,i
-------t
iI
LocK
Lock
Lock
outpul
- ':
I
I
Nlr
UNIT
'. i; u
Bus
Remote
Securiiy
Securiiv Bus
o
rnout d
'de2
L
E Dccontrol
o n t r o ld
a t a0
LED
data
d€,.az
outDut
--.;Y---^;Y---:Y
Bus
d
a t al
data
: l ;Pvttwte
#H Q" |bA T"3
tl
t)vtEwte
i I
ll C422
P1oTo
58
, :
- aI - - - - - - r ;-.tr'---
[I$'
Iffi;*l
lfil
85A
87A
811 |'
Bt2 |'
813 |'
ii'=::t:::ti------r------s------r,
:i iffi$
S€curity
input
8us
data2
Remot€
ffiDul
Bus
datao
Bus
|
vtEw68
! saer.teadli
-"** i :
Reieiver
datalI
iunrr
! 8yJfu;
! ; --_ _.._ll
!:""'"^l
7-1 e4re4lon
(cont'd)
133-1
SecuritySystem
- '96-'98USA:HX, LX, EX;'96-'98Canada:EX,Si (cont'd)
-----l
I
ooor
sEcuRlrY
I CoNTROL
! UNIT
I PHora73
sB
JvtEw
trllnx
switch
Inpur
| input
#Ifl
2
LT CRN/FED
---{
F6,i,",.
ooo.
i:<
"?;",o,"
BLU/ALK
c503
6
LT GFN/RED
BLU/ALK
c562
12
(Sedan'15)
vtEvl 42
BLU/BLK
-{
BLU/BLK
EAA
i,i-"i
Light
c411
H
":-f
PHOIO 60
TRUNKLATCH
vtEw60
swrTcH
Closedwith
vunKopen.
SeeGround
DislrihJtion,
pag€1*10.
Or--<
".^
LTGBN/REO
|
l- G601
LTGRN/FED
a
" *
[
LT.FN,BED
i
.l:T,lT_t
i __;T_-----l Hui.'n*f'
ffi
,
!E ilf8t+
lffi'il* !
!
LE:E,jJ_i*-|
I
t___:'I______l
; LTGFN/
E
D
|. :-:?-'IINTEGB]ATED
Tll """,
*'^lft?{,,'
l-.'F-l DRtvER.s
| 1 I DooR
Ir-Il3)lll8l,*
oooropen.
=-
PHOfOg6
I PHoro58
ll
LTGRN/REO
i
T
I
,
H
F
:
i
i
FRONT
PASSENGER'S'
DOOR SWICH:
Closed with
:
door open.
PHOTO96
c401
------Sedan
i
H
LEFT
REAR
DOOR
SWITCH
Closedwith
dooropen.
rflf5ii'
lCJEfii:t*,,,'i
-
.l^^r
^^6^
PHOfO 97
133-2
:
|
\
.
STEERING
!l
ii^
/
:ll*cK (
I LOCK
f-+ iffi,iiilili. lsivvncrr
_;l"d:lt':"i
i
I
I
- t*.r.$r
fl''i"
i!tff^.I^-.-f
iL---------J-{,5=;==---)
! ti't|l
r
!
r
"'*TA
"o'u
Pflllodo
etxret I
a
l:'iI
".orr.i
tr-
;-
--
SECURITY
STARTER
CUTRELAY
PHOTO53
PTOIO56 ( 98 modsls)
vlEW12
to :l cat t
*"1.;
[;z*e'
Mrr
SECURIry
!'G";1
CONTROL
cut
\r;
ouiput
UNIT
"a*-",
Io
vtEw58
BLKTTVHT
.I A/T GEAR
I POSTflON
a swtTcH
an
('98 model 5)
PHOfO 78
STARTER
CUT
RELAY
('98 model 3)
4
CVT
lll exceptCW
--T6-';'d"r
tlf
3 l
".,u".o
I
T
BLU/BLK
Bt( vHT
fr
aL|( vHr
ll
Slig:i*
clutch
J,
TNTERLoCK
pedalfully
oepresseo.
Se€G.ound
Distribution,
pagel4$.
T
rl r
Y
I
I
L____l
+.
:
G401
t A/T GEAR
I POSTTTON
8LK/FED
c433
11
aswrTcH
o
t - r
\
BLKRED
L!
I
cLUrcH
c433
10
L---J---
I
I
I
J
ALI(RED
",#"It#f;,.+,"
I
".o"ro!
.@
BLvFEo
"'o"'r"f,
"'ot
See
Starting
System
ro'ffzr----,
BLKAVHT
STARTER
r::1
I
t
uo'r STARIER
I soLE orD
l
PHOTO57
L--------J
133-3
SecuritySystem
- '99-'00USA: HX, LX, EX, DX-VSi; '99-'00Canada:EX,
Si
@@
- ---- -----t@
-- --F;
I i"t]:.:*'
i | ffii:- I i['"",llae'
i
1
F,...
L-i:i--:::.J
@
L-t----------i::=t s:i
F#r""
;Tto"
t*x;,3''
u:;
;ntn" "..f
",-^:"\P;!i?,"
...'*lii:i',,"
I lft:i:3''.I::,
wHr'cuN
--^*[ftFi"
*nr
--f
"..
2 lf c353
7 t'
8 Y C352
C4l9
1 v C423
-"r,"""Iq
**l -"'"""[q
I
l
SeePowsr
Disti brrtion,
i
!
I
C4il8
Batiery
!,"1{}"'
{Not
--t----
rsnidon
IEBP*'
tgnitionkey
f
\.
vabr
L-----t:gg-____
--;;----.T _gs___ggg___-,r
---C214
;iP,li:
r:[3o-.o<
BLU/FEo
I
ffi8i?;g"'fu,
I
".u,"?!..,uR8fr.,!3"Iii,
".^l
lgdIon Kry
Swhch
Gbssd with
key in ignition.
-----J
'l?,ii;'?,ffi8lli"?,1
Pag€14-6.
".*
fl
133-4
I
. 1"*.
.+i"ili""
swtTcH
STEERING
LOCK
BLUAAIHT
HORN
--i
BLU
I
!---J r
1
-^l
o
I
SeeGround
Distribrtion,
pag€l+7.
:':l
ELK
c450
\
a
i
----'canada
;;;;-gr"Srrif,fI
"
:
-
-=l
*i'[?'29
i r-----
: | 3;::,
I
unlock
I
unlock
: L-j5----j!g-------':g:-j
'
6l-----r-T--------
i e""e'I o"no"n!
_
i
t
,
lock
I
qNPEE-llqgo
i I l[+'ffi!l[?::'*'
:
;
1T
@
r1----1
o"n-"'! i
LJ,----.1
sf_e_3s-?
wHr
lwi:iiz-
iff*f{#i!
ffil *smi i""'iF'as€i;;
cnnronr
I
I
or
ii I I i - , d I i " " r l - - - ] r l
i'uf---rilf-----".u.".,.1
o"no""i
lsYef.ify,',
fillTli-ix11,,
*n,",1''",u,i
i
lEqlJF,:*:;
i, zof----f-------ttit!;k"':'f------T
\lr
".u"..
i
:
i;
I
o"n,o"u
I
o"n,""'I
|
|
l
I
|
I
I
i
"ro,c"nI
"ro [
! "'oo*
?asee'ead'sht
i i*i
i
i
*""""
I
I
zl-----8l---------qf------rJ
-l:'.:=il
ir---l-------------'-------------------i-tt'ilr'iiililil
rl-,:f'-,."",rr .. .--il'-:::::'.1..
[
-":
iii:;i"'"
,
i
3-----
"I-----'1------1
i *"I *'*'.!
I *..*"!
.."1
i
|
i ,,[-----[-----,J
iI
i
rlr
i-ffi;----;;------'"i-l
i
i -- --
-;
J
------i
i
l'"i::""
7 ^
v E w1 6
i-T;-'*-'-"*trJnl
i !1.,9,.:'-'
i ! lN+;**i*o'o
"-**,-'
i "-i";f
[ib,!".p."i
I;yJ;l*,"'""t1'ffi"'r3o
!33lY"o
----i*o i
I
13tr8"?*1
I
+
(cont'd)
133-5
SecuritySystem
- '99-'00USA: HX, LX, EX, DX-VSi; '99-'00Canada:EX,Si (cont'd)
LT ONN/BED
LTGFN/REO
13
LTGBN/RED
PHOTO113
?-a@
c41r
i
"i:,1'**
LT GFN/REO
I
Lr cRNiBED
I
c401
LT GFN/BED
I
------Sedan
T
'll------'l
I
Bsl
I
a
UNDER.DASH
FUSE/RELAY
BOX
'
*l;;
!l :i-------T-'lsFs6l'"
t !u x r
ll:nJffeffii*4'aw"o'"
! L------J-J
RIGHT
REAR
DOOR
SWITCH :
Closedwith;
dooropen.,
L_____":r----__
I-'r|
DRIVER'S
I q IDooR
Ir-\l3l3ll3T*
H-
133-6
door open.
PHO\O 96
IT GBN/FED
E
FRONT
PASSENGER'S
DOOR SWITCH
Closed with
door open.
STEEBING
LOCK
ii-=1;-i*r*iTfifil
Ir
il.^-..
./ _r.n:'o !
!!r3"'.rhil.1ilri !
--ii-;;;I'-----==---**,^r..!i'i"i'
SECURITY
SIARTEF
CUTRELAY
"-dI
iryissu'Y
I
PHO|O 56
vtEw 12
Mrt
BLKAIIIfIT
o
STARTER
cur
RELAY
------;r
PHO|O 135
cw
A/f sxceptCW
"'li'l
t**,"
BLK,^,HI ll
I
I
I
I
I
V/Ew4 r
POSTTtON
I
Ia
,It
t
swrTcH
TX
a.
\*
l:l
I
c433
I
't0
BLK/IIT/HT
A/T GEAR
POStTtON
swtTcH
*\"
t
I
LL
BLK/FED
i
"."JJ"!F;?',?,-
$fri*'fl:J
I
clutch
pedalfully
oepresseo.
c433
PHOIO 76
I
",-o"ao
I
T
cLUrcH
BLKr{VHT
-
".o"ro!
o@
PHO|O 130
BLKFED
See
Starting
System
SeoGfound
Distribution,
page 14-6.
il
c101
)21
vtEw2A
2lI
\
.
STARTER
START
34
r::-1
STAHTER
uo"
I
lsoLENotD
t
l
L--------J
133-7
Security System (cont'd)
- '96-'97CX and DX Models(cont'don page 133-10)
NOTE:Wiresthat look likethis e:=---{
betweenfactorvharnessconnectors.
arepan of the optionalSecuritySystemharnessinstalled
STEERING
LOCK
@
r-------
FUSE 52
toRr{,
sTorlrotir
t5a
!'"*'!i
iltr?
_ili*
!i*.1-/*.,i
I L---*--J
"",,""i"1---"-",-,""rf
&f,.f,,,
t--"-.*-*t------J
I
uAcgt
Ho'nReray
ll Connector
t A-----1.:A
ll
'l lonltion I
ar-x,ver"erorooo
ll
"""o"n *""T
ll
ll
1A-------/{
HORN
RELAY
".,,".:J[-'I
.--.tf
rvll
a:
"ll
sEcuRrw
GAY
IN.LINE
FUSE
HOLDER
H( Relay
114 Horn
a l Connecto.
c(
.-t
GRY
"""'
+
ALK,YEL
11
)e florns
Horn
""''"h
[*u
c214
vtEw21
/1H?#,
SECURITY
CONTROL
UNIT
vtEw58
O ___________1F_(
c415
".u "eo ll
" U c+ts
'i!,1fl0
See Seat Belt
ano ronrl|on
KeYReminder
gd!ryi--],.,,.*,"o
eLu,,,viiYll9,'9.60
!"*"
ilnffi"*
L+
kevInignition.I
I
L--ll------J
"'utTf,
"o',u
PHofo46a
BLU/FED
c20'l
oLK
ll
PHO|O 23
vtEw 3a
BLK
G401
133-8
lgnition
Batiary
V
- '98-'00CX and DX Models(cont'don page 133-10)
NOTE:Wiresthat look likethis e=-*
betweenlactoryharnessconnectors.
arepartof the optionalSecuritySystemharnessinstalled
STEERING
LOCK
UNOER-HOOD
FUSE/RELAY
BOX
-1[::_5J*nt ,trft?;","
s Y c3s1
,n"r,".oI i[o"to,'
liuF;lt"ls'rs?
i
iL:"::Ifui
'--T'Il,].----r
HORN
RELAY
PHOIO t35 ( 99 0o models)
;.;l
i-t-fii;r,'im:";
c926
OPTION
PHO|O 62
sEcuRrw
t
IN.LINE
FUSE
HOLDER
cnvllConnector
9""
Horns ll
;.'".*"'
TBriE:,,
Lii+
,""
l-l--';]
ll
'Jl
'' lL--l[JL---:-----------C
- - - tt*
--,
- . :- ;_:
't--J'''*uo
i.rl::t;;;[.?jsor+3r
I ii}"*:*
i lff], ;,:"1.
iw,E"
lc,o,na
i Y#,iln,"o*
i - 9JlflB'],iff,
-J--------- . l .-- - - ' -i'.
- -- --s-J[-J
rsy]sf
l-'
J
L:;;
ll
;
'
i
"
ll
*ll
ll
Itr
fl
'fi
BLU
REo| | ".r,".o
' ---
2 gLuneo
--;'
-
i ".,".oii----iiiu
see seat
Bettand
[tJ.li'fll5"t
"i-jttz---'rsrEER
STEERTNG
l/rlu'-'u"i
i ,#
ll ;i'".'J^
i
Fii;i,"
eLull
11
:
'
: -BLU^YHr
z!9X;2""|"i!'}?.""
r{i y*sr..
SWITCH'
' ; r { i fs si;;;i;
"l{
-l-'-
ll
BLK
ll
'
i iQffi*"it*"
"'u*TI
L--IF-----J
i
,
. - - - -.
"o,u
r atv
r
lt PHofo 60
v / E w' 4
_8!Kll
HOBN
:
G401
133-9
SecuritySystem
- AIICX and DX Models(cont'd)
arepartof the optionalSecuritySystemharnessinstalled
NOTE:Wiresthat look likethis -:=
betweenfactorvharnessconnactors.
SECURITY
LT GFN/BLK
Lf GRN/REO
2
c407
PHO|O 52
Y/El4 ? ( 98' 00 mod€rs)
LT GFN/BLK
('99' 00 modsls LT GBN/RED)
14
c41t
PHO|O 6A
vtEw 60
'99-'00models
LT GFN/REO
(Not
useo)
c411
13
vtFw20
LI GFN/BEO
a,o^n,"ao
I
r-----{asl
I
- - -l.l' il-
LTGFN/FED
-----1
UNDER.OASH
FUSE/RELAY
11
BOX
1 INTEGRAT€D PHoro
5a
(,99_,00
models15)
ififlLliF"#t::-
LTGAN/BED
Sedan - - -
LTGBN/RED
H
fTl33'J"*''
FRONT
PASSENGER'S
DOOR
lldi$"",""',:;llswtTcH
PHO|O96
Closed with
door open.
IT
rui=ifl
H
RIGHT
REAB
DOOR
:
dooropen.
Closedwith
dooropen.
;
PHO|OqT
PHO|A9T
R EAR
=-
I
133-10
c40'r
SWITCH
Closed with
swtTcH
l t FUsE4s
! \ xamucnr
I I.A
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UNDER.HOOD
I FUSEiRELAY
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7
I PHoro
c352
vtEw27
SoePow€rDistdbulion,
page1&12,
E2
CombinationLight
SwitchConnector
See
lndicators
LIGHT
FLASHER
RELAY
COMBINATION
I LIGHTSWITCH
| v;iw;
I
|
4
aLUor ALU/YEI
c503
iTFffiliBi+B,il
:"'s#Ji""I coNrRoL
iI #input$ iI
vtEw58
L ----J
3Y
BLU/BLK
ll
:a
Brui
8rK
ll
ftT-f.","
*,rlfr
Combination Light
Switqh Connector
,^ftslllflli^ir,, Ha,chback
Coupatnd
Sedan
"'u'"t*X
".u,"."
See
Trunk
aE,<
aau,"a"
fi
-*;"1
' * 9 # 1 " ,,,
'9+ 97 models
SeeHeadlight
Swiich,
peg61(n.
vEwe g8-,oomodets
BLU/BLKrf
Light
TRUNK
LATCH
swrTcH
";-f"^'
l
qi*$qlilljij::,:}#x
I-I-t
I swtrcx
I I
se€Ground
5--r< !#itl8
or14-11
".*
I o"o'
PHOIO ro2lorcoDr'99 oo sedan)
PHofo 113
FE
HATCH LATCH
""'*if
":^f
.|:
r = l\,lale- Female
reversed
termrnals
lor'99-'00models
"tut
o tr<
1
11 12
13 14 15
7
6
rGlxllT 1 8
8
9
10
1 9 20 21 22
USA:HX,LX,EX,DX-VSi;Canada:EX,Si:
1 USA:YEUBLU
(Set)
2 LTGRN/RED
(Door swiich input)
3 BLU/BLK
(Trunkswitch rnput)
4
5 BLU (valet switch inpu0
6 CanadaiGFNAVHT
(Lock output)
7 Canada: BLU/YEL
(Driver'sdoor lock
oulpurJ
I Canada:GRN/OBN
(Unlockoutput)
9
10 WHT (Battery)
11 YEL (lgnition)
12 USA:OHN (Alarmin)
13 BLK (G401)
14 BLUMHT
(SecurityLED conkol)
15 BLU/RED(lgnition
key switchinput)
17 REDAVHI
(Lightflashcontrol)
18 GRY (Hornconkol)
19 RED/YEL
(Startercut output)
20 Canada:LTGRN
(Nolused)
21 ,96-,98USA:LT BLU
(Securityoutput)
22 '96 98 USA: WHT/BLK
(Bus data 0)
'99-'00
USA:BLU/YEL
(Unset)
CX and DX:
1 RED/BLK(Dashlights)
2 BRNMHT (Audelivery)
(Airdelvery)
4 GRNA/VHT
5 GBN/BED(Airdelivery)
6 GRN/YEL(Alrdelivery)
7 YEURED(Airdelivery)
(Au delivery)
8 BLU,ryVHT
9 YEL (Andelivery)
10 YEUBLU(Arrdelivery)
11 LTGRN/BLK
(Blowercontrols)
12 ORN,AiVHT
(Blowercontrols)
I
13 BBN (Airdelivery)
14 RED(Dashlights)
15 GRY (Airdelrvery)
(Air delivery)
16 RED,ryVHT
17 RED/YEL(Airdelivery)
18 PNK/BLK(Airdelivery)
19
20 BLU/RED(A/C
compressorcontrols)
21 BLUI/EL
(Bearwindowdefogger)
22 WHT/BLU(Fuse47)
23 BLKryEL(Fuse17)
24 BLK \G402)
1
2 LTGRN/BLK
(Dooropen input)
3 BLU/BLK
(Trunk/hatchopen
input)
5
'96 '98: BLU (Security
ndicatorcontrol)
99- 00: BLU
(Valelswitchinput)
6
7
B
I
10 WHT (Batteryinput)
11 BLK/YEL(lgnitioninput)
13 BLK (Ground)
14 RED (Securityindicator
control)
15 BLU/RED
(Keyin ignitioninput)
16
17 BLUor BLU/YEL
(Lighttlash control)
18 GRY(Horncontrol)
19GRN
(Slartercut control)
20
22
202-17
ConnectorViews (cont'd)
59. Cl31
- Green
- Behindrightkick panel
- Connectsmainwire harnessto enginewire harness
'96.'98D16Y5,'99-'00D16Y5with M/T:
1 '98-'00models:LTGRN
(PGl\4-Fl)
2'991001
M a l e ' L TG R N M H T
Female (Notused)
A/TrRED/BLK
(A/Tcontrols)
'98r00 models:
3
YEL/BLU
(PGrV-Fr)
4 A/T: LT GRN (PGl\.4-Fl)
lVl/T:RED (PGi.4-Fl)
5 '97 models with l\4/T:
Male - RED/GRN
Female - WHT/BED
(PGl\,4-Fl)
A/T:WHT/RED
(lnterlock)
6 GRN (Fans)
7 BLU/RED(A/T
compressorcontrols)
I GFN/OnN(PGl\4-Fl)
I BRN (PGr\,4-Fr)
10 WHT/BLU(PGM-Fl)
'98-'00models:BLU
11
(PGir-Fr)
12 A,/T:WHT/RED(PG|VI-FD
13 A/T:RED/GRN
(A/Tcontrols)
M/T:GRN/BLK
(PGr\,1-Fr)
14 A/T:PNK(PGM-FD
M/T;GRN/BLK
(Back-uplights)
15 A/T:GRY(PGl\,l-Fl)
l\,4,rT:
Male- YEURED
Female YEL
(Back-up
lights)
16 USA GRN/RED
(Charging)
(PGMFD
17 GRN,ryVHT
(Vehicle
18 BLUAVHT
speeosenso4
(A,IT
19 BLK/RED
controls)
compressor
(PGM-FD
20 GRN/YEL
- BLU/YEL
21 N,4ale
Female- LTBLU
(PGM-Fr)
22 Male- BLU/WHT
Female BLU/ORN
(PGt4,Ft)
'96.'98016Y7:
1 *1: LTGRN (PGM-F|)
2 *2: GRN/BLK
(A/T controls)
3 *2: WHT (A/T controls)
'98 models:
[rale - WHT/RED
Female- (Notused)
4 A/Ti LT GRN
(A/T controls)
5 *1i YEL/BLU(PGM-Fl)
*2: WHT/RED
(lnterlock)
6 GRN (Fans)
7 BLU/RED(A/C
compressorcontrols)
I GRN/ORN(PGlvl-Fl)
9 BRN (PGT,I-FD
10 WHT/BLU(PGM-Fl)
1 1 * 1 r B L U( P G L 4 - F | )
13 *1i GFN/BLK(PGl\4'Fl)
*2: BLU (A/T controls)
14 A/TiYEL (A/Tconlrols)
M/T:GRN/BLK
(Back-uplights)
15 A/TiMale - GRN
Female- PNK
(A/Tconkols)
lvl/tT:Male - YEL/RED
Female- YEL
(Backup lights)
16 USA:GRN/BED
(Charging)
(PGIVI.FD
17 GRN,^/VHT
18 BLU,ryVHT
(Vehicle
speedsensor)
19 BLI(RED(A/C
compressorcontrols)
20 GRN/YEL(PGM-Fr)
21 ftIale BLUffEL
Female - LT BLU
(PGM,Fl)
22 Male - ELUMHT
Female - BLU/ORN
(PGrvl,Fr)
'96-'98016Y8:
1 *3: LTGRN (PGlvl'Fl)
2 lvlale- GRNIVHT
Female- GRN/BLK
(PGr\.4,F1)
3 WHT/RED(PGl\,4-F0
4 A"rT:LT GHN
(A/T controls)
5 *3: YEUBLU(PGM-Fl)
6 GRN (Fans)
7 BLU/RED(A/T
compressorcontrols)
8 GRN/ORN(PGr\4'F|)
9 BRN (PG|\4-F|)
10 WHT/BLU(PG[,4-Fr)
11 *3: BLU (PG[.4-F|)
(PGl\4-Fl)
12 BLK,ryVHT
13 *3r GBN/BLK(PGM-Fl)
14 A/T:YEL (A,rTcontrols)
M/T:GRN/BLK
(Back-uplights)
- GRN
15 A/Tr l\,4ale
Female- PNK
(A/T controls)
lVl/T:[/ale YEUBED
Female- YEL
(Back'up lights)
16 USA:GRN/RED
(Charglng)
(PG[r-Fl)
17 GRN,ryVHT
18 BLUAVHT
(Vehiclespeed senso4
19 BLK/RED(A/T
compressorcontrols)
20 GRN/YEL(PG[' Fl)
21 Male - BLU//EL
Female- LT BLU
(PGr,1-FD
22 l\,4ale- BLUMHT
Fernale BLU/ORN
(PGt\r-Ft)
*1 = '97 models:California
sedanLX
coupes,Californla
'98
modelsiall models
*2 = '96 models: all A,rT
'97 modelsrall A"lTexcept Coupe DX
*3 = '96 models:allcoupes
'97 models:all coupes,California
Sedans
'98 models:all models
202-18
'99-'00 Models exceot D16Y5 with M/T and D1685:
Dt685:
1 RED(PG[,1-F0
2 BRN(PGM,F|)
3 Male BLU/BLK
- BLUMHT
Female
(Starting
system)
4 lrale ORN/8LU
Female ORN
(Fuelgauge)
5 LTGRN(PGM-FD
6 GRN(Fans)
(r,/C
7 BLU/RED
compressor
controls)
(PGM-Fr)
8 GRN/ORN
9 BRN(PGM-FD
(PGM.FO
1OWHT/BLU
11 BLU(PGM-F|)
12 YEL(PGM-FI)
13 WHT/BED
(lnterlocksystem)
\
14
15 l\.4ale- BLU/GRN
Female- BLU/RED
(Low fuel indicator)
16 GRN/RED
(Chargingsystem)
17 GRNA/VHT(PGl\.4
FD
18 BLUAVHT
(Vehiclespeed sensor)
19 BLTVRED(r,/C
compressorcontrols)
20 GBN/YEL(PGr\.4-FD
21 N4ale- BLU/YEL
Female - LT BLU
(PGr\,,rFr)
22 l\4ale BLU&VHT
Female - BLU/ORN
(PGr,4-Fr)
1 D16Y5/D16Y7:
BLI(WHT(PGM.FI)
2 D16Ys/D16Y7:
wHr/RED(PGt\4-Ft)
WHT(4,/Tcontrols)
3 A,rT:
4 *1: LTGRN
(A/Tcontrols)
6 M/T:Male- YEURED
Female- YEL
(Backup lights)
7 GRN(Fans)
(PG[,4-Fr)
8 GRN/8LK
Fl)
9 USA:GRN(PGf.4
(PGM-FD
1OWHT/BLU
13 *1: BLU(A/Tconkols)
1 4 * 1 :Y E L
*2: GRN/BLK
(A/T controls)
15 *1:Male GRN
Female- PNK
(A/T controls)
*2: Male - GRN
Female- LTGRN/RED
(A,fTconkols)
18 M/T:GRN/BLK
(Backup lights)
19 BLUMHT
(Vehiclespeed sensor)
20 YEUBLU(PGI\4-FD
21 RED/YEL(PGt\,'l,FD
22 BRN/BLK(G101)
*1 = A/T except CVT
)
202-19
ConnectorViews (cont'd)
60. c411
- Blue
- Mountedto top ol under-dash
fuse/relaybox
- Connectsmainwireharnessto dashboardharness
'98 GX and All '99-'00Models:
'95198 Models excepl GXI
1 *1: RED/GRN
(PGrvr-FD
2 A2:WHT
(Security
system)
(Security
system)
4
5 BLU(SRS)
6 *2rGRY
(Cruisecontrol)
7 *2: BLU/RED
(Security
system)
8 RED/BLU
(Cruise
control)
9 LTGRN(Cruisecontrol)
10 '96- 97models:
(ABS)
BLU/YEL
(Gauges)
11 YEUGRN
12 RED(Dashand
consolelights)
'13LTGRN/RED
(Ceiling
light)
*1 = Withshitt-upindicator
202-20
14 USALX,EX,andHX:
LTGRN/BLK
light)
{Ceiling
ExceptUSALX,
EXand HX:
ftrale- LTGRN/RED
Female- LTGRN/BLK
(Ceiling
light)
15 WHT/BLK
(Hazardwarninglights)
16 *2: RED|YEL
(Security
system)
17 *2: REDA/VHT
(Security
system)
(Stereo
18 WHT/BLU
soundsystem)
system)
19 BLU(lgnition
20 RED/BLU
(Seatbettreminder)
(PGN4
21 GRN/OBN
FD
(VSS)
22 BLUAVHT
(Oilpressure
23 YEURED
indicatorsystem)
(ABS)
24 BLU/RED
USA:LX:EX,HX
CanadarEX,Si
14
1
2
15 WHT/BLK
(Hazardwarninglights)
4 All except GX: BLU/YEL
(Rearwindow defogger)
5 BLU (SRS)
7
B RED/BLU
(Cruisecontrol)
9 LT GRN {Cruisecontrol)
10 *1: PNK (lndcators)
GX: BLU/YEL(Bear
window defo9ger)
1l YEL/GBN(Gauges)
12 RED (Dashand
console lights)
13 *2: Male- LT GRN/RED
Female- Not used
(Ceilinglight)
18 WHT/BLU
(Stereosoundsystem)
19 BLU(lgnition
system
anogaugesl
20 RED/BLU
(Seatbellreminder)
(PG[,4-Fl)
21 GRN/ORN
22 BLU,ryVHT
O/SS)
23 YEURED
(Oilpressureindicator)
(ABS)
24 BLU/RED
*1 = Allexcept
CW andGX
*2= AllexceptGX
\
61. C556(withPowerDoorLocks)
- Gray
- In driver's
doorjamb
- Connectstloorwireharnessto driver'sdoor
wtrenarn€ss
'I
2
7
)
- Gray
- In frontpassenger's
doorjamb
- Connectsfloorwireharnessto passenger's
doorwireharness
4
8
9
10
7
8
4
5
9
10
13 14 15
1 1 12 t3 14 15
1 6 1 7 1 8 1 9 20
1 6 1 7 1 8 1 9 20
21 22 23 24
2'l 22
11
\
62. C557(withPowerDoorLocks)
1 '9: GRN/BLK
(Powerwindows)
2 *9: BLU/BLK
(Powerwindows)
3 *7: YEUBLK
(Powerwindows)
4 *7: REDMHT
(Powerwindows)
5 .3: WHT/GRN
14rBLU,TWHT
(Powerdoorlocks)
6 i9: BLU//EL
(Powerwindows)
7 '9: BLU/ORN
(Powerwindows)
I *7:YEL
(Powerwindows)
9 *7:YEUGRN
(Powerwindows)
10 *7: GRN/VEL
(Powerwindows)
1 1 * 7 iG R N
(Powerwindows)
12 WHT/RED
(Powerdoorlocks)
13 "3: YEUBED
(Powerdoorlocks)
14 *1:YEURED
*2: BLU/BLK
(Powermirrors)
15 '96-'97models:
BLU/BLK
(Powermirrors)
13:BLU/YEL
(Powerdoorlocks
*4: BLU/BED
(Powerdoorlocks)
Powermirrorswithout
Powermirrorswith
deloggers
'98 model:All
'99-'00models:Without
Keyress
'99r00models:With
Keyress
'98modelr
All
'99-'00models:
Power
16 '96. 97models:
BLU
'98-'00models:
Male- RED/GRN
Female- BLU
(Stereosoundsystem)
17 '96197modelsl
GRY/BLK
'98r00modelsl
Male- BRN/BLK
Female- GRY/BLK
(Stereosoundsystem)
18 *8:GRN/WHT
(Powerdoorlocks)
19 *8rGRN/ORN
(Powerdoorlocks)
20 t1 | BLU,TWHT
r2:YEURED
(Powermirrors)
21 '96-'97
models:
BLU/TEL
(Powerdoorlocks)
*5: BLU/BLK
(Powermirrors)
*6: BLU,TWHT
(Powermir.ors)
22 BLK(Gssl)
23 BLK(G551)
24 *2: ORNMHT
(Powermirrors)
mirrorswithout deloggers
99100 mod6ls: Power
mirrorswith deloggers
*7= Sedan
*8= '96- 98USA:LX,HX, EX
'99-'00
USA:All
*9= All except '00 Canada
DX-V:With Power Door
Locks Only
l GRN/BLK
{Powerwindows)
2 BLU/YEL
(Powerwindows)
3 BLU/ORN
(Powerwindows)
4 WHT/RED
(Powerdoorlocks)
5 YEURED
(Powerdoorlocks)
6 '96197models:
RED/GRN
'98-'00modelsl
l\4ale- BLU
- RED/GRN
Female
(Stereosoundsystem)
7 '96-'97
models:
BRN/BLK
'98-'00
models:
Male- GRY/BLK
Female- BRN/BLK
(Stereosoundsystem)
24 25
9 YEUBLK
(Pow€rmirrors)
10 *1:GRNA/VHT
*2rYEURED
(Powermirrors)
12
13 12:ORNMHT
(Powermirrors)
14 *2: BLK
(Powermirrors)
18
20-
23
*2: GRN,TWHT
(Powermirrors)
'6=
r1= Withoutmirrordefoggers
*2= With mirrordefoggers
202-21
ConnectorViews (cont'd)
64. CombinationLightSwitch
63. ABSControlUnit
- Lettsideof steeringcolumn
- AboverightkickPanel
A
Connector
A
Connector
- Natural
- On main wire harness
- Orange
- On mainwireharness
1 RED/BLU(FR-|N)
12 YEUBLU(FR.OUT)
3 4 BRN (SCS)
14 LTBLU(DLC)
7 BLU/BED(WALP)
'96197 models:
8
BLU|YEL(Not used)
9 _
10 YEUBLK (FL-OUT)
11 RED/BLK(FL-|N)
ConnectorB
- Natural
- On mainwireharness
(+81)
14 WHT/GRN
(+82)
15 WHT/GRN
16 BLK{GND2)
(FRl)
17 GRN/yEL
1 819 LTBLU(RL1)
8 GRN(FRo)
(STOP)
9 GRNAVHT
(FLo)
10 BRNAVHT
(FRl)
21 GRN/BLK
22_
(FL1)
23 GRN/ORN
12 YEL(RL-OUT)
(RR"IN)
13 REDAVHT
25 RED(RL-IN)
26 BLK{GND3)
202-22
(Rightturn
GRN/YEL
signalpoweroutput)
21 BLU(RR-OUI)
22 BLK(GND1)
- Orange
- On mainwireharness
6 GRY(RLo)
3
1 6(MCK)
17 BRN/YEL
1 819 YEURED(PlVlR)
ConnectorB
(PCOM)
1 GRN^VHT
2 BLr(wHT{SCOM)
(lG2)
3 BLIVBLU
4 BLU/fEL(RRo)
GRN/ORN
Ournsignal
switchpowerinput)
(Lettturn
GRN/RED
signalpoweroutqut)
(Headlight
RED/GRN
switchoutpUt)
WHT(Fuse48)
(Dimmer
REDAvHT
switchLOoutpu0
CanadarRED
(DRLoutput)
(Dimmer
FED/BLU
switchHl output)
6 WHT(Fuse48)
'98100models:GRY
7
{Horns)
65. Combination
WiperSwitch
- Rightsideot steering
column
66. DaytimeRunningLightsControl
Unit
- Behind left side ol dash
ConnectorA
- Natural
- On mainwire harness
ConnectorA
- Natural
- On mainwirenarness
ffi
3
I
6
1 BLU(Windshield
wiper
motorLOWconkol)
BLU/YEL
(Windshield
wiper
motorHIGHcontrol)
YEUBLU(lntermittent
wiperONinput)
8
4 GnN/BLK(Fuse26)
5 BLK(G401)
1 WHT/RED
3
(H€adlight
control)
(Battery)
2 BLKAVHT
RED(Lights-on
input)
7 BLU/BLK(lntermittenv
parkwipercontrol)
(Windshield
8 WHT/BLK
washermotor)
\
ConnectorB (C4271(withRearWiper)
ConnectorB
- White
- On mainwire harness
- Gray
- On mainwireharness
1
3
4
lilale - GRN
Female - LT GRN
(Rearwindow wiper
motor conkol)
lrale - LT GRN
Fema|e_ LT GRN/BLK
(Rearwindowwiper
motor control)
3
5
6
BLK (G401)
Male - WHT
Female- GRN (Fuse3)
Male - BLU
F€male _ GRN/BLK
(Rearwindow washer
motor control)
1 BLK(Ground)
(lgnition)
2 YEUBLK
3 GRN/RED
(Brakesystem
indicatorlightconkol)
4
5
6
RED/GRN
(Parkingbrakeinput)
7
8
)
202-23
GonnectorViews (cont'd)
67. IntegratedControlUnit
68. StereoRadioTuner('96-'98)
- On underdashfuse/relaybox
- Centerot dash
A
Connector
ConnectorA
- Connectscontrolunitto under-dash
fuse/relaybox
- Gray
- On dashboardwireharness
1 Notused
4
5
6
7
Erakebulbcheckoutput
input
lgnition
input
lgnition
lgnjtioninput
8 Lights
ONinput
input
9 Battery
1 1_
13 Startinput
14 Ground
- Natural
- On mainwireharness
202-24
9 BRN/BLK
-)
(RFspeaker
1OGRY/BLK
(LFspeaker-)
12RED
(lllumination
control)
14 BLK(Ground)
15 GFY,4/VHT
(LRspeaker-)
16 BRNAVHT
(RRspeaker-)
ConnectorB (USAHX,UX,and EX;
CanadaEXandSi)
Connectol B
l BLU/BLK
{Frontwiper/washer)
2 BLUA/VHT
(Frontwiper/washe0
3 YEUBLU
(Frontwiper/washer)
4 '98-'00models:
WHT/BLK
(Frontwiper/washer)
1 RED/GRN
(RFspeaker+)
2 BLU(LFspeaker+)
3 RED/BLK
(lllumination
control)
4 WHT/BLU
(Batteryinput)
(lgnition
input)
5 YEURED
6 7 BLU/YEL
(LRspeaker+)
8 RED/TEL
(RRspeaker+)
- Green
- Ondashboard
wireharness
(Driver's
7 RED/BLU
seatb€ltswitchinput)
8 LTGRN/RED
(Dooropeninput)
I GRN(Oriver's
doorswitchinput)
't0 BLU/RED
(Keyin
ignitioninput)
l BLU/RED
(Keyswitchinput)
2 LTGRN(Notused)
3 BLU/'EL(Drivels
doorunlockoutput)
4 BLU(Security
system)
5 LTBLU
system)
{Security
(lgnitioninput)
6 BLIVYEL
7 ORN(Security
system)
8 LTGRN/BLK
(Dooropenoutput)
9 GRN/ORN
(Unlock/lock
output)
1OGRNAVHT
(Unlock/lock
output)
11 BLU/WHT
(Security
system)
'2 WHT/BLK
(Security
system)
13 YEUBLU
(Security
system)
14 LTGRN/RED
(Dooropeninput)
15 BLK(Ground)
16 GRY(Hornconkol)
-
69. Transmission
ControlModule(TCM)('96-'98CVT)
- Behindleftkickpanel
\
ConnectorA
ConnectorB
- Gray
- On mainwireharness
- Gray
- On mainwireharness
1 PNI(BLU (SC LS -)
2 PN|(BLK (H LS -)
3 GRN/YEL(SH LS _)
4 BRN/BrK(LG1)
5 BLU (NE)
6 7 BLU (ATP-L)
I GRN (ATP-S)
9 YEL (ATPD)
1O LT GRN (ATPPN)
11 WHT (ATPR)
12 BL(WHr (rG1)
13 BLK (PG1)
14 YEL(SCLS +)
15 GRNMHI(HLCLS +)
(SHLS+)
16 BLU/YEL
(LG1)
17 BRN/BLK
18
1 9_
(DIND)
20 GRN/BLK
23 WHT/BLU
ryBU)
24
2s BLI(WHT(rG1)
26 BLK(PG1)
(SOLrNH)
1 GRN/BLK
(MAP)
2 RED/GRN
4 RED/BLK
|rPS)
5 BLUMHT(VSS)
6 PNK[rMB)
7 GRYrrMA)
(NDNSG)
8 RED/BLU
9 WHT(NDN)
(NDR)
1ORED/BLU
(STOPSVV)
12 GRNAVHT
13 LTBLU(DIAG-H)
14 BRN(SCS)
(VEL)
15 WHT/RED
(vErSG)
16 ORN/BLU
17 GRN(NDRSG)
(HBRKSW)
18 GRN/RED
19
(VREF)
20 WHT/RED
)
202-25
ConnectorViews (cont'd)
70. PCMor ECM(All '96-'98ModelsexceptD1685;'99-'00D16Y5MfO
Note:Forall othermodels,seepage202-28.
- Belowrighttrontfootrest
ConnectorB (A/Tonly - exceptCW)
- Gray
- On enginewireharness
- Gray
- Onenginewireharness
6
't6
'18
12 13 14 15
17
1
2
ConnectorA
3
25 26 2?
10
11
20 21 22
23
24
3'r
32
28 29 30
1 YEL(rNJ4)
2 BLU(rNJ3)
3 RED(rNJ2)
4 B R N( N J 1 )
5 BLI(WHT(SO2SHTC)
6 BL(WHT (PO2SHTC)
7 D16YswithM/Tl
PNK(E-EGR)
CWi RED(ESOL)
8 D16Y5/016Y8:
GRN/rEL(wS)
(LG1)
9 BRNiBLK
10 BLK(PGl)
(lGPl)
11 YEUBLK
12 D16Y5/016Y8
BLI(BLU0ACV)
13 11:ORN{IACVN)
14 11rBLKBLU(IACVP)
(PCS)
15 RED/yEL
*1 = D16Y5/D16Y8:A"/T
D16Y7:All
202-26
9
I
4
16 GRNffEL(FLB)
17 BLI(FED(ACC)
(MrL)
18 GRN/ORN
(ALTC)
19 USA:WHT/GRN
20 YEUGnN(CM)
(LG2)
22 BRN/BLK
23 BLK(PG2)
24 YEUBLK(tGP2)
(VBEF)
2s CW: WHT/REO
27 USA|GRN(FANC)
28 .2r BLU(2WBS)
(VSV)
29 .2r LTGRNAVHT
30 with shift-upindicator:
(Shift-up
WHT/RED
indjcatorcontrol)
CW; WHTiRED(SLU)
I
2
3
4
s
wHT (LS-)
RED(LS+)
(SHA)
BLU/YEL
GRNiBLK(LCB)
YEL(LCA)
8 PNK(ATPD3)
9_
1 0_
11 GRN,4HT(SHB)
(SLU)
12 WHT/RED
(D4rND)
13 GRN/BLK
14 WHT(NMSG)
1s RED(NM)
16 WHT(ATPR)
17 BLU(ATP2)
1 81 9-
22 GRN(NCSG)
23 BLU(NC)
24 YEL(ATPD4)
25 LTGRN(ATPNP)
\
ConnectorC
ConnectorD
- Blue
- On enginewireharness
- Gray
- On enginewireharness
'I
4
8
9
10
1 1 1 2 1 3 1 4 't5 't6 1 7 1 8 1 9 20 21 22
23 24 25
\
26 27 2a
(CKFP)
1 BLU/RED
2 BLU(CKPP)
3 GRN[rDCP)
4 YEL(CYPP)
(ACS)
5 BLU/REO
(STS)
6 BLU/ORN
7 BRN(SCS)
8 LTBLU(K.LINE)
I CVT:GRY[rMA)
(VBU)
10 WHT/BLU
(CKFM)
11 WHT/RED
12 WHT(CKPM)
13 RED[rDCM)
14 BLK(CYPM)
1s Dl6Ys/D16Y8i
(VTM)
BLU/BLK
16 USA:GRN(PSPSW)
17 WHT/RED
{ALTF)
29 30 3 1
(VSS)
18 BLUA/VHT
19 -,.
20
21
22
23 016Y5withl\.4/T:
BLK(lP+)
24 D16Y5withM/T:
RED(rP-, VS-)
25 D16Y5withM/T:
wHT (VS+)
26_
27_
28
29 CW: LTGRN(ATPNP)
D16Y5withl\4/T:
RED(CLSW
30 CW: PNKOMB)
L
2
1
7
8
4
9
13 14 15
1 RED/BLK
[TPS)
2 REDMHT(ECI)
(MAP)
3 RED/GRN
(vCC1)
4 YEURED
(BKSW)
5 GRN,A/VHT
6 CWD16Y8:
(KS)
RED/BLU
7 WHT(AllexceptD16Y5
M/'T- PHO2S)
(D16Y5M/T- LABEL)
(IAT)
8 RED/YEL
10 1 1
12
16
I D16Y5iWHT/BLK
(EGRr)
10 YEUBLU(VCC2)
(SG2)
11 GRN/BLK
(SG1)
12 GRN,ryVHT
13 016Y5/D16Y8:
GRN/BLK
RED//EL
D16Y7:
(sHo2sG)
(SHO2S)
14 WHT/REO
15 '2: LTGRN(PTANI9
(EL)
16 USA:GRN/RED
*2 = '96D16Y8
AllCoupes
enoine:
97 D16Y7
enoine.
Calitornia
CouoeandCalifornia
Sedan
LX
'97 D16Ygengine:All CoupesandCalifornia
Sedan
'98- 99:All
t
202-27
ConnectorViews (conrd)
70. PCM or ECM (D1685,All '99-'00Modelsexcept Dl6Y5 Mff)
Note:Forall othermodels,see page202-26.
- Belowrighttrontfootrest
ConnectorA
ConnectorB
- Gray
- On mainwireharness('99100except01685)
- On enginewireharness
(D1685)
- Gray
- On enginewireharness
2
4
6 7
8 9
't2 1 3 1 4 t 5 1 6 '17 '18 1 9 20 21 22
25 26 27
2a 29 30 31
1 *1: BLUAVHT
(srscHrL)
2 *1:GRNffEL[rFO)
(FWARN)
3 -1I BLU/RED
14:BLU{2WBS)
4 * 1 : O R N( FM E T E R )
.ar LTGRN/WHT
(VSV)
5 *2: BLU/GFN(CRS)
(PCS)
6 .4r RED/YEL
7 CVT:YELiATPD)
I BLI(WHT(SO2SHTC)
9 CW: LTGRN(ATPDN)
10 BRN(SCS)
t0
11
23
24
32
17 BU(RED(ACC)
(Mrr)
18 GRN/ORN
19 .4: BLU(NEP)
20 GRN(FANC)
21 *1: LTBLU(K-LINE)
.4: BLU/YEL
(K-LINE)
(PFO)
22 *1: BLU/YEL
CVT:ALU(ATPL)
(SHO2S)
23 WHT/RED
(STS)
24 *1: BLU/ORN
*4: BLU/^,iVHT
(STS)
(D4|ND)
14 13:GRN/BLK
26 GRN(PSPSW)
(ACS)
27 BLU/BED
WHT/RED
28 A"/T:
29 *4: LTGRN(PTANK)
(EL)
30 GRNiRED
(FLR)
16 GRN/yEL
(BKSW)
32 GRNAVHT
'1 =
"2 =
a3 =
*4 =
D16B5
D16Y7/D16Y8 with A"/T
A,/Texcept CW
ExceptD1685
202-28
(IGP1)
I YEUBLK
2 BLK(PG1)
3 RED(rNJ2)
4 BLU(rNJ3)
5 YEL(NJ4)
6 i4: BL(BLU (IACVP)
7 D1685:PNK(E-EGR)
CW: RED(ESOL)
8 'l: WHT(LS-)
CVT:PNIVBLK
(HLCLSI\,!)
9 YEUBLK(IGP2)
1o BLK(PG2)
1 1 B R N( N J 1 )
(VTS)
12 '2: GRN/YEL
(CM)
13 YEUGRN
a1 =
a2 =
'3 =
14 =
A"fTexcept CVT
Except 016Y7
M,/Texcept D16Y7
A/T,All D16Y7
14 01685:LTGRN
(NJ MOD)
15 .4r ORN(IACV
N)
1 6_
1 7 . 1 r R E D( L S + )
CW: GRN/WHT
(HLCLSP)
18 CW:PNKBLK
(scLsM)
19
(LGl)
20 BRN/BLK
(VBU)
21 WHT/BLU
(LG2)
22 BRN/BLK
23 r3: BL(BLU (IACV)
25 CW: YEL(SCLSP)
ConnectorC
ConnectorD
- Blue
- On enginewireharness
- Gray
- On enginewireharness
1
2
3
6
4
7
8
26 27 2A
(PO2SHTC)
1 BLK/WHT
(ALTC)
2 WHT/GRN
(KS)
3 al: RED/BLU
\ I
(ALTP)
5 WHT/RED
(EGR2)
6 12WHT/BLK
(SGl)
7 GRNAVHT
8 BLU(CKPP)
9 WHT(CKPM)
(VTM)
10 *3: BLU/BLK
13 D1685:GRN/RED
OF2)
(PF2)
14 01685:BLU/RED
16 WHT(PHO2S)
cw D16Y8,816A2
cw D1685
Dl6Y7
Except
6
29 30 31
(MAP)
17 RED/GRN
(SG2)
18 GRN/BLK
(VCC1)
1s YEURED
20 GRN(TDCP)
21 REDfiDcl\4)
(CKFP)
22 BLU/RED
(VSS)
23 BLU,ryVHT
24
25 RED/yEL(lAT)
(ECT)
26 REDAVHT
(TPS)
27 RED/BLK
28 YEUBLU(VCC2)
29 YEL(CYPP)
30 BLK(CYPr,,t)
31 WHTiRED(CKFrVr)
4
1
1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 20 21 22
23 24 25
J
I
s l 't0
o
13 14 15
10
r r l lr z
16
D1685,'99100exceptCW:
1 YEL(LCA)
(SHB)
2 GRN,ryVHT
(LCB)
3 GRN/BLK
5
6
7
8
.1 : BLIVYEL
(VBSOL)
WHT(ATPR)
BLU/YEL
{SHA)
PNK(ATPD3)
9 YEL (ATPD4)
10 BLU (NC)
11 RED (Ntvl)
12 WHT (NMSG)
13 LT GRN (ATPNP)
14 8LU {ATPP2)
16 GRN (NCSG)
*1= ExceptD1685
'99100cw:
(VEL)
1 WHT/RED
(rNHSOL)
2 GRN/BLK
3 GRN/vEL(SHLSl\4)
(SHLSP)
4 BLUAVHT
5 BLK^fEL(VBSOL)
6 WHT(ATPR)
7 BLKWHT(VELSG)
8
I
1OWHT(NDN)
(NDR)
11 RED/BLU
12 GRN(NDRSG)
(ATPS)
13 LTGRN/RED
(DIND)
14 GRN/BLK
16 REDMHT(NDNSG)
t
202-29
Connector Views (conrd)
71. GaugeAssembly
- Left side of dash
ConnectorA (A/Tonly)
ConnectorC
- Green
- On dashboardwireharness
1 YEL(lgnition
input)
(Headlight
2 RED/BLK
switchON input)
3 RED
(Dashlightbrightness
controllerinput)
4 BLU(L or 2
indicatorcontrol)
6 D16Y7/D16Y8:
BRN(Notused)
8 BLK(G401)
- Blue
- On dashboardwireharness
1 *: YEL(lgnition
input)
2 *: PNK(Washer
lluid
levelinput)
3 YEUBED
(Lowoil pressure
indicatorlightcontrol)
4 YEL(lgnition
input)
(Malfunction
5 GRN/ORN
indicatorlightcontrol)
6 RED/GRN
{Lightson Hl input)
(Hazard
7 GBN/RED
warningswitchinput)
9 D16Y7/D16Y8:
YEL
01685/016Y5:
GRN/BLK
(D4or D indicator
control)
10 GRN(03or S
indicatorcontrol)
1 1R E D
(N indicatorcontrol)
1 2W H T
(F indicatorcontrol)
13 BLI(BLU
(P indicatorcontrol)
14 LTGBN
(Park/neutral
output)
8 BLU
(Enginespeedinput)
10
1 2F E D
(Dashlightbrightness
controllerinput)
13 RED/BLK
(Headlight
switchONinput)
*= '99-'00:All except CVT
ConnectorB
ConnectorD
- Blue
- On dashboardwireharness
- Orange
- On dashboardwireharness
2 BLK (G401)
3 BLU/BLK(Trunkopen
indicatorlight control)
4 GRN/YEL(Hazard
warning switch input)
5 GRN/RED
(Brakesystem indicator
lightcontrol)
6 RED/BLU(Seat belt
indicatorlight control)
7 '96-'97 model: BLU,ryEL
(not used)
8 ExceptGX: GRN/YEL
GX: 8LU/GRN
(Lowfuel indicatorlight
control)
202-30
10 ExceptGX:YEUBLK
cX: ORN/BLU
(Fuelgaugecontrol
input)
11 BLUAVHT
(Vehicle
speedsensor
(VSS)input)
(Engine
12 YEUGRN
coolanttemperature
sending
unitinput)
14
15 BLI(IVHT
(lgnitioninput)
16 WHT/BLU
(Chargingsystem
indicatorlight control)
I
2
(ABS
BLU/RED
indicator
lightcontrol)
3 BLK (G401)
4
5 YEL (lgnitioninput)
\
ConnectorE
- Groen
- On dashboardwireharness
Wllh Crulss:
1 (Cruise
2 RED/BLU
conkol
indicator
control)
3 BLK(G401)
(Headlight
4 RED/BLK
switchON input)
5 YEL(lgnitioninput)
WlthShtft-upIndlcator:
T
1 RED
(Dashlightsbrightn€ss
controllerinPut)
(Shift-up
2 RED/BLU
indicatorcontrol)
3 BLK(G401)
(Headlight
RED/BLK
switchONinput)
YEL(lgnitioninput)
ConnectorF
- Yellow
- On dashboardwir€harness
1 BLU(SRSindicator
BLK(G401)
lightcontrol)
2
)
5 YEL(lgnitioninput)
-
202-31
Connector Views (cont'd)
72. C1s0 (GXModel)
74. Audio Unit ('99-'00Models)
- Lightgreen
- Leftrearof enginecompartment
- Connectsenginewireharnessto mainwireharness
1
2
3
4
5
(PGM-FI)
YEUBLU
(PGM.FD
GRN/BLK
LTGRN(A/t controls)
(PGM-FD
YEURED
GRN/rEL(PG|\,1-FD
6 BLU/IEL(PGM-FD
7 Male- PNK
Female- GRN
(4,/Tconvols)
YEL(A,/Tcontrols)
73. C575 (GXModel)
- Gray
- Behindleftsideof rearseatback
- Connectsfloorwireharnessto subluel cord
1 BLK(PGM.FD
2 WHT/RED(PGI\4-FD
(PGM.FI)
3 GRN/YEL
202-32
5
(PGr\4-Fr)
GRN/BLK
(PGI\'-FD
BLU/YEL
YEUBLU(PGI\,4,FD
- LightBlue
- Centerol dash
- On dashbaord
wireharness
']]](lgnition
2 YEURED
input)
12*
14
5 RED/YEL
(RFspeakerf)
6 BLU/YEL
(LRspeaker+)
7 RED/GRN
(BFspeaker
+)
I BLU(LFspeaker+)
9 RED/BLK
(lllumination
control)
10 WHT/BLU
(Batteryinput)
15 BRN,^/VHT
-)
{RRspeaker
16 GRYAVHT
(LRspeaker-)
17 BRN/BLK
(RFspeaker-)
18 GRY/BLK
-)
{LFspeaker
19RED
(lllumination
control)
20 BLK(G501)
75. KeylessDoorLockControlUnit
(USAOnly)
- Gray
- At lettkickpanel
- On mainwireharness
l LTGRN/BLK
(Dooropenoutput)
2 BLU,ryVHT
(Lockinput)
3 BLU/RED
(Keyswitchinput)
4 BLK/YEL
(lgnition
input)
5 BLU/RED
(Unlock/lock
control)
6 FED/BLK
(Lightflashcontrol)
7 WHT/RED
(Unlock/lock
output)
8 YEURED
(Unlock/lock
output)
9 GRN/ORN
(Unlock
input)
'10GRNA/VHT
(Lockinput)
11 ORN{Securiiy
system)
12 LTGRN/RED
{Dooropeninput)
13 YEUBLU
(Security
system)
14 BLU/YEL
(Security
system)
15 GRY(Horncontrol)
17 BLK(G401)
18 WHT/GRN
(Batteryinput)
76. HeaterControlPanel
('99100Models)
- Centerof dash
ConnectorC
ConneclorA
- Black
- Toheaterpushswitches
- Gray
- On heatersub-harness
A
1 BLUiBLK
(Blowercontrols)
(Airdelivery)
GRNAVHT
(Airdelivery)
GRN/RED
(Dashlights)
4 RED/BLK
RED(Dashlights)
BLK(G402)
7 BLUfYEL
(Rearwindowdefogg€0
(Fuse17)
8 BLK,TYEL
1 ORN(Airdelivery)
2
4 WHT(Airdelivery)
5 GRN(ry'Ccompressor
control)
6 PUR(Roarwindow
delogge4
7 RED(Dashlights)
8 BLU(Dashlights)
I BLK(Airdelivery)
compressor
10 GRY(Ay'C
controls)
1'1BRN(Airdelivery)
12 YEL(Rearwindow
defogge0
\
ConnectorB
77. Injectorcontrol Module
(GXModel)
- Black
- On heatersub-harness
A
- Gray
- Behindleftkickpanel
- Onmainwireharness
1 LTGRN/BLK
(Blowercontrols)
2 BRN,A/VHT
(Airdelivery)
)
(Airdelivery)
4 REDA/VHT
(Airdelivery)
5 YEUBLU
(Airdelivery)
6 YEURED
(Airdelivery)
7 GRN/YEL
(Airdelivery)
8 BLU,ryVHT
(Airdelivery)
9 YEL
{Airdelivery)
1OWHT/BLU
(Fuse47)
11 BLU/RED
WC
controls)
compressor
1 2B R N
(Airdelivery)
13 ORNAVHT
(Blowercontrols)
1 415 PN(BLK
(Airdelivery)
1 6_
1 9_
20 GRY
(Airdelivery)
1
2
3
4
RED(rNJ2)
BRN(rNJl)
BLK(G401)
_
8 YEL(TNJCNTL4)
9 BLU(TNJCNTL3)
1o RED(tNJCNTL2)
11 BRN0NJCNTL1)
(G101)
12 BRN/BLK
13 YEURED(Switched
ignition
input)
14 YEL (tNJ4)
15 BLU (rNJ3)
16 BLK (G401)
1 92021
24 LI GRN (INJMODE)
25 BRN/BLK(Gr01)
26 YEURED (Switched
ignition input)
202-33
Connectorldentificationand Wire HarnessRouting
Connector Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Starter Cables
T1
r2
Rightside of enginecompartment Under-hood
luse/relay
box
Rightside of engine
Stanermotor
t+l
Battery
Batterypositiveterminal
Rightfrontshocktower
Bodyground,via batteryground
cable
Battery
Batterynegativeterminal
Leftend of engine
Powersteeringpumpbracket
Tooleftsideot bulkhead
Bodyground,via engineground
cableA
BatteryGroundCable
o
EngineGroundCableA
t!t
EngineGroundCableB
T4
Bightsideof enginecompartmentTransmission
(rit
Rightsideof frontframe
Bodyground,via engineground
Under-hood
ABSFuse/Relay
BoxWireHarness
Rightsideof enginecompartment Under-hood
ABSfuse/relaybox
tc
o
Battery
Batterypositiveterminal
Leflfrontof enginecompartment
Leftfrontof enginecompartment
Leflfrontof enginecompartment
Lefttrontof enginecompartment
Enginecompartment
wireharness
A,/Ccompressor
clutch
Condenser
fan motor
A,/Cpressureswitch
A,/CWireHarness
c209
wtJl
/,\-7Ee
c754
G751
4-GRY
1.GRY
2-GRY
2-GRY
Leftfrontof enginecompartment Bodyground,via A,/Cwire
harness
Notes
\ . .
STARTER
CABLES
BATTERY
GROUND
cAELE
\ . .
UNDER.HOOD
ABS FUSE/RELAY
BOXWIRE
HARNESS
ENGINE
GROUND
CAELEB
)
A/C WIRE
HARNESS
-
203-1
Connectorldentificationand Wire HarnessRouting
Connector Numberot
or
Cavities/
Terminal
Golor
Location
Connectsto
Notes
EngineWire Harness(Dl6Y5,D16Y8engines):'96-98modelsand '99;00 D16Y5dM/T
c101
c102
c 103
c104
Q104
c105
c106
c107
cl 08
cl09
cl10
c1l1
cl'12
c113
c114
c'115
c116
c'117
c 118
c119
c120
c121
c122
c123
c123
c124
Q124
c125
c 126
c127
c128
c129
c130
c131
cl32
c 134
c135
c136
c137
c138
c139
c'140
c141
c142
c143
c144
c'|44
c145
c146
c147
203-2
1O-GRY
3.GRY
1-CLR
4-GRN
3-N/A
2-BLK
2-BLK
2-BLK
2-BLK
3-GRY
3-GRY
3-GRY
2.BLK
2.GRY
2-BLK
14-BLU
14-GRY
3.GRY
2-BLK
2-GRY
1O-GRY
1.BLK
2.GRY
4-GRY
8-GRY
2-GRY
2.GRY
4-GRY
2.BLK
2.BLK
2-GRY
1.BLK
2O.BRN
22.GRN
32.GRY
25.GRY
31-BLU
16.GRY
14-GRY
8.GRY
2-GFIY
2.GRY
1-GRY
2-GRY
2-BLK
2-GRY
2.BLK
3-GRY
6-GRY
2.BLK
8-GRY
2-BLK
Left side of engine compartment
Left side of engine
Middleof engine
I att .i.la
^f an^i^6
Left side ot engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
[,liddleof engine
Middleot engine
Middleot engine
Middleof engine
Middleof engine
Middleof engine
l\,liddleof engine
Rightside of enginecompartment
Rightsideof enginecompartment
Middleot engine
Middleof engine
Middleof engine
Middleof engine
l\,liddleof engine
Nliddleof engine
Middleot engine
Middleof engine
Middleot engine
Middleof engine
Middleof engine
Nliddleof engine
Rightside of engine
Underrightside of dash
Behindrightkickpanel
Below right front footrest
Below right front footrest
Below right front footrest
Below right front tootrest
Left side ot engine compartment
Left side of engine compartment
Middleof engine
liliddleot engine
Middleof engine
Nriddleol engine
Right side of engine compartment
Middleol engine
Rightside of enginecompartment
Middleof engine
N,liddle
of engine
Rightside of enginecompartment
Rightside of enginecompartment
Bightsideof enginecompartment
Mainwireharness
CKFsensor
Engineoil pressure
switch
Alternator
Alternator
No.1 fuelinjector
No.2 fuelinjector
No.3 fuelinjector
No.4fuelinjector
IACvalve
TP sensor
MAPsensor
IATsensor
Powersteeringpressureswitch
EVAPpurgecontrolsol€noidvalve
Junctionconnector
Junctionconnector
Vehiclespeedsensor(VSS)
Countershatt
speedsensor
Enginecoolanttemperature
switch
Distributor
Enginecoolant
temp.sending
unit
ECTsensor
Primary
HO2S(sensor'1)
Primary
HO2S(sensor'1)
Back-uplightswitch
Lock-upcontrolsolenoidvalves
SecondaryHO2S(sensor2)
lvlainshafl
speedsensor
Lanear
solenoid
Shiftcontrolsolenoidvalves
Startersolenoid
Junction
connector
Mainwireharness
ECM/PCMconnector
A
PCMconnectorB
ECM/PCNI
connectorC
ECM/PCl\,,|
connectorD
Mainwireharness
Malnwireharness
Knocksensor(KS)
IACvalve
VTECsolenoidvalve
VTECpressureswitch
EVAPcontrolcanisterventshutvalv€
EGRcontrolsolenoid
valve
gearshattspeedsensor
Secondary
EGRvalve
EGRvalve
Drivepulleyspeedsensor
CVTtransmission
solenoid
Drivenpulleyspeedsensor
USA
Canada
AlT
USA
'2( tr\
'3
-1(M/r)
t\4/T
'2 (Anl
'1
'2 (An)
'2 (Nr)
'2 (AtT)
'2 (Atr)
-1 (An)
-2( fi|
M/T
.1 (Arr)
.1 (A,T)
"1 (A/r)
-1 (M/r)
.1 (CVT)
,1 (cw)
'1 (CVT)
Connector Numberof
Cavitiesl
or
Color
Terminal
Notes
Connects to
Location
'9&98 modelsand'9$'fl) D16Y5dIWT (cont'd)
EngineWire Harness(D16Y5,D16Y8engines):
Lett side of engine
Rightside of enginecompartment
T101
r102
Alternator
fuse/relaybox
Under-hood
Engineground.viaenginewirehamess
Rightof engine
G101
'1:D16Y5
engine
.2: D16Ygengine
'3: D16Y5(A,/T).
D16Y8enoines
'4: '96model:dtlcoupes,'97
model:all
Sedan,'98-'00
California
model:allcoupes,
'96-'98modelsand '99-'00D16Y5dM/T:
I
clll
cr19 I
c138
c110
c109
cl13
Tlor
c141.
T102.
c147cl4:t'
cl17'
clal
c1|{)
cl18
c139
cl20
c129
c1a6
c1a5
€NGINEwlRE
HARNESS
cl l5
c116
c137
cr02
c105
c106
) - f
203-3
Connectorldentificationand Wire HarnessRouting
Connector Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
Enginewire Harness(Dl6Y5, Dl6Y8 engines):'99-'00modelsexceptD16y5w/M/T
c 101
c102
c103
cl04
c104
c105
c106
c107
c108
c109
c110
c111
cl12
c 11 3
c115
c117
c118
c119
c120
c120
c12'l
cl22
c123
c124
c124
c125
c126
c127
c128
c129
c130
c'131
c133
ct34
c 135
c137
c138
c139
c 140
c142
c143
c144
c'|45
c147
203-4
1O-GRY
3.GRY
1-CLR
4-GRN
3-N/A
2.BLK
2.BLK
2-BLK
2.BLK
3-GRY
3-GRY
3.GRY
2-BLK
2.GRY
2-BLK
14-BLU
14-GRY
3-GRY
2-BLK
2-GRY
1O-GRY
8.GRY
,1-BLK
2.GRY
4.GRY
4.GRY
2.GRY
2.GRY
4.GRY
2.BLK
2-BLK
2-GRY
1-BLK
2O-BRN
22-GRN
25-GRY
31-BLU
16-GRY
2-GRY
2.GRY
1-GRY
2-GRY
2-GRY
2-BLK
3.GRY
2.BLK
8-GRY
2.BLK
Left side of engine compartment
Leftside of engine
Middleof engine
Leftsideof engine
Leftside of engine
Middleot engine
Middleof engine
N,liddle
of engine
l\4iddle
of engine
Middleof engine
Niliddle
of engine
N,,liddle
of engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Rjghtside of enginecompartment
Rightside of enginecompartment
Middleof engine
Mlddleof engine
l\4iddle
of engine
Middleof engine
Middleof engine
[iliddleof engine
lvliddleof engine
Middleof engine
Middleof engine
l\4iddle
of engine
Middleol engine
Middleof engine
N,liddle
of engine
Rightside of engine
Under right side of dash
Behindrightkick panel
Below right front tootrest
Below right front footrest
Below right lront footrest
[iliddleof engine
l\,liddleof engine
Middleof engine
Middleof engine
L4iddle
of engine
Rightside of enginecompartment
Middleof engine
Rightside of enginecompartment
Rightside of enginecompartment
Rightside ot enginecompartment
Mainwireharness
CKFsensor
Engineoilpressure
switch
Alternator
Alternator
No.1 fuelinjector
No.2luel injector
No.3 fuel injector
No.4fuelinjeclor
IACvalve
TP sensor
MAPsensor
IATsensor
Powersteeringpressureswitch
EVAPpurgecontrolsolenoidvalve
Junctionconnector
Junction
connector
Vehiclespeedsensor(VSS)
Countershaft
speedsensor
Enginecoolanttemperature
switch
Distributor
Distributor
Enginecoolant
temp.sending
unit
ECTsensor
Primary
HO2S(sensor1)
Primary
HO2S(sensor1)
Back-uplightswitch
Lock-upcontrolsolenoidvalves
SecondaryHO2S(sensor2)
Mainshaitspeedsensor
Linearsolenoid
Shiftcontrolsolenoid
valves
Startersolenoid
Junction
Connector
Mainwireharness
ECN4/PCM
connectorB
ECM/PCMconnectorC
PCMconnectorD
Knocksensor(KS)
IACvalve
VTECsolenoid
valve
VTECpressureswitch
EGRcontrolsolenoidvalve
Secondary
gearshaftspeedsensor
EGRvalve
Drivepulleyspeedsensor
CVTtransmission
solenoid
Drivenpulleyspeedsensor
USA
Canada
ATT
USA
'2 (An\
'1
-1(cw)
'2
Mft
lNr)
'1
'2 (Afil
'2 (An)
'2 (Anl
Atf
t\4/T
-1 (CVr)
'1 (CVT)
.1 (CW)
-1 (CVT)
'1 (CVT)
.1(cw
\
-
Connector
ol
Terminal
Numberof
Cavities/
Color
Connectsto
Location
Notos
EngineWireHarness(Dl6Y5,D16Y8engines):'99-'00modelsexceptD16Y5dM/T (cont'd)
T101
T102
Leftsideof engine
Right side oI engin€ compartment
Alternator
tuse/relaybox
Under-hood
G101
Rightsideot engine
Engineground.viaenginewirehamess
.1: D16Y5engine
-2:D16Y8engine
'99;00 models except Dl6Y5 w/M/T:
I .
C134
-\-
\ c133 ctrg
c130
c112
cr0g
l.tto
c123 ('21
ct13
cr38
Clilt
T102
Ctit3
cl17
G1a4
cltt
c139
ct20
c1?9
cr$
C1'15
) . .
c1l5 C124 cl25
c1z2 c121
203-5
Connectorldentificationand Wire HarnessRouting
Connector Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
EngineWire Harness(Dl6Y7):'96 model
c101
c102
c103
cl04
c104
c 105
c106
c107
c108
c109
c110
c111
c112
c 1 13
c114
c115
c116
c117
c118
c119
c120
c121
c122
c123
c124
cl24
c125
c126
c127
cl28
c129
c130
c131
cl32
nl2?
c134
al eR
T101
T102
G101
203-6
1O.GRY Leftsideof enginecompartment Mainwireharness
3-GRY
Leftsideof engine
CKFsensor
Middleof engine
Engineoil pressure
switch
4.GRN
Leftsideof engine
Alternator
3-N/A
Leflsideof engine
Altemator
2.BLK
Middleof engine
No. 1 fuel injector
2-BLK
Middleof engine
No.2 fuelinjector
2-BLK
Middleof engine
No.3 fuelinjector
2-BLK
Middleof engine
No.4 fuelinjector
3.GRY
Middleof engine
IACvalve
3-GRY
Middleof engine
TP sensor
3.GRY
Middleof engine
MAPsensor
2-BLK
Middleof engine
IATsensor
2.GRY
Middleof engine
Powersteeringpressureswitch
2-BLK
Middleof engine
EVAPpurgecontrolsolenoidvalve
14-BLU Middleof engine
Junction
connector
14-GRY Middleof engine
Junction
connector
3.GRY
Rightsideof enginecompartment Vehiclespeedsensor(VSS)
2.BLK
Rightsideof enginecompartment Countershaft
speedsensor
2-GRY
Middleof engine
Enginecoolanttemperature
switch
1O-GRY Middleof engine
Distributor
1-BLK
Middleof engine
Enginecoolanttemperature
sendingunit
2-GRY
Middleof engine
ECTsensor
4.GRY
Middleof engine
PrimaryHO2S(sensor1)
2.GRY
Middleof engine
Back-uplightswitch
2-GRY
Middleof engine
Lock-upcontrolsolenoidvalves
4-GRY
Middleof engine
SecondaryHO2S(sensor2)
2.BLK
Middleof engine
Mainshaft
speedsensor
2-BLK
Middleof engine
Linearsolenoid
2-GRY
Middleof engine
Shiftcontrolsolenoidvalves
1-BLK
Rightsideof engine
Startersolenoid
2O-BRN Underrightsideof dash
JunctionConnector
22-GRN Behindrightkickpanel
Mainwireharness
32.GRY Belowrightfrontfootrest
ECM/PCM
connector
A
25-GRY Belowrightfrontfootrest
PCMconnectorB
31-BLU Belowrightfrontfootrest
ECM/PCM
connector
C
16.GRY Belowrightfrontfootrest
ECM/PCM
connector
D
Leftsideof enginecompartment Alternator
Rightsideof enginecompartment Under-hood
fuse/relaybox
Rightside of englne
Engineground,viaenginewire
narness
USA
Canada
A/T
USA
Atf
M/T
Arl
AtT
A/T
Afi
Aff
a
'96 model:
ENGINEWIREHAFNESS
c135 cl3a
c133 cl32
I
c106
cr07
c12Eci2s
c103
c121bros
."r. "irt cltr "\r,
) . .
203-7
Connectorldentificationand Wire HarnessRouting
Connector Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Noles
EngineWire Harness(Dl6Y7 engine):'97-'98models
c101
c102
c103
c104
c104
c105
c106
c107
c108
c109
c110
c111
c113
c114
c115
c116
c118
c119
c'120
c121
c122
c124
c124
c125
c126
c127
c128
c129
cl30
c131
c132
c133
c134
c135
\, | 'tO
c141
1O-GRY
3-GRY
1.CLR
4.GRN
3.N/A
2-BLK
2-BLK
2-BLK
2-BLK
3.GRY
3-GRY
3-GRY
2-BLK
2.GRY
2-BLK
14.BLU
14.GRY
3.GRY
2-BLK
2-GRY
lO.GRY
1-BLK
2-GRY
4.GRY
2.GRY
2-GRY
4.GRY
2.BLK
2.BLK
2-GRY
1-BLK
2O-BRN
22-GRN
32-GRY
25.GRY
31-BLU
16.GRY
8-GRY
2-BLK
Leflsideof enginecompartment Mainwirehamess
Lettsideof engine
CKFsensor
Middleof engine
Engineoil pressure
switch
Leftsideof engine
Alternator
Leflsideof engine
Altemator
Middleof engine
No. 1 fuel injector
Middleof engine
No.2 fuel iniector
Middleof engine
No.3 fuel iniector
Middleof engine
No.4 fuelinjector
Middleof engine
IACvalve
Middleof engine
TP sensor
Middleof engine
MAPsensor
Middleof engine
IATsensor
Middleof engine
Powersteeringpressur€switch
Middleof engine
EVAPpurgecontrolsolenoidvalve
Middleof engine
Junctionconnector
Middleof engine
Junctionconnector
Rightsideof enginecompartment Vehiclespeedsensor(VSS)
Rightsideof onginecompartmont Countershaft
speedsensor
Middleof engine
Enginecoolanttemperature
switch
Middleof engine
Distributor
Middleof engine
Enginecoolanttemperatu
re
senorng
unI
Middleof engine
ECTsensor
Middleof engine
PrimaryHO2S(sensor1)
Middleof engine
Back-uplightswitch
Middleof engine
Lock-upcontrolsolenoidvalves
Middl€of engine
SecondaryHO2S(sensor2)
Middleof engine
Mainshaftspeedsensor
Middleof engine
Linearsolenoid
Middleof engine
Shiftconirolsolenoidvalves
Rightsideof engine
Startersolenoid
Underrightsidoof dash
Junclionconnector
Behindrightkickpanel
Mainwireharness
Belowrightfrontfootrest
ECM/PCMconnectorA
Belowrightfrontfootrest
PCMconnector
B
Belowrightfrontfootrest
ECM/PCMconnectorC
Belowrightfrontfootrest
ECM/PCMconnsctorD
Leftsideof enginecompartment Mainwireharness
Rightsideof enginecompartmsnt EVAPcontrolcanisterventshut
VAIVE
T101
T102
Leftsideof engine
Altemator
Rightsideof enginecompartment Under-hood
fuse/relaybox
G101
Rightsideof engine
203-8
Engineground,viaengine
wtrenarness
USA
Canada
USA
Nf
M/T
A/T
Atl
An
AIT
NT
A/T
'97-'98models:
ENGINEWIREHARNESS
cl30 cl3l
T1
l'qii
c101
c117
\ t
T10l
c119
c104
c120
cl09
c11s
clt6
c102
22
cl21
203-9
Connectorldentificationand Wire HarnessRoutino
Conneclor Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
EngineWire Harness(Dl6Y7 engine):'99100models
c101
Q102
c103
c104
c104
c105
UIUO
c107
c108
c109
c110
c111
c112
c113
c114
c11s
c116
c117
c118
c119
c120
c121
c122
c123
c124
cl24
c126
c\27
cl28
cl29
c 130
c131
c'133
c134
v tJc
1O-GRY
3.GRY
1-CLR
4-GRN
3.N/A
2-BLK
2.BTK
2.BLK
2-BLK
3-GRY
3-GRY
3-GRY
2.BLK
2-GRY
2-BLK
14-BLU
14.GRY
3-GRY
2.BLK
2-GRY
8-GRY
1.BLK
Leftsideof enginecompartment
Leftsideof engine
Middleof engine
Leftsideof engine
Leftsideof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleol engine
Middleof engine
Middleof engine
Middleof engine
Rightsideof enginecompartment
Rightsideof enginecompartment
Middleof engine
Middleof engine
Middleof engine
2-GRY
4-GRY
2-GRY
2-GRY
4.GRY
2-BLK
2-BLK
2-GRY
1-BLK
2O.BRN
22-GRN
25-GRY
31-BLU
16-GRY
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Middleof engine
Rightsideof engine
Underrightsideof dash
Behindrightkickpanel
Belowrightfrontfootrest
Belowrightfrontfootrest
Belowrightfrontfootrest
Mainwireharness
CKFsensor
Engineoil pressure
switch
Alternator
Altemator
No.1 fuelinjector
No.2 fuelinjector
No.3 fuelinjector
No.4 fuel injector
IACvalve
TP sensor
MAPsensor
IATsensor
Powersteeringpressureswitch
EVAPpurgecontrolsolenoidvalve
Junction
connector
Junction
connector
Vehiclespeedsensor(VSS)
Countershaft
speedsensor
Enginocoolanttemperature
switch
Distributor
Enginecoolanttemperature
sendingunit
ECTsensor
PrimaryHO2S(sensor1)
Back-uplightswitch
Lock-upcontrolsolenoidvalves
H02S(sensor2)
Secondary
Mainshatt
speedsensor
Linearsolenoid
Shificontrolsolenoidvalves
Startersolenoid
Junction
connector
Mainwireharness
ECM/PCM
connector
B
ECM/PCM
connector
C
PCMconnector
D
T101
r'l02
Leftsideof engine
Alternator
Rightsideof enginecompartment Under-hood
fuse/relaybox
G101
Rightside of engine
203-10
Engineground,via enginewire
narness
USA
Canada
USA
AIT
Mrl
Atf
AN
A/T
AlT
Afi
I
'99-'00models:
WIREHARNCSS
cr10
ct 14
I I
c111
c112
c113
cl17
cr
1101
c10a
15
c102
ciz, cizs cizs cizz c121 c1o8 c1o7
203-11
Connectorldentificationand Wire HarnessRoutinq
Connector Numberot
oa
Cavities/
Terminal
Color
Location
Connectsto
Notes
EngineWire Harness(816A2engine):'99;00 models
c101
c102
c103
c104
c104
cl05
c106
c107
c108
c110
c111
c112
c113
1O-GRY
2-GRY
1.CLR
4-GRN
3.N/A
2-BLK
2-BLK
2-BLK
2-BLK
3.GRY
3.GRY
2-BLK
2-GRY
Leftsideof enginecompartmenl
Lettsideof engine
Middleof engine
Leftsideof engine
Leftsideof engine
Middleof engine
Middleof engine
Middleof engine
Middleol engine
Middleof engine
Middleof engine
Middleof engine
Middleot engine
c114
c115
c116
cl17
c119
c120
c121
2-BLK
14-BLU
14-GRY
3-GRY
2-GRY
1O-GRY
1-BLK
c't22
c123
c124
c129
c130
c131
c133
c134
c137
c138
2-GRY
4-GRY
2-GRY
1-BLK
2O.BRN
22-GRN
25-GRY
31-BLU
2-GRY
2-GRY
1-GRY
2-GRY
Middleof engine
EVAPpurgecontrolsolenoidvalve
Middleof engine
Junction
connector
Middleof engine
Junction
connector
Rightsideof enginecompanment Vehiclespeedsensor(VSS)
Middleot engine
Enginecoolanttemperature
switch
Middleof engine
Distributor
Middleof engine
Enginecoolanttemperature
sendingunit
Middleot engine
ECTsensor
Middleot engine
PrimaryHO2S(sensor1)
Middleof engine
Back-uplightswitch
Rightsideof engine
Startersolenoid
Underrightsideof dash
Junction
connector
Behindrightkickpanel
Mainwireharness
Belowrighttrontfootrest
ECMconnector
B
Belowrightfrontfootrest
ECMconnector
C
Middleof engine
KnockSensor(KS)
Middleof engine
IACvalve
Middleof engine
VTECsolenoid
valve
Middleof engine
VTECpressureswitch
c140
Mainwireharness
CKFsensor
Engineoil pressure
switch
Alternator
Altemator
No.1 fuelinjector
No.2 fuelinjector
No.3 fuel injector
No.4 fuelinjector
TP sensor
MAPsensor
IATsensor
pressure
Powersteering
switch
T101
T102
Lettsideof engine
Alternator
Rightsideof enginecompartment Under-hood
fuse/relaybox
G101
Rightsideof engine
203-12
Engineground,via enginewire
narness
USA
Canada
USA
a
\
-
'99-'00models:
cl12
c117
T102
) . -
ClO,l
cti9
Tl0t
c1:19
c115
c120
ct16
c129
cr37
c12l
c102
c1a2 cloE
)
<
l
203-13
Connectorldentificationand Wire HarnessRoutino
Connector Number
ot
or
Cavities
Terminal
Location
Connectsto
EngineWireHarness(D1685)
c101
cl02
c103
c104
c105
c106
c107
c108
c109
c110
c111
cl12
c113
cl15
cl16
c117
c118
c119
c120
c121
c122
c123
c124
1O-GRY
3-GRY
1-CLR
4-GRN
2.BLK
2-BLK
2-BLK
2-BLK
3-GRY
3-GRY
3.GRY
2-BLK
2.GRY
14-BLU
14-GRY
3-GRY
z.BLK
2.GRY
,1O.GRY
1-BLK
c139
c140
c144
c150
c151
c152
2-GRY
4.GRY
2.GRY
4-GRY
2-BLK
2.BLK
2-GRY
1.BLK
2O-BRN
22-GRN
32-GRY
25-GRY
31-BLU
16-GRY
8-GRY
.I-GBY
2-GRY
6.GRY
8-LTGRN
2-GRY
2.BLK
c153
3.N/A
wtlc
u tzo
c127
c128
c129
c130
c131
c132
t/ IJO
c134
UIJC
lJt.to
T101
7102
G101
203-14
Leftsideof enginecompartmenl Mainwireharness
Leftsideot engine
CKFsensor
Middleof engine
Engineoil pressure
switch
Leftsideof engine
Alternator
Middleof engine
No.1 tuelinjector
Middleof engine
No.2 fuelinjector
Middleof engine
No.3 fuelinjector
Middleof engine
No.4 fuel injector
Middleof engine
IACvalve
Middleof engine
TP sensor
Middleof engine
MAPsensor
Middleof engine
IATsensor
Middleof engine
Powersteeringpressureswilch
Middleof engine
Junction
connector
Middleof engine
Junction
connector
Rightsideof enginecompartment Vehiclespeedsensor(VSS)
Rightsideof enginecompartment Countershaft
speedsensor
Middleof engine
Enginecoolanttemperature
switch
Middleot engine
Distributor
Middleof engine
Enginecoolanttemperature
sendingunit
Middleof engine
EU I SenSOr
Middleof engine
PrimaryHO2S(sensor1)
Middleof engine
Lock-upcontrolsolenoidvalves
Middleof engine
SecondaryHO2S(sensor2)
Middleof engine
Mainshaft
speedsensor
Middleof engine
Linearsolenoid
Middleol engine
Shiftcontrolsolenoidvalves
Rightsideof engine
Startersolenoid
Underrightsideof dash
Junction
connector
Behindrightkickpanel
Mainwireharness
Belowrightfrontfootrest
PCMconnector
A
Belowrightfrontfootrest
PCMconnector
B
Belowrightfrontfootrest
PCMconnector
C
Belowrightfrontfootrest
PCMconnector
D
Leftsideof enginecompartment Mainwireharness
Middleof engine
WEC solenoid
valve
Middleof engine
VTECpressureswitch
Middleof engine
EGRvalve
Leftsideof enginecompartment Mainwire harness
Middleof engine
Fueltemperature
sensor
Rightsideof enginecompartment Fuelpressure
regulator
shut-oft
solenoid
valve
Rightsideof enginecompartment Fuelpressure
sensor
Leftsideof engine
Alternator
Rightsideof enginecompartment Under-hood
fuse/relaybox
Rightside of engine
Engineground,via enginewire
narness
Notes
-
c1lt clt1
cr
clts
ftog ctto
c113 T10t
16
12
I I
EMIINEIVIRE
HAFT{ESS
203-15
Connectorldentificationand Wire HarnessRoutino
Connector Numberof
or
Cavities/
Terminal
Color
Locatlon
Connectsto
Notes
EngineCompartment
WireHarness
c201
c202
c202
UZUJ
c204
c205
c206
c207
c208
c209
c210
c210
c212
c213
c214
c215
1O-BLU Leflsideof enginecompartment
6.GRY
Leftsideof enginecompartment
2.GRY
Leftsideol enginecompartment
4-GRY
Leftsideof enginecompartment
2-GRN
Behrnd
frontbumper
2-BRN/VVHT Behindfrontbumper
3-GRY
Leftsideof enginecompartment
1.BRN
Behindfrontbumper
Leftsideof enginecompartment
q-u11 r
Leftfrontof enginecompartment
2.GRY
Behindfrontbumoer
1-BLU
or BLK
2-GRY
3-BLK
3-GRY
8.GRY
2-GRY
G201
G202
'1
cruise
control
'2:: With
Without
cruisecontrol
203-1 6
Behindfrontbumoer
Mainwire harness
Mainwireharness
Mainwire harness
Cruisecontrolactuator
Windshield
washermotor
Rearwindowwashermotor
Leftfrontturnsignal/parking
light
Fronttog light
Leftheadlight
A,/Cwire harness
Horn
Horn
Rightfrontof enginecompartment Radiatorfan motor
Rightsideot enginecompartment Rightheadlight
Rightsideof enginecompartmont Righttrontturnsignal/parking
light
Rightsideof enginecompartment Mainwire harness
Behindfrontbumoer
Washerlevelswitch
Rightsideof enginecompartment Bodyground,via engine
compartment
wire harness
Leftsideot enginecompartment Bodyground,via engine
wire harness
comDartment
'1
"1
Optional
'96-'97
models
'98-'00
models
Canada
'99r00
models
qroo
c207
ENGINEOOMPA
WIREHARNESS
) < >
203-17
Connectorldentificationand Wire HarnessRoutino
Connector Numberot
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
MainWire Harness(Left side of enginecompartmentbranch)
c101
cI36
c136
c150
c201
c202
c202
c301
c302
c304
UOUO
c307
c310
1O.GRY
14-GRY
8.GRY
8.LTGRN
1O-BLU
6.GRY
2-GRY
5.GRY
2.NAT
3-N/A
1.BLK
1-BLK
2.ORN
Leftsideot enginecompartment
Leftsideof enginecompartment
Letlsideof enginecompartment
Lettsideof enginecompaftment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideof enginecompartment
Enginewireharness
.1
Enginewirehamess
'r.q
Enginewirehamess
r5
Enginecompartment
wireharness
Enginecompartment
wireharness
Enginecompartment
wireharness
.4
Enginecompartment
wireharness
Windshield
wipermotor
Testtachomeierconnector
Daytimerunninglightsresistor
Canada
Brakefluidlevelswitch(+)
Brakefluidlevelswitch(-)
LeftfrontABSwheelsensor
ABS
.1 '96-98A/TwithD16Y5enoine
'2:: '96-98A,/T
D16Y7/D16Y8
enoines
.3: Withcruisewith
control
*4:Withoutcruisecontrol
.5: GX model
MainWireHarness(Rightsideof enginecompartment
branch)
c214
c351
wacl
UJCJ
c356
c357
c358
UOCY
c360
c361
8-GRY
11.GRY
9.GRY
5-BRN
3-GRY
3-ORN
2.ORN
2-ORN
10-oRN
2.ORN
2-8RN
Rightsideof enginecompartment Enginecompartment
wirehamess
Rightsideof enginecompartment Under-hood
fuse/relaybox
Rightsideof enginecompartment Undef-hood
tuse/relaybox
Rightsideof enginecompartment Under-hood
fuse/relaybox
Rightsideof enginecompartment ELDunit
Rightsideof enginecomparlment Under-hood
ABSfuse/relaybox
Rightsideot enginecompartment UnderhoodABSfuse/relaybox
Rightsideot enginecompanment RightfrontABSwheelsensor
Rightsideof enginecompartment ABSmodulator
unit
Rightsideof enginecompartment ABSpumpmotor
Rightsideof enginecompartment EVAPcontrolcanistervent
shutvalve
Bightsideof enginecompartment Bodyground,via main
wtrenarness
.1: '99-'00modelsexceptGX model
G403
203-18
USA
ABS
ABS
Al'D
AE5
ABS
-1
ABS
-
I
)
203-19
Connectorldentificationand Wire HarnessRouting
Connector Numberol
or
Cavities/
Color
Terminal
Location
Connectsto
Notes
MainWire Harness(Left side of dash and floor branch):'96-'97models
Behindleftkickpanel
Behindleftkickpanel
Underleftsideot dash
Floorwire harness
ABS
Floorwire harness
Lightflasherrelayconnector
Optional
(Security)
14-GRY Underleftsideof dash
Cruisecontrolunit
c404
A
Canada
4-NAT
DRLcontrolunitconnector
Underleftsideof dash
c405
B
Canada
DRLcontrolunitconnector
8-GRY
Underleftsideof dash
c406
-2
Roofwireharness
2-GRY
Underlettsideot dash
c407
'4
Moonroofwireharness
2-GRY
Underleftsideof dash
c407
Optional
Frontfog lightconnector
1-BRN
Underleftsideof dash
c408
fuse/relay
controlunit
1O-WHT Behindunder-dash
box Integrated
c409
AtT
wire harness
12-GRY Aboveunder-dash
fuse/relaybox Dashboard
c410
wire harness
24-BLU
Aboveunder-dash
fuse/relaybox Dashboard
c411
Aboveunder-dash
fuse/relaybox SRSmainharness
3-YEL
c412
16-GRY
left
Datalinkconnector
Under sideof dash
c413
M/T
4.BLU
Underleftsideof dash
Startercut relay
c414
fuse/relaybox lgnition
7-BRN
Aboveunder-dash
switch
c415
Securitystartercut relayconneclor Optional
6.NAT
Underleft sideof dash
c416
'5
Clutchswitch
2-N/A
Underleft sideof dash
c417
M/T
2-YEL
Underleftsideof dash
Clutchinterlockswitch
c418
fuse/relay
Under-dash
fuse/relay
box
18-GRN Behindunder-dash
box
c419
fuse/relay
box Underdashfuse/relaybox
2O.GRN Behindunder-dash
c420
fuse/relaybox Under-dash
fuse/relaybox
18-GRN Behindunder-dash
c421
fuse/relaybox
iuse/relaybox Under-dash
7-GRN
Frontof under-dash
c422
Frontof under-dash
fuse/relaybox Underdashfuse/relaybox
w+4J
6-GRN
Hornrelay
4-NAT
Underleftsideof dash
c424
Brakeswitch
4-WHT
Underleftsideof dash
c425
wiperswitch
Combination
8.WHT
Behindsteering
columncover
connector
A
wiperswitch
Combination
6-WHT
Behindsteering
columncover
c427
connectorB
lightswilch
4-NAT
Behindsteering
Combination
columncover
c428
A
connector
lightswitch
7-NAT
Behindsteering
columncover
Combination
c429
connectorB
Underleftsideof dash
Cablereel
c430
3-GRY
Atl
lnterlockcontrolunit
c431
8-GRY
Underlettsideot dash
heatedoxygensensor
4.GRY
Belowfrontconsole
Secondary
c432
'6
sub-narness
AN
A,/Tgearpositionswitch
14-GRY Belowfrontconsole
c433
AN
2-GRY
Belowfrontconsole
Shiftlocksolenoid
c434
4-GRY
Belowfrontconsole
Parkpin switchand A,/Tgear
lJ+OC
position
Atf
consolelight
panel
CVT
26-GRY Behindlettkick
TCMconnectorA
c437
CVT
TCMconnectorB
v+.to
22-GRY Behindleftkickpanel
luse/relaybox
1-GRN
Behindunder-dash
fuse/relay
box Under-dash
c439
Leftkickpanel
Bodyground,via mainwire
G401
harness
.2: Withoutmoonroof .5: M/T(withcruisecontrolor for D16Y5engine)
.6: Withsecondaryheatedoxygensensor(HO2S)
"4: Withmoonroof
c401
c402
c403
203-20
14-GRY
4-ORN
4-NAT
-
'96-'97models:
8
C
0
C428 C426
c425 C429 I C4271 C431
i,lAlN WIRE
HARNESS
t
c421
UNDER.OASH
FUSE/RELAY
BOX
c424
c420
203-21
Connectorldentificationand Wire HarnessRouting
Connector Numberof
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
MainWire Harness(Left side of dash and tloor branch):'98 modeland all GX models
c401
c402
c403
c404
c405
c406
Q407
c407
c407
c408
c409
c410
c411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c421
c422
c423
c424
c425
c426
c427
c428
c429
c430
c431
c432
14-GRY
4.ORN
4-NAT
14-BLU
4-NAT
8.GRY
2.GRY
2-GRY
6.GRY
1-BRN
1O-WHT
12-GRY
24-BLU
3-YEL
16-GRY
5-BLK
7-BRN
6-NAT
2.N/A
2.YEL
18.GRN
2O.GRN
18-GRN
7.GRN
6.GRN
5-BLK
4.WHT
8-WHT
6-WHT
4-NAT
7-NAT
3.GRY
8-GRY
4-GRY
Behindlettkickpanel
Behindlettkickpanel
Underlettsideof dash
Underlettsideol dash
Underlettsideof dash
Underleftsideof dash
Underlettsideof dash
Underlettsideot dash
Underleftsideof dash
Underl€ftsideof dash
Behindundsr-dash
tuse/rBlay
box
Aboveunder-dash
tuse/relaybox
Aboveunder-dash
tuse/relaybox
Aboveunder-dash
fuse/relaybox
Underlettsideof dash
relaybox
Under-dash
Aboveunder-dash
tuse/relaybox
Underleftsideof dash
Underlettsideof dash
Underleftsideof dash
Behindunder-dash
tuse/relaybox
Behindunder-dash
tuse/relaybox
Behindunder-dash
tuse/relaybox
Frontof under-dash
tuse/relaybox
Frontol under-dash
fuss/relaybox
Under-dash
relaybox
Underlettsideot dash
Behindsteering
columncover
Behindsteering
columncover
Behindsteering
columncover
Behindsteeringcolumncover
Und€rleftsideof dash
Underlettsideof dash
Belowfrontconsole
c433
c434
c435
14-GRY
2.GRY
4.GRY
Belowfrontconsole
Belowfrontconsole
Belowfrontconsole
c437
c438
c439
c447
c448
26.GRY
22-GRY
1.GRN
4-N/A
26-GRY
Behindleftkickpanel
Behindleftkickpanel
Behindunder-dash
fuse/relaybox
Underlettsideof dash
Behindleftkickpanel
Floorwireharness
ABS
Floorwireharness
(Security) Optional
Lighttlasherrelayconnector
Cruisecontrolunit
Canada
DRLcontrolunitconnectorA
Canada
DRLcontrolunitconnectorB
,2
Bootwireharnsss
,4
Moonroofwireharness
'7
Boofwireharness
Optional
Frontfog lightconnector
Integrated
controlunit
AIf
Dashboard
wireharness
wireharness
Dashboard
SRSmainharness
Datalinkconnector
Mtf
Starlercut rslay
lgnitionswitch
Oplional
cut relayconnector
Securitystrarter
'5
Clutchswitch
M/T
Clutchinterlockswitch
Under-dash
fuse/relaybox
Under-dash
fuse/relaybox
fuso/rolaybox
Under-dash
UndeFdash
fuse/relaybox
Under-dash
fuse/relaybox
Hornrelay
Brakeswitch
wiperswitchconnectorA
Combination
wipersrvitchconnectorB
Combinalion
lightswitchconnectorA
Combinalion
Combinalion
lighiswilchconnectorB
Cablereel
AN
lnterlockcontrolunil
'6
heatedoxygensensor
Secondary
suD-narness
An
A,/Tgearpositionswitch
A,/T
Shiftlocksolenoid
Alf
Parkpin switchandA/T gear
position
consolelight
CW
TCMconnectorA
CVT
TCMconnectorB
'7
Underdashlus€/relaybox
'7
Fuelinjectorrelay
'7
Injectorcontrolmodule
Left kick panel
Bodyground,via mainwireharness
G401
-2: Withoutmoonroof
(exceptGX)
-4: Withmoonroof
'5: M/T(withcruisecontrolor for D16Y5engine)
'6: Withsecondary
heatedoxygensensor(H02S)
t7: GX model
203-22
s
t
'98 modelsand all GX models:
c417
c425
c408
c418
MAINWIRE
HARNESS
c413
c401
) e
c438
OT
c448
c439(Gx)
C412
o
C411 C4l0
c421
-----nn-----
) - j
UNOER-DASH
FUSE/BELAY
BOX
203-23
Connectorldentificationand Wire HarnessRouting
Connector Numberot
ol
Terminal
Cavlties/
Color
Location
Connectsto
Notes
MainWire Harness(Leftside of dash and floor branch):'9$00 modelsexceptGX model
c42A
c429
c430
c431
c432
2O.GRY
4.ORN
4.NAT
14.BLU
4-NAT
8-GRY
6.GRY
6.GRY
1-BRN
1o-wHT
12-GRY
24-BLU
3.YEL
16-GRY
5.BLK
7-BRN
6.NAT
2-N/A
2-YEL
18.GRN
2O.GRN
18.GRN
7.GRN
6.GRN
5-BLK
4.WHT
8.WHT
6-WHT
4-NAT
7.NAT
3.GRY
8.GRY
4-GRY
Behindleftkickpanel
Behindleftkickpanel
Underleftsideof dash
UnderlettsideoI dash
Underlettsideof dash
Underletl sideol dash
UnderlettsideoI dash
UnderletlsideoI dash
Underleflsidsol dash
Behindunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
fuse/relaybox
Aboveunder-dash
Aboveunder-dash
fuse/relaybox
Underlettsideot dash
Under-dash
relaybox
Aboveunder-dash
fuse/relaybox
Underleftsideof dash
Underleftsideot dash
Underlettsideof dash
Behindunder-dash
fuse/relay
box
Behindunder-dash
fuss/relaybox
Behindunder-dash
fuse/relaybox
Frontof under-dash
fuse/relaybox
Frontof under-dash
fuse/relaybox
relaybox
Under-dash
Underloftsideot dash
Bohindsteeringcolumncov6r
B6hindstesringcolumncover
Behindsteering
columncover
Behindsteeringcolumncover
Underlettsideot dash
Underlettsideot dash
Belowfronlconsole
c433
c434
c435
14-GRY
2-GFY
4-GRY
Belowfrontconsole
Belowfrontconsole
Belowfrontconsole
c447
c448
c450
c451
22.GRN
2-GRY
3-GRY
18-GRY
Underlettsideot dash
Underlettsideof dash
Underleftsideof dash
Behindlettkickpanel
c401
c402
c403
c404
c405
c406
c407
c407
c408
c409
c4t0
Q411
c412
c413
c414
c415
c416
c417
c418
c419
c420
c42'l
c423
c424
c425
c426
G401
Leftkickpanel
'2: Withoutmoonroof
"4: Withmoonroof
'5: M/T(withcruisecontrolor for D16Y5engine)
'6: Withsecondary
heatedoxygensensor(HO2S)
203-24
Floorwireharness
Floorwireharness
(Sscurity)
Lightflasherrelayconnector
Cruisecontrolunil
DRLcontrolunitconnectorA
DRLcontrolunitconn€ctor
B
Roofwireharness
Moonroofwireharnsss
Fronttog lightconnector
Intsgratgd
controlunit
Dashboard
wireharn€ss
Dashboard
wireharness
SRSmainharness
Datalinkconnector
Startercut relay
lgnitionswitch
S€curitystartercut relayconnector
Clutchswitch
Clulchinterlockswitch
Under-dash
fuse/relaybox
Under-dash
tuse/ralaybox
Under-dash
tuse/ralaybox
Under-dash
fuse/relaybox
fuse/relaybox
Under-dash
Hornrelay
Brakeswitch
A
wiperswitchconnector
Combination
Combination
wiperswitchconn€ctorB
A
Combination
lightswitchconnector
lightswitchconn€ctorB
Combination
Cablereel
lnterlockcontrolunit
heatedoxygensensor
Secondary
sub-narnsss
A/T gsarpositionswitch
Shittlocksolenoid
Parkpin switchandA/T gear
positionconsololight
Securitycontrolunitconnactor
SecurityLEDconnector
Valetswitchconnector(Security)
Keylessdoorlockcontrolunit
Bodyground,via mainwire
narness
ABS
Optional
Canada
Canada
Optional
AN
Mrl
Optional
'5
M/T
AN
'6
An
Atf
Atf
Optional
Optional
Optional
MKoyloss
\
5'
'99-'00modelsexceptGXmodel:
MAINWIRE
HARNESS
c435
) t
c432
c433 C434
c421
-rr3OOO
FUSE/RELAY
BOX
) - :
203-25
Connectorldentificationand Wire HarnessRouting
Connector Numberol
Cavities,/
or
Terminal
Color
Connectsto
Location
MainWire Harness(Rightside of dash branch)
c131
c440
c441
c442
c443
c444
c445
c452
G402
22.GRN
16-BLU
2.BLU
2O-WHT
or GRN
7-BRN
22-ORN
26-ORN
32.GRY
Behindrightkickpanel
Undermiddleof dash
Underrightsideof dash
Underrightsideof dash
Enginewireharness
A
Heatersub-harness
Servicecheckconnector
Junctionconnector
Underrightsideof dash
Behindrightkickpanel
Behindrightkickpanel
Belowrightfrontfootrest
PGM-Flmainrelay
A
ABScontrolunitconnector
ABScontrolunitconnectorB
A
ECM/PCM
connector
Rightkickpanel
Bodyground,via mainwire
namess
.1: '99100modelsexceotD l6Y5withM/TandD1685
MAINWIREHARNESS
203-26
Notes
)
Connector Numberof
Cavities/
or
Color
Terminal
\
Location
Connectsto
Notes
12-GRY
24-BLU
2O.GRN
16-BLU
5-GRY
3-GRY
2O-WHT
or BLU
5-YEL
5-GRN
14.GRN
16.8LU
13-BLU
1O-GRY
5-N/A
16-GRN
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Aboveunder-dash
fuse/relaybox
Frontof under-dash
fuse/relaybox
Belowunder-dash
Leftof steeringwheel
Leftof steeringwheel
Belowgauges
Mainwireharness
Mainwireharness
Underdashfuse/relaybox
Floorwireharness
Cruisemainswitch
controller
Dashlightsbrightness
connector
Junction
Afi
Leftsideof dash
Lettsideof dash
Leftsideof dash
Leflsideof dash
Leftsideof dash
Centerot dash
Csnterof dash
Behindmiddleof dash
SRS
.1
c515
c516
20-N/A
22.GRN
Behindmiddleol dash
Behindmiddleof dash
F
connector
Gaugeassembly
E
connector
Gaugeassembly
GaugeassemblyconnectorA
GaugeassemblyconnectorB
GaugeassemblyconnectorC
Hazardwarningswitch
Rearwindowdefoggerswitch
B (Keyless
Audiounitconnector
receivercircuit)
Audiounil
Securitycontrolunit
c518
16-GRY
5.N/A
Behindmiddleof dash
Behindmiddleof dash
AudiounitconnectorA
SecurityLEDconnector
c520
2-BLK
5-ORN
Behindmiddleof dash
Leftsideof dash
Accessorypoweroutlet
GaugeassemblyconnectorD
Undermiddleof dash
wire
Bodyground,via dashboard
narness
WireHarness
Dashboard
c410
c411
c501
c503
TJJUC
UCUO
(Jcu/
c508
cs09
c510
tJctl
c512
uc t.t
c514
.'
G501
AN
.2
-2
Optional
-2
.2
Optional
("2 Canada)
ABS
'1: Withshift-upindicatoror cruisecontrolsystem('96-'97models) .2: '96198models
.3: '99-'00models
Withcruisecontrolsystem('98-'00models)
c5o9csrr c510 c515
13 1c517
DISHAOABDw|RE
IIARNESS
)
- ,
203-27
Connectorldentificationand Wire HarnessRouting
Connector Numberot
or
Cavities/
Terminal
Color
Location
Connectsto
Notes
Floor Wire Harness (Coupe/Hatchback)
c401
c401
c402
c503
Behindleftkickpanel
Behindleftkickpanel
Behindleftkickpanel
Belowunder-dash
fuse/relaybox
Behindunder-dash
fuse/relaybox
Behindunder-dash
fuse/relay
box
Driveasdoor
Driver's
door
Passenger's
door
Passenger's
door
Belowcenterconsole
Lettsideof floor
LeftB-pillar
Belowleftsideof rearseat
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Topof fueltank
Topof fueltank
Belowrightsideof rearseat
RightB-pillar
Topot fueltank
trco.'
14.GRY
2O-GRY
4-ORN
16-BLU
16.GRN
8-GRN
25-GRY
2-NAT
25-GRY
2-NAT
1-WHT
2-GRY
1-WHT
2.ORN
14-GRY
2O-GRY
2-BRN
3.BRN
2.BRN
2-ORN
1-WHT
6-GRY
vcov
1O-GRY Leftsideof dash
v)az
ucco
ucc/
trcc/
u556
uccv
UCOU
c561
u30z
UCOZ
UCOJ
c564
u5b5
ucoo
uco/
Leftkickpanel
Leftsideof tloor
G552
-1: Withpowerwindows
"4: '96-98models
.2: Withoutoowerwindows
.5: '99-'00models
.3: Withfueltankoressure
sensor
203-28
Mainwireharness
Mainwireharness
Mainwireharness
Dashboard
wireharness
Underdashfuse/relaybox
fuse/relaybox
Under-dash
Driver's
doorwireharness
Drivefsdoorwireharness
Passenger's
doorwire harness
Passenger's
doorwire harness
Parkingbrakeswitch
Driver'sseatbeltswitch
Driver'sdoorswitch
LeftrearABSwheelsensor
Rearwire harness
Rearwireharness
Rearwireharness
Fueltankunit
Fuelpump
RightrearABSwheelsensor
Passenger's
doorswitch
pressure
Fueltank
sensor
sub-harness
Powermirrorswitch
Bodyground.via floorwire hamess
Bodyground,via floorwire hamess
"5
ABS
"1
'1
'2
AEIJ
'4
'5
'tI'D
-3
ll-
)
\
c558
C555
FLOORWIREHARNESS
) t
c402
)
qo1
-tt
203-29
Connectorldentificationand Wire HarnessRouting
Connector
ol
Terminal
Numberof
Cavities/
Color
Location
Connectsto
Notes
FloorWire Harness(Sedan)
c401
c401
c402
c503
c551
trccz
vcco
ucc/
\,CC/
u55b
UCDY
UCOU
c561
lJcoz
ucoz
UCOZ
1'-coJ
lJ50.t
ucoc
ucoo
uco/
ucoo
c569
c570
c571
wJt z
TJC/J
v3/c
14-GRY
2O-GRY
4.ORN
16-GRN
16-GRN
8-GRN
25-GRY
2-NAT
25-GRY
2-NAT
Behindleftkickpanel
Behindleftkickpanel
Behindleftkickpanel
Belowunder-dash
fuse/relay
box
Behindunder-dash
fuse/relay
box
Behindunder-dash
fuse/relay
box
Driver's
door
Driver's
door
Passenger's
door
Passengels
door
1-WHT
2.GRY
1-WHT
2-ORN
8-GRY
16.GRY
20-GRY
2-BRN
3.BRN
2-BRN
2-OBN
1-WHT
6-GRY
Belowcenterconsole
Leftsideof floor
RightB-pillar
Belowleftsideof rearseat
LeftC-pillar
LeftC-pillar
LeftC-pillar
LeftC-pillar
Topof fueltank
Topol fueltank
Belowrightsideof rearseat
LeftB-pillar
Topof tueltank
1O-GRY
6-BLU
6.BLU
'1-WHT
Leftsideof dash
RightB-pillar
LeftB-pillar
Leftquarterpanel
Rightquarterpanel
Behindleftsideof rearseat
1.WHT
6-GRN
Leftkickpanel
Leftsideof floor
.1: Withpowerwindows
-3: '96-'98modelsexceptGX
.2: Withoutpower
windows .4: '99-'00modelsexceptGX
G551
tftcz
203-30
Mainwireharness
Mainwireharness
Mainwireharness
Dashboard
wireharness
Under-dash
fuse/relay
box
Under-dash
fuse/relay
box
Driver's
doorwireharness
Driver's
doorwireharness
Frontpassengeas
doorwire
harness
Frontpassenger's
doorwire
harness
Parkingbrakeswitch
Driver's
seatbeltswitch
Frontpassenger's
doorswitch
LeftrearABSwheelsensor
Rearwireharness
Rearwireharness
Rearwireharness
Bearwireharness
Fueltankunit
Fuelpump
RightrearABSwheelsensor
Driver's
doorswitch
Fueltankpressure
sensorsubharness
Powermirrorswitch
Rightreardoorwireharness
Lettreardoorwireharness
Leftreardoorswitch
Rightreardoorswitch
Fuelsub-harness
Bodyground,viafloorwirehamess
Bodyground,viafloorwirehamess
-3, GX
"4
ABS
"1
'1
ABS
GX
o
-3, GX
exceptGX
exceptGX
ABS
exceptGX
GX
\
I.r
Sedan:
FLq)N w|REHARNESS
cs64
)
)
-
c565
l
,
203-31
Connectorldentificationand Wire HarnessRouting
Connectol Numberof
or
Cavlties/
Terminal
Color
Location
Connectsto
Notes
RearWire Harness(Hatchback)
lJ50z
ucoz
LJco.t
c603
c604
UOUC
TJOUO
c607
c608
14.GRY
2O-GRY
2.BRN
2-GRY
6.GRY
6.GRY
2-GRY
6-BLU
2-BRN
G601
.1: '96-'98models
.l: '99-'00models
203-32
Lettquarterpanel
Leftquarterpanel
Leftquarterpanel
Lettquarlerpanel
Leftsideof cargoarea
Rightsideof cargoarea
Rightquarterpanel
Rightquarterpanel
Rightquarterpanel
Floorwire harness
Floorwireharness
Floorwireharness
Leftrearspeaker
Leftoutertaillight
Rightoutertaillight
Rightrearspeaker
Hatchwiroharness
Hatchwire harness
Middleof cargoarea
Bodyground,via rearwireharness
"1
,2
Optional
Optional
I \
)
Connector Numberot
or
Cavities/
Color
Terminal
\
Locatlon
Connectsto
Notes
RearWire Harness(Coupe:'96-'00models/Sedan:'96-'98models)
UCOZ
w?oz
c562
tJJO.t
c603
c604
TJOUC
TJOUO
c609
c610
c611
c612
c613
c614
c615
c616
uot/
G601
) r l
8.GRY
14-GRY
2O-GRY
2-BRN
2-GRY
4-GRY
4-GRY
2-GRY
1-BLK
2.BRN
2.GRY
1-BLK
4.GRY
2.BRN
2.BTK
2-BRN
4.GRY
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftsideof trunk
Rightsideof trunk
Rightquarterpanel
Leftsideof rearwindow
Middleof rearshelf
Middleof rearshelf
Rightsideof rearwindow
Leftsideof trunklid
Middleof trunklid
Middleot trunklid
Middleof trunklid
Rightsideof trunklid
Floorwireharness
Floorwireharness
Floorwireharness
Floorwireharness
Leftrearspeaker
Leftoutertaillight
Righloutertaillight
Rightrearspeaker
Rearwindowdefogger(+)
Highmountbrakelight
Trunklight
Rearwindowdefogger(-)
Leftinnertaillight
Leftlicenseplatelight
Trunklatchswitch
Rightlicenseplatelighl
Rightinnertaillight
Middleof trunk
Bodyground,via rearwirehamess
GX
"1
'96r98
Optional
Optional
.1: CouDe:'96198models,Sedan:'96-98 modelsexceptGX
'2: CouDe:'99r00 models
EEARWIREHARNESS
)
-:'
203-33
Connectorldentificationand Wire HarnessRoutinq
Connector
ol
Terminal
Numberof
Cavities/
Color
Location
Connectsto
Notes
RearWireHarness(Sedan):'99-'00models
c562
cs62
c563
c603
c604
UOUS
c609
c610
c611
c612
c613
c614
c615
c618
c619
c620
c621
c622
c623
2O.GRY
8.GRY
2-BRN
2.GRY
4-GRY
4-GRY
2-GRY
'I-BLK
2.BRN
2.GRY
1-BLK
3-GRY
2.GRY
2.BLK
2-GRY
3.GRY
2-GRY
2.GRY
2-GRY
2-GRY
1-BRN
1.BRN
G601
G602
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftquarterpanel
Leftsideof trunk
Rightsideot trunk
Bightquarterpanel
Lettsideof rearwindow
Middleof rearshelf
Middleof rearshelf
Rightsideol rearwindow
Lettsideot trunklid
Middleot trunklid
Middleot trunklid
Middleof trunklid
RightsideoI trunklid
Leftsideof trunk
Rightsideof trunk
LettsidsoI lrunklid
Rightsideof trunklid
Mlddleol rearshell
Mlddleol rearshelf
Middleof trunk
Mlddle ot rear shelf
Floorwireharn€ss
Floorwir€harness
Floorwireharness
Leftr€arspgaker
Lettbrakelighvouter
taillight
Rightbrakelighuouter
taillight
Rightrsarspeaker
Rearwindowdetogger(+)
Highmountbrakelight
Trunklight
Rearwindowdefogger(-)
Lettback-uplighl
Lettlicenseplatelight
Trunklatchswitch
Rightlicenseplatelight
Rightback-uplight
Lettrearturnsignallight
Bightrearturnsignallight
Leflinnertaillight
Rightinnertaillight
Windowantsnnacoilconnector
C
Windowantennacoilconnector
A
Bodyground,via rearwirehamess
Bodyground,via rearwirehamess
exceptGX
GX
GX
Optional
Optional
GX
GX
exceptGX
excsptGX
exceptGX
RearWindowDefoggerWire(exceptGX)
c831
c832
c883
2-BRN
'1-BLK
'1-BLK
Middleof r€arshelt
Leltsideot rearwindow
Rightsideof rearwindow
WindowantennacoilconnectorB
Rearwindowdefogger(+)
Rearwindowdefogger(-)
c610
c619
c605
c617
ca21
c616
c615
G601(GX)or
G602(excepiGX)
c614
c562 Cs63 C609
c603
REARWIRE HAFNESS
203-34
canl
c62,.
c6t3
c6m
G6O1(excrpt GX)
ll..
)
\
Connector Numberot
Cavities/
or
Color
Terminal
Connectsto
Location
Noteg
Driver'sDoorWireHarness(Coupe/Hatchback)
.E
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