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Generallnformation 1-2 Chassis andPaintCodes....................... 1-10 NumberLocations......... ldentification Warning/Caution LabelLocations.......1-11 Under-hoodEmissionsControl . . . . . . . . . . . . . .1 . .-.1. .5. . L a b e l. . . . . . . . . . Lift and SupportPoints 1-19 LiftandSafetyStands....................... FloorJack ....................... 1-20 .........1-21 Towing ServicePrecautions 1-22 PaftsMarkingLocations..,................. for Real-time4WD Precautions (Four-wheel Drivel......... ................. 1-23

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Chassisand PaintCodes U.S. 1997Model VehicleldentificationNumber JHLRD184*VC000001

JHL: HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) line, Body and Engine Type RDl: CR V/82084 Body Type and TransmissionType 8: 5-door/4-soeed Automatic Vehicle Grade (Series) 4: LX 5: LX (with ABS) CheckDigit Model Year Vt 1997 C: SaitamaFactoryin Japan(Sayama)

B-84P NH-552M NH-592P R-94

Vehicleldentification Number and FederalMotor Vehicle

SupermarineBlue Pearl CypressGreenPearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed

(o

COLORLABEL

INT.COLOR

WPEF

EXT.COLOR

B-84P

KA S2BA1 C

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1-2


U.S.1998Model

JHLRD174*WC000001

B20B4t2.01 DOHCSequentialMultiport Fuel-injected engine

JHL: HONDAMOTORCO.,LTD HONDA.Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RD1:CR-V/82084 RD2:CR'V/82084 Body Type and TransmissionType 7: 5-door/s-soeed Manual 8; 5-door/4-soeed Automatic

MDLA: 4-speedAutomatic M4TA: 4-speedAutomatic S B X M : s - s p e eM danual MDLA,SBXM:1000001M4TA: 3000001C: SaitamaFactoryin Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

VehicleldentificationNumber and CanadianMotor Vehicle

SupermarineBlue Pearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT. COLOR

8.84P

KA S2BA1 C

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1-3


Chassisand PaintCodes U.S. 1999Model Vehicle ldentification Number JHLRDIT4*XC000001

B2OZ2:2.0 | DOHCSequentialMultiport Fuel-injected engine

JHL: HONDAMOTORCO.,LTD HONDA.Multipurpose

RDlt CR-vlB20Z2 RD2t CR-V1B2OZ2 Body Type and TransmissionType 7: 5-door/5-speed Manual 8: 5-door/4-spsed Automatic MDLA: 4-speedAutomatic MDMA:4-speedAutomatic SBXM: s-speedManual

4: LX

6:Ex Chock Digit Model Year X: 1999

MDLA:2000001MDMA:1000001SBXM:2000001-

C: SaitamaFactoryin Japan(Sayama)

B-84P B-92P G.95P NH-578 NH-552M R,81

Vehicle ldentification Number and CanadianMotor Vehicle

SupermarineBlue Pearl NighthawkBlackPearl CloverGreenPearl TaffetaWhite SebringSilverMetallic MilanoRed

COLORLABEL

INT.COLOR

TYPEF

EXT. COLOR

B.84P

KA S2BA1 C

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1-4


Model U.S.2000

J H L R D 1 7 4 *Y C 0 0 0 0 0 1

B20Z2t2.0I DOHCSeouentialMultiDort Fuel-injected engine

JHL: HONDAMOTORCO.,LTD HONDA,Multipurpose Vehicle(MPV) Passenger Line. Body and EngineType RDlt CR-V/82022 RD2iCR-v/BzOz2 Body Type and TransmissionType Manual 7: 5-door/s-speed 8: 5 door/4-soeed Automatic

MDLA; 4-speedAutomatic MDMA:4-speedAutomatic SBXM: s-speedManual

MDLA:3000001MDHA:2000001SBXM:2000001CrSaitamaFactoryin Japan(Sayama)

B-92P B-95P G-95P NH-578 NH-552M R-81

NighthawkBlackPearl ElectronBluePearl CloverGreenPearl Taffeta White SebringSilverMetallic M i l a n oR e d

COLORLABEL

Safety Standard Certification. lrl ..V

INT.COLOR

TYPEF

EXT, COLOR

8.92P

KA S2BA1 C

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1-5


Chassisand PaintCodes Canada1997Model

J H L R D 1 8 5 *V C 8 0 0 0 0 1

B20g4t2.0| DOHCSeouentialMultiDort Fuel-injected engine

HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDl: CR-V/B2084 Body Typ€ and TransmissionTyp€ 8: s-door/4-soeedAutomatic

MDMA- 1000001

MDMA:4-speedAutomatic SDMA: 4-speedAutomatic C: SaitamaFactoryin Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

Vehicle ldentification Number and Canadian Motor Vehicle Safety Standard Certification.

SupermarineBluePearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.COLOR

B-84P

KCS2BC2 C

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Canada1998Model

J H LR D 17 4 * W C 8 0 0 0 0 1

JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Vehicle(MPV) Passenger Lino, Body and EngineType RD1:CR-V/82084 Body Type and TransmissionType Manual 7: 5-door/s-speed Automatic 8: 5-door/4-speed

8208 4:2.0| DOHCSequentialMultiport engine Fuel-injected

M4TA: 4-speedAutomatic SBXM:5-speedManual SBXM:1000001M4TA: 3000001* C: SaitamaFactoryin Japan(Sayama)

B-84P G-82P NH-552M NH-592P R-94

SupermarineBIuePearl CypressGreen Pearl SebringSilverMetallic FlamencoBlackPearl San MarinoRed

COLORLABEL

INT.COLOR

TYPEF

EXT.COLOR

8.84P

KCS2BC2 C

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1-7


Chassisand PaintCodes Canada1999Model Vehicle ldentification Number J H LR D l T 4 * X C 8 0 0 0 0 1

B20Z2i2.0I DOHCSequentialMultiport Fuel-injected engine

JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Passen0er Vehicle{MPV) Line, Body and Engin6Type RD1:CB-Y/B2OZ2 Eody Typ6 and Transmi$ion Type 7: 5-door/5-speed Manual 8: s-door/4-speedAutomatic 4: LX 5: EX ChockDigit Model Yeal X: 1999

MDMA:4-speedAutomatic SBXM: s-speedManual

C: SaitamaFactoryin Japan{Sayama)

B-84P a-92P G.95P NH.552M R-81

VehicloldentificationNumber and CanadianMotor Vehicle Safety Standard Certification.

SupermarineBluePearl NighthawkBlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed

COLORLABEL

INT.COLOR

TYPEF

EXT. COLOR

B-84P

KCS2BC2 C

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1-8


J H LR D l7 4 * Y C8 0 0 0 0 1 Manulacturer, Make and Type of Vehicle JHL:HONDAMOTORCO.,LTD HONDA,Multipurpose Passenger Vehicle(MPV) Line, Body and EngineType RDlt CR-VlB2oZ2 Body Type and TransmissionType Manual 7: 5-door/s-soeed Automatic 8: 5-door/4-sDeed Vehicle Grade (Seriesl 4: LX 5: EX

8 2022:2.0| DOHCSequentialMultiport engine Fuel-injected

MDMA:4-speedAutomatic SBXM: s-speedManual

Check Digit Model Year Yr 2000 FactoryCode C: SaitamaFactoryin Japan(Sayama) Serial Number B-96P B-92P G-95P NH-552M R-81 YR-524M

Vohicle ldentification Number and Canadian Motor Vohicle

EternalBlue Pearl NighthawkBlackPearl CloverGreenPearl SebringSilverMetallic MilanoRed NaplesGold lVetallic

OOLORLABEL

tNrcoL0R

TYPEF

COLOR EXT.

B-92P

KCS2BC2 C

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1-9


ldentificationNumberLocations

Vehiclâ‚Źldentific.tion Number tvtNl

VehicleldentificationNumber lVlNl

-

TransmissionNumb6r lManudl)

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1-10

TransmissionNumbor {Aulomaticl

EngineNumbel


Warning/CautionLabelLocations

A: CABLEREELCAUTION

OF THE SRSCABLEREELIS CRITICAL TNSTALLATION TO THE PBOPEROPERATIONOF THE SRS SYSTEM. REFERTO THE SERVICEMANUAL FOR DETAILED INSTALLATIONINSTRUCTIONS. B: DRIVERMODULEDANGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID, WATEROR HEAVY METALS S U C H A S C O P P E R ,L E A D O R M E R C U R YM A Y PRODUCEHARMFULAND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS.STOMGE TEMPERATURES M U S T N O T E X C E E D2 O O " F{ 1 O O ' C }F. O R P R O P E R HANDUNG,STORAGE,AND DISPOSALPROCEDURES. REFERTO SERVICEMANUAI- SRSSUPPI.EMENT, POTSON C O N T A I N S P O I S O N O U SS O D I U M A Z I D E A N D POTASSIUMNITRATE. FIRSTAID tF CONTENTS ARE SWALLOWED, INDUCE VOMITING.FOR EYE CONTACT,FLUSH EYESWITH WATERFOR 15 MINUTES.IF GASES IFROMACID OR WATER CONTACTIARE INHALED,SEEK FRESH A I R . I N E V E R YC A S E , G E T P R O M P T M E D I C A L ATTENTION. KEEPOUT OF REACHOF CHILDREN

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C: DRIVERMODULEWARNING A WARNING T H E A I R E A GI N F L A T O RI S E X P L O S I V EA N D , I F ACCIDENTALLYDEPLOYED,CAN SERIOUSLYHURT OR KILLYOU. TEST EOUIPMENTOR . DO NOT USE ELECTRICAL PROBINGDEVICES. THEYCAN CAUSEACCIDENTALDEPLOYMENT. . N O S E R V T C E A B LP EA R T S l N S l D E . D O N O T DISASSEMBLE. . PLACEAIRBAGUPRIGHTWHEN REMOVED . F O L L O WS E R V I C EM A N U A L I N S T R U C T I O N S CAREFULLY.

(cont'd)

1-11


Warning/CautionLabelLocations (cont'dl

(U.S.A.modelonlyl {U.S.A.modolonlyl

o: SRSWARNING{HOOD} SUPPLEMENTAL RESTRAINT SYSTEM{SRSI THIS VEHICLEIS EOUIPPEDWITH DRIVERAND FRONT SEATPASSENGER AIRBAGS, ALL SRS ELECTRICAL WIRINGAND CONNECTORS ARE 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 ELECTRICAL TEST EOUIPMENTON THE SRS WIRINGCAN MAKETHESYSTEMINOPERATIVE OR CAUSEACCIDENTAL FIRINGOF THEINFLATOR. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D . I F ACCIDENTALLYDEPLOYED,CAN SEBIOUSLYHURT YOU. FOLLOWSERVICEMANUAL INSTRUCTIONS CAREFULLY.

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1-12

E: STEERINGCOLUMNNOTTCE tHOODI NOTICE TO PREVENTSRS DAMAGE, REMOVESTEERINGWHEEL BEFOREREMOVINGSTEERING SHAFTCONNECTING BOLT. F: MONITORNOTICE NOTICE . NO SERVICEABLE PARTStNStoE. . REFER TO SERVICEMANUAL FoR DETAILED

rNsrRucTtoNs.


AIRBAGMODULEDANGEN G: FRONTSEATPASSENGER A DANGER EXPLOSIVE/FLAMMABLE CONTACTWITH ACID,WATER.OR I{EAVY METALSSUCH HARMFUL T.EAD. OR MERCURYMAY PRODUCE AS COPPER. AND IRRITATINGGASESOR EXPLOSIVECOMPOUNDS. MUST NOT EXCEED2OO"F STORAGETEMPERATURES I l O O ' C ) . F O R P R O P E RH A N D L I N G ,S T O R A G E ,A N D REFERTO THESERVICEMANUAL, DISPOSALPROCEDURES SRSSUPPLEMENT. POTSON SODIUM AZIDEANO POTASSIUM CONTAINSPOTSONOUS NITRATE. FIRSTAID IF CONTENTSARE SWALLOWED,INDUCEVOMITING.FOR E Y E C O N T A C T ,F L U S H E Y E S W I T H W A T E R F O R 1 5 MINUTES. IF GASES (FROM ACID OR WATEN CONTACT) ARE INHALEO.SEEKFRESHAIR. IN EVERYCASE,GET PROMPTMEDICALATTENTION. KEEPOUTOF REACHOFCHILDREN. A WARNING T H E A I R B A G I N F L A T O R I S E X P L O S I V EA N D , I F CAN SERIOUSLYHURT OR DEPLOYED, ACCIDENTALLY KILLYOU. L E S T E O U I P M E N TO R . D O N O T U S E E L E C T R I C AT PROBINGDEVICES, DEPLOYMENT. THEYCAN CAUSEACCIDENTAL . NO SERVICEABI-E PARTSlNSlDE.DO NOT DISASSEMBII. . PLACEAIRBAGUPRIGHTWHENREMOVEO. . FOLLOWSERVIC€MANUAL INSTRUCTIONSCAREFULLY INFORMATIONlU S.A. modell H: PASSENGER {U.S.A.'97model} AIEBAGSEEOTHERSIDE,

lU.S.A.'98- 00 models) WARNING DEATHOR SERIOUSINJURYCAN OCCUR' . CHILDREN12 ANO UNDERCAN BE KILLEDBY THE AIRBAG. . THE BACKSEATlS THESAFESTPLACEFORCHILDREN. C H I L DS E A T l N T H E . N E V E RP U T A R E A R - F A C I N G FRONT. o SIT AS FARBACKAS POSSIBLEFROMTHEAIRBAG . ALWAYSUSESEATBELTSAND CHll-DRESTRAINTS. TEN YEAnS AFTERlT lS . THE SRSMUST BE TNSPECTED INSTALLED. . T H E O A T EO F I N S T A L L A T I O Nl S S H O W N O N T H E DRIVER'SDOORJAMB. AIRBAGWARNING J: FRONTPASSENGER lU.S.A.'98- 00 models) WARNING C H I L D R E NC A N B E K I L L E D O R I N J U R E D 8 Y T H E AIRBAG. PASSENGER THE BACKSEAT IS THE SAFESTPLACEFORCI{ILDREN12 AND UNDER. MAKE SURE ALL CHILDRENUSE SEAT BELTSOR CHILD SEATS. WARNING K: FRONTSEATBELTTENSIONER WABNING EXPLOSIVEMATERIALINSIDE HURTOR BURNED, YOU CAN BE SERIOUSLY . DO NOT TAMPEROR DISASSEMBLE PARTSINSIDE. NO SERVICEABLE . REFERTO SERVICEMANUAL FORCOMPLETE INSTRUCTIONS.

{U.S.A.'98- 00 modelsl AIRBAGWARNING FLIPVISOROVER. l: SRSINFORMATION

model lU.s.A.'97 i '97 lcanada - 00mod€lsI CAUTION TO AVOIDSERIOUSINJURY: lN ALL TYPESOF . FORMAXIMUM SAFEW PROTECTION CRASHES,YOU MUST ALWAYS WEAR YOUR SAFETY 8ELT. CHILOSEATSlN o OO NOT INSTALLREARWARD-FACING SEATPOSITION. ANY FRONTPASSENGER CLOSETO THE . DO NOT SIT OR LEAN UNNECESSARILY AIRBAG. . DO NOT PLACE ANY OBJECTSOVERTHE AIRBAGOR BETWEENTHEAIRBAGAND YOURSELF. . SEE THE OWNER'S MANUAL FOR FURTHER INFORMATIONAND EXPLANATIONS TEN YEARSAFTERlT lS . THE SRS MUST BE INSPECTED INSTALLED. . T H E D A T E O F I N S T A L L A T I O Nl S S H O W N O N T H E DRIVER'SDOORJAMB.

(cont'd)

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1-13


Warning/CautionLabelLocations (cont'd)

VACUUM HOSEROUTING DIAGRAMlUndor-hood EmissionsControl Lrb6ll ENGINECOOLANT INFORMATION

SERVICE INFORMANON {Under-hood Emission3 Control l.rbell STEERING COLUMNNOTICE (s€epage 1-12)

(Canadamodel)

RAOIATORCAP CAUTION

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1-14

AIR CONDITIONING INFORMATION


Under-hoodEmissionsControlLabel EmissionGroupldentification (1997modell Example: VACUUMHOSEROUTINGDIAGRAM

INFORIMATION VEHICLE Ii/PORTANT VHN2 OIJCrcK ENGINE FAMILY OLITER DISPIACEMENT'2 VNNl0778YMBP VEf AM]LY EVAPORAT

CATALYST

NFORMATON. REfERTOSEBVICEMANUALfORAODITIONAL I-]P TUNT CONDITIONS TEMPERATURE, ATNORI\,!AL OPERATNG ENGINE FANOIF OFFCOOLING ESTL]RNED ALLACCESSOR NNEUTRAL TRANSM1SSION ADJUSTMENIS NEEDED NOOTHEB

ap'

| \6( Zror '.

ND\. 61FL r

TO U.S EPAREGUI.ATIONS TNISVENICLE CONFORMS TO I99] MODET YEARN€WL GNI DUTYTRACKS APPICASLE

E n g i n eF a m i l y :

Year Model v:1s97

l JGKE vHN2.o

T_fT

I I | L

Manufaqturer H N :H o n d a Displacement Class 1: Light DutyVehicle Fuol Systom ,nd Numb€r of valves J: ElectronicSequentialMultiport Injection(threeor more valvesper cylinder) Fuel Type G: Gasoline Standard F: 49 or 50 StatesTier 1 K: 49 or 50 StatesTier 1 1: CaliforniaTier 1 2: CaliforniaTLEV 3: CaliforniaLEV 4: CaliforniaULEV Catalyst E, F, G, H: ThreeWay Catalyst

i I

OBD

@

K - T: OBDEquipped

ONCONTROL'EOLJIPPED OSVEORTRACT fOUBWHEEL OFPERMANENT LOADED IM TEST]NG ZED ON A IOUR WHEELDRVE SPEEOSYNCHRON VEHTCLES MUST BE CONDUCTED ANONLOADEDTESTPBO(EOUBEMUSIBEPERFORMEO

50ST (50 Statesl: TO U.S.EPAAND STATEOF CONFOBMS THISVEHICLE 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 7 MODELYEARNEWLIGHTDUTYTRUCKS. 49ST{49 Statos/Federall: TO U.S.EPA REGULATIONS CONFORMS THISVEHICLE YEARNEW LIGHTDUTY TO 1997IVIODEL APPLICABLE TRUCKS. CAL (Calitornial: TO U.S.EPAAND STATEOF CONFORMS THISVEHICLE TO '1997 APPLICABLE I A R E G U L A T I ONS CALIFORN M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S THAT THISVEHICLEIS ONLY INTRODUCED PROVIDED I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F CALIFORNIA.

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Families Engineand Evaporative

Evaporative Family: "r0",

V HNlOTTBYMBP T|

"*,

V: 1997 Manufacturer HN: Honda Storago System 1: Canister CanistorWorking Capacity (gramsl CanisterConfigulation A: PlasticHousing(ClosedBottom) B: PlasticHousing(OPenBottom) Fusl System Y: FuelInjection FuelTank M: Metal Standard A: CurrentEvap B: EnhancedEvap Wild C.rd

1 - 15


Under-hoodEmissionsControlLabel EmissionGroupldentification (1998modell

Engineand EvaporativeFamilies EngineFamily:

Example: DwlF\AIo|NG oBcha\GtftcI + cootr\r -s€msoru1or or FoNoA-IEaoTTxD-ibl a\D wATfB. M w r or_ut-ir coolqNt,oR-l;ir,FEaFEf1'v!Lrff EzEcoo-aN' ENGINE MAY BESEflIOUSLYSIONTENEO. DSEPLACI CoOTANT AnEs85 itNlgsloF@ MILIS l@0 rnl, wHrcHEvEs coMEs

Mod€l Year W: 1998 ManufacturerSubcods HNX:HONDA

TNEREAFT€R, REPLACE EvEny fmAFSlm m M[Esi@ kml,wHcHrvEB coMEs DCHEC(ONADOCOOLqNTATTHE RSSEFVETANX. NOTTHE iAD]ATOR. DFOR FUFTNEfr INFO8MATION ONIN€COOT]NC SYSIEM NEAD THE OWNEN'S MANUAL, . CHECK W|TH YOUR NONDA OEALEF.

FamilyTypo V: LDV T: LDT

IMPORTANT VEHICLE INFORMATION THISVEHICLE CONFOEMS TOI], S.EPA FEGIJLAIIONSAPPLICASLE TO1993MOOEL Y€AFNEWLIGHTDUIYTNUCXS.

CATALYST

rwqHozst2l/sFt/osD l cERI|FtEO vAlvttAsH lrr0.l010.02nm icolo) EX:01310.02mm SPAS( PIUGGAP I.O IINM 686,13G96 lDLlSPTED 750I 50rym PROCEOURESI 2.0L TlNt UPCoND/ToNS: ENGINE ATNOiM IEMPETAIURT,ALLACCESSORIESTUNNI fANOFf.TRAI1SMISSON INNEUTMI NOOIIIERAOJUSTI\TFIIS IIEEOED.

GD

@

50ST {50 States}: THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF C A L I F O R N I AR E G U L A T I O N S APPLICABLE TO 1998 MODELYEARNEWLIGHTDUTYTRUCKS, /$ST (itg Statos/Fodsrsll: THISVEHICLE CONFORMS TO U.S.EPA REGULATIONS APPLICABLE TO 1998MODELYEARNEW LIGHTDUTY TRUCKS. CAL {California}: THISVEHICLE CONFORMS TO U.S.EPAAND STATEOF C A L I F O R N I AR E G U L A T T O NASP P L I C A B L E TO 1998 M O D E LY E A R N E W T L E V L I G H T D U T Y T R U C K S PROVIDED THATTHIS VEHICLEIS ONLY INTRODUCED I N T O C O M M E R C EF O R S A L E I N T H E S T A T E O F CALIFORNIA.

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1-16

W HNX T O2.OUF1

Displacomsnt Soqu€ncoCharaciors

Evaporative Fami Family: Model Yeat W:1998 Manufastu16rSubcode HNX:HONDA Family Type E: EVAP R; EVAP/ORVR CanisterWork Capacity SgquoncoCharaqtsrs

W HNXEOOSOAAB


EmissionGroupldentification (1999model) Example: U-ECo-q.NOEDI USE THE COOLANT. NGORCNANGINC @SOLU I ONOfFONOA '.WNEN AOO 0FTNE LIFE THE CooLANT,0RTHE oILLJTE mcrtniuvcoourr mo wlttt NEVEF

coMEs lmo rhl,wNrcHEVEn "Eifil:$o""niii?i,THffiffi'"R@ MLEs os@

i'lrt^torrrr,^,r*a, rurr"*

coMEs MLEs 1@ kmrwNICHEVER

TAN(NOTIHENADIATOS ATTHERESER!'E }CNECK ORADDCOOLANT MANUAL' READ THEOWNER'S NCSYSTEM ONTHECOOL DFOfifWTHEFNFORMATION ' CHECK HONOA OEALER. WIIHYOUS

INFORMATION VEHICLE IMPORTANT S EPANLEV CONFOAMSTOU. THISVEHICLE TO1999MOD€L APPLICCBLI FEGULANONS YEA8NEWTIEVLIGHTDUTY]nUCKSAND IO 19S9 APPLICASLE REGULATIONS CALIFORNIA YEARNEWTLEVLIGHTDUTYIFIJCKS, MOOEL

CATALYST mm IASN lN:010r0.02 VALVE E X0 1 3 1 0 0m 2m lCoLDj PLUG GAP 10- l l nm SPA8K rPm 130 t 5{ IDLE SPEED

NOB I]PCONDIIIONS INGINEAT TUNE ESTLJRN ATLACCESSOS TEI\'PERATUR€ NNEL]TML FANOFf IRANSMSSION NEEOEO. ADJUSTMTNTS NOOINER

EngineFamily:

,| F

--'-

Ll:.-.-,1 I rFrll \=#_H* JL

SPEED MUsT BE coMoufitooNArounwNEElDslvE Iooro nr tist rc orn svtncrE MU sT8EPfRrouRE DrEsrPRoCE iitriunor mo ovuvo uenn orr EnwsEaNoN.loaDE

X HNXT02,OUA2

Model Year X:1999 Manutao{urerSubcode HNX:HONDA

FamilyType V: LDV T: LDT Displacoment SaquenceCharactors

EvaporativeFamily:

OBDIICERT]ATD 201

Engineand EvaporativeFamilies

X HNXEOO8OAAB

Model Yoal X:1999 ManutacturarSubcode

HNX:HONDA Family Typo E: EVAP R: EVAP/ORVR Canbter Work Capacity S€quonceChartsters

GD 50 state TLEV + NLEV {Unrestricted} 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 V E O 1 9 9 9 M O D E LY E A R R E G U L A T I O NA SP P L I C A B L T T R U C K SA N O C A L I F O R N I A N E W T L E V L I G H TD U T Y T O 1 9 9 9 M O D E LY E A R A P P L I C A B L E REGULATIONS NEWLIGHTDUTYTRUCKS.

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1-17


Under-hoodEmissionsControlLabel EmissionGroupldentification (2000model)

EngineFamily:

Example: DWFEN aDDr,tc0RChA\CtN! rlt cooraN.ust MsoLU- oNor fioNpAq-af6MrNp-ol

\rvEn u u'r+-E coo|-d',r os-Fiiiiifi-' lfi ;!,."5:P!$t:1t9ffilf 1

DREpf cEcoolaNrAFTEBt3tlomistoR@MtLEs r@km),wH ctlEvrscoMEs T|E8EAFTER, BEprAcE EVEny ErdFstoB@ MttEs lmr,t, ffitcHEVER coMEs DCIIICXOF ADDCOOLA\I I'-FE

":3lliJ#fl

AISIRVI TAI{I\.NOI THEMDIAIOR

s,5TEM 8r!D TrE owrEp sMA\u.r. "lj,9lx6L;T&Iji(0or|]\G IMPORTANT VEHICLE INFORMATION

IHIS\/IHICLECONFONMS TOU.S.EPANLEV SEGULATIONS APPIJCq3LE TO2OOO IVOOEL YEAFNEWT!!V LIGHTDUTYTBUCKS AND CALIFONNIA SEGULATIONS APPLICASLE TO2OOO MOO€LYIAA NEWTLEVLIGHT.OUTY TFIJCKS.

vALvtLA5h tN:0,10r0.02 mm {C0t0l E l : 0 . 1 3 ! 0 0m2h S P A n ( P L U G G A1P. 0 - 1 1 m m O8OCENTFIED l D l ES P E E o 734150lpm ?.0t TUNIUPCoNDIToNS: ENGINE ATNORM TTMPERAIURE ATLACCESSORIES fu BNI TANOFFTiANSMISS ONINN€UTRAL NOOTHER AD.ILJSTMENIS NEEDEO.

.l-L

gt couolorooN,{raua.wxEtt |oAoEDr/MTESTNG oFTHsvtHrctE uLrst onuspreo syNoiRoN zEoDvNAMoMETER. olrEiwsE.ANoN.LoAoEo rEsrpBocEounr uust sr pair

m

1

50 State TLEV + NLEV (Unrestricied, 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 V R E G U L A T I O NA SP P L I C A B L T EO 2 O O O M O D E LY E A R N E W T L E V L I G H TD U T Y T R U C K SA N D C A L I F O R N I A REGULATIONA S P P L I C A B LT EO 2 O O O M O D E LY E A R NEWLIGHTDUTYTRUCKS.

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Y HNX TO2.OUA2

Model Y€ar Y: 2000 ManufaqturerSubcodo HNX:HONDA

FamilyType V: LDV T: LDT Displacement SaquencoCharasters

Evaporative Family:

CATALYST

1-18

Engineand EvaporativeFamilies

Modol Yea. Y: 2000 ManufacturerSubcode HNX:HONDA Family Type E: EVAP R: EVAP/ORVR CanisterWork Capacity SoquencaCharactet3

Y HNXEOOSOAAB


Lift and SupportPoints Lift and SafetyStands place ffi When heaw rear components such as suspension,Iuel tank, spare tire and tailgate are to bâ‚Ź lemoved, vehicle, the !iiii-'rn"t r""igtrt in the trunk before hoisting. When substantial weight is removed flom the lear ot the center of gravity may change and can causethe vehicle to tip fotward on the hoist' NOTE:Sinceeachtire/wheelassemblyweighsapproximately30 lbs (14 kg),placingthe front wheelsin the cargoareacan assistwith weight distribution. 1. Placethe lift blocksas shown. and rockthe vehicleto be sure it is firmly supported. 2. Raisethe hoista few inches(centimeters), 3. Raisethe hoistto full height,and inspectthe lift pointsfor solidsupport' NOTE:Usethe samesuppon pointsto supportthe vehicleon safetystands'

FRONTSUPPORTPOINT

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LIFTBLOCKS

REARSUPPORTPOIMT

1-19


Lift and SupportPoints FloorJack 1 . Blockthe rear wheelswhen raisingthe front of the vehicle;blockthe front wheelswhen raisingthe rear of the vehicle. Placethe blocksbehindand aheadof the wheels, Raisethe vehicle high enough to insert the safety stanos.

Always usg safety standg when working on or under any vehicle that is supported by only a iack. Nevor attempt to use a bumper jack for tifting or supporting ths vehiclâ‚Ź.

Adjust and place the safety stands so the vehicle will be approximatelylevel,then lower the vehicle onto them.

Front:

Center the jack

bracketin the middle of the jack lift platform.

JACK LIFTPLATFORM

Rsar:

Centerthe iack bracketin the middle of the iack lift platform. www.emanualpro.com

1-20

JACK LIFT PLATFORM


Towing

l f t h e v e h i c l en e e d st o b e t o w e d , c a l l a p r o f e s s i o n a l towing service.Never tow the vehicle behind another vehjclewith just a rope or chain.lt is very dangerous. 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 usestlvo pivoting armsthat go underthe tires lfront or 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 t i r e s r e m a i no n t h e g r o u n d . T h e v e h i c l e ' ss u s p e n s i o na n d b o d y c a n b e seriouslydamagedif this methodof towing is attempted. Sling-typeEquipment- The tow truck usesmetalcables with hookson the ends.Thesehooksgo aroundpartsof the frame or suspensionand the cableslift that end of the vehicleoff the ground.The vehicle'ssuspensionand body can be seriouslydamagedif thjs methodof towing i s a t t e m p t e d .T h i s m e t h e d o f t o w i n g t h e C R - Vi s unaccePtable. The onlv recommendedway of towing the CR-Vis on a f l a t - b e dt r u c k . T w o w h e e l d r i v e C R - V ' sm a y a l s o b e towed with all four wheelson the ground.

Front:

lOwlNG HOOKS.nd TIE DOWN BRACKETS

Rear:

Towing the four-wheel dlive CR-v with only two wheels on the ground will damage parts of the 4wD system. It this vehicle is damaged, it should be towed on a flat-bed truck ol trailel. It the 2 wheel drive CR-v is towed wiih all tour wheels on the ground, do the following: Manual Transmission . Release the parkingbrake. . Shiftthe transmissionin Neutral Automatic Transmission . Releasethe parkingbrake. . Start the engine. . Shiftto lD.lposition.then E position. . Turn off the engine. TIEDOWNBRACKET lmproper towing preparation will damage the transmission.Follow the above procedure exactly. lf you cannot shift the transmission or start the engine, the vehicle must be transported on a flat-bed truck. lf the vchicle is towed with four wheels on the ground, il is best to tow the vehicle no larther than 50 miles (80 km), and keep the speed below 35 mph {55 km/h). Trying to lift or tow the vehicle by ihe bumpers will cause serious damage. The bumpers ale not dosigned to support the vehicle's weight.

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1-21


ServicePrecautions PartsMarkingLocations To deter vehicletheft, cenain major componentsare markedwith the vehicleidentificationnumber {VlN).Originalparts will have self-adhesivelabelsor labelsattachedwith a break-offbolt. Replacementbody parts will have self-adhesive labels,and replacement engineand transmissionpartswill be stampedwith a codetor spareparts. NOTE: . Be carefulnottodamagethe partsmarkinglabelsduringbody repairs.Maskthe labelsbeforerepainting. ' Labellocationletterswithout parenthesisindicateoriginalparts.Letterswith parenthesisindicate replacement pans. A, (A): Engine B, (B): Transmission C, (C): FrontBumoer D, (D); Hood E, (E): Tailgate F, (F): RearBumper G, (G):FrontFenders(Lefrand Right) H, {H): FrontDoors(Leftand Right} l, (l): RearDoors(Leftand Right) J, (J): OuterSide Panel(Leftand Right)

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1-22


for Real-time4WD(Four-wheelDrivel Precautions U n d e r n o r m a l c o n d i t i o n s t, h e v e h i c l ei s i n 2 W D ( f r o n t - w h e edl r i v e ) .H o w e v e r ,t h e s y s t e m w i l l i n s t a n t l yt r a n s m i t appropriatedrivingforceto the rearwheels{dependingon the drivingforceof the front wheelsand the road conditons) The Real-time4WD-DualPump Systemdoes not have a manual switch to disablethe 4WD system.Wheneverservice work requiresspinningthe front or rearwheelswith the engine,alwayslift up and supportthe vehicleso all lour wheels are off the ground (seepage1-19).

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1-23


Specifications 2-2 Standardsand ServiceLimits............... .......... 2-12 DesignSpecifications .................. ..........2-14 BodySpecifications

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Standardsand ServiceLimits EngineElectrical- Section4 MEASUREMENT lgnitioncoil

R a t e dv o l t a g e V P r i m a r y w i n d i n g r e s i s t a n c e0 a t 6 8 ' F ( 2 0 ' C )

lgnition wire

Besistance at 68"F(20 C) ktl Firingorder

Sparkplug

STANDAFDINEWI

1 3

l g n i t i o nt i m i n g

Type Gap At idle

Alternator belt*r

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 )

Alternator

Belttension N {kgf,lbt) Measuredwith bek tensiongauge OutputA (at 13.5V, hot and 6,000alternatorrpm

4-2

See Section 4 1 . 0 - 1 . 1 ( 0 . 0 3 9- 0 . 0 4 3 )

BTDC

AII M/I

Brushlength Staningmotor

SERVICELIMIT

12 0.63 0.77 25 max.

A/f Mfi

Output kW Micadepth Commutatorrunout CommutatorO.D. Brushlength Brushspringtension N (kgf,lbf)

1 6 12 { R e d ) 8 . 5 1 1 . 5 1 0 . 3 30 . 4 5 ) w i t h u s e db e l t 5.5- 8.0 (0.22- 0.31)with new belt 340- 490{35- 50,77 110)with usedbelt 690 880(70 90, 150- 200iwith new belt 95 90 1 0 . 5( 0 . 4 1 ) 1.5(0.06i 1.1 1.0 0.5- 0.8{0.02- 0.03) 0,0.02 (0 0.0008) 2 7 . 9 2 8 . 0( 1 . 0 9 8 41 . 1 0 2 4 ) 14.0 14.5(0.55 0.57) - 3.97) 13.7- 17.7(1.40- 1.80,3.09

0.2 (0.008) 0.0s(0.002) 2 7 . 0( 1 . 0 6 ) 9.0 (0.35)

' 1 W h e n u s i n g a n e w b e l t , d d i u s t d e f l e c t i o nt o n e w v a l u e . R u n t h e e n g i n e f o r 5 m i n u t e s t h e n t u r n i t o f { . B e a d i u s t d e f l e c t i o nt o u s e d b e l t v a l u e .

CylinderHead/ValveTrain - Section6 MEASUREMENT Compression

250rpm and wide openthrottle , kPa(kgflcm' psi)

Cylinderhead

Warpage Height E n dp l a y

Camshaft

STANDARD{NEW}

Camshaft to hoider oil clearance

Totalrunout Cam lobe height

'97,'98models '99,'00models

(Cold)* Valveclearance ValvestemO.D. Stem'to-guide clearance width Steminstalledheight

lN EX lN EX lN EX lN EX lN EX tN EX lN EX

Valve spring

Freelength

lN EX

Valve guide

I,D,

IN EX tN EX

Installedheight *: Measuredbetweenthe camshaftand rockerarm,

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2-2

SERVICELIMIT

Nominal 1,230i'12.5, 11Al Minimum 930(9.s,135) Maximumvariation 20012.0,2al 1 3 1 . 9-5 1 3 2 . 0{55 . 1 9 -5 5 . 1 9 9 ) 0.05 0.1s(0.002 0.006) - 0.0027) 0.030- 0.069(0.0012 0 . 0 3{ 0 . 0 0 1 ) m a x . 33.204\1.30721 33.528{1.3200) 33.116 \1.3214) 33.528{'1.3200) 0.08- 0.12(0.003 0.005) 0.16 0.20(0.006- 0.008) 6.580- 6.590(0.2591 0.2594) 6.550- 6.560(0.2579 0.2s83) 0.02- 0.05{0.00t 0.002) 0.05- 0.08(0.002 0.003) 1.25- 1.55(0.049- 0.061) 1 . 2 5 1 . 5 5( 0 . 0 4 -9 0 . 0 6 1 ) 40.765- 41.235{1.6049 1.6234) - 1.70221 42.765- 43.235i'1.6837 42.36(1.668i 44.32t1.1451 - 0.261) 6.61 6.6310.260 6.61 6.63{0.260- 0.261i 1 3 . 7 -5 1 4 . 2 5 1 0 . 5 4 10 . 5 6 1 i 15.75- 16.25{0.620 0.640i

0.05{0.002) 0.5(0.02) 0.15(0.006) 0.04(0.002)

u* to.rutt 6.52lO.257l 0.08{0.003i 0.'1t(0.004) 2.0 (0.08) 2.0 (0.08) 41.485{1.6333} 43.485{1.7120i

6.6510.2621 6.65(0.262i


o

STANDARD(NEWI

MEASUREMENT Cylinder block

Piston

Pistonring

Warpageof deck surface Borediameter Boretaper bottomof skart SkirtO.D.*1trom in cylinder Clearance Groovewidth {Forringi

clearance Ring-to'groove Ringend gap

PistonPin

0.07(0.003)max. 84.00- 84.02(3.307 3.308)

Top Second oil ToP Second ToP Second oil

o.D.

Pin-to-piston clearance Pin-to-rodinterference Smallend borediameter Nominal Largeend borediameter Endplayinstalledon crankshaft Mainjournaldiameter Crankshaft N o .1 , 2 , 4 a n d5 i o u r n a l s No.3 journal Rodiournaldiameter Taper Out ol round Endplay Bunout Main bearing-to-iournal oil clearance Bearing N o .1 ,2 , 4 a n d 5 i o u r n a l s No.3 journal oil clearance Rodbearing-to-,ournal *1: '97,'98models15 mm (0.6in) '99,'00models20 mm (0.8ini rod Connecting

o

Unit of length: mm (in)

EngineBlock- Section7

83.98- 83.99(3.306- 3.307) - 0.00161 0.01- 0.04(0.0004 - 0.0492) 1.240- 1.250{0.0488 - 0.0484) 1.220 1.230{0.0480 2 . 8 0 5 2 . 8 2 51 0 . 1 1 0- 40 . 1 1 1 2 ) 0.055- 0.080(0.0022 0.0031) - 0.0024) 0.035 0.060(0.0014 0.20 0.30(0.008- 0.012) 0.40- 0.55(0.016 0.022) 0.20- 0.50(0.008- 0.020) - 0.8268i 20.996- 21.000(0.8266 - 0.0007) 0.010- 0.017(0.0004 - 0.0013) 0.015- 0.032(0.0006 -0.8260) 20.968-20.98110.8255 48.0(1.89) 0.15- 0.30{0.006- 0.012i

SERVICELIMIT 0.10(0.004) 84.07(3.310) 0.05(0.002) 83.97(3.306) 0.05{0.002) 1.26(0.0s0) 1.25(0.049) 2.44lo.112l 0.13(0.005) 0.13(0.005) 0.60(0.024) 0.70(0.028) 0.70(0.028)

oroto.oroi

- 2.1654) 54.976- 55.000(2.' l644 - 2.1651) 54.970 54.994(2.1642 - 1.71111 44.976- 45.000/.1.1707 0.005(0.0002)max. max. 0.005(0.0002) 0.10- 0.35(0.004- 0.0r 4) 0.03(0.001)max.

0.010(0.00041 0.010(0.0004) 0.45(0.0r8) 0.04(0.002)

- 0.042 0.024 10.00090.0017) - 0.048(0.0012 - 0.0019) 0.030 0.020- 0.038(0.0008 0.0015)

0.06(0.002) 0.06(0.002) 0.05(0.002)

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2-3


StandardsandServiceLimits EngineLubrication

Section8 MEASUREMENT

Engineoil

Capacity f (US qt, lmp qt)

Oilpump

Inner-to-outer rotorclearance Pumphousing-to-outer rotorclearance Pumphousing-torotoraxialclearance Pressure settingat engineoil temp. 176'F(80'C) kPa(kgt/cm,,psi) At ldle At 3,000rpm

R e l i e fv a l v e

Cooling

Radiatorcap Thermostat

Coolingfan

70 (0.7,10)min. 3 4 0{ 3 . 5 , 5 0m ) in.

Section 10 MEASUREMENT

Radiator

STANDARO{NEWI SERVICELIMIT 4.6(4.9,4.0)Iorengineoverhaul 3 . 8{ 4 . 0 , 3 . 3 ) f oori l c h a n g ei n , c l u d i nfgi l t e r 3.5 (3.7,3.1)for oil change,withoutIilter 0.04- 0.16(0.002- 0.006) 0.20(0.008) 0 . 1 0- 0 . 1 9 ( 0 . 0 0-4 0 . 0 0 7 ) 0.20(0.008) 0.02-0.07 (0.001- 0.003i 0.15(0.006)

Coolantcapacity , (USq1,lmp qt) llncludingengine,heater,I lineand reservoirl Lcooling Reservoir capacity: 0 . 6 1 ( 0 . 6 3U S q t , 0 . 5 3 l m pq t ) psi) Openingpressure kPa(kgf/cm?, Startsto open 'F 1"C) Fullyopen 'F ("C) Valvelift at tully open "ON" temperature "F Thermoswitch {'C) "OFF"temperature 'F ('C) Thermoswitch

Fueland Emissions

M/T

STANDAROINEW} 5.9{6.2,5.2}toroverhaul 3.9(4.1,3.4ifor coolantchange 6.0(6.3,5.3ifor overhaul 4.0(4.2,3.5)for coolantchange 9 3 - 1 2 3( 0 . 9 5- 1 . 2 5 1, 4 1 8 ) 169- 176(76- 80) 194(90) 8 . 0( 0 . 3 1 i m i n . 196- 203 (91- 95) Subtract5 - 14 (3 - 8) trom actual"ON" temperature

Section 11 MEASUREMENT

STANDARDINEW}

Pressureregulator Pressurewith regulatorvacuum hose disconnected '97,'98models , kPa(kgflcm' psi) '99, '00 rnodels Fueltank (US gal, Capacity / lmp gal) En g i n e ldle speedwith headlights and coolingfan off rpm '97 model '98 model '99,'00 models Fastidle rpm

ldle CO %

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2-4

'97 model '98 model '99,'00 models

260- 31012.7 3.2,38- 46) 270-32012.8 3.3,40- 471 5 8 ( 1 5 . 31, 2 . 8 ) MT

750r 50 7301 50 1,5001200 1,600r 200 0.1max.

AT {E or E position)

750t 50 750r 50 7 3 0 15 0 1 , 5 0 0 12 0 0 1 , 5 0 0 12 0 0 1,600r 200


Clutch

Unitof length:mm lin)

Section 12 MEASUREMENT

Clutchpedal

Pedalheight Stroke Freeplay Pedalplay Disengagement height Clutchsurfacerunout

to floor

to floor

Clutchdisc

Rivet head depth Thickness

plate Pressure

Warpage Diaphragmspringfingeralignment

SERVICELIMIT

STANDARDINEWI 183(7.20) 1 3 5 - 1 4 5 1 5 . 3- 15 . 7 1 ) 7 - 2210.24- 0.41J 1-9 (0.04-0.35) 7 2 1 2 . 8 3m) i n .

max. 0.05(0.002)

0.r5(0.006)

1 . 2- 1 . 7 1 0 . 0 50-. 0 7 ) 8 . 4 9 . 1( 0 . 3 3 , 0 . 3 6 ) 0 . 0 3( 0 . 0 0 1 ) m a x . 0.6 (0.02)max.

0.2(0.01) 6.0i0.24) 0.15(0.006) 0.8 (0.03)

ManualTransmission Section 13 Transmission fluid Mainshaft

STANDARDINEW}

MEASUREM€NT Capacity f (USqt, lmp qti

I

SERVICEI-IMIT

1 . 71 1 . 8 1 , . 4 ) f o ro i l c h a n g e 2 . 1 ( 2 . 2 ,1 . 8 ) { o r o v e r h a u l

0.'11- 0.18(0.004- 0.007) - 1.1020) 27.977- 27.990(1.1015 37.984- 38.000(1.4954-1.4961)

Endplay Diameterof ball bearingcontactarea(clutchside) Diameterof needlebearingcontactarea Diameterof ball bearingcontactarea (transmission housingside) Runout

Adjust 2 7 . 9 4( 1 . 1 0 0 ) 37.93(1.493)

- 1.1024) 27.987- 28.000(1.1018 0.02(0.0011max. 43.009- 43.02511.6933- 1.6939) 0.06- 0.21 (0.002- 0.008) - 1.377) 34.92 34.9711.375 31.42- 31.4'711.237, 1.2391

Mainshaftsth gear

LD. Endplay Thickness

Countershaft

Diameterol needlebearingcontactarea DiameteroI ball bearingand needlebearingcontact

27.94(1.100) 0.05{0.002) 43.08011.6961) 0.3 (0.01) 34.811.37) 31.311.23) - 43.02511.6933 1.6939) 43.08011.6961) 43.009 - 0.008) 0 . 3( 0 . 0 1 ) 0.06- 0.21(0.002 - 1.219) - 30.97 3 0 . 8( 1 . 2 1 ) 30.92 {1.217 36.000 36.015{1.4173 1.4179) 3s.95(1.415) (0.982) 24.94 24.987- 25.000(0.9837- 0.9843)

Diametero{ 1st gear contactarea Runout

-1.4567) 36.984- 37.00011.4561 0.02(0.001)max.

(1.4s4) 36.93 0.0s(0.002)

LD. Endplay Thickness t.D. Endplay Thickness

- 43.025 (1.69331.6939) 43.009 - 0.007i 0.06- 0.18(0.002 - 1.063) (1.061 26.9s,27.00 - 47.025 - 1.8514) (1.8507 47.009 ,0.006) 0.07- 0.1410.003 2As2- 2a.97l 1.139-1.1411

43.08(1.696) 0.2310.009)

3 1 . 0 6( 1 . 2 2 3 ) 37.94(1.494)

Mainshatt3rd and 4th gears

countershatt1st gear Countershaft2nd gear

LD. Endplay Thickness

3rd gear 4th gear

47.08{1.854) 0.18(0.007)

Spacercollar (Mainshaft 4th and 5th gears)

t.D. o.D.

Reverseidlergear

t.D. gearshaftclearance Gear-to-reverse

31.002- 31.O1211.2205, 1.2205) 37.989- 38.000(1.4956 1.4961) 56.45- 56.55Q.222- 2.2261 26.03,26.08(1.025- 1.027) 20.01 6 - 20.043(0.7880,0.7891) - 0.0033) 0.036- 0.084(0.0014

R i n g - t o - g e a rc l e a r a n c e ( r i n g p u s h e d a g a i n s l g e a r )

0.85- r.10(0.0330.043)

0.4 (0.02)

(ringpushedagainstgear) Clearance Outersynchroring to synchrocone Synchrocone-to-gear Outersynchroring-to-gear Fingerthickness 3rdl4thshiftlork Exceptabove Fork-to-synchrosleeveclearance

0.5 1.0(0.02 0.04) - 0.04) 0.5- 1.0(0.02 - 0.066) 0.95- 1.68(0.037 - 0.30) 7.4- 7.6(0.29 6.2- 6.4(0.24-0.2s) - 0.026) 0.35- 0.65(0.0't4

0.3(0.01) 0 . 3( 0 . 0 1 ) 0.6(0.02)

Synchroring Dualcone

Shift fork

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Length

A

l' les

I

26.01t1.0241

20.09(0.7909) 0.16010.0063)

't, torag)


Standardsand ServiceLimits ManualTransmission{cont'd}- Section 13 MEASUREMENT Raverseshift Iork

Pawl groove width Fork-to-reverseidler gear clearance Groovewidth*l

STANDAROINEW) '13.0 - 13.3(0.5' -j 0.52) 0.5- 1.1(0.02- 0.04) 7.O5- 7.25 i.0.21 4 - 0.2451 7.4-7.7 t0.29 0.301

at A atB

Fork-to-5th/reverse shift shaft clearance*'

PinionshaftcontactareaLD. Carrier-to-pinion shaftclearance Driveshaft,intermediateshatt contact area LD, Carrier-to-driveshaft clearance Carrierto-interrnediateshaft clearance

Backlash t.D. Piniongearto-pinion shaftclearance

- 0.006) 0.05-0.r5{0.002 - 18.066 - 0.7113) (0.7103 18.042 - 0.0037) 0.059- 0.09510.0023

oru ro.ooor

1.4 2.5i'14 26,12-231

Adjust

33.984- 34.000(1.337- 1.339) 21.977- 27.99011.1011.1021 - 1.576) 40.002- 40.01811.575 - 1.379) 35.002- 35.01811.378 26.975,26.988(1.062 1.063) 0.06- 0.16{0.002 0.006) 2.64 3.41 \21.3,35.4,23.1 30.t|

33.93(1.336) 27.92 (1.O99) 39.95(1.573) 34.95(1.376) 26.92(1.060) Adjust Adjust

Shift arm A

Shift fork diameter at contact area Shift arm A-to-shitt tork shaft clearance

Shiftarm C

Shiftarm C'to-shiftarm B clearance Diameterof shift arm B contactarea Selectarm'to-shift arm A clearance Diameterof shiftarm A contactarea

Selectlever

o.D. Transmission housingclearance

Shift lever

o.D. Shift arm cover clearance

Differential carner

Differential piniongear

Ditferential taperedrollâ‚Źrbesringpreloac Staningtorque N.m (kgf.cm,lbl.ini Transter

11:fuleasuring points

Diameterof rollerbearingcontactarea Translershaft {driven gear side} Translorshaft {middle of shaft) Transterdrive gear Translordrivengearshaft{drivengearside) Transterdrivengearshaft(splinedside) Trans{ergear backlash TotalstartingtorqueN.m (kgicm,lbiin)

A

A 'Ay"

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2-6

18 (0.07)

0.05- 0.35(0.002- 0.014) 0.4,0.8 (0.02 0.03) 12.9- 13.0(0.508- 0.512) 0.2- 0.5 (0.008-0.020) 0.05 0.25(0.002 0.01) r2.9- 13.0(0.508- 0.512) 0.05- 0.25(0.002 0.01) 7 . 9- 8 . 0( 0 . 3 1-1 0 . 3 1 s ) - 0.6287) 15.94r- 15.968(0.6276 - 0.0034) 0.032- 0.086(0.0013 - 0.6287) r5.941- 15.968(0.6276 - 0.0050) 0.032- 0.127(0.0013 - 0.7098) 18.010 18.028(0.7091 - 0.0022) 0.027- 0.057(0.0011 28.005- 28.025(1.1026,1.1033) 0.025- 0.066(0.0010,0.0026) - 0.0036) 0.055- 0.09110.0022

at B'

Selectarm

SERVICELIMIT

*2: Measuringpoints

0.5{0.02) 1.0(0.04) 0.6{0.024i

0.1 (0.004) 0 . 1 2{ 0 . 0 0 5 i 0 . 1 5( 0 . 0 0 6 i

A'

-l-...

_{-P)


U n i t o f l e n g t h :m m ( i n )

Automatic Transmission Section 14 STANDAROINEW}

MEASUREMENT Transmission fluid

Capacity I {US qt, lmp q0

4WD 2WD

Hydraulic pressure kPa (kgflcm', psi)

Linepressureat 2,000rpm in LII or El position 1slclutchpressureat 2,000rpm in Da position 1st-holdclutchpressureat 2,000rpm In l position

2nd clutchpressureat 2,000rpm in El position 3rd clutchpressureat 2,000rpm in E position('97, '98 models),or positionwith O/DOFFindicator E light ON ('99,'00models) 4th clutchpressureat 2,000rpm in gl position('97, '98 models),or E positionwith O/DOFFindicator lightoFF ('99,'00models) Stallspeedrpm (Checkwith vehicleon levelground) 1st Clutchinitialclearance 2nd,3rd,4th 'lst-hold Clutchreturnspringfree length Clutchdiscthickness Clutchplatethickness Clutchend platethickness (lsti

1st,2nd,3rd,4th '1st-hold 2nd,3rd, 4th 1st,1st-hold Mark1 Mark2 Mark3 Mark4 Mark5 Mark6 Mark7 Mark8 MarkI Mark 10

Clutchend platethickness {2nd,4th)

Mark6 Mark7 Mark8 Mark9 M a r k1 0 M a r k1 1 lvlark12 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 Mark17

Clutchend platethickness {3rdi

Mark8 MarkI M a r k1 0 M a r k1 1 M a r k1 2 M a r k1 3 M a r k1 4 M a r k1 5 M a r k1 6 M a r k1 7 Mark1 M a r k2 Mark3

Clutchend platethickness ( 1 s th o l d )

No mark Mark6 Mark7

SERVICELIMIT

6.8(7.2,6.0)for overhaul 2.9(3.1,2.6)for fluid change 5.9{6.2,5.2)foroverhaul 2.7{2.9,2.4}forfluid change 830- 880(8.5- 9.0,120 130)

780(8.0,1' t0)

800- 850(8.2 4.7,120 1241

760t7.7,1101

2,550 0.65- 0.85(0.026-0.033) 0.40- 0.60(0.016- 0.024) 0.5- 0.8(0.020- 0.031) 31.1 11.22) 3 4 . 6( 1 . 3 6 ) 1.88- 2.00(0.074- 0.079) 'r.95- 2.05 {0.077 0.081) '1.55-1.65(0.061- 0.065) 2.05- 2.r0 (0.081- 0.083) 2.15 2.20(0.085- 0.0871 2.25 2.30(0.089,0.091) 2.35 2.40{0.093- 0.094} 2.45- 2.50{0.096-0.098} 2.55- 2.60(0.100- 0.102) 2.65- 2.70(0.104- 0.106) 2.75 2.80i0.108- 0.110) 2 . 8 5- 2 . 9 0 1 0 1. r2 0 . 1 1 4 ) 2 . 9 5- 3 . 0 0 1 0 . 1 1 6 0.118) - 0.102) 2.55 2.6010.100 2.65 2.70(0.104,0.106) 2.75- 2.80(0.108 0.110) 2 . 8 5- 2 . 9 0( 0 . 1 1-20 . r r 4 ) 2 . 9 5 3 . 0 0( 0 . 1 1 6 - 0 . 1 1 8 ) 3 . 0 5- 3 . 1 0( 0 . 1 2-0 0 . 1 2 2 ) 3 . 1 5 3 . 2 0( 0 . 1 2 4 - 0 . 1 2 6 ) 3.25- 3.30(0.128 0.130) 3.35- 3.40(0.r32- 0.134) 3.45- 3.50(0.136- 0.138) 3 . 5 5 3 . 6 0( 0 . 1 4 -0 0 . 1 4 2 ) 3.65- 3.70(0.144- 0.146) 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 . 9 5- 3 . 0 0( 0 . 1 1 -6 0 . 1 ' j 8 ) 3.05 3.10(0.120- 0.122) 3 . 1 5 - 3 . 2 0{ 0 . 1 2 4 0 . 1 2 6 ) 3.25- 3.30(0.128- 0.r30) 3.35- 3.40(0.132- 0.r34i 3.45- 3.50(0.136- 0.138) 3.55- 3.60{0.140- 0.142) 3.65- 3.70{0.144- 0.r46) 2.05 2.10(0.081- 0.0831 2.r5 2.20(0.085- 0.087) 2.25- 2.30{0.089- 0.091} - 0.094i 2.35- 2.4010.093 2.45- 2.50(0.096-0.098i 2.55- 2.60(0.r00- 0.102) 2.65- 2.70(0.r04- 0.106)

2,400,2,700

2 9 . 1( 1 . 1 5 ) 32.6(r.28) Untilgroovesworn out Discoloration Discoloration Discoloration

Discoloration Discoloration

Discoloration

Discoloration

Discoloration

(cont'd)

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2-7


Standardsand ServiceLimits Automatic Transmission (cont'd)- Section 14 MEASUBEMENT Transmission

Diameterof needlebearingcontactarea On mainshaftstatorshaftbearing On mainshaft2nd gear On mainshaft4th gearcollar On mainshaft1stgearcollar (torqueconverterhousingside) On countershatt On countershaft 3rd gear 4th gear On countershaft On countershaft reversegearcollar 1stgearcollar On countershaft housingsidei On sub-shaft{transmission On sub shaft4th gearcollar On reverseidlergearshaft Insidediameterof needlebearingcontactarea On mainshaft1stgear On mainshaft2nd gear On mainshaft4th gear 1stgear On countershaft 3rd gear On countershaft 4th gear On countershaft reversegear On countershaft On sub-shaft4th gear On reverseidlergear fleverseidlergearshaftholderl.D. Endplay Mainshaft1stgear Mainshaft2nd gear Mainshaft4th gear Countershaft 1stgear Countershaft 3rd gear Countershaft4th gear Sub-shaft4th gear Reverseidlergear Countershaftreversegear Selectorhub O.D. Mainshaft4th gearcollarlength Mainshaft4th gearcollarflangethickness Mainshaft1stgearcollarlength Countershaft distancecollarlength

Countershaft 3rd gearcollarlength reversegearcollarlength Countershaft Countershaft reversegearcollarflange thickness 1stgearcollarlength Countershaft lst gearcollarflangethickness Countershaft Sub-shaft4th gearcollarlength Sub shatt4th gearcollarflangethickness

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2-8

STANDARD{NEW}

SERVICELIMIT

- 0.9446) Wearor damage 23.980-23.993(0.9441 35.975 35.99'!(1.4163 1.4169) ( 1 . 2 5 8 91 . 2 5 9 5 i 3 1 . 9 7 53 1 . 9 9 1 - 1.2201l' 30.975- 30.99111.2195 - 1.4180) 36.004- 36.017(1.4175 35.980 35.996(1.4165 1.4172) ( 1 . 1 0 1-61 . 1 0 2 1 i 2 7 . 9 8-0 2 7 . 9 9 3 ( 1 . 2 5 8-9' j . 2 5 9 5 i 3 1 . 9 7 5 -3 1 . 9 9 1 ( 1 . 2 5 8-91 . 2 5 9 5 ) 3 1 . 9 7 53 - 1.991 - 1.0236) 25.991- 26.000(1.0233 - 23.006s(0.9053 0.9058) 22.9935 - 0.5512) Wearor damage 13.990- r4.000(0.5508 35.000 35.016(1.3780 1.3786) 4 1 . 0 0-0 4 1 . 0 1 (61 . 6 1 4-21 . 6 1 4 8 ) -' 1.4967) 38.000- 38.016(1.4961 - 1.4967) 38.000- 38.016(1.496'1 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 - 1.2605) 32.000- 32.016(1.2598 - 0.7094) 18.007- 18.020(0.7089 14.416 14.434(0.5676 0.5683) 0.05- 0.16{0.002- 0.006) 0.05- 0.13(0.002- 0.005) 0.05,0.'16(0.002 0.006) 0.1 0.5(0.004 0.020) 0.05 0.17{0.002 0.007) 0.10 0.18(0.004 0.007) 0.0s 0.17(0.002- 0.007) 0.05- 0.18(0.002- 0.007) 0 . 1 0 , 0 . 2 5 ( 0 . 0 0 40 . 0 1 0 ) 51.87- 51.90(2.042- 2.043) - |.9508) 49.50- 49.55(1.9488 4 . 4 3 5 4 . 5 2 5( 0 . 1 7 4 6 - 0 . 1 7 8 1 ) 2 7 . 0 0 , 2 7 . 0{51 . 0 6 3 ' 1 . 0 6 5 i 38.97- 39.00(1.534- 1.535) 39.02 39.05(1.536, 1.537) 39.07 39.10(1.538 1.539) 3 9 . 1 2- 3 9 . 1 5( 1 . 5 4-0 1 . 5 4 1 ) 39.17- 39.20(1.542* 1.543) - 1.545) 39.22- 39.2511.544 - 1.547i 39.27 39.301'1.546 38.87 38.90{1.530 1.531) 38.92 38.95(1.s32 1.533) 21.15- 21.20rc.4327- 0.4346) 14.5, 14.6(0.57't, 0.575) 2.4- 2.6(0.094- 0.102) 14.5- 14.6(0.571- 0.575) 2.4- 2.6(0.094- 0.102) 24.0 24.1(0.945 0.949) 2 . 9 5- 3 . 1 0( 0 . 1 1 -6 0 . 1 2 2 )

Wearor damage

Wearor damage

il*=lo'.d"'.n"n" Wearor damage

Wearor damage Wearor damage Wearor damage


Unit of length:mm (in)

Automatic Transmission - Section 14 (NEWI STANDARD

MEASUREMENT Transmission

Mainshaft 2nd gear thrust washer thickness

Thrustwasherthickness l'rainshaftballbearingleftside Mainshaft1stgear Countershaft 3rd gearsplinedwasher Sub-shaft4th gear thrust washer

o

ATFpump

One-wayclutchcontactareaLD. 1stgear Countershaft Parkinggear Mainshaftfeed pipeA, O.D.(at 15 mm trom end) Mainshaftfeed pipe B, O.D.(at 30 mm from end) teed pipeO.D.lat 15 mm from end) Countershaft Sub-shaft feed pipeO.D.(at 15 mm from end) Mainshattsealingring thickness (29mm and 35 mm) MainshaftbushingI.D. Mainshaftbushingl.D. Countershaft bushingl.D. Sub shattbushingLD. Mainshaftsealingring groovewidth ATFpump gearsideclearance ATFpump gear'tobody clearance Drive Driven ATFpump drivengearLD. ATFpump drivengearshaftO.D.

Regulator valve body

Sealing ring contact area l.D,

Stator shaft

Insideof diameteroI bearingcontactarea On torqueconvenerside On ATFpump side Reverseshittfork fingerthickness Parkingbrakepawl Parkinggear Shiftfork shattborel.D. Shiftfork shattvalvebore l.D.

Shiftingdeviceand parkingbrakecon' trol Servo body Differential carrier

Differential prnrongear

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- 0.157) 4.0010.156 4.05{0.158- 0.159) 4.1010.160 .161) 4 . 1 5( 0 . 1 6-2 0 . 1 6 3 ) 4.20(0.164 0.165) - 0.167) 4.2510.166 4.30(0.168- 0.169) 4 . 3 5( 0 . 1 7 0 - 0 . 1 7 1 ) 4.40(0.172 0.173) 4.45(0.174- 0.r75)

2.95 2.434.9s2 . 9 3-

3 . 0 5( 0 . 1 1 6 0 . 1 2 0 ) 2.50(0.096- 0.098) 5.00(0.195- 0.197) 3 . 0 0( 0 . 1 1 -5 0 . 1 1 8 1

Wearor damage

83.339 83.365(3.2810 3.2821) - 2.6259) 66.685- 66.698(2.6254 8.97- 8.98 (0.353- 0.354) 5.97 5.98{0.2350- 0.2354) - 0.3142) 7.97- 7.98(0.3138 - 0.3142) 7.97,7.98 (0.3138 1.87- 1.97(0.074-0.078)

Wearor damage Wearor damage 8.95(0.352) 5.95(0.234) 7.95(0.313) 7.95{0.313) 1.42$.O72)

- 0.2374) 6.018- 6.030(0.2369 - 0.3549) 9.000- 9.015(0.3543 8.000- 8.022(0.3150-0.3158) 8.000- 8.022(0.3150 0.3158) 2.025- 2.075(0.0797 0.0811) 0.03- 0.05(0.001- 0.002) 0.1050 0.1325(0.004,0.005) - 0.002) 0.0350- 0.062510.001 14.016*14.034(0.5518 0.5525) 13.980- 13.990{0.5504 0.5508) - 1.3782) 35.000 35.025{1.3780

5.045(0.2380) 9.03(0.356) 8.03(0.316) 8.03(0.316) 2.095(0.082)

2't.o00 27.021I '1.063, 1.064) 2 9 . 0 0-0 2 9 . 0 1 3 1 1 . r 4 117. 1 4 2 2 )

Wearor damage Wearor damage 5.40(0.213)

5.90- 6.00{0.232,0.236)

I I

I

Wearor damage

t

I Wearor damage

0.0710.003) Wearor damage Wearor damage 35.050(1.3799)

lWear

or otherdefect

Carrierto driveshaltclearance Carrier-to-intermediate shaftclearance

- 0.5516) 14.000- 14.010(0.55' l2 - 1.4582) 37.000- 37.039(1.4567 '18.010 - 18.02810.709 - 0.710) 0.023- 0.057{0.001- 0.002} - 1.0254) 26.025- 26.045(1.0246 28.025- 28.045(1.103- 1.104) 0.045- 0.08610.0020.003) 0.075- 0.11110.003-0.004)

Backlash t.D. Piniongear'to-pinion shaftclearance

- 0.006) 0.05- 0.15(0.002 - 18.066 - 0.7113) (0.7103 18.062 - 0.0037) otu to.oout 0.055- 0.09510.0022

PinionshaftcontactareaLD. Carrierto-pinion shaftclearance Driveshafvintermediate shaftcontactare l.D.

S e t r i n g - t o - b e a r i n go u t e r r a c e c l e a r a n c e

Transfer

SERVICELIMIT

3.974.024 . 0 74 . 1 24.17 4.224.274.32 4.374.42-

Diameterof rollerbearingcontactarea Transfershaft(transfergearside) Transfershaft(middleof shaft) Transferdrive gear Transferdrivengearshaft{drivengearside) Transferdrivengearshaft{splinedside) Transfergearbacklash TotalstartingtorqueN.m (kgf.cm,lbf.in)

2WD 4WD

37.045(1.4585) 0.r {0.004) 0.12(0.005) 0.15(0.006)

0 0.15(0- 0.006)

Adjust

38.485 38.500(1.515- 1.516) - 1.102) 27.917- 21.990 |.1.101 40.002- 40.018(1.575- 1.576) 35.002 35.018(1.378- 1.379) 26.975 26.988(1.062-' l.063) 0.060 0.160(0.002- 0.006) 2.64- 3.41 - 35.4,23.1 30.71 127.3

3 8 . 4 3( 1 . 5 1 3 ) 27.92(1.099) 39.95(1.573) 34.95(1.376) 26.92(1.060) Adiust Adiust

(cont'd)

2-9


Standardsand ServiceLimits Automatic Transmission(cont'dl - Section 14 STANDAROINEWI MEASUREMENT Wire Dia. Springs

Regulator valvespringA Regulator valvespringB Statorreactionspring Modulatorvalvespring Torqueconvenercheckvalvespring '97 model '98 - 00 models Coolerreliefvalvespring Reliefvalvespring 2nd orilicecontrolvalvespring 1-2shittvalvespring 2 3 shiftvalvespring 3-4shiftvalvespring 1staccumulator spring 4th accumulator springB 4th accumulator springA 2nd accumulator springA 3rd accumulator springA 2nd accumulator springB 3rd accumulator springI 3rd sub accumulator spring 2nd accumulator springC Lock-upshiftvalvespring Lock-uptiming valvespring Lock'upcontrolvalvespring 3'4 orificecontrolvalvespring Servocontrolvalvespring CPBvalvespring 4th exhaustvalvespring

o.D.

Fiee Length

1 . 81 0 . 0 7 1 ) 1 . 8i 0 . 0 7 1 ) 4 . 5( 0 . 1 7 7 ) 1.4{0.055)

14.7(0.579) 9.6 (0.378) 35.4{1.394} 9.4 (0.370)

87.8(3.457) 44.011.1321 30.31r.193) 35.0{1.378)

1.1(0.043) 1.2(0.047) 1.0(0.039) 1 . 1( 0 . 0 4 3 ) 0.7 (0.028) 0.9 (0.035) 0.9 (0.035) 0.9 (0.03s1 2.1 (0.083) 2.3 (0.091) 2.6 (0.102) 2.410.094) 2 . 8( 0 . 1 1 0 ) 1.6(0.063) 2.1(0.083) 2.7{0.r06) 2.2lO.OA7) 0.9 (0.035) 0.9 (0.035) 0.7 (0.028) 0.6 (0.024) 1.0(0.039) 0.9 (0.035) 0.9 (0.035)

8.4 (0.331) 8.4 (0.331) 8.4 (0.331) 8.6(0.3391 6.6(0.260i 7.6{0.299} 7.6{0.299) 7.6{0.299) 16.0(0.630) 10.2to.402l 17.0(0.669) 29.0\1.1421 'r7.510.689) 9.0 (0.354) 3 1 . 0( 1 . 2 2 0 ) 17.0(0.669) 14.510.571) 7.610.299i 8 . 1{ 0 . 3 1 9 } 6.6(0.260) 6.6(0.260i 8.1(0.319) 8.1{0.319) 6.t (0.240)

36.4{1.433) 32.4tl.216J 3 3 . 8{ r . 3 3 1 ) 3 7 . 1( 1 . 4 6 1 ) 34.8(1.370) 41.3(1.626) 57.0 (2.2441 57.0 12.2441 89.1(3.508) 5 1 . 6( 2 . 0 3 1 ) 88.4(3.480) 39.011.s35) 94.313.713) 20.710.8r5) 38.2(1.504) 39.0(1.535) 68.0(2.677) 73.7 12.902) 8 r . 4( 3 . 2 0 5 ) 38.0fl.496) 37.9(1.492) 5 2 . 1( 2 . 0 5 1 ) 41.2 t\ .A5Al 36.4(1.4331

Differential (4WDl * Section 15 MEASUREMENT

STANOABD{NEW' 1 . 2( 1 . 3 1, . 1 )a t o v e r h a u l 1 . 0( 1 . 10, . 9 1a t f l u i dc h a n g e

Capacity f (US qt, lmp ql)

Steering

Section 17 STANDARD INEWI

MEASUREMENT Steeringwheel

Gearbox

Pump

playat steeringwheelcircumference Rotational Staningloadat steeringwheelcircumference N {kgf,lbl) Enginerunning Angleof rack$uide-screw loosenedlrom lockedposition '97, '98 models '99, '00 models Pumppressurewith shut off valveclosed kPa (kgvcm,,psi)

Powersteering fluid

Recommended tluid Fluidcapacity I {USqt, lmp q0

Powersteering belt*

Deflection with 98 N {1Okgl,22lht) betweenpulleys Belttension N {kgt,lbf} Measuredwith belttensiongauge

0 - 1 0( 0- 0 . 3 9 ) 29 (3.0,6.6) 10"1 5" 20" MAX. 6,900- 7,800(70 80,995 1,138)

Hondapowersteeringfluid. For overhaul 0.85(0.90,0.75) For reservoir 0.4{0.42,0.35) 11.0 14.5(0.43 0.57)withusedbelt 7.5- 10.0(0.30 0.40)with new belt 390- 540(40- 55,88 - 121)with usedbelt 740-880 (75 90, 165 198)withnew belt

* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off. Readjustdellectionor tensionto usedbeltvalues.

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2-10

No. of Coils

r 1.0 1.9 10.9 12.O 12.7 8.2 13.4 22.0 26.4 26.8 13.8 14.2 2.9 15.9 2.6 6.3 32.0 47.A 20.8 '18.3 '19.5


Unit of length:mm {in)

Suspension Section18

STANDARD{NEW)

MEASUREMENT Wheelalignment

Front Rear Front Front near Inwardwheel Outwardwheel

Camber Caster Totaltoe Frontwheelturningangle

Wheelbearing

E n dp l a y

Rim runout

Front Rear Aluminumwheel

Axial Badial Axial Radial

Steelwheel

0"00'1 1' - 1"00'1 1' 2"10'! 1" 0J3(011/8) r N2 r i ( 1 / 1 6 11 / r 6 ) 37"00'! 2 31'30'(Referencei 0 - 0.05{0- 0.002} 0 - 0.05(0 0.002i STANOARD(NEW) 0 - 0.7 (0 0 , 0 . 7 ( 00 1.0(0 0 - 1.0{0 -

0.03) 0.03) 0.04) 0.04)

SERVICELIMIT 2.0(0.08) 'r.5 {0.06) 2.0{0.08) 1.s(0.06)

Brakes Sec'tion 19 STANDARDINEWI

MEASUREMENT Parkingbrake lever Footbrakepedal

To be lockedwhen Dulled:2 - 6 notches

Playin strokeat 196N (20kgf,44lbf) leverforce Pedalheight(withtloor mat removed) NT Freeplay

Mastercylinder Discbrake

tl o

Piston-to-pushrod clearance Front

Discthickness

Front Front Front

Discrunout Discparallelism Padthickness Rearbrakedrum

'97,'98 models '99,'00 models

LD. Liningthickness

Air Conditioning

155(6 1/8) 1 6 1( 6 5 / 1 6 ) 1 5 (1/16- 3/16) 0 - 0.4(0- 0.02) STANDARD{NEW' 22.9- 23.1(0.902- 0.909) 23.6 23.8(0.929- 0.937) 10.5- 11.5(0.4' t 0.45) 2r9.9 220.0(8.657- 8.661) 3 . 9- 4 . 5( 0 . 1 5- 0 . 1 8 )

Compressor (KEIHIN)

Compressor belt*

221.O8.7011 2.0(0.08)

Section 22 STANDARD {NEWI

MEASUREMENT Air conditioning

SERVICE LIMIT

21.0(0.83) 21.0(0.83) 0.10{0.004) 0.015(0.0006) 1.6(0.06)

Lubricanttype: KEIHINSP 10 (P/N38897- Pl3 - A01AHor 38899P l 3- A 0 1 ) Condenser Lubricantcapacity Evaporator mf {floz, lmp oz) Lineor hose Receiver

25 (5/6,0.9) 40 {1 1/3,1.4) 1 0{ 1 / 3 , 0 . 4 ) 10(.]/3,0.4)

Lubricant type:SP 10 Lubricantcapacity ml ({l 02,lmp oz} Stator coil resistanceat 68'F (20"C)O plate clearance Pulley-to-pressuae Deflection with 98 N (10kgl,22lbli betweenpulleys Belttension N (kgf,lbf) Measuredwith belttensiongauge

130'3'{41fi'3o,4.6;"} 3.05- 3.35 0.51 0.15(0.021 0.006) 7.5- 10.5{0.30- 0.41)with usedbelt 5.0- 7.0(0.20- 0.28)with new belt 3 9 0- 5 4 0( 4 0 5 5 , 8 8 - 1 2 0 ) w i t h u s e d b e l t 740- 880 {75 90, 170- 200)with new belt

* When usinga new belt,adjustdeflectionor tensionto new values.Runthe enginefor 5 minutesthen turn it off. Readjustdeflectionor tensionto usedbeltvalues.

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2-11


DesignSpecifications ITEM DIMENSIONS

WEIGHT(USA) WEIGHT(CANADA) ENGINE

METRIC

Overalllength Overallwidth Overallheight Wheelbase Track

Front Rear

Seatingcapacity Grossvehicleweightrating(GVWR) Grossvehicleweightrating(GVWR) Type Cylinderarrangement Bore and stroke Displacement Compression ratio

'97,'98mooers '99,'00 models

Lubricationsystem Oil pump displacement at 6,000enginerpm Waterpump displacement at 7,600enginerpm Fuelrequired Type Normaloutput Nominalvohage Hourrating Directionof rotation Weight CLUTCH

Clutchtype

MIT

Clutchlacingarea Transmission type

MIT

TRANSMISSION

MIT

PrimaryredLrction Type 1st 2nd 3rd 4th 5th Reverse

Finalreduction

Geartype Gearratao

Transfer Type

Transfer

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2-12

3.500 1.956 1.344 1.071 0.812 3.000*,.3.461*' Single helicalgear 4.562

0.434

Reardifferential

Finalreduction

4 , 1 6 5t b s | 1,900kg Water-cooled,4-strokeDOHC gasolineengine Inline4-cylinder, transverse 84.0x 89.0mm 3.31x 3.50in .1,973 cm3(m{) 1 2 0c u - i n 9.2 9.6 Beltdriven,DOHC 4 valvesper cylinder Forcedandwet sump,trochoidpump 501 (53 US qt,44 lmp qt)/minute 1401(148US qt, 123lmp qt)/minute gasoljnewith 86 UNLEADED PumpOctaneNumberor Higher gearreduction Planetary A/T:1.1kW M/T: 1.0kW 12V 30 seconds Clockwiseas viewedfrom gearend 3.7kg 8.2 lbs Singleplatedry, diaphragmspring Torqueconverter 203cm, 31.5sq-in Synchronizeds-speedtorward, 1 reverse Electronically controlled 4-speedautomatic,1 reverse Direct I : 1

Approx.

Manualtransmission

Gearratio

Gearratio

NOTES

1 7 7 . 6i n 68.9in 63.3in 1 0 3 . 2i n 60.4in 60.4in 5lf

Valvetrain

STARTER

ENGLISH

4 , 5 1 0m m 1,750mm 1,608mm 2,622mrn 1,533mm 1,534mm

1st 2nd 3rd 4th Reverse Geartype Gearratio

2.533 Automatictransmission 2.722 1.079 0.711 1.955 Singlehelicalgear 4.357

0.393

*1: '97- 99 models *2: '00 model


ITEM AIR CONDITIONING

Compressor

-Condenser Evaporator Blower

-

METRIC

Cooling capacity

Type/manutacturer No. of cylinder CaPacity Max.speed Lubricantcapacity Lubricanttype Type Type Type Motor input Speedcontrol Max.capacity

ENGLISH

NOTES

j 14,000BTU/h 3,520Kcal/h Scroll/KElHlN 85.7mf/rev

| 5.23cu'in/rev 10,000rpm algIloz 130mf 1 sP-10 fin Corrugated Corrugated fin Siroccofan

200w 112v 4-Speeo 15,500 cu fvh

440 m3/h

Temperature control Compressor clutch Befrigerant

Type Powerconsumption Type Ouantity

STEERING SYSTEM Type Overallratio Turns, lock to lock Steeringwheeldiameter SUSPENSION

Type

Front Bear

Shockabsorber WHEEL ALIGNMENT Camber

Tvpe

Front hear Front Front Rear Front

Pad surface area Lining surfacearea P a r k i n gb r a k e

Rear Front Rear Tvpe

Caster Totaltoe

BRAKESYSTEM

TIRE ELECTRICAL

Frontand Rear

Sizeand pressure Baftery Starter Alternator In under-dash fuse/relaybox In under hood fuse/relaybox In underhoodABSfuse/relay box Headlights Frontturn signallights Frontparkinglights Frontsidemarkerlights Rearsidemarkerlights Rearturn signallights Erake/parkinglights Back-uplights Ceilinglights{fronvrear) Licenseplatelight Spotlights Highmountbrakelight lgnitionkey light Ashtraylight Gaugelights Indicatorlights lllLrmination and pilotIights Heaterilluminationlights

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Dry,singleplate,poly-V-belt drive 40 W max./12V HFC-134a 1R-134a) 24j anoz zoo o' g Powerassisted,rackand pinion

At 68'F (20 C)

Independent doublewishbone,coil spring with stabilizer Independent doublewishbone,coil spring with stabilizer hydraulicnitrogengas tilled Telescopic,

0' - r"00' 2.10' 0mm 0in l n 1 / 1 6i n ln2mm Power-assisted selt-ad,usting ventilateddisc Power assistedself-adiustingdrum 49 cm, x 2 7.6sq-inx 2 7 3 c m ,x 2 1 1 . 3s q - i nx 2 reartwo wheelbrakes Mechanical actuating, Seetire inlormationlabel.

Drum brake

12V, 36 AH/sHR 1 2 V 1 . 0 ,1 . 1k W 12V 100A 7.5A, 10A, 15A, 20 A 7.5A, 10A, 15A, 20 A, 30 A, 40 A '100A 7 . 54 , 2 0 A . 4 0A 12V 60/55W 12V- 21 W ('97model), 1 2V - 2 7W ( ' 9 8 - 0 0m o d e l s ) 12V 5 W {'97model),3CP('98- 00 models) 12V-8W 1 2V , 3 C P 12V-21W 12V 2115W 1 2 V 2 1C P( 1 8W ) 12V-8W 12V-8W 12V-5W 1 2 V- 2 1 W 1 2V - 1 . 4W 1 2 V 1 . 4W 1 2V 1 . 4W , 3 W , 3 . 4W 1 2 V - 0 . 8 4 W ,1 . 1 2W , 1 . 4W , 3 W , L E D 12V - 0.84W, 1.4W, LED 1 2V , 1 . 4W

2-13


Body Specifications U n i t :m m ( i n )

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2-14


Maintenance ............3-2 Points Lubrication MaintenanceSchedulefor 1997Model (NormalConditions) ...".3-4 Schedulefor 1997Model Maintenance (SevereConditions) ."...3-6 Schedulefor 1998- 2000Models Maintenance (NormalConditionsl ..'."3-8 Schedulefor 1998- 2000Models Maintenance (severeConditionsl '....'3-10

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LubricationPoints

Forthe detailsof lubricationpointsand type of lubricantsto be applied.referto the illustratedindexand variouswork procedures(suchas Assembly/Reassembly, Replacement, Overhaul,Installation, etc.)containedin eachsection. NO.

LUBRICATION POINTS Engine

Transmission

Manual

2

3

Automatic Reardifferential Brakeline(includesABS line) ClutchLine

6

Shift lever pivots (Manual transmission)

1

Release fork (Manualtransmission)

10 l1 12 14 16 17 18 19 20 21 22 23 24

GenuineHondaMTF*1 GenuineHondaPremiumFormulaAutomaticTransmission Fluid (ATF)*' GenuineHondaCVTFluid

4 5

I

LUBRICANT gradeoil.The oil APIServiceGrade:UseSJ "EnergyConserving" containermay alsodisplaythe APICertitication sealshown "For below.Makesure it says GasolineEngines."SAEvjscosity: Seechartbelow.

Power steeringgearbox

GenuineHondaDOT3 BrakeFluid*3 Brakefluid DOT3 or DOT4*3 Greasewith molybdenumdisultide - PYs- 305 LJrea GreaseUM264P/N4'1211 SteeringgreaseP/N 08733- B070E

T h r o t t l e c a b l e e n d { D a s h b o a r dl o w e r p a n e l h o l e l

Siliconegrease

Throttlecableend (Throttlelink) Brakemastercylinderpushrod Pedallinkage Batteryterminals F u e l f i l ll i d Clutchmastercylinderpushrod Hoodhingesand hood lock Tailgatehinges Hatchglasshinges Doorhinges,upperand lower Dooropeningdetent Caliper Pistonseal,Dustseal, Caliperpin, Piston Shiltcableand selectcable{Manualtransmission) Brakeline ioints(Frontand rearwheelhouse) Powersteeringsystem Air conditioningcompressor

25

API SERVICELABEL

/,.*-G\

/.'z-\e\ t / 6 A

E \ l l-;-1 5w-30/---l

w

SEAL API CERTIFICATION

ffi

Multi purposegrease

HondaWhiteLithiumGrease

Silicone grease

Rustpreventives GenuineHondaPowerSteeringFluid-. Compressor oil: SP 10 lP/N38897- P13- A0lAH or 38899-P13-A01) For Refrigerant: HFC134a(R,134a)

Recomm6ndedEngine Oil Engine oilviscosity for ambient temperature ranges

-20

0

20

-30 -20 .10

100'F

10 20 30 40'c 0 r1: Always use GenuineHonda Manual TransmissionFluid {MTF).Using motor oil can causestiffer shifting becauseit does not containthe orooeradditives. *2: Always use GenuineHondaPremiumFormulaAutomaticTransmissionFluid(ATF).Usinga non-HondaATF can affect shift qualitv. +3rAlways use GenuineHondaDOT3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of the system. *4: Always use GenuineHondaPowerSteeringFluid.Usingany other type of power steeringfluid or automatictransmission fluid can causedincreasedwear and poor steeringin cold weather.

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3-2


NOTE:Lubricateall hinges,latches,and locksoncea year. In corrosiveareas,more frequentlubricationis necessary. We recommendHondaWhite LithiumGrease.

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3-3


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3-11


EngineElectrical 4-2 ChargingSystem ............. SpeciafTools 4-22 ComponentLocationIndex ............ Starting System 4-23 ....................,........... Diagram 4-3 Circuit ComponentLocationIndex ............ 4-24 Troubleshooting.............................. 4-4 CircuitDiagram................................ 4-30 ..........,....... AlternatorReplacement ........... 4-5 StarterTest 4-31 AlternatorOverhaul.......,,................ 4'5 StarterSolenoidTest ...................... .........4-32 RectifierTest 4-7 StarterReplacement....................... ........... 4-32 Inspection Alternator Brush 4-7 FieldWindingTest ........................... 4-33 4-8 RotorSlip RingTest ........................ StarterOverhaul............................,. 4-33 ............. Stator Test 4-9 BrushInspection...........................,., Alternator Belt Inspectionand OverrunningGlutchInspection ......4-9 ........4-34 Adiustment Armaturelnspectionand Test ........4-10 GruiseControl 4-12 BrushHolderTest ............................ 4-36 ComponentLocationIndex .,,,........ 4-12 StarterReassemb|y......................... 4-37 CircuitDiagram................................ 4-13 PerformanceTest ............................. 4-38 ControlUnit InputTest ................... lgnition System Main Switch Test/Replacement.....4-40 4-14 ComponentLocationIndex ............ Set/ResumeSwitch Test/ 4-15 CircuitDiagram................................ 4'40 Replacement.......................,........ lgnition Timing Inspectionand ....,,., 4-41 Actuator Test 4-16 Setting .......................................... 4-42 Actuator Replacement...............,.... 4-17 ........,........ DistributorReplacement 4-43 Actuator CableAdiustment ............ 4-18 DistributorOverhaul.............,,......... 4-43 ClutchSwitchTest .......................... lgnition Control Module (lCM)Input 4-44 .......... SwitchTest .................. T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , .4.-. 1 . .9. . . . . . . . .Brake .. ...,. 4-44 Test .............. Actuator Solenoid 4-2O fgnitionCoilTest .............................. 4-45 ActuatorDisassembly..................... lgnition Wire Inspectionand 4-20 Test ............................................... 4-21 SparkPlugInspection.....................

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-

+

ENGINE


SpecialTools

Ref. No.

Tool Number

o -o o

A973X- 041 XXXXX 0 7 J G G- 0 0 1 0 1 0 A 07PAZ- 0010100

Description

Oty

VacuumPump/Gauge, 0 30 in.Hg. BeltTensionGauge SCSServiceConnector * Includedin the BeltTensionGaugeSet,T/N 07JGG- 0010004

o

I

PageReference 4-41 434 4-16

@

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4-2


StartingSystem ComponentLocationIndex

CLUTCHINTERLOCK

swtTcH{M/T) BATTERY Test,section23

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Test,page 4-43 Switchpositionadiustment, section12

A/T GEARPOSITIONSWITCH{A/T} Test,section14 Reolacement. section14

Test,page4 5 SolenoidTest,page4-6 Replacement,page 4-7 Overhaul,page4 8 page4-12 Reassembly, PerformanceTest,Page4-13

4-3


StartingSystem CircuitDiagram IGNTION SWITCH

UNDER.HOOD FUSE/RELAY 8OX N0.41(100A)

N0.42(40A)

-+o

/ BAI

\i7

\

cf-.|

I

BLKMHT

II I

t

l

ELKMHT

BLK'WHT

t

IGNITIONCONTROL MOoULE ( CM)

l

STARTEF CUl RELAY

-.1

GRY

BLKRED

GRN

I

I PosrroN! I A/TGEAR (A/T) | i swrTcH ll \/ o N E o r N \ | !--

p . s i t o n/ : -_ --___J

f';--"-l I TNTERLooK I

fYl""yl, I

8LK

STARTEB (Fieldwndnglype)

Gl0l

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4-4


StartingSystem Starter Test NOTE: The air temperaturemust be between 59 and '100'F(15and 38"C)beforetesting. RecommendedProcedure: . . .

Usea stanersystemtester. Conneca t 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.

.

4. Unplug the connector(BLK /VHTwire and solenoid terminal)from the starter. 5 . Connecta jumper wire from the bafterypositive(+) terminalto the solenoidterminal. The startershouldcrankthe engine.

Alte.nate Procedure: .

Checkthe battery, battery positivecable, ground. stanercut relay,and the wire connectionsfor loosenessand corrosion.Testagain. lf the staner still does not crank the engine,go to step 4.

Usethe followingequipment: - Ammeter,0 - 400A - Voltmeter,0 - 20 V (accurate within 0.1volt) T a c h o m e t e r ,-01 , 2 0 0r p m Hookup a voltmeterand ammeteras shown.

NEGATIVETERMINAL

NOTE: After this test, or any subsequentrepair. reset the ECM/PCM to clearany codes(seesection11).

. .

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 startercranksthe engine,go to step6.

Checkthe Starter Engagement: '1. Removethe No. 44 (15A) fuse from the under-hood fuse/relaybox. 2.

Turn the ignitionswitchto START(lll)with the shift lever in E or E position (A/T) or with the clutch pedaldepressed{M/T).The startershouldcrankthe e n gi n e . . .

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lf the starter does not crank the engine, go to step3. lf it cranksthe engineerraticallyor too slowly,go t o " C h e c kf o r W e a r a n d D a m a g e "o n t h e n e x t page.

6 . Checkthe ignitionswitch(seesection23). 7 . Checkthe startercut relay{seesection23}. 8. Checkthe IVT gear position switch (A/T)or the clutch interlockswitch (M[). Checkfor an open in the wire betweenthe ignition switchand starter.

(cont'd)

4-5


StartingSystem StarterTest (cont'dl

Starter Solenoid Test

Checklor Wear and D8mage T h e s t a r t e rs h o u l dc r a n kt h e e n g i n es m o o t h l ya n d s t e a d i l y l.f t h e s t a n e re n g a g e s b, u t c r a n k st h e e n g i n e erratically,removeit, and inspectthe starterdrive gear and torque converterring gear or flywheelring gear for oamage.

1.

Checkthe drive gear overrunningclutchfor binding or 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 d r i v e gear held.lf damaged,replacethe gears.

Checkthe hold-incoil for continuitybetweenthe S t e r m i n a la n d l 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 continuity. STARTER

B TERMINAL MOUNTINGNUT 9 N.m 10.9kgtm, 7 tbtftl

CheckCrankingVoltage and Current Draw Crankingvoltageshouldbe no lessthan 8.7 volts on Ay'T models,and 8.0volts on M/T moders. Currentdraw should be no more than 230 ampereson A,/Tmodels,and 200ampereson M/T models. lf crankingvoltageis too low, or currentdraw too high, checkfor: . deador low battery. a 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. . excessivedrag in engine. CheckCrankingrpm Enginespeedduringcrankingshouldbe above 100rpm. lf speedis too low, checkfor: a loosebafteryor starterterminals. . excesslvely worn stanerbrushes . opencircuitin commutatorsegments. . dirty or damagedhelicalsplinesor drivegear. a defectivedrive gearoverrunningclutch. CheckStarter Disengagement With the shift lever in @ or @ position(A,iT)or with the clutchpedaldepressed{M/T).turn the ignitionswitchto START(lll).and releaseto ON (ll). The starterdrive gear shoulddisengagefrom the torque c o n v e r t e rr i n g g e a r o r f l y w h e e l r i n g g e a r w h e n y o u releasethe key. lf the drive gear hangs up on the torque converterring gearor flywheelring gear,checkfor . solenoidplungerand switchmalfunction. . dirty drive gear assemblyor damaged overrunning clutch.

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4-6

TERMINAL

ARMATURE HOUSING (GROUND}

BLK/WHT WIRE 2.

Checkthe pull in coil for continuitybetweenthe S and M terminals.The coil is OK if thereis continuity.


StarterReplacement

Field Winding Test

1 . Disconnectthe battery negativecable.

t.

Disconnectthe startercablefrom the B terminalon the solenoid. then disconnectthe BLK/WHTwire from the S terminal. B TERMINAL MOUNNNG NUT I N.m (0.9kgl.m,

Checkfor continuitybetweenthe brushes.lf there's no continuity,replacethe armaturehousing, Checkfor continuity between each brush and the a r m a t u r eh o u s i n g{ g r o u n d ) l. f t h e r e i s c o n t i n u i t y . replacethe armaturehousing.

STARTER ERUSHES

7 rbtftl

RE

l0 x 1.25mm 4,1N.m {4.5 kgf.m, 33 tbt.ftl 5.

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.

4.

I n s t a l l i n t h e r e v e r s eo r d e r o f r e m o v a l . W h e n i n s t a l l i n gt h e s t a r t e r c a b l e , m a k e s u r e t h a t t h e crimpedside ofthe ring terminal is facing out, Crimpedside of ring terminal

TERMINAL

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Connectthe batterypositivecableand negativecable to the batterv.

4-7


Starting System Starter Overhaul STARTERSOLENOID

STARTER SOLENOID Test,page4 6 OVEBRUNNING CLUTCH

w ARUSH

-6^l MOLYBDENUM DISULFIDE

SPRINGCLIP Replace. BBUSHHOLDER Test,page4-12 GEARHOUSING ARMATURE HOUSING

ARMATURE Inspection and Test.page4-10 ENDCOVER

BAUSH InsPeclon,page4-9

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4-A

..'...:|@{ MOLYBDENUM DISULFIDE


BrushInspection

ClutchInspection Overrunning

Measurethe brush length.lf it is not within the service limit, replacethe brush(or brushholderassembly).

1.

2. Brush Lsngth Standard{Newl:14.0- I'1.5mm (0.55- 0.57inl ServicoLimit: 9.0 mm (0.35in)

Slidethe overrunningclutchalongthe shaft.Doesit move freely?lf not, replaceit. 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,reDlaceit.

BRUSH

NOTE:To seat new brushesafterinstallingthem in their holders.slip a strip of #500or #600sandpaper,with the grit side up, over the commutatorand smoothly rotate the armature.The contactsurfaceof the brusheswill be sandedto the samecontouras the commutator.

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3.

lf the starterdrive gear is worn or damaged,replace t h e o v e r r u n n i n gc l u t c ha s s e m b l yt;h e g e a r i s n o t availableseparately. Checkthe conditionof the torqueconverterring gear or the flywheel ring gear if the starter drive gear teethare damaged.

4-9


StartingSystem ArmatureInspectionand Test 1.

I n s p e c t h e a r m a t u r ef o r w e a r o r d a m a g ed u e t o contact with the field winding. lf there is wear or damage.replacethe armature.

3.

C h e c kt h e c o m m u t a t o rd i a m e t e r .l f c o m m u t a t o r d i a m e t e r i s b e l o w t h e s e r v i c el i m i t , r e o l a c et h e armalure. Commutator Diameter Standard(Newl:27.9- 28.0mm (1.09- 1.10in) ServiceLimilr 27.0mm (1.06inl

lnspectfor damage.

Checkthe commutatorsurface.lf the surfaceis dirty or burnt,resurfacewith emery cloth or a lathewithor reconditionwith in the tollowing specifications, #500or #600sandDaoer.

4.

Measurethe commutatorrunout. 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 brasschipsbetweenthe segments. lf the commutator runout is not within the service limit, replacethe armature. CommutatorRunout Standard(Newl:0 - 0.02mm (0 - 0.0008in) ServiceLimit: 0.05mm {0,002inl

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4-10


I

5.

Checkthe mica depth. lf necessary,undercutthe mica with a hacksawbladeto achieveproperdepth. l f t h e s e r v i c el i m i t c a n n o tb e m a i n t a i n e dr,e D l a c e the armature.

7.

Placethe armature on an armaturetester. Hold a hacksawbladeon the armaturecore.

NOT GOOD

MICA DEPTI{

Commutator Mica Depth Standard (Nsw): 0.5 - 0.8 mm 10.02- 0.03 inl ServicoLimit: 0.2 mm (0.008in) 6.

Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuit exists betweenany segments.replacethe armature.

lf the bladeis attractedto the core or vibrateswhile the core is turned.the armatureis shorted.Replace the armature. 8.

COMMUTATOR

With an ohmmeter,checkthat no continuityexists betweenthe commutator and armature coil core, and betweenthe commutatorand armatureshaft.lf there is continuity.replacethe armature,

cotLcoRE

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4-11


StartingSystem Starter Reassembly

Brush Holder Test 1.

Checkthat there is no continuitybetweenthe O and O brush holders.lf there is continuitv,replacethe brushholderassembly.

O BRUSHHOLDER

NOTE:Use the illustrationon page 4I as referencefor reassemDty. 1.

Pry backeachbrushspringwith a screwdriver, then positionthe brush about halfwayout ol its holder, and releasethe springto hold it there.

2.

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.

@ BRUSHHOLDER

Insertthe brushinto the brushholder,and bring the brush into contactwith the commutator,then attach a springscaleto the spring.Measurethe springtension at the momentthe spring liftsoff the brush.

-

E ^

F*4#-@ 6t ta

al

la

tl l l ft

SPRINGSCALE

3.

SpringTension:13.7- 17.7N (1.40- 1.80kgf, 3.09- 4.00lbf)

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4-12

I n s t a ltlh e e n dcovero n t h e b r u s hh o l d e r .


,r

?

Test Performance 1.

Disconnect the wire from terminalN4.

5.

Disconnectthe battery also from the body. lf the pinion retractsimmediately,it is working properly, To avoiddamagingthe starter,do not leavethe batterv connectedfor more than 10 seconds.

6.

Clampthe starterfirmly in a vise.

7.

Connectthe starter to the battery as describedin t h e d i a g r a m b 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.

8,

lf the electric current and motor soeed meet the when the batteryvoltageis at 11.5V, specifications the starteris workingproperly.

M a k e a c o n n e c t i o na s d e s c r i b e db e l o w u s i n g a s heavy a wire as possible(preferablyequivalentto the wire usedfor the vehicle). 3.

Connectthe batteryas shown. lf the starterpinion pops out. it is working properly.To avoid damaging the starter,do not leavethe batteryconnectedfor more than 10 seconds.

@

o

12V BATTERY

ie

Disconnectthe batteryfrom the M terminal. lf the pinion does not retract,the hold-in coil is working p r o p e r l y .T o a v o i d d a m a g i n gt h e s t a r t e r ,d o n o t leavethe batteryconnectedfor more than 10 sec onds.

Specifications: Maker DENSO

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Electriccurrent 90 A or less

Motor speed 3,000rpm or more

4-13


lgnition System ComponentLocationIndex IGNITIONTIMINGCONTROLSYSTEM . ldle speedInspection/Adjustment, section11 . Inspectionand Sening.page4-16

SERVICECHECKCONNECTOR(2P) lwi.c colo6: BRNrnd BLKI

TESTTACHOMETER

SPARKPLUGS page4-21 Inspection, DISTRIBUTOR page4-17 Replacement, Overhaul,page4-18 lgnitionCoilTest,page4,20 lgnitionControlModule CM) InputTest,page4,19

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4-14

WIRES Inspection and Test,page4-20


CircuitDiagram IGNITON SWTCH

UNDEF.HOOD FUSE/RELAY 8OX

UNDEF,DASH FUSEiRELAYBOX

6\ l;;l i{Hr6-(-\9-'-'*'.--EII

Eci,.pcM

' i Vl

BLK/YEL

l^

IGNITION cotL

IGN]TION CONTROL MODULE (CM) / Hasbuil-if\ I no|se l

TDCTopdeadcenler poslion CKP Cran[shan C Y PC y l n d epro s r l o n TDC/CKP/CYP SENSOR

l-- r

f

IGNTION W]BES

i l ' i - - ,l l i f r BLU

I

IJltfi --cMFcr,r

SPARK PLUGS

I

BLU BLU

l l / ' i |

| I

I I

resr

TACHOMETER

tott"to*

LTTCHoMEIEB '97-'98 models

j

I I l: www.emanualpro.com

'99- 00models

Gt01

4-15


lgnition System lgnition Timing Inspectionand Setting 1.

Checkthe idle speed,and adjustit if necessary(see section11).

2.

Pull out the servicecheckconnector2P (BRN and BLKwires)from the connectorholderlocatedunder the dash on the front passengerside,then connect to the scs serviceconnector(P/N07PAz- 0010100) it.

6.

lf necessary,adjust the ignition timing as follows. Loosenthe distributormountingbolts,and turn the to distributorignition(Dl)housingcounterclockwise advancethe timing or clockwiseto retardthe timtn o , To RETARD

Startthe engine.Holdthe engineat 3,000rpm with no load (A/T in N or E, Mff in neutral)until the radiatorfan comeson, then let it idle. Connectthe timing light to the No. I ignitionwire, then point the light towardthe pointeron the timing belt cover. 5.

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. lgnitionTiming: M/T: 16"12" BTDC(RED)idling in neutral AlTt'16"!2" BTDC(RED)idling in E or E

MOUNTING BOLTS 24 N.m{2.4kgfm, 17lbtft} 7 . Tightenthe distributormountingbolts,and recheck t h e i g n i t i o nt i m i n g . 8.

CRANKSHAFT PULLEY

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4-16

Disconnectthe SCSserviceconnectorfrom the servicecheckconnector.


DistributorReplacement Removal: e o

5.

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.

R e m o v et h e m o u n t i n gb o l t s f r o m t h e d i s t r i b u t o r , then removethe distributorfrom the cylinderhead.

Connectthe ignitionwires to the distributorignition (Dl)cap as shown,

I'

CAMSHAFT END

No. 1 CYLINDER MARK

6.

Connectthe connectorto the distributor.

7.

Setthe ignitiontiming (seepreviouspage).

8.

After settingthe ignitiontiming, tightenthe mounting bolts.

BOLTS MOUNTING 8 x 1.25mm 17lbfftl 2,1N.m{2.,1kgrf.m,

lnstallation: 1.

Bringthe No. 1 pistonto compressionstrokeTDC.

2.

Coata new O-ringwith engineoil, then installit.

3.

Align the lug on the end of the distributorand its mating grooves in the camshaftend, then slip the distributorinto position. NOTE:The lug on the end of the distributorand its mating groovesin the camshaftend are both offset to eliminatethe possibilityof installingthe distributor 180oout of time.

4.

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Installthemountingbolts,and tightenthem lightly.

4-17


lgnition System Distributor Overhaul LEAK COVEN

CAPSEAL Checkfor damage.

DISTRIBUTOR IGNITIONIDII ROTOR IGNITION{DII CAP OISTRIBUTOR Checkfor cracks,wear, damage,and to!ling. Cleanor replace.

IGI{ITIONIDOHOUSING OISTBIBUTOR forcracks anddamage. Check

O.RING Replace.

b

IGNITIONCOIL Test, page 4 20

@_ IGNITIONCONTROL MODULE{ICMI InputTest,page4-19

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4-18.


lgnitionControlModule(lCMlInputTest NOTE: . See section11 when the malfunctionindicatorlamp ( M l L )c o m e so 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 atl e s t sf o r t h e ignitionsystemand the fuel and emissionssystems. . '97 -'98 models:The tachometershouldoperatenorm a l l yi f t h e I C Mi s O K .

Turn the ignition switch ON {ll). Checkfor voltage betweenthe BLK,^/EL wire and body ground.There shouldbe batteryvoltage. . .

lf there is no batteryvoltage,checkthe BLK/rEL wire betlveenthe ignitionswitchand the lclvl. lf there is bafteryvoltage, go to step 4.

L

Removethe distributorignition(Dl)cap,the distributor ignition(Dl)rotor,and the leakcover.

T u r n t h e i g n i t i o ns w i t c hO N ( l l ) .C h e c kf o r v o l t a g e betweenthe WHT/BLUwire and body ground.There shouldbe batteryvoltage.

2.

Disconnect the wiresfrom the lCM.

.

8LU WIRE '98 models} {'97 -

lf thereis no batteryvoltage,check: - ignitioncoil. - WHT/BLUwire betweenthe ICM and ignition corl. . lf thereis batteryvoltage,go to step5, '97 model: Disconnectthe ECM/PCM connectorA (32P)C . h e c kf o r c o n t i n u i t yo n t h e Y E L / G R Nw i r e betweenthe ICM and ECM/PCM.There should be continuity. '98 - 00 models: Disconnectthe ECM,PCM connector B (25P).Checkfor continuityon the YEUGRNwire betweenthe ICM and ECM/PCM.There should be continuity. Checkfor continuityon the YEUGRNwire to body ground.Thereshouldbe no continuity. 7 . Reconnect the ECM/PClvl connector. '97 -'98 models: Checkfor continuityon the BLU wire betweenthe test tachometerconnectorand the lCM.Thereshouldbe continuity. 9 . ' 9 7 - ' 9 8 m o d e l s :C h e c kf o r c o n t i n u i t yo n t h e B L U wire to body ground.Thereshouldbe no continuity. '10. lf all the

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testsare normal,replacethe lCM.

4-19


lgnition System lgnitionCoilTest

lgnition Wire Inspectionand Test

Using an ohmmeter, measureresistancebetweenthe terminals.lf the resistanceis not within sDecifications, replacethe ignitioncoil.

1 . C a r e f u l l yr e m o v et h e i g n i t i o nw i r e s b y p u l l i n go n the rubber boots.Do not bendthe wires;you might breakthem inside.

NOTE: Resistancewill vary with the coil temperature; specifications are at 68"F(20'C).

Checkthe conditionof the ignitionwire terminals.lf any terminalis corroded,cleanit, and if it is broken or distorted,replacethe ignitionwire.

Plimary Winding Resistance {Betweenthe A and B terminals): 0.6it- 0.77 0 SecondaryWinding Resistance {Betweenthe A and secondarywinding terminals): 12.8- 19.2kO

IGNITIONWIRE

e

Connectthe ohmmeter probesand measureresistance.

o

lgnition Wire Resistance: 25 kO max. at 68'F 120'Cl

TERMINALA {+l

IGNITIONWIRE 4.

4-20

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lf the resistance exceeds 25 kO, replace the ignition wire.


SparkPlugInspection Inspectthe electrodesand ceramicinsulatorfor:

2.

Checkthe electrodegaP. .

Adjustthe gap with a suitablegappingtool.

ElectrodeGap

I

. . . .

lmpropergap Oil-fouling Carbondeposits Crackedcenter electrodeinsulator

in) 1.1 3 ' mm (0.043Loo.

Standard

the plug if the centerelectrodeis rounded Replace as shownbelow: ROUNDEO ELECTRODE

,--, (--/ Burned or worn electrodesmay be causedby: . Advancedignitiontiming . Loosesparkplug . Plugheat rangetoo hot . Insufficientcooling Fouledplug may be causedby: . Retardedignitiontiming . O i l i n c o m b u s t i o cnh a m b e r . Incorrectsparkplug gap . Plug heatrangetoo cold . Excessive idling/lowspeedrunnang . C l o g g e da i r c l e a n eer l e m e n t . Deteriorated ignitionwires

| |

/ r--'--'--r

-.-l-:=---:1 : Spark Plugs '97 - '98 modsls:

Z F R 5 F - 1(1N G K ) (D KJ16CR-11 1E N S O ) '99 - 00 models; NGK) Z F R 6 F - 1( 1 (DENSO) KJ2OCR-111 Apply a small quantity of anti-seizecompound to the plug threads,and screwthe plugs into the cylinder head finger-tight.Then torque them to 18 N'm (1.8kgf.m.13lbf.ft).

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4-21


ChargingSystem ComponentLocationIndex CHARGINGSYSTEMLIGHT (ln the gaugeassembly) Test, page 4-24

BATTERY

Test,

ALTERNATOR Troubleshooting, page4-24 Replacement, page4-30 Overhaul,page4-31 RectifjerTest,page 4,32

4-22

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ALTERNATOR BELT Inspection and Adjustment,page4 34


CircuitDiagram BOX FUSUFâ&#x201A;¬tAY UNDES.HOOD BATTERY

(1Cr0A) N0.41

,-a\

(40A) N0.42 WHT/8tK

l.

( tot,o, )

Y

IGNITON SWITCH

8LI(YEL

GRN/RED

ECM/PCM

V I

WHT/RED

ALTERNATOR

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4-23


GhargingSystem Troubleshooting lf the chargingsystemlight does not come on or does not go off, or the batteryis dead or low, test the followingitems in the order listedbelow: 1. Battery(seesection23) 2. Chargingsystemlight 3. Voltage 4. Alternatorcontrolsystem(U.S.A.model) 5. Alternator/regulator ChargingSystem Light Test ChsrgingSystomLight Check: Turn the ignition switch ON {ll), and makesure the chargingsys tem lightcomeson.

Doesthe chargingsystem lightcome on?

Check for a blown No. 15 17.5Al fuse and a blown charging system light bulb. lf the tusa .nd bulb are OK, repair thâ&#x201A;Ź open in thâ&#x201A;Ź WHT/BLUwire.

I

I

Charging System Light Check {com'd}: Startthe engine.

I

Doesthe chargingsystem light go offf

Perform the Alte.nator/Regulator Test lsee page +281.

ALTERNATOR 4P CONNECTOR {U.S,A.modell

2

Voltage Check: Measurethe voltageat the No. I lNo.2iterminalof the 4P [3Plconnectorwith the ignitionswitch ON

(BLK/YEL)

3

Wiresadeof femaleterminals

{ ).

ls there battery voltage?

Ropair the open in the BLK/YEL wiae betwoen the altemator and under-da3hluso/relay box.

ALTERNATOR 3P CONNECTOR lCanedamodel'

Iemale terminals

(To next page)

[ ] : C a n a d am o d e l

4-24

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(Frompreviouspage)

in

Ch6ckthe L circuil: 1. Turnthe ignitionswitchOFF. 2. Disconnectthe 4P [3P] connectorfrom the alternator. 3. Turnthe ignitionswitchON (ll).

Doesthe charging system lightcomeon?

Repairthe short to ground in the WHT/BLUwire.

[ ]: Canadamodel

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(cont'd)

4-25


ChargingSystem Troubleshooting(cont'dl '97 modol:

Alternator Control System Test {U.S.A.model)

NOTE:Beforetesting,checkproperoperationofthe ELDby checkingfor a DTC(seesection.11). BATTERY Chockfor a short in the circuit IALTCline): 1. Disconnectthe 4P connector from the alternator. 2. Startthe engine,and turn the headlights thigh beamiON. 3. Me8surevoltage between the 4 P c o n n e c t o tre r m i n a lN o . 2 and the positiveterminal of the battery.

CAUTION: Be sure to use a voltmeter with ils positive terminal connectedto battery positive and hs negative terminalto the 4P connectorterminal No. 2.

{WHT/GRNI ALTEFNATOR 4P CONNECTOR

Wiresideof femaleterminals

ECM/PCMCONNECTOR A I32PI

,/1./

lstherelVorless?

1 t4

./ l./

8

26 27 Check for an open in the wire (ALTClinel: 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF. 2. Disconnectthe 32P connector from the ECN4/PCM. 3. Checktor continuitybetween the EcM/PcM 32P connector terminalNo.30 and alternator 4P connectorterminalNo.2-

ls therecontinuity?

Râ&#x201A;Źprir short in the wire between the altornator and the ECM/PCM.

4-26

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2A 29 30

Wire side of femaleterminals

I

femaleterminals

21 32

] ALTC I tWHT/cRNl

tl

WHT/GRN)

1

ALTERNATOR irP CONNECTOR

Repairopen in the wi.e betwoen the atternatorand ECM/PCM.

ls therecontinuity?

Check for a shorl in the wiro IALTCline): 1 . T u r n t h e h e a d l i g hat n d i g n ; , I|on swrtcnUFF 2. Disconnect the 32Pconnector from the EcM/PcM. 3. Checktor continuitybetween the ECM/PCN4 32P connector t e r m i n a lN o . 3 0 a n d b o d y ground.

10

1 6 1 7 1 8 t9 20 21

ECM/PCMCONNECTOR A {32P} 4

,/ ,/

,/1,/

14

6 8 1 6 l 7 t 8 '19 20 21

10

27

:t2

2A 2S 30

Wire side of femaleterminals Subslitute a known-good ECM/ PCM,and recheck. It prescribedvoha96 b now available, replacethe original ECM/ PCM.

23 21

I ALTC {WHT/GRNI f)


'98 -'9O modols: Alternator Contlol SYstemTe3t (U.S.A'model) NOTE:Beforetesting,checkproperoperationof the ELDby checkingfor a DTC(seesection11) EATTERY

R

'oR

Chock tor . short in tha circuit IALTClino): 1. Disconnoctthe 4P connector Irom the alternator. 2. Startthe engine,and turn the headlights(highbeam)ON. 3. Measurevoltage between the 4P connectorterminal No. 2 and the positive terminal oI the battsry.

CAUTION: Be surc to uso a voltmetor with its oo3itive torminel connccted to battery po3hivo tnd its negativo teami' nal to the 4P connectortorminal No 2.

c IWHT/GRN) Wire sideol femaleterminals

ALTERNATOR 4P CONNECTOR

l s t h e r e1 V o r l e s s ?

Check for an opon in the wire IALTCline): 1 . T u r n t h e h e a d l i g hat n d i g n i tion switchOFF. 2. Disconnect the 31Pconnector from the ECM/PCM. 3. Checktor continuitybetween th6 ECM/PCM31P connector terminalNo. 2 and alternator 4PconnectorterminalNo. 2.

ECM,/PCM CONNECTOR c {31P) Wire sideol temaleterminals

Ropairopen in the wiro between the ahornrtor and ECM/PCM.

C {31P} ECM/PCMCONNECTOR ALTC IWHT/GBNI Chack lor a rhort in tho wire {ALTClincl: ' ! . 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 Irom the ECM/PCM. 3. Ch6ckfor continuitybetween the ECM/PCM31P connector terminalNo. 2 and body ground.

lu

Substituto . known-good ECM/ PCM,.nd rochock. lf prdcdbâ&#x201A;Źd voltage b now av.ilable, repl.ce the original ECM/

rcM. Rcpair rhort in thc wire b.twcon th. ahGrn.tol.nd the EcM/PcM.

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(cont'd)

4-27


GhargingSystem

I

(cont'd) Troubleshooting Alternator/RegulatorTest NOTE:Makesurethe batteryis sufficientlycharged(seesection23). Alternator/RegulatorTest: 1 . C o n n e c ta S u n V A T - 4 0( o r e q u r v a l e ntte s t e r ) ,a n d t u r n the selectorswitchto position 1{sraning). 2. Shift to neutral(A/T in E or , n d s t a r tt h e N) positiona e n g a n eH. 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 ?

(BED)

FIELD SELECTOR TEST

NEGATIVE TESTER CABI.E{BLKI

swtTcH Ahernator/Regulator Test (cont'd)l I Releasethe accelerator pedal, and let the engineidle. 2 Makesure all accessories are turned off. Turn the selector switchto posjtion2 (charging). 3 Removethe inductivepickup, and zerothe ammeter. { P l a c et h e i n d u c t i v ep i c k - u p over the batterygroundcable so that the arrow pointsto the bafterynegativeterminal. 5 . R a i s et h e e n g i n es p e e dt o 2 000rpm, and hold ir there.

t

VOLTMEIER POSmVE

INDUCTIVE PICK.UP {GRN)

TESTER CABLEIREDI

I

WHTWIRE

(

T

l s t h e v o l t a g e l e s st h a n 1 3 . 5V ?

Altarnator/Regulator Test (cont'd: Apply a load with a VAT-40 until the battery voltage drops to b e t w e e n 1 2 - 1 3 . 5V .

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4-28

I


Frompreviouspage

ls the amperage65 A or more?

Aharnator/Regulator Tesl (cont'd): W i t h t h e e n g i n e s p e e ds t i l l a t 2.000rom,fulllield the alternator.

The charging sy3tem b OK. CAUTION:The voh.ge will tise quickly whon th. ahornato. is tull-li.lded Do not allow the voltage to exceod18 V; it mry damagothe .loctrictl 3yaiGm. into the tull field NOTE: Attach a probe to a VAT-40Iull tield test lead,and inseft the probe "A lGround)"posiaccessholeat the backof the altemator'Switchthe fieldselectorto the and checkthe amperagereadrng. tion momentarily. REGULATOR (Locatedinside the ond coverl FULLFIELD ACCESSHOLE

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4-29


ChargingSystem AlternatorReplacement

l I

v

' t . Disconnect the batterynegativeterminalfirst, then

}

^

the positiveterminal.

Removethe adjustingbolt and mounting nut, then removethe alternatorbelt.

N ir

Disconnectthe 4P (or 3P) connectorand WHT wire from the alternator.

Pullout the throughbolt,then removethe alternator.

T n

THROUGH BOLT

WHT WIRE

MOUNTINGNUT 10x 1.25mm 44 N.m 14.5kgf.m. 33 tbtftt

LOCKNUT 8 x 1.25 mm 24 N.m (2.4kgt m, 17 lbl.ft,

Installthe alternatorin reverseorderof removal. o.

4-30

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'll

l

Adjust the alternatorbelt tension after installation (seepage4-34).

t


AlternatorOverhaul

PULLEY

NOTE:Do not removethe pulley unlessthe front bearing needsreplacement. To loosenthe pulley locknut,use the tools as shown. lf necessary, usean impactwrench.

,T PULLEYLOCKNUT 111N.m (11.3kgf.m,81.7lbf.ft)

BEARINGINSULATOR

FRONTBEARING

PULLEY

CAUTION: Do not get grease or oil on the slip rings.

"'^.^t% BRUSHHOLDER INSULATOB

THROUGHBOLT

RECTIFIER ASSY Test.page4 32

PULLEYLOCKNUT 111N.m {11.3kgf.m,81.7lbf,ft)

REARHOUSING

COVER www.emanualpro.com

4-31


ChargingSystem RectifierTest

AlternatorBrushInspection

NOTE:The diodesare designedto allow currentto pass in one directionwhile blockingit in the oppositedirec t i o n . S i n c et h e a l t e r n a t o r e c t i f i e ri s m a d e u p o f e i g h t diodes(four pairs),each diode must be testedfor conti nuity in both directionswith an ohmmeterthat hasdiode checkingcapability;a total of 16 checks.

1.

Removethe end cover,thentakeout the brushholder by removing its two screws.

2.

M e a s u r et h e l e n g t ho f t h e b r u s h e sw i t h a v e r n i e r calrper.

'l.

Checkfor continuityin eachdirectionbetween - t h e B a n dPt e r m i n a l s . - E ( g r o u n da) n d P t e r m i n a l s . A l l d i o d e ss h o u l dh a v ec o n t i n u i t iyn o n l y o n e d i r e c tion.

Alternator Brush Length: Standard(Newl:10.5mm 10.41inl ServiceLimit: 1.5mm {0.06in)

VERNIERCALIPER

2.

lf any of the diodesfails,replacethe rectifierassembly. (Diodesare not availableseparatelv.)

4-32

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lf the brushesare lessthan the servicelimit, replace the alternatorbrushassemblv.

I


Stator Test

RotorSlip RingTest 1.

betweenthe slip rings. Checkthe resistance Thereshouldbe 1.8- 3.0ohms. go to step2 . lf resistance meetsthe specification, . 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 , replacethe alternator.

1.

Checkthat there is continuitybetweeneach pair of leads. LEADS

ROTORSHAFT

corLcoRE SLIPRINGS

Checkthat there is no continuitybetweeneach lead and the coil core. It the coil fails either continuitycheck,replacethe alternator.

Checkthat there is no continuity betweenthe slip ringsand the rotoror rotor shaft. lf the rotor fails eithercontinuitycheck,replacethe alternator.

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4-33


ChargingSystem AlternatorBelt Inspectionand Adjustment 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. Deflection methodi A p p l ya f o r c eo f 9 8 N ( 1 0 k g t , 2 2 l b l l , a n d m e a s u r et h e deflectionbetweenthe alternatorand crankshaftpulley. Detlection: UsedBelt:8.5- 11.5mm (0.33- 0.45inl New Beft: 5.5 - 8.0 mm 10.22- 0.31 inl NOTErlf the belt is worn or damaged,replaceit.

Measurehere

4-34

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Belt tension gauge m6thod: Attachthe belttensiongaugeto the beltand measurethe tension.Followthe gaugemanufacturer's instructions. Tension: Used Belt:340 - /â&#x201A;Ź0 N (35 - 50 kgf, 77 - 1r0 tbf) New Belt: 690 - 880 N (70 - 90 kgf, 150- 200 tbt) NOTE:lfthe belt is worn or damaged,replaceit.


lf adjustment is necessary: 1.

Loosenthe mountingnut and the locknut.

2.

Move the alternatorto obtain the proper belt tension,then retightenthe nuts.

LOCKNUT 8 x 1 . 2 5m m 24 N.m (2.4kgtm,'17lbf ft)

NUT MOUNTING 10x 1.25mm 14N.m{4.5kgl.m.33lbf.ft)

Recheckthe deflectionor tensionof the belt. NOTE: For the power steeringpump belt and A,/C referto section17 and compressorbelt adjustments, section22.

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4-35


GruiseControl

I

ComponentLocationIndex CRUISEINDICATORLIGHT (Builtinto gaugeassembly) BulbLocations. section23

BA

(

SET/RESUMESWITCH Test,page 4 40 Beplacement, page4-40

CRUISECONTROLUNIT Input Test,page 4 38

swtTcH Test, page 4-44

CLUTCHINTERLOCK

swrTcH{M/T)

PedalHeightAdjustment, section19.

Test,page 4-43 Switchposkionadjustment, section12 ACTUATOfiASSEMBLY and VACUUMTANK Test,page4 41 SolenoidTest,page4 44

A/T GEABPOSITION swlTcH (A/Tl '14 Test,section www.emanualpro.com

+36

ACTUATORCAELE Adjustment,page4-43

I


GircuitDiagram IGNITON SWITCH

FUSEi RELAY BOX UNDER.HOOD

FUSARELAYBOX UNDER.OASH

COMEINATON L GH'I SWITCH

No41(100A) No42(404)

f7 I

RED/BLK

INDICATOR LIGHT (0.84W)

lP

IOSET

J

5

BRAKâ&#x201A;¬ LGHTS

2 1

6 1

7 1 2 C R U I SCEO N T R OUTN L T 1 1

8

1

3 10

4

CRUISE PNK CONTROL ACTUATOR

BLK

It

4F\ /lr,mcern

t'

BLK

*: '98 00 modelswith AutomaticTransmission.

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n: G202

BLK

L_ll I I

Y{"^i?tr'.flffi'JF )l t

I

rereasedl /l loN: Pedar

8LK

BLK

G101

G401

T

I 4-37


CruiseControl ControlUnit Input Test and proceduresin the SRS SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations.precautions, section(241beforeperformingrepairsor seryice. '1. Removethe driver'sdashboardlowercoverand kneebolster{seesection20). 'l4P connectorfrom the controlunit.

2.

Disconnect the

3.

Inspectthe connectorand socketterminalsto be surethey are all makinggood contact and recheckthe system. lf the terminalsare bent,loose,or corroded,repairthem as necessary, lf the terminalslook OK, makethe followinginput testsat the connector. - lf any test indicatesa problem.find and correctthe cause,then recheckthe system. - lf all the input testsproveOK,the controlunit must be faulty;replaceit.

*: '98- 00 modelswith AutomaticTransmission.

4-38

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Wire sideol femaleterminals


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