Manual de Honda by Oscar Fernandez

INTRODUCTION How to Use This Manual This manualis dividedinto 23 sections.The first pageof each seclionis markedwith a blacktab that linesup with its corresponding thumb indextab on this pageand the backcover. You can quicklyfind the first pageof eachsectionwithout lookingthrougha full tableof contents.The symbolsprintedat the top cornerof each pagecan also be used as a quick re{erencesystem.

Sp e c i fi c a ti o n s

1)ll:{l+'

Ma i n te n a n c e

Eachsectionincludes: 1. A tableof contents,or an explodedview index showingl . Partsdisassemblysequence. . Bolttorquesand threadsizes. . Pagereferencesto descriptionsin text. proceduresand tools. 2. Disassembly/assembly 3 . Inspefiron. g. 4. Testing/troubleshootin 5. Repair. 6. Adjustments.

Safety Your safety,and the satetyof others,is very important.To help you make informeddecisions,we have providedsafety messages,and othersafetyinformationthroughoutthis manual. Of course,it is not practicalor possibleto warn you aboutall the hazardsassociated with servicingthis vehicle.You must use your own good judgment.

Emissions

You will find impoftantsafetyinformationin a varietyof forms including: . SatetyLabels- on the vehicle. . Satetv Messages preceded by a salety alert symbol A and one of threesignalwords, DANGEF,WARNING,or CAUTION. Thesesignalwords mean:

tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir HURT ir E$EEEE ys,: f#,ff ,:hl:3,:JjERrousLY tlGtltT]llilll

YoucAN b€ HUBTif vou don'tfollow

. lnstructions - howto service thisvehiclecorrectlv andsafelv. All informationcontainedin this manualis basedon the latest productinformationavailableat the time of printing.We reserve the right to makechangesat any time without notice.No part of this Oublication maVbe reDrodLrced, or storedin a retrieval system,or transmitted,in any form by any means,electronic, photocopying,recording,or otherwise,without the mechanical, priorwritten permissiono{ the publisher.This includestext, figures,and tablesAs vou readthis manual,vou will tind informationthat is precededby a @ symbol.The purposeof this messageis to help preventdamageto your vehicle,other property,or the environment,

* Bo d y

z-tl! ^ t

FirstEdition8/2002 1,168pages HONDAMOTORCO..LTD. All RightsReserved ServicePublicationOffice Specifications applyto U.S.A.and Canada As seclion3 with *inclode SRS comoonentsi special precautionsare required when servicing.

*Restraints

GeneralInformation Ghassisand PaintCodes - 2 0 0 2M o d e l

. . . . . . . . . . . . . 1. .-.2.

Chassisand PaintCodes - 2 0 0 3M o d e l

. . . . . . . . . . . . .1. .-.3.

ldentification NumberLocations ........1-4 Warning/Caution LabelLocations......1-5

)

Under-hoodEmission ControlLabel ...........

.... 1-7

L i f ta n dS u p p o r P t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , . Towing

......1-9

PaftsMarkingLocations...................... 1-10

GeneralInformation Model Chassisand PaintCodes- 2OO2 VehicleldentfficationNumber S H H E P 33 5 ' 2

U 300001

[[tttrtF

c d e f g h

a. Manufacturer, Make and Type of Vehicle S H H ; H O N D A O F T H EU . K .M F G . ,L T D .U . K . H O N D AP a s s e n g evre h i c l e b. Line, Body and EngineType EP3: CIVIC/K20A3 c. Body Type and Transmission Type Manual 3: 2-door HatchbacUs-speed d. VehicleGrade lSeries) 5:Si {U.S.} 5 ; S i R( C a n a d a ) 6: Si with side airbagsystem (U,S.) 6: SiR with side airbagsystem (Canada) e. CheckDigit l. ModelYear 2i 2002 g. Factory Code U : H o n d ao f U . K .M a n u f a c t u r i nign S w i n d o n , En gl a n d h. Serial Number U . S , :3 0 0 0 0 1 1-

EngineNumber K2OA3 1700001 a a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injectedengine b. Serial Number

Transmission Number NBH3

1000001

a TransmissionType N R H 3 ; s - s D e eM danual

PaintCode Code

B-92P NH-578 NH-623M R-81

Y-62P

Color Niqhthawk BlackPearl TaffetaWhite Satin Silver lvletallic M i l a n oR e d E u r oY e l i o wP e a r l

u . s . Canada

V€hicle ldentif ication Numbo. and Federal Motor Vehicle Safety Standard Certification/ Color Label.

1-2

Chassisand PaintCodes- 2003Model VehicleldentificationNumber S H H E P 33 5 * 3

U 400001

[--t-rlF

c d e fg h

Manufacturer, Make and Type of Vehicle S H H : H O N D A O F T H EU . K .M F G . ,L T D .U . K . HONDAPassengervehicle Line. Body and EngineType EP3: CIVIC/K20A3 G . Body Type and Transmission Type Manual 3: 2-door HatchbacldS-speed d . Vehicle Grade (Series) 5:Si (U.S.) 5 : S i R( C a n a d a ) 6: Si with side airbagsystem (U.S.) 6: SiRwith side airbagsystem (Canada) Check Digir f. Model Year 3: 2003 Factory Code U: Hondaof U.K. Manufacturingin Swindon, England SerialNumber U.S.:400001 :700001

EngineNumber K2OA3 2700001

I a a. EngineType K20A3: 2.0 0 DOHCVTECSequentialMultiport Fuel-injectedengine b. SerialNumber

Transmission Number NRH3 - 2000001

I a TransmissionType N R H 3 : 5 - s p e eM d anual SerialNumber

PaintCode Code

B-92P B-520P NH-578

NH-623M R-81

Y-62P

Color Niohthawk BlackPearl V i v i d B l u eP e a r l Taffeta White Satin Silver N4etallic M i l a n oR e d EuroYellow Pearl

U , S . Canada

VehicleldentificationNumber and FederalMotor Vehicle Saletv Standard Certif ication/ Color Label.

)_.

1-3

GeneralInformation ldentificationNumber Locations

Vehicle ldentif ication Number {vlN}

(

Vehicle ldentificalion Numbe.lvlN)

EngineNumber

1-4

, I O

warning/cautionLabelLocations NOTE:FRONTPASSENGER AIRBAG WARNING TAG (CHILD SEAT)is installedon the glovebox on the U.S. mooet. Passenger's Compartment: SRSINFORMATION U.Sm . odel

Steering Wheel: DRIVERMODULE DANGER CABLEREEL CAUTION

SRS WARNING INFORMATION FRONTPASSENGER MODULE DANGER

MONITOR NOTICE

! ,/ FRONT SEATBELT TENSIONER CAUTION SIDEMODULE DANGER

SIDEAIRBAG CAUTION Located on driver's ano passen9ers doorjamb(not shown)

..r' (cont'd)

1-5

GeneralInformation Warning/CautionLabelLocations(cont'dl

SRSWARNING LABEL

SERVICEINFORMATIONLABEL (Undor-hood Emission Control Informationlab€l)and ENGINE COOLANTINFORMATION

TIREINFORMATION

RADIATOR CAPCAUTION

BATTERY CAUTION

1-6

Under-hoodEmissionControlLabel EmissionGroupldentification

Families: Engineand Evaporative

Example:2002model

EngineFamily:

2 HNX V O2.O VBP

rr-tt--[ t t l a b

. P AT I E R2 B I N5 T H I SV E H I C LCEO N F O R MTSO U . S E APPLICABLE TO 2002 LEV REGULATIONS AND NLEV CARSAND MODELYEARNEWPASSENGER TO 2OO2 APPLICABLE REGULATIONS CALIFORNIA CARS. MODELYEARNEWLEVIi LEVPASSENGER Example:2003model

c d

ModelYear 2:2002 3: 2003 ManulacturerSubcode H N X :H O N D A c. FamilyType V: LDV d . Displacement e . SequenceCharacters V B P2: 0 0 2 X K C 2: 0 0 3 Evaporative Family:

rH/

THISVEHICLECONFORMSTO U.S. EPATIER2 BIN 5 TO 2O03 APPLICABLE AND NLEVLEVREGULATIONS CARSAND MODELYEARNEWPASSENGER TO2OO3 APPLICABLE REGULATIONS CALIFORNIA CARS, MODELYEARNEWLEVII LEVPASSENGER

2 HNX R OO99 AAH

t[-l=[

a b

c d

Model Year 2t 2002 3: 2003 Manufacturer Subcode H N X :H O N D A c. Family Type R: EVAP/ORVR d . Canister Work Capacity e . Sequence Charactets AAH: 2002 AAA: 2003

1-7

GeneralInformation Lift and Support Points NOTE:If you are going to remove heavycomponents such as suspensionor the fuel tank from the rear of the vehicle,first supportthe front ofthe vehiclewith tall safetystands.When substantialweightis removed from the rear of the vehicle,the centerof gravity can changeand causethe vehicleto tip forward on the hoist.

FrameHoist 1. Positionthe hoist lift blocks(A),or safetystands, under the vehicle'sfront support points (B)and rear support points (C).

FloorJack 1. Set the parkingbrake. 2. Blockthe wheels that are not being lifted. 3. When liftingthe rear of the vehicle.put the gearshiftIever in reverse. 4. Positionthe floor jack underthe front jacking bracket(A) or rearjackingbracket(B),centerthe jacking bracketin the jack lift ptatform(C),and jack up the vehiclehigh enoughto fit the safetystands u n d e ri t .

0 2. Raisethe hoist a few inches,and rock the vehicle gentlyto be sure it is firmly supported. 3. Raisethe hoistto full height,and inspectthe lift pointsfor solid contactwith the lift blocks.

Safety Stands

c Positionthe safetystandsunderthe support points and adjustthem so the vehiclewill tevet. Lower the vehicleonto the stands.

To supportthe vehicleon safetystands.use the same suppon points (B and C) as for a frame hoist,Always use satetystandswhen working on or under any vehiclethat is supportedonly by a jack.

1- 8

Towing lf the vehicleneedsto be towed, call a professional towing service.Nevertow the vehiclebehind another vehiclewith just a rope or chain.lt is very dangerous. EmergencyTowing T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n ga v e h i c l e . Flat-bedEquipment The operatorloadsthe vehicle on the backof a truck.This is the bestway of transportingthe vehicle. To accommodateflat-bedequipment.the vehicleis equippedwith towing hooks(A)and tie down hooks{B). The towing hook can be usedwith a winch to pull the vehicleonto the truck, and the tie down hooks slotscan be used to securethe vehicleto truck.

Wheel Lift Equipment The tow truck usestwo pivoting arms that go underthe tires (front or rear)and lifts them off the ground.The other two wheels remain on the ground.This is an acceptableway of towing the vehicle. Sling-typeEquipment The tow truck uses metal c a b l e sw i t h h o o k so n t h e e n d s .T h e s eh o o k sg o a r o u n d parts of the frame or suspensionand the cableslift that e n d o f t h e v e h i c l eo f f t h e g r o u n d .T h e v e h i c l e ' s suspensioa n n d b o d y c a n b e s e r i o u s l yd a m a g e di f t h i s method of towing is attemPted. lf the vehiclecannot be transportedby flat-bed,it should be towed with the front wheels off the ground lf due to damage,the vehiclemust be towed with the front wheels on the ground, do the following: . Releasethe parkingbrake. . s h i f t t h e t r a n s m i s s i o inn N e u t r a l . It is bestto tow the vehicleno farther than 50 miles (80 km), and keepthe speed below 35 mph (55 km/h).

. l m p r o p e rt o w i n g p r e p a r a t i ow n i l l d a m a g et h e transmission.Follow the above procedureexactly.lf you cannot shift the transmission,the vehicle must be transDortedon a flat-bed. . Trying to lift or tow the vehicle by the bumperswill , h e b u m p e r sa r e n o t c a u s es e r i o u sd a m a g e T designedto supportthe vehicle'sweight.

1-9

GeneralInformation PartsMarking To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts. NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.

r a

1-10

ra Specifications

Standardsand ServiceLimits Enqine ne Electrical

Item

Measurement

lgnitioncoil

Rated voltage

Sparkplug

Type

Oualification

Standard or New

A t i d l e ( c h e c kr h e

12V 1 3-4 2 N G K t: Z F B 6 K 1 1 DENSO: SKJ20DR-M11 1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3 in.) in neutral:8t2' ETDCat 650150rpm

F i r i n go r d e r

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

Alternator

Output

Coillrotor)resistance 5|lp flng u.u.

Starter

Brushlength Brushspringtension Output Commutator micadepth Commutator tunout Commutator O.D. Brushlength

Service Limit

(

1 . 3 m m ( O . OiSn 1. )

At 13.5V and 80A normalengine temperature At 68.F(20'C) 2.2 3.0 A 14.4mm {0_57 in.) 14.0mm (0.55in.) 10.5mm (0.41in.l 1.5mm {0.06in.) 2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs) 0.50 0.80mm (0.020-0.031 in.)

0.20mm 1O.OO8 in.)

o:BlalqryL4i) max

o.o5mm(0.002 in.)

2 8 . 0m m ( 1 . 1 0 in.) 14.0 14.5mm {0.55 0.57in.)

2 7 . 0m m ( 1 . 0 6 in.) 9.0mm {0.35in.)

Enqtne Item Measurement Compression Pressurecheckat 250rpm with wide openthroftle. (SeeDesignSpecsfor rato,

Oualification

Minimum Maximum vanatton

Standard or New

Service Limit

930kPa(9.5kgflcmr,135psi) 200kPa{2.0kgf/cm',28psi)

.l 2-2

nder Head Item Head

Camshaft

Measur6ment

Oualification

'103.95104.05 mm (4.093 4.096in.) 0.05 0.20mm (0.002 0.008in.)

Endplay No.l journal N o . 2 , 3 ,4 , 5 journals

Totalrunout Cam lobe height

Intake,primary Intake, Exhaust

(cold) clearance

lntake

StemO.D-

lnlaKe

Exhaust Exhaust

S t e m - t o - g L r i d cel e a r a n c e

lntake

height stem installed

Exhaust lntake Exhaust lntake Exhaust lntake Exhaust

Valvesprings

Freelength

Valveguides

LD.

Intake Exhaust

I n s t a l l e dh e i g h t

lntaKe

Exhaust Rockerarms

Arm-to-shaftclearance

lntaKe Exhaust

Service Limit

0.05mm {0.002in.)

Warpage Height

C a m s h a f tt o h o l d e r o i l c l e a r a n c e

Standard or New

0.030 0.069mm {0.001 0.003in.) 0.060 0.099mm (0.002-0.004in.) 0.03mrn (0.001in.)max. in.) 33.925mm (1.3356 in.) 2 9 . 6 3m 8 m (l.1668 in.) 34.092mm (1.3422 0.21 0.2smm 10.0080.010in.) 0.28 0.32mm (0.011 0.013in.) 5.475 5.485mm 10.21560.2159in.) 5.450 5.460mm (0.2146 0.2150in ) 0.030 0.055mm (0.0012 0.0022in.| 0.055 0.080mm (0.0022 0.0031in ) 1.25 1.55mm (0.049 0.061in.) 1.25 1.55mm (0.049 0.061in.) 4 0 . 8 -4 1 . 0m m ( 1 . 6 0 6 1 . 6 1 4 i n . ) in.) 5 4 . 6 5 4 . 8m m ( 2 . 1 5 02 . 1 5 7 (1.874 in.) 47.61mm 49.64mm (1.954in.)

0.4mm (0.02in.) 0 . 1 5m m { 0 . 0 0i6n . ) 0.15mm (0.006in.) 0.04mm {0.002in.)

5.445mm (0.214in.) 5 . 4 2m m ( 0 . 2 1i3n . ) 0.08mm (0.003in.) 0.11mm (0.004in.) 2.00mm {0.079in.) 2.00mm {0.079in.)

5.515 5.530mm |.0.21710.21174n.1 mm 5.515 5.530 \0.2111 0.2177in.l 1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . ) 15.5 16.5mm (0.610 0.650in.)

5.55mm (0.219in.)

0.025 0.052mm (0.00'100.0020in.) 0.018 0.056mm (0.0007 0.0022in.)

0.08mm (0.003in.)

5 . 5 5m m { 0 . 2 1i9n . )

0.08mm (0.003in.)

lo 2-3

Standardsand ServiceLimits n q t n e Block Enqine Item Block

Measurement I Warpageof deck tsorediameter

Oualification

Aori Borll

Standardor New 0.07mm (0.003in.)max. 86.010 86.020mm (3.3862 3.3866in.)

ServiceLimir

foro.. (ulur^^-"1

86.070mm (3.3886 in.)

86.000 86.010mm (3.3858 3.3862in.)

86.070mm (3.3886 in.) 0 . 0 5m m ( 0 . 0 0 2I n . J

R e b o r i n gl r m i t

Piston

Pistonring

SkirtO.D.at 11mm (0.4in.)from bottom of skirt

",";"* lFis,.€-"'"

L-

Ringend gap

0 . 2 5m m ( 00 l i n . ) 85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l in.) F" LetterB €s.980 r"i33846 85.920mm (3.3827 l-il?0 in.) 0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.) Top 1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049 rn ) Second 1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049 in.) i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt ) i.'.f 0.13mm (0.005in ) fo.o:s o.oto.rnlo.oorao.ooza i") 0 . 1 3m m ( 0 . 0 0i5n . ) EO3t 0 056rn. {OJ01rOOO2 Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in ) I\4OGUL) Top 0.20 0.35mm (0.008 0.014in.) 0.60mm (0.024in.)

btt"' "' A

Second

OiI(REKEN) OiI(FEDERAL I\4OG UL) Pistonpin

Connecting rod

0.70mm (0.028in.) 0.75mm (0.030in.) 0.80mm 10.031 in.)

o.D.

21.961 21.965mm {0.8646 0.8648in.) 2 1 . 9 5 3m m l 0 8 6 4 3 i n

Pin'to-piston clearance

0.005-*0.002 mm( 0.00020+ 0.00008 in.)

Pin to-rod clearance

0.005 0.015mm (0.0002 0.0006in.) 0 . 0 2 m m l O 0 O O 8i n I 21.970 21.976mm (0.8650 0.8652in.) 4 8 . 0m m ( 1 . 8 9 in.) 0.15 0.30mm (0.006 0.012in.) 0 . 4 0m m ( 0 . 0 1i6n . ) s4.e84 s5.008mm (2.1648=16illl

Small end bore diameler L a r g e - e n db o r e d i a m e t e r ( N o r m a l )

Endplayinslalledon crankshaft Crankshaft

0.40 0.55mm {0.016 0.022in.) 0.25 0.65mm (0.010 0.026in.) 0 20 0.70mm i0.008 0.028in.)

Main journal diameter

No. l journal No.2 journal N o .4 j o u r n a l No.5 journal No.3 journal

4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l

Rod/main

0.005mm 10.0002 in.)max. 0.005mm (0.0002 in.)max. 0.10 0.35mm (0.004 0.0'14 in.) 0.03mm (0.0012 in.)max. 0.017 0.041 m m ( 0 . 0 0 0 70 . 0 0 1i6n . )

Runout . . - ' . : - - ' +

M a r n o e a r , n 9 - t o J o u r n ao t t t c t e a r a n c e No. l journal Deaflngs

5 4 . 9 7 65 5 . 0 0 m 0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )

Rodjournal diameter

Rod/mainiournalout of,round E n dp l a y

0.005mm (0.0002 in.)

0.010mm (0.0004 in.) 0.010mm (0.0004 in.) 0 . 4 5m m 1 0 . 0 1i 8 n.) 0.04mm {0.0016 in.) 0.050mm (0.0020 in.)

No.2 journal No.4 journal No.5

No.3 journa/ Bodbearingclearance

q0rr034, -rn {O'o010 0-o01r|"tl 0.055mm (0.0022in.) 0.021 0.049mm (0.0008 0.0019in.)

0.060mm (0.0024 in.)

2-4

o i

nqlne Lubrication |tem

Measurement

Engineoil

Capacity

Oilpump

lnner-toouterrotorclearance Pumphousingto outerrotor clearance axial Pumphousing-to-rotor clearance Balancer shafts,journaldiameter

Oualificalion

ServiceLimil Standerdor New 5.30 (5.6US qt)for engineoverhaul 4.20 (4.4US qt)for oil change,includingfilter 4.00 (4.2US qt)for oil change,withoutfilter 0.20mm (0.008in.) 0.02 0.16mm {0.001 0.006in.) in.) 0.23mm (0.009in.) 0-15 0.21mm {0.006-0.008 0.02 0.07mm (0.001 0.003in.)

No.1 journal,front shaft

0.12mm (0.005in.)

19.938 19.950mm 10.78500.7854in.) 19.92mm (0.784in.)

23.938 23.950mm (0.9424 0.9429in.) 23.92mm (0.942in.) in.l 32.93mm (1.296in.) No.2 journal,frontand 32.949 32.961mm 11.29121.2911 rearshaft in.)max. 0.005rnm (0.0002 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.) Front 0.070 0.135mm (0.0028 0.0053in.) 0.15mm (0.006in.) Rear 0.050 0.082mm (0.0020 0.0032in.) 0 . 1 0m m ( 0 . 0 0i4n . ) No. 1 iournal,front

No 1 journal,rearshaft

Ealancer shafts,journaltaper shafts,end play Balancer Balancershatts,shaft-to'bear;ng clearance

shaft N o . 1 J o u r n a l ,r e a r s h a f t N o . 2 j o u r n a l ,f r o n t a n d

0.050 0.082mm (0.0020 0.0032in.) 0.060-0.120mm (0.0024 0.0047in.)

0.10mm (0.004in.i 0.15mm (0.006in.)

rear shafl

LD. shaftbearings, Balancer

20.000 20.020mm (0.1814 0.7442in.l 20.03mm (0.789in.) No. 1 journal,front shaft ZI.OZO m- tOSa+e-OSa57ir'.) 24.03mm (0.946in.) No. 1 iournal,rearshaft Z+.OOO in.) 33.09mm {1.303in.) No.2 journal,frontand 33.021 33.069mm (1.3000 1.3019

R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )

At idle

7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .

At 3,000rpm

300kPa{3.1ksf/cm',44psi)min.

rearshaft

Standardor New 6 . 7L ( 7 . 1U S

engine, Coolantcapacity {includes heater,hoses,and reservoir)

Thermostat

ServiceLimit

0.53L (0.56US 93 123kPa(0.95 1.25kqtcm , 14 18psi) 't69 176'F(76 80'C)

OPeningtemPerature

8.0mm {0.31in.)min. TurnsOFF

Subtract5 15'F(3 8"C)fromactualON

a 2-5

Standardsand ServiceLimits Fueland Emissions Item Fuelpressure regulator Fueltank Engineidle

Measulement Oualification Pressurewith fuel pressuregauge connected Capacity ldlespeedwith headlights and radiator Neutral fan off F a s ti d l e

Neutral

Standardor New ServiceLimit 320-370kPa13.3-'3.8 kgtcm',47 52psi)

f .

5 04 ( 1 3 . 2U Sg a l i 750 50 rpm 1,600150rpm

Clutch Item Clutchpedal

Mea3urem€nl Heightfromthe floor Stroke

Oualification

D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r

Clutchdisc Pressureplate

Bunouton clutchmatingsurface Bivetheaddepth Ihickness Warpage Heightof diaphragm spring fingers

Measured with specialtooland feelergauge

Slandardor New 193mm (7.60in.) 1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . ) 10 16mm (0.39 0.63in.) 1'15 mm (4.53 i n . )m i n . 0.05mm 10.002 in.)max. 1.65 2.25mm (0.065 0.089in.) 8.3 8.9mm (0.33 0.35in.) 0.03mm (0.001in.)max. 0.6mm (0.02in.)max.

ServiceLimit

0.15mm (0.006in.) 0.7mm {0.03in.) 6.0mm (0.24in.) 0 . 1 5m m ( 0 . 0 0i1n . ) 0.8mm (0-03in.)

r a

\ < c 2-6

nualTransmissionand M/T Differential

O E

Adiust 20.75mm 10.817 in.) 3 ' 1 . 9m 3 m ( 1 . 2 5i7n . ) 27.92 m m ( 1 . 0 9i9n . )

'1.5354 in.)

38.93mm (1.5334n.)

27.987 28.000mm (1.10'191.1024in.)

2 7 . 9 3m m { 1 . 1 0i0n . )

0.02mm (0.001in.)max. in.) 44.009 44.025mm 11.73261.7333 0.06 0.16mm {0.002 0.006;n.) 23.92 23.97mm (0.94'10.944in.) in.) mm (1.3780 '1.3785 35.000-35.015

0.05mm (0.002in.) 44.08mm (1.735in.) 0 . 2 5m m ( 0 . 0 1i0n . ) 23.80mm (0.937in.) 34.95mm (1.376in.)

39.937 39 950mm (1.5723 1.512ain.|

39.88mm (1.570in.)

D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a ( t r a n s m i s s i o nh o u s i n g s i d e )

30.020-30.0m 3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )

29.97 m m ( 1 . 1 8i0n . )

Runout innerrace 35 mm shim-to'bearing

0.02mm {0.001in.)max. 0.04 0.10mm (0.0016 0.0039in.)

0.05mm (0.002in.) Adjust

in.i 52.010 52.029mm (2.0476-2.0484 0.06 0.16mm (0.002 0.006in.) -0.904in.) 22.92 22.91$m 10.902 52.010 52.029mm (2.0476 2.0484in.) 0.06 0.16mm (0.002 0.006in.) 21.92 27.91mtn \1.099 1.101in.) 39.95 39.96mm (1.572a 1.5132in.) in.) 46.989-47.000mm (1.8499-1.8504 in.i 23.03 23.08mm (0.907-0.909 in.l 39.95 39.96mm {1.5728'-1.5732 in.) 46.989 47.000mm (1.8499 1.8504 mm (l.104 1.106in.) 28.03 28.08

52.08mm (2.050in.) n.) 0 . 2 5m m 1 0 . 0 1i 0 22.87mm (0.900in.) 52.08mm {2.050in.} 4n.) 0.25mm 10.010 in.) 27.87mm 11.097 39.97mm (1.574in.) 46.94mm (l.848in.)

Transmission Capacity fluid Endplav Mainshaft Diameter of bushingsurface D i a m e t e ro f d i s t a n c ec o l l a r

Diameter of ballbearingcontactarea (clutchhousingside) Diameter of needlebearingcontact area Diameter of ballbearingcontactarea (transmission housingside) Runout Mainshaft 3rd, t.D. 4th and sth Endplay gears Thickness Countershaft Diameterof needlebearingcontact area(clutchhousingside) of distance collarcontact Diameter alea

Countershaft

clearance LD. End play

Thickness Countershaft 2ndgear Countershaft 'lst gear

t.D. Endplay Thickness LD.

o.D.

collar Length distance Countersha{l l . D . o.o. 2ndgear distance coliar L e n g t h

Se.viceLimit

Standardor New Forfluidchange:1.50 (1.6US qt) F o ro v e r h a u1l :. 70 1 1 . 8 U Sq t ) ' l 0 . 1 7 ( 0 . 0 0 4 mm 0.007in.) 0.1 20.80 20.85mm {0.819 0.821in.) mm (1.2594 1.2598 in.) 31.984-32.000 2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . )

M€asurement

Item

Oualification

38.984 39.000mm (1.5348

39.97mm (1.574in.) 46.94mm (1.848in.)

o 2-7

Standardsand ServiceLimits ?

Manual anuatTransmission I ransm and Differentialcont' Measutemenl

Item

Nlainshaft4th and5thgears

Oualification

LD.

o.D.

distance collar L e n g t h B

MBSdistance LD. Len9th

t.D.

Reverseidler gear

G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e

Synchroring

Bingto'gearclearance

Triplecone

Outersynchroring-tosynchrocone clearance Synchrocone-to-gear clearance

Shift fork Reverseshift fork Shiftarm

Outersynchroring-to-gear cone clearance Fingerthickness Forkto-synchro sleeveclearance Fingerthinkness Fork-to-reverse idlergear clearance

t.D. S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e

Selectlever Shiftlever

Mfi differential carrier Mfi differential pinionqear 80 mm shim

Fingerwidth Shaft-to-selectleverclearance Groove{to selectlever) Shaftto shiftarm clearance Pinionshaftcontactareal.D. C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e

DriveshaftcontactareaLD. Backlash

t.D. P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e

80 mm shim to-bearing outerrace clearance in transmission housing

Ringpushed againstgear Ringpushed againstqear Ringpushed againstgear Ringpushed againstgear

Standardor New 32.00-32.01mm (1.2598 1.2602 in.) 38.989 39.000mm (1.5350 1.5354 in.) 51.95 52.05mm (2.045 2.049in.) 24.03 24.08mm (0.946-0.947 in.)

ServiccLimit 3 2 . 0 2m m ( 1 . 2 6i1n . ) 38.94mm (1.533in.)

28.00 28.01mm(1.102 1.103in.) 23.95 24.05mm (0.943 0.947in.) 20.016 20.043mm (0.7880 0.7891in.) 0.036 0.08amm (0.0014 0.0033in.) 0.70 1.49mm (0.028 0 059in )

2 8 . 0 2m m ( 1 . 1 0i3n . ) 20.90mm (0.832in.) 0 . 1 6m m { 0 . 0 0i6n . ) 0.4mm (0.0164n.)

0.70- '1.19 mm {0.028 0.047in.)

0.3mm (0.012in.)

0.50 1.04mm (0.020 0.041in.)

0.3mm (0.012in.)

0.95 1.68mm (0.037 0.066in.)

0.6mm (0.024in.)

7.4 7.6mm 10.29 0.30in.) 0.35 0.65mm (0.014 0.026in.i 13.4 13.7mm (0.527 0.539in.) 0.20 0.59mm (0.007 0.024in.) 13.973 '14.000 mm (0.5501 0.5512in.) 16.9 '17.0 mm (0.665 0.669in.) 0.2 0.5mm (0.008 0.020in.) 14.85 '14.95 mm (0.585 0.589in.) 0.05 0.25mm (0.002 0.010in.) 15.00 15.10mm {0.591 0.594in.) 0.013 0.07mm (0.0005 0.003in.) 18.010 18.028 mm (0.7091 0.7098in.) 0.027 0.057mm (0.0011 0.0022in.) 28.025 28.045mm (1.1033 1.1041 in.) 0.05 0.15mm {0.002 0.006in.) 1 8 . 0 4 21 8 . 0 6m 6 m ( 0 . 7 1 0 30 . 7 1 1 3 i n . ) 0.059 0.095mm (0.0023 0.0037in.) 0 0.10mm (0 0.0039in.)

1.0mm (0.039in.) 1.3mm (0.051in.)

0 . 6 2m m ( 0 . 0 2i4n . )

L O

0.50mm (0.020in.) 0.1mm {0.004in.) 0.1mm (0.004in.l

0.15mm (0.006in.) Adjust

2-8

Rotational at outside olavmeasured

0 10mm (0 0.39in.)

at outside Startingloadmeasured

2 9 N ( 3 . 0k g f . 6 . 6 l b s )

A n g l e o f r a c kg u i d e s c r e w l o o s e n e d

n Item W h e e l a l i g n m e nCamber t

Measurement

Caster TotalToe

Oualitication Front Rear Front

lrytt Rear

Frontwheelturningangle

l n s i d ew h e e l

Aluminumwheelrunout

Axial

Outsidewheel Radial Wheelbearing

Endplay

Front

Rear

Standardor New 0'00' 45' 0'45'- 45

ServiceLimit

1"33' 11"

in.) 0-3 mm(0::0.12 lN 2 ' , mm (0.08"' ,, in.) 37'40'-2' 29'50'(Reference) 0 0.7mm (0 0.03in.) 0 - 0 . 7m m ( 0 0 . 0 3 i n . ) 0 0.05mm (0 0.002in.) 0 0.05mm (0 0.002in.)

2.0mm (0.08in.) l.5mm{0.06in.)

a 2-9

Standardsand ServiceLimits Brakes Item Parkingbrake lever Brakepedal Mastercylinder Erakedisc

M€asurement Distance traveledwhen leverpulled with 196N (20kgf, 44 lbs) ol force Pedalheight(carpetremoved) Freeplay Piston-to-pushrod clearance Thickness Runout Parallelism

Brakepads

Thickness

Oualification

Standardor New 7 8 clicks

ServiceLimit

1 8 4m m ( 7 4 / 1 6i n . )

Front Rear Front Rear Frontand rear Front llear

0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8 in.) 0 0.4mm (0 0.02in.) 2 1 . 0m m ( 0 . 8 3 in.) 9.0mm {0.35in.)

10.0mm (0.39in.) 9.0mm {0.35in.)

19.0m 0 m (0.75 in.) 8-0mm (0.31in.i 0.10mm (0.004in.) 0.10mm (0.004in.) 0.015mm (0.0006 in.) 1 . 6m m ( 0 . 0 6 in.) 1 . 6m m ( 0 . 0 6 in.)

Air Gonditionin Item Refrige.ant

Tvpe

Refrigerant oil

Capacityof system Type

Moasurement

Capacity ofcomponents

Oualilication

Condenser Evaporator Eachline and

Standard or New

Service Limit

H F C1 3 4a ( B - 1 3a4) 500 550g 117.6 19.4oz) S P1 O (P/N38897-P13-A01AH or 38899-P13-A01 ) 25 m0,15/6fl ozl 45 mA111/2fl ozt 10m0 (1/3fl or)

hose

Compressor Drivebelt

Startercoil resistance plateclearance Pulley-to-pressure

Compressor At 68"F(20"C)

1 3 0 1 5 0m 0 1 41 / 3 5 f l o z ) 3.05 3.350 0.35 0.6mm (0.014 0.024in.) Autotensioner lneedsno adjustment)

2-10

DesignSpecifications

Measurement

|tem

DIMENSIONS

Overallwidth Overallheight

Track

Specilication

Oualification

Overalllength

rront Rear

Groundclearance

4 , 2 1 0m m { 1 6 5 .i8n . ) in.) 1,695mm 166.7 in.) 1,44m 0 m (56.7 m m ( 1 0 1 .i2n . ) 2,570 1,470mm (57.9in.) '1,470 mm (57.9in.i 152mm (5.98in.) four {4) 3,660rbs

S e a t i n gc a p a c i t y

wEtGt-iT {u.s.A.) G r o s s V e h i c l eW e i g h t R a t i n g (GVWR)

WEIGHT (CANADA) ENGINE

1,660kg

GrossVehicleWeightRating {GVWR) Tvpe Cylinderarrangement Boreand stroke Displacement

ratio Compression Valvetrain system Lubrication Oil pumpdisplacement Waterpumpdisplacement

At 6,000engine rpm At 3,400engine

Tvpe Normaloutput

12V 30 seconds

Nominalvoltage

Hourrating Directionof rotation CLUTCH

C l o c k w i s ea s v i e w e c lf r o m g e a r e n d

C l u t c ht v p e

S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g

Clutchfrictionmaterialsurfacearea

1 7 4c m ' { 2 6 . 9s7q i n . ) forward,1 reverse s-speed Svnchronized, D i r e c1t : 1 3.062 1.769 1.212 0.921 0.738 3.583 Sinolehelicalgear

Tvpe I\,1AN UAL TRANSMISSIONPrimarvreduction Gearratio

lst 2nd 3rd 4th

Finalreduction

82 0 (87US qt)/minute gasolinewith 86 pumpoctanenumberor higher UNLEADED Gearreduction

F!el required STARTER

Watercooled.4 strokeDOHCV-ECengin( transverse Inline4'cylinder, 86 x 86 mm (3.39x 3.39in.) cuin.) 1 , 9 9 c8 m ' ( 1 2 2 9.8 Chaindrive.DOHCVTEC4 valvespercylinder Forced, wet sump,withtrochoidpumP (57.4 54.30 US qo/minute

5th Reverse Type Gearratio

4.164

o 2-11

DesignSpecifications cont' Item

Measuremeni Type Overallratio Turns,lockto-lock Steeringwheeldiameter Type

STEERING

SUSPENSION

Shockabsorber

WHEEL ALIGNMENT

Camber Caster

BRAKES

AIR

I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g

Rear Front Rear Front Bear Front Front

Typeof servicebrake

Rear Front Bear

Sizeoffront and reartires Sizeo{ sparetire Compressor

CONDITIONING

Front Rear

Type Numberof cylinders Capacity Maximumspeed

D o u b l ew i s h b o n e

Telescopic, hydraulic. nitrogengas-frlled Telescopic, hydraulic, nitrogengas,filled

0"00' 0.45' 1'33' 0 mm (0 in.) I n 2 m m ( 1 / 1 6i n . ) P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c

Power-assisted self-adjusting soliddisc Mechanical actuating, rearwheels 4 5c m ' ( 7 . 0s q i n . ) x 2 2 8c m ' ( 4 . 3s q i n . )x 2 Pl95/6081588V T125r0 D1595M Scroll

Type Motor type

85.7m015.23 cu in.)/rev. 12,000rpm 130m0 {4 1/3floz) SP-10(P/N38897'P13-A01AH or38899-P13 A01) Corrugated fin Corrugatedfin Siroccofan 220 Wl12 V

Speed control

4 Speeo

L u b r i c a n tc a p a c i t y

Condenser Evaporator Blower

Specilication Electric, Powerassisted rackand pinion 15.1 3 6 0m m ( 1 4 . 2 in)

Totaltoe

Typeof parkingbrake Padfriction surfacearea TIRES

Oualification

Lubricanttype Type

Tvpe

M a x i m u m c a p a c i t y 480m" 116.900 cu ft)/h T e m p e r a t u r ec o n t r o l

Compressor clutch

Tvpe

Refrigerant

Electricalpower cons!mptronat 68"F(20.C) Type Capacity

Airmixtype Dry,singleplate,poly-Vbeltdrive 42W maximumat 12V

HFC134a(R-134a) 500 550g (17.6 19.4oz)

../a 2-12

Item ELECTRICAL RATINGS

Measurement

Specitication

Oualilication

Battery

1 2 V 3 6A H / 5h o u r s

Starter Alternator Fuses

Under-hood fuse

1 2V - . 1 . 1k W ,1 . 2k W 12V 95A,90A 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A

Under'dash Iuse

3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A

Light bulbs

Headlight high beam Headlight low beam Frontturnsignal liqhts Front parlinq lights

Bearturn signal lights FronVrear side markerlights Brale/taillighls H i g h m o L r n tb r a k e

'12v.' 60w 12V 55W 12V 21W 12V 5W 1 2 V" 2 1 W

12V 5W 12V 21/5W 12V 5W

light

Backup lights platelight License Ceilinglight

12V 21W 12V 5W

Cargoarea light

12V 5W 12V 5W

Spotlights

'12v'.8 w

Gauge lights I n d i c a t o rl i g h t s

Sideturn signal light

LED 12V 5W

2-13

Body Specifications

Unit: mm {in.) 1.555{61.6) 1,i140(56.71

2-14

Maintenance Lubricantsand Fluids MaintenanceSchedulefor Normal Conditions Listed by Distance/Time

MaintenanceSchedulefor Severe Gonditions Listedby Distance/Time

\.4

MaintenanceSchedule Listedby Maintenance ltemfor Normal Conditions ................... 3-8 Listedby Maintenance ltem for Severe Conditions ...................3-9

Lubricantsand Fluids

For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n . ures{suchasAssem

LUBBICANT

LUBBICATION POINTS

NO. 1

Eng ine

The oil container Honda Motor Oil (P/N08798-9023). must disolavthe API Cenificationseal shown below. " AE M a k es u r ei t s a y s" F o r G a s o l i n eE n g i n e s . S Viscositv:See chart below.

2 3

Transmission

HondaMTF*'(P/N08798-9016)

Brakesvstem (includesABS line) C l u t c hl i n e Release f o r k ( m a n u a tl r a n s m i s s i o n l Throftlecableend (throttleIink) Shift and selectcable ends (manual transmission) Throttlecable end (dashboardlower panel hole) Brakeboosterclevis CIutchboosterclevis Shift lever pivot Pedalinkage Batteryterminals F u e lf i l l d o o r H o o dh i n g e sa n d h o o d l a t c h H a t c hh i n g e s , o D e ra n d l o w e r D o o rh i n o e s u Caliperpiston boot, caliperpins and boots A i r c o n d i t i o n i n cg o m p r e s s o r

HondaDOT 3 BrakeFluid*' (P/N08798-9008)

5 6 7 I 9 10 11 1'

14 16 17 18 19

S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 ) S i l i c o n eg r e a s e

grease Multi-purpose

HondaCaliDerGrease(P/N08C30-80234lvl) o rH C o m p r e s s o r o iS l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A 38899-P'13-A01) a ( R - 1 3 4a ) F o rr e f r i q e r a nH t;FC'134

Recommond6dEngineOil fanges E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e

-30 -20

-10

* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does not containthe Drooeradditives. " 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of the system.

3-2

t o o o o o

o@@ a9

3-3

MaintenanceSchedule Listedby Distance/Timefor Normal Conditions Thistwo pagel/lanitenance Schedule outlinesthe minimunrequiredmaintenance. Serviceat the indicated distance or time,whichevercomes if the vehiclemeetsanyof the qualifiers in the SevereConditions first.use the lvlaintenance Schedule for Severeconditions schedule or if the vehicleis normallydrivenin Canada.

(cold)(seepage6-321r Intake: 0.21-0.25mm (0.008 0.010in.)Exhaust: 0.28 0.32mm (0.011 0.013in.) Inspectvalveclearance. (NGK)or SKJ20DR-M11 (DENSO). Replace sparkplugs.UseIZFR6K'11 1 . 0 1 . 1m m km/6 years 120,000 mi/ 192,000 fluid.UseHondaMTF(seepage13-3). I Replace transmission ! Do items in A,B,alqq., /

/ Y vcdrs

120,000 mil 192,000 Type2. 5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant Beplace coolant(seepage106).Capacity: tailureto do the maintenance itemsmarkedwith an asterisk According to stateandlederalregulations, {*) will not voidthe customer's intervalto ensurelong-term warranties, However,Hondarecommends thatall maintenance services be doneat the recommended emissions reliability.

3-4

Dothe itemsin partsA, B, C, D, andE as requiredfor mileage/time intervallisted. A Replace engineoillseepage8-5i. Capacity withoutlilterchange:4.0S (4.2US qt, 3.5lmp qt) Rotatetires.Followthe patternshownin the Owner'sManual Checktireinformationandcondition. B Replace engineoil filterlseepage8-6). Capacity with filterchange:4.20(4.4US qt,3.7lmp qt) Inspect frontandrearbrakes(seepage19 3i. . Checkpadsand djscsfor wear(thickness), damage,andcracks. ' Checkcalipers tor damage,leaks,andtjghtnessot mountbolts. Checkparkingbrakeadjustment. ShouldbeIullyappliedwithin7 to I clicks. Inspect tie rod ends,steeringgearbox,and boots{seepage17 5). . Checkrackgreaseandsteeringlinkage. . Checkbootsfor damageand leakinggrease . Chackfluidline{or damageand leaks. lnspectsuspensioncomponents. . Chockboltsfor tightness. . Checkconditionof balliointbootslor deterioration and damage. Inspectdriveshaftboots.Checkbootsfor cracksand boot bandsfor tightness(seepage16-3). proponioning Insp€ctbrakehosesandlines{including ABS). Checkthemastercylinder, controlvalve,andABSmodulator{ordamage andleakage. Checkall fluidlevelsandconditionot tluids;checkfor leaks.lf necessary, add MTFlseepage13'3),engioecoolant,brakefluid,and windshield washerfluid. system*.Checkcatalytic L lnspectexhaust converterheatshield, exhaustpipeand mufflerfordamage,leaks, andtightness{soepage9,8). lnspect{uellinesandconnections*. Checkfor looseconnections, cracksand deterioration; retightenlooseconnoctions and replace damagedparts(s€epage11 146). andadiustdrivebelt. l InsDect . Lookfor cracksanddamage,andinspectautotensioner(needsno adjustment). Replace the dustandpollenlilter(seepage21 39). . Replacethe dustandpollenfilterwheneverairflow lrom the heatingandcoolingsystemis lessthannormal.

Replace air cleanerelementevery30,000miles(48,000 km)(independent of time).

oI mileage). i I Replace brakefluidevery3 years(independent

* ) will not voidcustomer's According to stateandfederalregulations, failureto do the maintenance itemsmarkedwith asterisk( emissions warranties. However,Hondarecommends thatall maintsnance servicebe doneat the recommended intervalto ensurelongterm reliability.

3-5

MaintenanceSchedule Listedby Distance/Timefor SevereConditions or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the Serviceat the indicated distance (seepage3-4). il onlyOCCASIONALLY tollowingconditions; drivenin theseconditions, usethe NormalConditions schedule SevereDrivingConditions . Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures, drivinglessthan 10miles(16km)pertrip . Drivingin extremelyhot (over90"F/32"C) conditions . Extensive deliveryvehicle. idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial . Trailertowing,drivingwith a car-topcarrier,or drivingin mountainous conditions. . Drivingon muddy,dusty,or de'icedroads

R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .

(cold)(seepage6 32):lntake:0.21 0.25mm (0.008 0.010in.)Exhaust: 0.28 0.32mm (0.011 0.013in.) Inspectvalveclearance. 11 (NGK)or SKJ20DR'M 11 {DENSO) Replace sparkplugs.Use IZFR6K

km/ 6 years R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .

mil 192,000 km/ 10years,thenevery60,000mi/ 96,000km/5 years 5.0015.3US qt) UseHondaAll SeasonAntifreeze/coo lantType2. Replace coolant(seepage10-6).Capacity:

3-6

Dothe itemsin partsA, B, C,D, E,F,and G as requiredfor mileage/time intervallisted. A q (4.2US qt,3.5lmpqt) Feplaceengineoil(seepageS5). Capacity withoutlilterchange:4.0 I Replace engjneoil filter(seepageI 6). Capacity with filterchange:4.20 14.4US qt,3.7lmp qt) Insoectfrontand rearbrakes, . Checkpadsanddiscsforwearlthickness), damage,andcracks. . Checkcalipers for damage,leaks,andtightnessof mountbolts. Lubricate doorlocks,latchesand hingeswith Hondawhitelithiumgrease. Rotatetires,if the vehiclehasbeendriventhe distancelisted.Followthe patternshownin the Owner'sManual-Checktire inflaronaoo condition, Inspecttierod ends,steeringgearbox,and boots(seepage17,5). . Checkrackgreaseandsteeringlinkage. . Checkbootsfor damageand leakinggrease. . Checklluidlinefordamageandleaks. components L Inspectsuspensron . Checkboltsfor tightness. . Checkconditionof balljointbootsfor deterioration anddamage. Inspectdriveshaft boots.Checkbootsfor cracksand bootbandsfor tightness(seepage16-3). Checkparkingbrakeadjustment. Shouldbe fullyappliedwithin7 to 9 clicks. Insp€ctbrakehosesandlioes.(including ABS). Checkthe mastercylinder,proportioning controlvalve,andABSmodulatorfor damage (seepage19-24). and leakage (see page13 3),enginecoolant,brakefluid,and Checkall fluidlevelsandconditionot lluids;checkfor leaks.lf necessary, add MTF windshield washerf luid. Inspectexhaustsystem*.Checkcatalytic converterheatshield,exhaustpipeand mufflerfor damage,leaks,andtightness(seepage9 8). Inspect fuel linesandconnections*. Checkfor looseconnections, cracksand deterioration; retightenlooseconnections and replace damagedpans(seopage11'146). (seepage22-68). Checkalllights.Checkfunction otallinteriorandexteriorlights,andthepositionofthe headlights Inspect the v€hicleunderbody. Checkthe paintfor damage,scratches, stonechippin0,anddents.

L D

InsDectand adiustdrive belt. . Looktor cracksanddamage,and inspectautotensioner {needsno adjustment). Reolace dustand oollenfilter.

E Replace aircleanerelementevery15,000 miles124,000 km) in dustvcondition{independent ol timei otherwiseuseNormalConditions (seepage11-162). scredule F

lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162). Replace oJmileagei. brakefluidevery3 years(independent H

Replacethe dustandpollenIilterevery15,000 milesifvehicleis drivenmostlywhereair hashighconcentration olsootfrom industryand dieselpoweredvehiclesj alsoreplace the dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39). A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,

3-7

MaintenanceSchedule

Listedby Maintenanceltem for NormalConditions on the nextpagedo for SevereConditions in the lMaintenance Schedule if the severedrivingconditions specified Followthe NormalSchedule drivenin severedrivingconditions. not apply,and if onlyOCCASIONALLY scheduleif the vehicleis drivenMAINLYin Canada. Followthe SevereConditions ortime, distance Serviceatthe indicated whichevercomesfirst.

milesx 1,000

km x 1,000

months Replace engineoil

100

112

128

144

160

110

192 12

r20

R o t a t et i r e s { C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )

Replace engineoil filter

Inspect frontand rearbrakes C h e c kp a r k i n g b r a k e a d j u s t m e n t

Visuallyinspectthefollowingitems: . Tie-rodends,steeringgearboxand boots . Suspension components . Driveshaftboots . Brakehosesand lines(including ABSi . Allfluidlevelsandconditionof{luids . Exhaust system* . Fuellinesandconnections*

Inspectandadjustdrivebelt

Replace dustand pollenfilter

fluid Reolace transmission Servicethefollowing items at the recommendedintervals R e p l a c ea i r c l e a n e re l e m e n t

km) Every 30,000 miles(48,000

Replace sparkplugs

Lm) Every 110,000 miles(176,000

Inspectvalveclearance

km),otherwise adiusl onlyif noisy. Inspect miles{176,000 every110,000

I n s p e c ti d l e s p e e d *

km)or8 years Every 160.000 mres1256,000

R e p l a c ee n g i n e c o o l a n t

km)or5 miles(96,000 km)or 10years, thenevery60,000 At 120,000 miles(192,000

brakefluid Replace

Every3 years

(*) will not voidcustomer's emissions * : According itemsmarkedwith asterisk failureto do the maintenance to stateandlederalregulations, intervalto ensurelong-termreliabilityservicebe doneat the recommended thatall maintenance However,Hondarecommends warranties.

3-8

Listedby Maintenanceltem for SevereConditions Usethisschedule if the vehicleis drivenMAINLYin Canadaor in anvof thefollowinaconditions. NOTE:it onlyOCCASIONALLY drivenin these conditions, usethe NormalConditions schedute. SovereDrivingConditions . Drivinglessthan5 miles(8 km)pertrip or, in lreezingtemperatures, drivinglessthan 10miles(16km)pertrip. . Drivingin extremely hot over90 "F 132'C)conditions. . Extensive idling,or longperiodsot stop-and-go-driving, suchas a taxior a commercial deliveryvehicle. . Trailertowing,drivingwith a cartop carrier,or drivingin mountainous conditions. . Drivingon muddy,dusty,or de icedroads. Serviceat the indicated distance or time, whichevercomesfirst.

milesx 1,000

km x 1,000

months

100

110

120

112

128

144

160

176

192

Replace engineoil

Replace every 5,000 miies18,000 km)or6 months

Rotatetires intlationandconditionat leastonceper monthi {Checktire

R e p l a c ee n g i n e o i l f i h e r

Inspectfrontand rearbrakes L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s

Visuallyinspectthe followingitems: . Tie rod ends,steeringgearboxand boots . Suspension components ' Driveshaftboots Checlparkingbraleadjuslment

Visuallyinspectthefollowingitems: . Brakehosesand lines{including ABSi . Allfluidlevelsandconditionoflluids . Exhaust system* . Fuellinesandconnections* . Lightsandcontrols, vehicleunderbody

Inspectand adjustdrivebeh

R e p l a c ed u s t a n d p o l l e n f i l t e r " o ' t '

Replace transmission lluid

Servicethe following items atthe recommendedinteruals Replace aircleanerelement

Every15,000 miies(24,000 km)in dustyconditions, otheMiseusenormalschedule.

Replace sparkplugs

Every 110,000 miles(176,000 km)

Inspectvalveclearance

Inspect every110,000 miles(176,000 km),otheMise adiust onlyif noisy.

I n s p e c ti d l e s p e e d '

Every 160,000 miles(256,000 km)or8vears

Replace enginecoolant

At 120,000 miles(192,000 km)of 10years,lhen every miles(96,000 km)or5 60,000

Replace brakefluid

Every3 years

* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v . N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .

3-9

EngineElectrical EngineElectrical SpecialTools

4-2

StartingSystem Comoonent Location Index ............... CircuitDiagram StarterCircuit Troubleshooting ClutchInterlockSwitchTest StarterSolenoid Test .............. Starter Performance Test StarterReolacement ............... StarterOverhaul.......................

4-J

4-4 4-5 4-6 4-7 4-8 4-9 4-10

lgnition System 4-15 Component LocationIndex ............... 4-16 CircuitDiagram lgnitionTimingInspection 4-17 lgnitionCoilRemoval/1nsta11ation 4-18 ....................... 4-19 SparkPlugInspection

ChargingSystem Component LocationIndex .................................. 4-2O CircuitDiagram ........................... 4-21 Charging ....................... 4-22 CircuitTroubleshooting DriveBeltInspection ................... 4-26 DriveBeftReplacement .............. 4-26 DriveBeftAuto-tensioner Inspection.................. 4-27 DriveBeftAuto-tensioner Replacement .............. 4-28 Alternator Reolacement ............. 4-29 Alternator .... 4-30 Overhaul................

CruiseControl Component Location Index .................................. 4-36 CircuitDiagram ........................... 4-37 Index ....................... 4-38 SymptomTroubleshooting CruiseControlUnitlnDutTest ............................. 4-40 MainSwitchTesVReolacement ........................... 4-42 .. 4-42 SeVResume/Cancel SwitchTesVReplacement CruiseControlActuatorTest ......4-43 CruiseControlActuator/Cable Replacement ......4-44 ActuatorCableAdjustment.................................. 4-45 ClutchPedalPositionSwitchTest ....................... 4-45 \.

ENGINE

EngineElectrical

\ C

SpecialTools Number

Tool Number

07746-0010400 07749-0010000

Description Attachment,52 x 55 mm Driver

otv 1 1

\(a 4-2

Starting System ComponentLocationIndex

UNDER-DASH FUSE/RELAYBOX

- l - ar]]]ll

-i

-_rt_.1 -. _-- _. / Itti: : - l t . i t -i t! -t !t:!|-

CLUTCH INTERLOCKSWITCH Test,page4-6

STARTERCUTRELAY Test,page22-51

\ r \ ' l \'\l I

\r\, l,

, . \ \ \ \ /

'....",r.v

\:,...)

\ /'\ t l

STARTER page4 5 StanerCircuitTroubleshoot,ng, SolenoidTest,page 4-7 PerformanceTest,page4-8 Replacement,page 4-9 '10 Overhaul,page4

4-3

Starting System CircuitDiagram -

ilo.20lOA) :USAmotkl No.2!l50A) : C.nid. model

UiIOENH@DfUSE/REI.IY BOX

STHOTin STA8Tilll

UNDEiOASTI FUST/ifLAY 80x

cLuTot [{Tr8LocK swtlcH

a 4-4

StarterCircuitTroubleshooting NOTE: . Airtemperaturemust be between59'and 100'F(15' and 38'C) during this procedure. . After this test, or any subsequentrepair,resetthe enginecontrolemodule (ECM)to clear any diagnostlc trouble codes (DTCS){seepage 11-4). . The batterymust be in good conditionand fully charged. . lf you disconnectthe baftery,do the ECM idle learn p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . RecommendedProcedure: . Use a startersystemtester. . Connectand operatethe equipmentin accordance with the manufacturer'sinstructions. Alternate Procedure 1. Hook up the following equipment: . Ammeter,0 400A . Voltmeter,0 20 V (accuratewithin 0.1 volt) . Tachometer,0 1200rpm

4. Checkthe batterycondition.Checkelectrical connectionsat the battery,the negativebaftery cableto body, the engine ground cablesand the starterfor loosenessand corrosion.Then try startingthe engine again. Did the statter crank the engine? YES Repairingthe looseconnectionfixed the problem.The startingsystem is now OK.! N O l f s t a r t e r w i l ln o t c r a n k t h e e n g i n ea t a l l ,g o t o step 5. lf it cranksthe engine erraticallyor too slowly, go to step 7. lf it won't disengagefrom the flywheel ring gear when you releasethe key, check for the following until you find the cause. . Solenoidplungerand switch malfunction . Dirty drive gear or damagedoverrunningclutch 5. Make sure the transmissionis in neutral,then disconnectthe startersubharness1Pconnector(A) 'lP from the enginewire harness connector(B). Connecta jumper wire from the batterypositive 'l terminalto the startersubharness P connector.

2 . Removethe No. 17 (15A)fuse from the under-dash fuse/relaybox.

3 . With the clutch pedal pressed,turn the ignition switchto start (lll). Did the starter crank the enginenormally?

Did the starter crank the engine?

YES-The startingsystem is OK.I YES-Go to step 6. NO-Go to step 4.

wire betweenthe starter NO Checkthe BLK,ANHT subharness1Pconnectorand the starter.lf wire is OK, removethe starter,and repairor replaceas necessary.

L (cont'd)

4-5

StartingSystem StarterCircuitTroubleshooting (cont'dl

ClutchInterlockSwitch Test

6. Checkthe following items in the order listeduntil you find the open circuit. . Checkthe BLIVWHTwire and connectors betweenthe under-dashfuse/relaybox and the ignition switch,and betweenthe under-dash fuse/relaybox and the starter. . Checkthe ignition switch {seepage 22-53). . Checkthe clutch interlockswitch and connector. . Checkthe startercut relay (seepage 22-51). . CheckLT GRNwire betweenthe startercut relayl under-dashfuse/relaybox and the clutch interlockswitch. . Checkthe BLKwire betweenthe clutch interlock switch and G501.

1. Disconnect the clutchinterlockswitch2Pconnector.

7, Checkthe crankingvoltageand currentdraw. ls ctanking voltagegreatet than or equal to 8.7 V and current draw less than or equal to 230 A? YES-Go to step8. NO Replacethe starter.or remove and disassembleit, and checkthese items until you find thecause. . Starterarmaturedragging . Shortedarmature winding . E x c e s s i vder a g i n e n g i n e 8 . C h e c kt h e e n g i n es p e e dw h i l ec r a n k i n gt h e e n g i n e .

2. Removethe clutch interlockswitch (A). Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch interlockswitch. . lf OK, installclutch interlockswitch and adjust the pedal height (seepage 12-4l..

ls the engine speed above 100 tpm? YES Go to step 9. NO-Replace the starter,or remove and disassembleit, and checkfor the following until y o u f i n dt h e c a u s e . . Excessivelyworn starterbrushes . Open circuit in commutator brushes . Open circuit in starterarmaturecommutator segments . D i r t yo r d a m a g e dh e l i c asl p l i n e so r d r i v eg e a r . Faultydrive gear clutch 9. Removethe starter,and inspectits drive gear and the flywheel ring gear for damage.Replaceany d a m a g e dp a n s . I

4-6

Terminal \ Cl","f ri"t.tf ."tS""*Jrl

PRESSED RELEASED

o--

- --o

StarterSolenoidTest from thestarter 1. Disconnect the S andlvlconnectors solenoid.

2. Checkthe hold-incoil for continuitybetweenthe S terminal and the armaturehousing(ground).There should be continuity. . lf there is continuity,goto step 3. . lf there is no continuity,replacethe solenoid,

3. Checkthe pull-incoil for continuitybetween the S . h e r es h o u l db e terminaa l n d M t e r m i n a lT continuity, . lf there is continuity,the solenoidis OK. . lf there is no continuity,replacethe solenoid,

4-7

StartingSystem Starter PerformanceTest 1 , Disconnectthe wires from the S terminal and the M termrnal.

5. Disconnectthe batteryfrom the starterbody. lfthe pinion retractsimmediately,it is working properly.

Make a connectionas describedbelow using as heavya wire as possible(preterablyequivalentto the wire used for the vehicle).To avoid damaging the starter,never leavethe batteryconnectedfor more than 10 seconds, Connectthe batteryas shown. Be sure to disconnectthe startermotor wire from the solenoid. lf the starterpinion moves out, it is working propefly.

6 . Clampthe starterfirmly in a vise. 7 . Connectthe starterto the batteryas describedin the diagram below, and confirm that the motor starts and keepsrotating.

Disconnectthe batteryfrom the M terminal.lf the pinion does not retract,the hold-incoil of the solenoidis working properly.

lf the eiectriccurrent and motor speedmeet the specificationswhen the batteryvoltage is at 11.5V, the staner is working properly, Specifications: 1.1 kw

90 A or less (Electriccurrent), ot more

4-8

Starter Replacement 1. Make sure you havethe anti-theftcode for the radio. then write down the frequenciesfor the radio's presetbuttons. 2. Disconnectthe negativecablefrom the batteryfirst, then disconnectthe positivecable.

5. Disconnectthe startercable (A)from the B terminal wire on the solenoid,then disconnectthe BLK,/WHT

{ B )f r o mt h eS t e r m i n a l . 10x 1.25mm 44N.m{a.5kgf.m,33lblft)

3. Disconnectthe knocksensorconnector. 4. Removethe bolt (A) securingthe harnessbracket, then removethe intakemanifold bracket(B). A 6x1,0mm 12 N.m {1.2kgf.m, 8.7 tbt.ft)

8 x 1 . 2 5m m 9Nm 10.9kgf.m,7 lbl ft)

S'-12x12smm 6ilNm

{ 6 . 5k g l m , 4 7 l b f f t )

Removethe two bolts holdingthe starter,then removethe starter. 8 x 1.25mm 22 N,m 12.2kgt.m, 16rbf.ftl

7 . lnstallthe starterin the reverseorder of removal. Make sure the crimped side of the ring terminal (A) is facing out.

I Connectthe positivecable and negativecableto the batterY.

9 . Start the engineto make sure the starteroperates propeny.

'10.Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. 1 1 .Set the clock.

' t 2 .Performthe enginecontrol module (EcM) idle learn procedure(seepage 1'1-139).

4-9

StartingSystem

Starter Overhaul Disassembly/Reassembly

STARTERSOLENOID

@ @

;

----_2<-

,--\

rw.h \:!@a

,/ 1(-\

SOLENOIDLEVER

- @-A -z\hsc6

b-.-

," OVERRUNNING

CLUTCHASSEMBLY

o*"lu*.

7:- o S#o

V*rN*

A*@

\#. \

c^)* -#""Jli[X:"" a<-4 -v t^ fr/ /

ffiA

9\:-/ ffitr D lW

,..

END COVER

'!4/ t/ BRUSHHOLDER

\ r 4- 10

\ Armature Inspection and Test

5. Checkthe commutatordiameter.lf the diameteris below the servicelimit, replacethe armature.

1. Removethe starter(seepage 4-9). 2 . D i s a s s e m b lteh e s t a r t e ra s s h o w na t t h e b e g i n n i n g of this procedure.

Commutator Diameter Standard(Newl: 28.0mm (1.10in.l ServiceLimit: 27.0 mm (1.06in.)

3. Inspectthe armaturefor wear or damagefrom contactwith the permanentmagnet.lf there is wear or damage,replacethe armature.

6 . Measurethe commutator (A) runout.

?.-

Checkthe commutator(A) surface.lf the surfaceis dirty or burnt, resurfacewith emery cloth or a lathe within the specificationsin step 5, or recondition with # 500 or # 600 sandpaper(B).

. lf the commutator runout is within the service limit, checkthe commutatorfor carbondust or brasschips betweenthe segments. . lf the commutator runout is not within the service limit, reolacethe armature. Commutator Runout StandardlNew): 0.02mm 10.001in.) max. ServiceLimit: 0.05mm (0.002in.)

(cont'd)

4-11

StartingSystem StarterOverhaul(cont'dl 7. Checkthe mica depth (A).lf the mica is too high {B), undercutthe mica with a hacksawbladeto the properdepth.Cut away allthe mica (C)between the commutatorsegments.The undercutshould not be too shallow,too narrow,or V-shaped(D).

9. Placethe armature(A) on an armaturetester (B). Hold a hacksawblade (C)on the armaturecore. lf the blade is attractedto the core or vibrateswhile t h e c o r ei s t u r n e d ,t h e a r m a t u r ei s s h o n e d .R e p l a c e thearmature.

Commutator Mica Depth Standard(New):0.50-0.80 mm {0.020-0.031in.) ServiceLimit: 0.20 mm (0.008in.)

1 0 ,Checkwith an ohmmeterthat no continuityexists

Checkfor continuitybetweenthe segmentsof the commutator.lf an open circuitexists betweenany segments,replacethe armature.

betweenthe commutator(A) and armaturecoll core (B),and betweenthe commutatorand armatureshaft (C).lf continuityexists,replacethe armature.

M \

4-12

Starter Brush Inspection

Starter Brush Holder Test

11. lvleasurethe brush length.lf it is not within the servicelimit, replacethe brush holder assembly.

14, Checkthat there is no continuitybetweenthe (+ ) b r u s hh o l d e r{ A )a n d ( ) b r u s hh o l d e r( B } .l f t h e r e is continuity,replacethe brush holder assembly.

Brush Length Standard{New): 14.0-14.5 mm (0.55-0.57 in.) 9.0 mm {0.35 in.) Service Limit:

Brush Spring Inspection Starter Field Winding Test 12. Checkfor continuitybetweenthe brushes(A).lf there is no continuity.replacethe armature h o u s i n g( B ) .

15. Insen the brush (A) into the brush holder,and bring the brush into contactwith the commutator,then attacha spring scale(B)to the spring (C).Measure the spring tensionat the moment the spring lifts off the brush.lf the springtension is not within specification,replacethe spring. Spring Tension: 13.7-17.7 N {1.40-1.80 kgf, 3.09 3.97lbf)

1 3 .Checkfor continuitybetweeneach brush (A) and the armaturehousing(B).li there is continuity, replacethe armaturehousing.

(cont'd)

4-13

StartingSystem StarterOverhaul(cont'dl Planetary Gear Inspection

Starter Reassembly

1 6 . C h e c kt h e p l a n e t a r yg e a r s( A )a n d r i n g g e a r{ B ) . Replacethem if they are worn or damaged.

20, Pry backeach brush spring with a screwdriver,then positionthe brush about halfwayout of its holder, a n d r e l e a s et h e s p r i n gt o h o l d i t t h e r e . NOTE:To seatthe new brushes.slip a strip of #5OO or # 600 sandpaper.with the grit side out, be&veen the commutatorand each brush,and smoothly rotatethe armature.The contactsurfaceof the brusheswill be sandedto the same contouras the commutator.

OverrunningCluich Inspection 17. Slidethe overrunningclutchalong the shaft. Replaceit if it does not slide smoothly. 18. Rotatethe overrunningclutch(A) both ways. Doesit lock in one directionand rotatesmoothly in reverse?lf it does not lock in eitherdirectionor it locksin both directions,replaceit.

21 l n s t a l l t h ea r m a t u r ei n t h e h o u s i n ga, n d i n s t a l l t h e brush holder.Next, pry backeach brush spring a g a i n ,a n d p u s ht h e b r u s hd o w n u n t i li t s e a t s againstthe commutator,then releasethe spring againstthe end of the brush.

s 1 9 .lf the starterdrive gear (B) is worn or damaged, replacethe overrunningclutch assembly;the gear is not availableseparately. Checkthe conditionof the flywheel ring gear. Replaceit if the starterdrive gear teeth are oamageo.

Installthe starterend cover to retainthe brush holder.

i.-

4-14

lgnition System ComponentLocationIndex

SPARK PLUG page4-'19 Inspection,

IGNITION COIL page4-17 lgnitionTimingInspection, page4-18 Removal/lnstallation,

4-15

lgnition System (

GircuitDiagram 'No.20lOA) :USAmo&l No.Al50A):Cmrda model

UNDEBHOOD FUST/8TIAY M)(

lG1tioT in 0N {ll) rd SIARIilll)

4-16

lgnition Timing Inspection 1 . Connectthe Honda PGM Testerto the data link connector(DTC),and checkfor DTC'S.lf a DTCis present,diagnoseand repairthe causebefore i n s p e c t i n tgh e i g n i t i o nt i m i n g . Startthe engine.Holdthe engine at 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . 4. Follow the tester'sprompts in the

"SCS" menu

6. Pointthe light toward the pointer (A) on the cam c h a i nc a s e .C h e c kt h e i g n i t i o nt i m i n g u n d e rn o l o a d conditions:headlights,blower fan. rearwindow defogger,and air conditionerare not operaling.lf the ignitiontiming differsfrom the specification, and there are no enginecontrol module {ECM)DTcs, r e p l a c et h e E C M( s e ep a g e1 1 - 4 ) lgnition Timing: 8"+2" BTDC{REDmark {B))during idling in neutral A

{seethe testeroperator'smanual),

5 . Connectthe timing light to the serviceloop.

7. Turn the ignition switch OFF. D i s c o n n e c t t hH e o n d aP G MT e s t e ra n dt h e t i m i n g light.

4-17

lgnition System lgnitionCoilRemoval/lnstallation 1. Removethe ignition coil cover (A),then removethe i g n i t i o nc o i l s( B ) . 6x1.0mm

9.8 N.m (1.0kgf.m,7.2lbf ftl

2. Installthe ignition coils in the reverseorder of removal.

4-18

---a

SparkPlug Inspection 1 . Inspectthe electrodesand ceramicinsulator. Burned or worn electrodes may be caused by: . Advancedignitiontiming . Loosespark plug . Plug heat rangetoo hot .Insufficientcooling

3. Replacethe plug at the specifiedinterval,or if the centerelectrodeis rounded{A). Use onlVthe spark plugs listedbelow. Spark Plugs: lZFR6Kl1(NGK) (DENSO) SKJ2ODR-M11

Fouledplug may be causedby: . Retardedignitiontiming . O i l i n c o m b u s t i o nc h a m b e r . Incorrectspark plug gap . Plug heat rangetoo cold . Excessiveidling/lowspeed running . C l o g g e da i r c l e a n e re l e m e n t . Deterioratedignitioncoils Worn or deformed electrodes

f .lmpropergap I J.Oil-touling . Cs6on deposits 'r- 1I . Crackedcenter \ electrodeinsulator

4 . Apply a small quantityof anti-seizecompoundto

the plug threads,and screwthe plugs into the cylinder headfinger-tight.Then torque them to 1 8 N m ( 1 . 8k g f . m ,1 3 l b f f t ) .

Do not adjustthe gap of iridium tip plugs (A); replacethe spark plug if the gap is out of specification. Electrode Gap: Standard(New): ServiceLimit:

1.0 1.1 mm {0.039-0.0€ in.) 1.3 mm {0.051in.l

4-19

GhargingSystem ComponentLocationIndex

CHARGING SYSTEMINDICATOR (ln the gaugeassembly)

q*o

BATTERY Test,page22-50

DRIVEBELT page4 26 Inspection, page4 26 Replacement,

4-20

ALTEBNATOR page4-22 Troubleshooting, page4-29 Replacement, page4-30 Overhaul,

CircuitDiagram 'flo.

{l0Al :uSAhod.l ilo.20l50Al:C.n.d.mod.l

UNDTRXOOD FUSI/RILAY MX

+--, I fmlil*t"t' T-

+ilt = l

4-21

GhargingSystem ChargingCircuitTroubleshooting lf the chargingsystem indicatordoes not come on or does not go off, or the batteryis dead or low, test these items in the order listedbelow: Battery(seepage 22-50) Chargingsystem indicator Alternatorand regulatorcircuit Alternatorcontrol system

6. Measurethe voltageat the No. 3 terminal of the e n g i n ew i r e h a r n e s s6 P c o n n e c t ow r iththe ignition s w i t c hO N {l l ) . ENGINEWIREHARNESS6P CONNECTOR

IBLK/YEL}

ChargingSystemIndicatorTest 1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . Does the chatging system indicator come on? YES Go to step 2.

Wiresideof femaleterminals

NO Go to step 3. ls there battery voltage? 2. Startthe engine. YES-Go to step 7. Does the charging system indicator go off? YES-Charging system indicatorcircuitis OK. Go to the Alternatorand RegulatorcircuitTest.t

N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A )f u s e i n t h e under-dashfuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe alternatorand the under-dashfuse/relaybox.I

NO-Go to step 3.

7 . Turn the ignition switch OFF. 3. Turn the ignitionswitch OFF. 4. Troubleshootthe multiplexcontrol system (see page 22 172).

8 . Disconnectenginecontrol module (ECM)connector B (24P).

9 . Checkcontinuitybetweenthe ECMconnector ls the multiplex control system OK? YES Go to step 5.

t e r m i n a lB ' 1 0a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r t e r m i n a lN o . 6 . ECM CONNECTOB A (24P)

NO Checkthe multiplexcontrol system as indicatedby the diagnostictrouble code (DTC) (see s t e p8 o n p a g e2 2 - 1 7 2 ) . 1 A C G L{ W H T / B L U )

5. Disconnectthe enginewire harness6P connector from the startersub harness6P connector. E N G I N EW I B E HARNESS 6P

L (WHT/BLUI

W i r e s i d eo f f e m a l e t e r m i n as

ls there continuity? YES Go to step 10. NO-Repair open in the wire betweenthe a l t e r n a t oar n dt h e E C N 4 . I

4-22

\"4

'10.

Checkcontinuitybetweenthe ECMconnector t e r m i n a l8 1 0 a n d b o d y g r o u n d . ECMCONNECTOR S I24PI

2 3 t 4t 5 8 I 10 ,/1,/ 3 1 1 8 ,N nt,/ 21

6 7 15

ACGL(WHT/BLUI t1'

Alternator and RegulatorCircuitTest 1. Be sure the batteryis sufficientlychargedand in good condition{seepage 22-50),and the connectionsat the fuse box and alternatorare clean and tight. 2. Raisethe hoist to full height. 3. Hook up the ammeter,0 subharness.

400 A, to the starter

Wire side ol femaleterminals

ls there continuity? YES- Repairshort to ground in the wire between the ECMand the enginewire harness6P connector. t NO-Go to alternatorand regulatortest.

Lower the hoist. Hook up the voltmeter,0 0.1V),toT101.

20 V (accuratewithin

(cont'd)

4-23

GhargingSystem (cont'd) ChargingCircuitTroubleshooting 6. Startthe engine.Hold the engineat 3,000rpm with no load (in Neutral)until the radiatorfan comes on, then let it idle. 7. Raisethe engine speedto 2,000rpm, and hold it there. 8. Turn the headlights(high beam)on, and measure voltageat the under-hoodfuse/relaybox terminal. ls the voltagebetween 13.9and 15.1v? YES-Go to step 9.

NOTE:After troubleshooting,performthe engine control module (ECM)idle learn procedure(seepage 11-139). 1. Checkfor proper operationof the electricalload detector(ELD)by checkingthe malfunction i n d i c a t o lra m p ( M l L ) ( s e ep a g e1l - 3 ) .l f a D T Ci s present,diagnoseand repairthe causebefore continuingwith this test. 2. Disconnectthe enginewire harness6P connector from the startersub harness6P connector.

NO Repairor replacethe alternatorcomponents (seepage 4-30).1 9. Readthe amperageat

Alternator Control SystemTest

'13.5V.

NOTE:Adjust the voltage by turning the blower motor, rearwindow defogger,brakelights.etc.ON.

3. Start the engine,and turn the headlights(high b e a m )O N , 4. Measurevoltage betweenthe enginewire harness 6P connectorterminal No. 2 and the positive terminal of lhe battery.

ls the amperage604 ot morc?

BATTERY

YES-Alternator/regulatoroperationis OK.I NO Repairor replacethe alternatorcomponents (seepage 4-30).1

C {WHT/GRN)

ENGINE WIREHARNESS 6PCONNECTOR Wiresideof femaleterminals ls there 1 V or less? YES Go to step 8. N O - G o t o s t e p5 . 5 . T u r nt h e h e a d l i g h t a s n d i g n i t i o ns w i t c hO F F . 6 . DisconnectECMconnectorB (24P).

4-24

\ 7, Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d b o d y g r o u n d . ECM CONNECTORB {24PI

1 2 3 t 4t 5

6 1

8 9 10 ,/1,/ 3

nt,/21

11o

ACGC{WHT/GRN}

10. Checkfor continuitybetweenECMconnector t e r m i n a l8 1 8 a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r t e r m i n a lN o . 2 . ECM CONNECTORB l2,lPI

1 2 3 1 4 l 5 l l6l 7 8 9 10 15 t.) 11o 21 23

ACGC(WHT/GRN)

Wire side ot femaleterminals

C (WHT/GRN) 2

ENGINEWIREHARNESS6P CONNECTOR Wire side oI lemale terminals

ls there continuity? ls therc continuity? YES-Repair short to ground in the wire between the alternatorand the ECM.I

NO-Check that the terminalsare firmly seatedat the ECMconnectorB. lf OK, substitutea knowngood ECM,and recheck(seepage 11-6). lf prescribedvoltage is now available.replacethe o r i g i n aE l CM,I

YES Repairor replacethe startersubharnessor the alternator(seepage 4-30).I NO Repairopen in the wire betweenthe a l t e r n a t oar n d t h e E C M . I

Turn the headlightsand ignition switch OFF. 9 . DisconnectECMconnectorB (24P).

4-25

ChargingSystem DriveBelt Inspection indicator(A)is withinthe Checkthatthe auto-tensioner (B) range as shown. lf it is out of thestandard standard range,replacethedrivebelt(seepage4-26).

DriveBelt Replacement 1, Move the auto-tensioner(A) to relievetensionfrom the drive belt (B).and removethe drive belt.

2. Installthe new belt in the reverseorder of removal.

4-26

DriveBelt Auto-tensionerInspection 1 . Checkwhether there is a changein the positionof

the auto-tensionerindicatorbeforestartingthe engineand after startingthe engine.lf there is a c h a n g ei n t h e p o s i t i o nr, e p l a c et h e a u t o - t e n s i o n e r .

Removethe auto-tensioner(seepage 4-28). I n s t a ltlh e t e n s i o n e p r ulley. 7 . Clampthe auto-tensioner(A) by using two 8 mm bolts (B)and a vise (C)as shown. Do not clamp the auto-tensioneritself.

C h e c kf o r a b n o r m a n l o i s ef r o m t h e t e n s i o n e p r ulley. lf abnorman l o i s ei s h e a r d ,r e p l a c et h e t e n s i o n e r pulley.

3 . Removethe drive belt (seepage 4-26). 8 . Set the torque wrench (D)on the pulley bolt. lMovethe auto-tensionerwithin its limit with the belt tension releasetool in the directionshown. Checkthat the tensionermoves smoothly and without any abnormal noise.lf the tensionerdoes not move smoothly or there is abnormal noise, replacethe auto-tensioner.

9 . Align the indicator{E)on the tensionerbasewith c e n t e rm a r k( F )o n t h e t e n s i o n e ar r m b y u s i n gt h e torque wrench, and measurethe torque. lf the torque value is out of specification,replacethe auto-tensioner, NOTE;lf the indicatorexceedsthe centermark, recheckthe torque. Auto-tensioner spring torque: 26.5-36.3 N.m 12.7-3.7 kg.m, 19.5-26.8lbt.ft)

4-27

ChargingSystem DriveBelt Auto-tensionerReplacement 1. Removethe drive belt (seepage 4'26).

4. Removethe auto-tensioner,

2 . R e m o v et h e i d l e rp u l l e y . 6xl.0mm 9.8 N.m (1,0kgl.m, 7.2 tbf.ft)

6x1,0mm 12 N.m ('1.2kgt.m.8.7lbt.ft)

x 1.25mm

22 N.m

{2.2 kgt m, 16 lbf ft}

3. Removethe tensionerpulley.

8 x 1.25mm 22 N.m (2.2kgf.m, 16lbt.ft) 5. lnstall in the reverse order of removal.

4-28

\-a

l\-

AlternatorReplacement 1. Make sure you havethe anti-theftcode for the radio, then write down the frequenciesfor the radio's preset buttons, 2. Disconnectthe negativecablefrom the batteryfirst, then disconnectthe positivecable.

9 . Removethe alternator. 1 0 . Installthe alternatorand drive belt in the reverse order of removal. 'I 1 . Connectthe positivecable and negativecableto the battery.

3. Removethe front bumper (seepage 20-85). tt.

4. Removethe right side headlight(seepage 22-79).

Enterthe anti-theftcode for the radio,then enter the customer'sradio station presets.

5. Removethe reservetank from the bracket.

1 3 .Set the clock.

6. Removethe drive belt (seepage 4-26).

1 4 . Performthe enginecontrol module {ECM)idle learn p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .

7. Removethe three bolts securingthe alternator. 8 x 1 . 2 5m m 22 N.n 12.2kgl.m,

Disconnectthe alternatorconnector(A) and BLK wire (B)from the alternator. 8 N.m 10.8kgf.m,6lbf.ft)

4-29

ChargingSystem AlternatorOverhaul ExplodedView

ROTOR W|UF.,.oy." REARBEARING / \

FRoNrBEARING B

@b.J.y{=RE+LN'"' I/ vVFko"-% \

qtr*njlv

V ("rV) , BRUSH HOLOER TNSULATOR \ \-

BRUSH HOLDER \ \ VOLTAGE REGULATOR

\11 -\\ \l } (-

@*F,-\: \

PULLEY / \

PULLEY LOCKNUT

v_re*^i \gP^@'I

*ffilw9 TERMINAL INSULATOR

REARHOUSING ASSEMBLY

INSULATOR BUSHING

4-30

\-a

L Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400

5 . R e m o v et h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .

NOTE:Referto the ExplodedView as neededduring this procedure. 1, Testthe alternatorand regulatorbeforeyou remove them (see page 4-22l,. 2. Removethe alternator(seepage 4-29). 3. lf the front bearingneedsreplacing,removethe pulley locknutwith a 10 mm wrench (A) and a 22 mm wrench (B).lf necessary,use an impact wrencn.

6 . Removethe brush holder (A),voltage regulator(B), a n dt h e r u b b e rs e a l{ C } .

, (( , t tI ; r _l L t

L1i.21---^

tqLJ Removethe harnessbracket(A),insulator(B).three flange nuts (C),and the screw (D),then removethe p l a t et e r m i n a l( E ) .

B-"--|.

1!q[-dr,:l

(cont'd)

4-31

ChargingSystem AlternatorOverhaul(cont'dl 7. Removethe four screws,then removethe rectifier ( A )a n d f o u r i n s u l a t o r (sB ) .

the frontbearingand/or 9. lf you arenot replacing '16. rearbearing,go to step Removethe rotorfrom the statordriveendhousing.

1 0 .Inspectthe rotor shaftfor scoring,and inspectthe bearingjournal surfacein the statorhousingfor s e t z u r em a r k s . Removethe four flange nuts,then removethe rear h o u s i n g( A )a n dw a s h e r( B ) .

. l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g isdamaged, replacethe alternator, . lf both the rotor and the stator housingare OK, g o t o s t e p1 1 . 'l

\" 1 . R e m o v et h e r e a rb e a r i n gu s i n ga p u l l e ra s s h o w n .

f.r,e 4-32

\1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a yvailable tools shown, installa new rear bearingon the rotor shaft. NOTE:Installthe bearingusing the inner race.

14. Supportthe stator housingin a vise, and drive out the front bearingwith a brassdrift and hammer.

1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si ,n s t a l a l new front bearingin the stator housing. 13. Removethe front bearingretainerplate.

6 u

e s

07749-0010000

f-\ \r-:1 \s---'^/

07746-0010400

( c o n t ' d)

4-33

ChargingSystem AlternatorOverhaul(cont'd) Rectitier Test

Alternator Brush Inspection

16. Checkfor continuityin each direction,betweenthe B terminal and P terminals,and betweenthe E terminaa l n d P t e r m i n a l so f e a c hd i o d ep a i r . 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 yi n o n l y o n e direction.Becausethe rectifierdiodes are designed to allow currentto pass in one direction,and the rectifieris made up of eight diodes (four pairs).you musttest each diode in both directionsfor continuitywith an ohmmeterthat has diode checkingcapability:a total of 16 checks.

1 7 . M e a s u r et h e l e n g t ho f b o t h b r u s h e s( A ) w i t ha v e r n i e rc a l i p e r{ B ) . . l f e i t h e rb r u s hi s s h o r t e r t h a n t h es e r v i c el i m i t , r e p l a c et h e b r u s ha s s e m b l y . . lf brush length is OK, go to step '18. Alternator Brush Length: Standard(New): 10.5mm (0.41in.) ServiceLimit: 1.5 mm (0.06in.)

. lf any diode is faulty. replacethe rectifier assembly.{Diodesare not availableseparately.) ' lf all the diodes are OK, go to step 17.

/--:',t-L -o \--

. -l'-=

\" Rotor Slip Bing Test 18. Checkthat there is continuitybetweenthe slip rings {A). . lf there is continuity,go to step 19. . lf there is no continuity,replacethealternator.

B P "

P, P. P, P.

1 9 . Checkthat there is no continuitybetweeneach slip ring and the rotor (B) and the rotor shaft (C). . lf there is no continuity,goto step 20. . lf there is continuity,replacethe alternator.

4-34

\r'a

Stator Test 20. Checkthatthereis continuitybetweeneach pair of leads(A). lf there is continuity,go to step 21. lf there is no continuity,replacethe alternator.

'--l-- --i 2 1 .Checkfor no continuitybetweeneach lead and the coil core (B). . lf there is no continuity,goto step 22. . lfthere is continuity,replacethe alternator.

22. Assemblethe alternatorin reverseorder of disassembly,and note these items: . Be carefulnot to get any greaseor oil on lhe slip nn g s . . lf you removedlhe pulley,tighten its locknutto 1 1 1N . m ( 1 1 . 3k g f m , 8 1 . 7l b f . f t ) w h e n y o ui n s t a l l it.

4-35

GruiseControl ComponentLocationIndex CRUISECONTROLINDICATOR (Builtinto gaug6assembly)

CLUTCH PEDALPOSITION swtTcH Test,page4-45 ClutchPedalAdjustment, page12-4

CRUISECONTROLUNIT lnputTest,page4-40 BRAKEPEDALPOSITION SWITCH Test,page22-84 page'19-6 PedalHeightAdjustment,

t.-

CRUISE CONTROL ACTUATOR Test,page4'43 page4-44 Replacement,

4-36

_,-

ACTUATORCABLE Adjustment,page4-45

\-a

CircuitDiagram ' fUS'/iILAY IOX UISEF NOOD

-to

ots

No.aloAl No.20itoAl

USAnod.l C.md! modrl

BU/YIL

lcl H0Tii0llilll mdSTARTlllll

1 Honilsffroi

1 uNtT cnu6EcoNTnoL

3 l0

CTuICIIPEDAL

P0sm0swtrct

4-37

CruiseControl Symptom TroubleshootingIndex NOTE: ' The numbersin the table showthetroubleshootingsequence. . Beforetroubleshooting. - checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A) fuse in the under-hoodfuse/relaybox, - checkthat the horn sounds. - checkthe tachometerto see if it works properly. - checkthe speedometerlo see if it works properly.

Symptom Cruisecontrol cannot be set

Diagnostic procedure 1. Checkmain switch (seepage 4-42) 2. CheckSET/RESUME/CANCEL switch (seepage 4-42) 3. Test brakepedal positionswitch (seepage 22-84)and check its adjustment{seepage 19,6) 4. Test clutch pedal positionswitch (seepage 4-45)and check its adjustment(seepage 12-41 5. Checkcruisecontrol unit {seepage 4-40} 6. Checkvehiclespeed sensor(VSS)(seepage 22-65)

Cruisecontrol can be set but indicatorlight does not go on

1. Checkcruisecontrolindicatorbulbin gaugeassembly{see page 22-631 2. Checkcruisecontrolunit(seepage4-40)

ar, 'i.a

1. Checkvehiclespeed sensor(VSS){seepage 22-65) Checkcruisecontrol actuator{seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40)

c^aa.l

noticeablh y i g h e ro r lower than what was set Excessiveovershooting or undershootingwhen trying to set speed Speedfluctuationon a flat road with cruise control set Vehicledoes not decelerateor accelerate accordinglywhen SET/ RESUME/CANCEL button is pushed Set speed does not cancel(enginerpm stays h i g h )w h e n c l u t c hp e d a l is pushed Set speeddoes not cancelwhen brakepedal is pushed

4-38

Also check for

. Poorground: G501 . Opencircuit, looseor disconnected t e r mi n a l s : L TG R N , BLI(ORN. GRY/RED, BLU. LTBLU, BLUAA/HT . Poor ground: G501 . Open circuit, looseor disconnected termrnats: YEL,BLUA/EL

1. Checkcruisecontrol actuator(seepage 4-43) 2. Checkvehiclespeed sensor(VSS)(seepage 22-65) Checkcruisecontrol unit (seepage 4-40) 3. 1. Checkvehiclespeedsensor(VSS)(seepage22-65) Checkcruisecontrol actuator(seepage 4-43) 2. Checkcruisecontrol unit (seepage 4-40) 1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) 2. Checkcruisecontrol unit {seepage 4-40)

Open circuit,loose or disconnected terminals: GRY/RED, LT GRN/BLK

1. Testclutch pedal positionswitch (seepage 4-45)and check its adjustment(see page 12-4) 2. Checkcruisecontrol unit (seepage 4-40)

Shortto groundin the LTBLUwire

'1. 2.

Test brakepedal positionswitch (seepage 22-84)and check Open circuit,loose its adjustment(seepage 19-6) or disconnected Checkcruisecontrol unit (seepage 4-40) terminals: WHT/BLK

g ,

svmptom Set speeddoes not cancelwhen main switch i s o u s h e dO F F Set speeddoes not c a n c ew l henCANCEL button is pushed

Set speedwill not r e s u m ew h e n R E S U M E button is pushed(with main switch on, and set speedtemporarily cancelledby pressingthe brakeDedal)

Diagnosticprocedure 1. Checkmain switch (seepage 4-42) 2. Checkcruisecontrol unit (seepage 4-40)

Also check for Short to power in the LT GRNwire.

ME/CANCELswitch (seepage 4-42) 1. CheckSET/RESU 2. Checkcruisecontrol unit (seepage 4-40)

Opencircuit,loose or disconnected terminals: GRYiRED, LTGRN/BLK

1. CheckSET/RESU ME/CANCELswitch (seepage 4-42) 2. Checkcruisecontrol unit {seepage 4-40)

Open circuit,loose or disconnected terminals: L TG R N / B L K

4-39

CruiseGontrol CruiseControl Unit Input Test SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service. 1. Disconnectthe 14Pconnectorfrom the control unit. 2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent, loose,orcorroded, repairthem as necessary,and recheckthesystem. . lf the terminalslook OK, go to step 3.

Wire sideof femaleterminals

3. With the 14Pconnectordisconnected,make these inDuttests. Cavity

Wire Test condition BRN/WHT Connectbattery power

BLU

BLK

4-40

lgnitionswitch ON (ll),main swltch ON and brakepedal pressed,then reteaseo

Test:Desiredresult Checkthe operationof the magneticclutch:Clutch s h o u l dc l i c ka n d o u t p u tl i n k should be locked. Checkfor voltageto ground; There should be 0 V with lhe pedal pressedand battery voltagewith the pedal released.

U n d e ra l l c o n d i t i o n s Checkfor continuityto grouno: There should be continuitv BLIVORN l g n i t i o ns w i t c hO N Checkfor voltageto ground: Thereshould be battery flr) vottaqe. WHT/BLK Brakepedal pressed, Checkfor voltageto ground: then released There should be battery voltagewith the pedal pressed,and 0 V with the pedal released.

Possiblecause ifresuhis notobtained ' Faultyactuator . P o o rg r o u n d( G 3 0 1 ) . An open in the wire . Shon to ground (arcswhen Doweris connected) . Faultybrakepedal position switch . A n o p e ni n t h e w i r e . Open in cruisecontrol main swrtcn . B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under/dashfuse/relavbox . P o o rg r o u n d( G 5 0 1 ) . An open in the wire B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under-dashf use/relaybox An oDenin the wire B l o w nN o . 7 { 1 5A ) f u s ei n t h e under-hoodfuse/relaybox Faultybrakepedal position SWIICN

A n o D e ni n t h e w i r e

Cavity

Test condition Wire GRYiRED Setbuttonpushed

LT GRN/ BLK

Resumebutton pusneo

BRN

Connectbattery

BRNI/EL power to the BRN

BLUIVEL

t e r m i n a la n d g r o u n d to the BRNIVEL termrnal lgnitionswitch ON

0r)

BLU/VVHT lgnitionswitch ON (ll) and main switch ON; raisethe front of the vehicle,and rotateone wheel s l o w l yw h i l e h o l d i n g the other wheel

Test:Desiredresult Checkfor voltageto ground: Thereshould be battery voltage, W h e nt e s t i n gt e r m i n a lN o . 6 , there should be no voltageon t e r m i n a lN o . 7 . Checkfor voltageto ground: Thereshould be battery voltage. W h e nt e s t i n gt e r m i n a lN o . 7 , there should be no voltageon t e r m i n a lN o . 6 . Checkthe operationof the actuatormotor: You should be able to hear the motor.

Possible cause il resultis notobtained B l o w nN o . 7 ( 1 5A ) f u s e i n t h e under-hoodfuse/relaybox Faultyhorn relay Faultysevresume/cancel swrtch Faultycable reel An open in the wire Shon to ground (horn sounds when button is pressed)

. Faultyactuator . An open in the wire

Attachto groundi C r u i s ei n d i c a t o lri g h ti n t h e g a u g ea s s e m b l ys h o u l dc o m e on.

Blown No. 10 (7.5A) fuse in the under-dashfuse/relaybox Blown cruise indicatorbulfl F a u l t yg a u g ea s s e m b l y An open in the wire

Checkfor voltage between (+) ANdBLK thE BLU/VVHT ( )terminals: T h e r e s h o u l d b e 05 V o r more repeatedly.

FaultyVSS An openin thewire Shortto ground

B l o w nN o . 4 ( 1 0A ) f u s e i n t h e under-dashfuse/relaybox Faultymain switch An oDenin the wire Faultyclutch pedal position swtlcn P o o rg r o u n d( G 5 0 1 ) Incorrectclutchswitch adjustment An open in the wire

LTGRN

lgnitionswitchoN { l l )a n dm a i ns w i t c h ON

Checkfor voltageto ground: Thereshouldbe battery voltage.

LT BLU

C l u t c hp e d a l reteaseo

Checkfor continuityto grouno: T h e r es h o u l db e c o n t i n u i t y . N O T E : T h e r se h o u l db e n o continuitywhen the clutch oedal is Dressed.

lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK, the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works properly,replacethe cruisecontrol unit.

4-41

CruiseControl Main Switch Test/Replacement

Set/Resume/Cancel Switch Test/ Replacement

1 . Removethe driver's dashboardlower cover (see page 20-59). 1. Removethe two screws.then removethe switch. Releasethe clips of the main switch and push the main switch 1A)out of the panel,then disconnect the 5P connector(B)from the main switch.

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. . lfthere is continuity,and it matchesthe table, but Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. lf the continuityis not as specified,replaceillumination bulbs (C)or the switch.

switchfailure occurredon the cruisecontrol unit input test, checkand repairthe switch circult. . lf there is no continuityin one or both positions, replacethe switch.

\-------11v1

\ 1

Position OFF

o @ o \J

Terminal '\

;"itl*

sET(ONt

RESUME ION)

o o

CANCEL{ON}

--o

r\--

4-42

CruiseControlActuatorTest 1. Disconnectthe 4P connector(A) from the cruise control actuator(B).

6. Checkthe operationof the actuatormotor in each output linkagepositionaccordingto the table.You should be able to hear the motor. Batterypower Dolarities

Output linkageposition

FULt MIDDLEFUtL OPEN CLOSE PO$TION The The The No.3 No,4 Terminal Terminal motor motor motor runs. runs. stoDs, The The The No.3 N o .4 Terminal Terminal motor motor motor sIoos. runs. runs. OUTPUTLINKAGE

2. Removethe cover (A),and checkthe output linkage (B)for smooth movement. ,to

FULLCLOSE

1 . lf the actuatormotor does not operateas specified, replacethe cruisecontrol actuatorassembly,

Connectbatterypower to the No, 2 terminal and g r o u n dt o t h e N o . 1 t e r m i n a l . C h e c kf o r a c l i c k i n gs o u n df r o m t h e m a g n e t i cc l u t c h . The output linkageshould be locked. 5 . lf the output linkageis not locked,replacethe cruisecontrol actuatorassembly,

4-43

CruiseControl CruiseControlActuator/CableReplacement 1 . Fully open the cruisecontrol link by hand,then removethe cruisecontrol cable{A) from link. Loosenthe locknut(B),and removethe cablefrom the bracket.

2 . Disconnectthe 4P connector,and removethe three

3 . Removethe actuatorcover (A),then removethe actuatorcable (B)from the cruisecontrol actuator.

4 . Installin the reverseorder of removal,and adjust the free play at the throttle linkageafter connecting the actuatorcable.

bolts securingthe cruisecontrol actuator.

6x1,0mm 12 N.m (1.2kgf.m,8.7lbf.ft)

\rla 4-44

ActuatorCableAdiustment 1. Checkthat the actuatorcable{A) moves smoothly with no binding or sticking.

ClutchPedalPositionSwitch Test 1. Disconnectthe 2P connectorfrom the clutch pedal positionswitch (A), SWITCH2PCONNECTOR CLUTCHPEOALPOSITION T e r m i n a l s i do ef m a l et e r m i n a l s

2. Startthe engine. 3. Measurethe amount of movementof the output linkage(B) until the engine speedstartsto increase. At first, the output linkageshould be locatedat the fully closedposition(C).The free play (D)should be 3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2i n , ) . 4. lf the free play is not within specs,loosenthe locknut(E).and turn the adjustingnut (F)untilthe free play is as specified,then retightenthe locknut

Removethe clutch pedal positionswitch. Checkfor continuitybetweenthe terminals accordingto the table. . lf the continuityis not as specified,replacethe clutch pedal positionswitch. . lf OK, installtheclutch pedal positionswitch and adjustthe pedal height (seepage 12-4). Terminal Cl"t"h P"d"l I PositionSwitch

PRESSED

RELEASED

4-45

EngineAssembly EngineRemoval Special Tools Required FrontsubframeadapterEOS02C00001 1

NOTE: . Usefender coversto avoid damagingpainted surfaces. . To avoid damage,unplug the wiring connectors carefullywhile holdingthe connectorportion. . Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts.

\, 6. Disconnecttheintakeairtemperature(lAT)sensor connector(A),removethe breatherhose (B)and v a c u u mh o s e( C ) ,t h e n r e m o v et h e a i r c l e a n e r housingcover/intakeair duct assemblv(D).

1. Securethe hood in the wide open position(support rod in the lower hole). 2. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the radio's presetbuttons. 3. Disconnectthe negativecablefrom the batteryfirst, then disconnectthe positivecable. 4. Removethe battery. 5. Removethe intakemanifoldcover.

5-2

7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .

8. Removethe intakeair duct.

10. Fullv ooen the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and c r u i s ec o n t r o lc a b l e( B ) f r o mt h e l i n k s .L o o s e nt h e locknuts{C),and removethe cablesfrom the bracket.

9. Removethe batterycables{A) fromthe under-hood fuse/relaybox. then removethe harnessclamp (B) a n d g r o u n dc a b l e( C ) .

1 1 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) . 1 2 . R e m o v et h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) . 13. Removethe evaporativeemission(EVAP)canister hose {A) and brakeboostervacuum hose (B).

(cont'd)

5-3

EngineAssembly

..4,

EngineRemoval(cont'dl 1 4 . R e m o v et h e c l u t c hs l a v ec y l i n d e r{ A )a n d c l u t c h l i n e bracketmounting bolt (B).

16. Disconnectthe engine control module (ECM) connectors(A) and main wire harnessconnector (B).

15. Removethe shift cable (A) and selectcable (B).

't7. Remove the harnessclamps (A) and grommet (B), t h e n p u l l t h ee n g i n ew i r e h a r n e s st h r o u g ht h e bulkhead.

\l,

5-4

30. Disconnectthe air fuel ratio {4,/F)sensorconnector (A) and secondaryheatedoxygen sensor (secondaryHO2S)connector(B),then removethe three way catalyticconverter{TWC)assembly{C).

1 8 .Removethe drive belt (seepage 4-26). 1 9 .R e m o v et h e l v C l i n e m o u n t i n gb o l t .

20. Removethe radiatorcap. 2 1 . R a i s et h e h o i s tt o f u l l h e i g h t . 22. Removethe front tires/wheels. 3 1 . R e m o v et h e l o w e rh o s e .

23. Removethe splashshield.

2 4 . L o o s e nt h e d r a i np l u g i n t h e r a d i a t o r t od r a i nt h e enginecoolant(seepage 10-6). 2 5 . D r a i nt h e t r a n s m i s s i ofnl u i d ( s e ep a g e1 3 ' 3 ) . 26. Drainthe engineoil {seepage8-5). 2 7 . D i s c o n n e ct h t e s t a b i l i z el ri n k s( s e ep a g e1 8 - 1 8 ) . 28. Disconnectthe suspensionlower arm ball joints ( s e es t e p3 o n p a g e1 8 - 1 9 ) . 29. Removethe driveshafts{seepage 16-3).Coat all precision f i n i s h e ds u r f a c e sw i t h c l e a ne n g i n eo i l . Tie plasticbags over the driveshaftends.

(cont'd)

5-5

EngineAssembly EngineRemoval(cont'd) 32. Lowerthe hoist. 33. Removethe upperhose(A)andheaterhoses(B).

34. Bemovethe radiator(seepage 10-10). 35. Attachthe chain hoist to the engine as shown.

5-6

36. Removethetransmission mountbracketsupport boltandnuts.

37. Removethe upperbracketmountingboltandnut.

(.g

Make sure the hoist bracketsare positioned properly.Raisethe hoist to full height.

41. Attachthe subframeadaptertofrontofthe subframe, thentightenthe knurledknob.

39. Removethe rear mount mounting bolts.

Raisethe jack. Line up the slots in the arms with the bolt holeson the corner of the jack base,then attachthe adaDterto the iack basewith the bolts.

40. Removethefrontmountbracketmountinqbolt.

(cont'd)

5-7

EngineAssembly EngineRemoval(cont'd) 43. Use a markerto make alignmentmarks on the referencelines(A) that align with the centersof the r e a rs u b f r a m em o u n t i n gb o l t s( B ) .

!:_- _l.=

---.-','-

45. Disconnectthe compressorclutchconnector(A), then removethe Ay'Ccompressor(B)without disconnectingthe A'./Choses.

ffi4 ffit'"

46. Checkthat the engine/transmission is completely free of vacuum hoses,fuel and coolanthoses,and e l e c t r i c awl i r i n g . 4 7 . S l o w l yl o w e rt h e e n g i n ea b o u t1 5 0m m ( 6 i n . ) . C h e c ko n c ea g a i nt h a t a l l h o s e sa n d w i r e sa r e disconnectedtrom the engine/transmission. 48. Lowerthe engineall the way. Removethe chain hoistfrom the engine. 4 9 . Removethe enginefrom under the vehicle. 44. Removethe front subframe(C).

5-8

Enginelnstallation Special Tools Required FrontsubframeadapterEOS02C00001 1 1. lnstallthe accessorybrackets,and tighten their bolts and nuts to the specifiedtorques. ENGINEMOUNTBRACKET

1 0x 1 . 2 5m m il4 N.m {4.5kgf.m,33lbl.ft)

A/C COMPRESSOR BRACKET

10 x 1,25mm 44 N.m {4.5kgf.m,33lbt.ft)

(cont'dl

5-9

EngineAssembly EngineInstallation(cont'd) Positionlhe engine under the vehicle.Attachthe chain hoistto the engine,then lift the engine into p o s i t i o ni n t h e v e h i c l e .

5. Installthe subframe(A).Alignthe reference marks (B)on the subframewiththe centerof the bolt h e a d st ,h e nt i g h t e nt h eb o l t s .

Reinstallthe m o u n t i n gb o l t s / s u p p o rntu t si n the sequencegiven. Failureto follow this sequencemay causeexcessivenoiseand vibration,and reducebushinglife.

- - -.'.: -

--=---=--

.-€..'tt-

---:- -

3. Installthe A,/Ccompressor(A),and connectthe compressorclutchconnector{B).

6r"

1 4 x 1 . 5m m 103Nm { 1 0 , 5k g f m . 76 rbt.ftl Replace.

6-_-'-

6. Tightenthe rear mount mounting bolts. 8 x 1.25mm 22 N.m 12.2kgf m. 16 lbf.ft) 4. Supportthe subframewith the subframeadapter a n da j a c k .

l 0 x 1 . 2 5m m 59 N.m (6.0 kgf.m, 4:] lbI.ft)

5 - 10

7. Looselytightenthe front mount bracketmounting bolt.

10. Tightenthe transmissionmount bracketsupport bolt and nuts. 1 2x 1 . 2 5m m 54 N m {5.5kgt m, 40 lbf.ft}

8 . Lower the hoist. 9 . Tightenthe upper bracketmounting bolt and nut.

'l '1.

Raisethe hoistto full height.

' t 2 . Tighten the front engine mount bracketmounting bolt. 12x 1.25rnrn 64 N.m{6.5kgf.m, 47 tbt.ftl

13. Lower the hoist. 1 4 . R e m o v et h e c h a i nh o i s tf r o m t h e e n g i n e . '15. I n s t a l l t h er a d i a t o r( s e ep a g e1 0 - 1 0 ) . '16. R a i s et h e h o i s tt o f u l l h e i g h t . 17. Installa new set ring on the end of each driveshaft, then installthe driveshafts.Make sure each ring "clicks" into place in the differentialand intermediateshaft. (cont'd)

5-11

EngineAssembly EngineInstallation{cont'dl 1 8 . Connectthe suspensionlower arm ball joints (see s t e p6 o n p a g e1 8 - 1 9 ) . 1 9 . Connectthe stabilizerlinks (seepage 18-18).

2 3 . I n s t a l l t h es p l a s hs h i e l d .

-t-

-- -

-- --r

20. Installthe three way catalyticconverter(TWC) assembly(A);use new gaskets(B) and new selflockingnuts {C). 10x 1.25mm 33 N.m{3.i1kgf.m, 25 tbt.ftl

24. Lowerthe hoist. 25. I n s t a l l t hder i v eb e l t . 26. InstalltheA,/Clinemountingbolt. 6 x '!.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl

-d ,ry

6\ \

8 x 1.25mm 22N.m |.2.2kglm, 16tbt.ft)

2 1 . Connectthe air fuel ratio (4,/F)sensorconnector(D) and secondaryheatedoxygen sensor(secondary HO2S)connector(E). Installthe lower radiatorhose.

v 5-12

27. lnstallthe upper radiatorhose {A) and heaterhoses (B).

30. Connectthe ECI\4connectors(A) and main wire harnessconnector(B).

Pushthe enginecontrolmodule(ECM)connectors through t h eb u l k h e a tdh, e ni n s t a l l t hger o m m e(tA ) . 3 1 .Installthe throttlecable (seepage 11-164),then a d j u s t t h ec a b l e{ s e ep a g e1 1 - ' 1 6 3 ) .

3 2 . Installthecruisecontrol cable (seepage 4-44),then adjustthe cable (seepage 4-45),

33. Installthe brakeboostervacuum hose (A) and the evaporativeemission(EVAP)canisterhose (B).

2 9 . I n s t a l l t h eh a r n e s sc l a m p s( B ) .

3 4 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .

(cont'd)

5-13

EngineAssembly EngineInstallation{cont'dl

Installthe selectcable (A) and shift cable(B) using the plasticwashers(C),washers(D),and new cotter p i n s( E ) . 6x1.0mm 9.8N.m(1.0kgf.m, 7.2tbl.ftl

37. Installthe batterycables(A) on the under-hood fuse/relaybox, then installthe harnessclamp (B).

6x1.0mm 12Nm{1.2kgt.m, 8.7rbf.ft)

"-.----->) "------'6 I n s t a l l t h eg r o u n dc a b l e( C ) .

3 9 . I n s t a l l t h ei n t a k ea i r d u c t . 6x1.0mm 12Nm{1.2kgf.m, 8.7 tbf.ft)

I n s t a ltlh e c l u t c hs l a v ec y l i n d e r( A )a n d c l u t c hl i n e bracketmounting bolt (B).

8 x '1.25mm 24 N.m (2.4kgl.m,

5-14

6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft)

4 0 . I n s t a ltlh e a i r c l e a n e rh o u s i n q .

4 3 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .

6x1.0mm 12 N m (1.2kgf.m,8.7lbt.ft)

6x1.0mm 12Nm11.2kgf.m. 8.7 tbf.ft)

E Y

4 1 . I n s t a ltl h e a i r c l e a n e rh o u s i n gc o v e r( A )a n d connectthe intakeair temperature(lAT)sensor connector(B),

44. Installthe battery.Cleanthe batterypostsand c a b l et e r m i n a l sw i t h s a n d p a p e rt ,h e n a s s e m b l e them and apply greaseto preventcorrosion. ]tE

Checkthat the transmissionshifts into gear smoothly.

46. Inspectfor fuel leaks.Turn the ignition switch ON (ll) {do not operatethe starter)so that the fuel pump runs for about 2 secondsand pressurizesthe fuel line. Repeatthis operationtwo or three times, then checkfor fuel leakageat any point in the fuel line. 41. R e f i l l t h ee n g i n ew i t h e n g i n eo i l ( s e ep a g e8 - 5 ) . n i t h f l u i d ( s e ep a g e1 3 - 3 ) . 48. R e f i l tl h e t r a n s m i s s i ow 4 9 . Refillthe radiatorwith enginecoolant,and bleed air from the cooling system with the heatervalve o p e n ( s e ep a g e1 0 - 6 ) . 4 2 . I n s t a l l t h eb r e a t h e hr o s e( C )a n d v a c u u mh o s e1 D ) .

5 0 . P e r f o r mt h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . 5 1 . Inspectthe idle speed (seepage 11-138).

52. I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) . 5 3 . C h e c kt h e w h e e la l i g n m e n {t s e ep a g e1 8 - 4 ) . 54. Enterthe anti-theftcode for the radio,then enter the customer'sradio station presets. 55. Set the clock.

5-15

EngineMechanical CylinderHead SpecialTools 6-2 Comoonent LocationIndex 6-3 EngineCompression Inspection b-t' VTECRocker Arm Test ........... ............ 6-7 VTCActuatorInspection .................... 6-8 ValveClearance Adjustment ............. 6-9 Crankshaft PulleyRemovaland Installation.............. 6-11 C a mC h a i nR e m o v a l . . . . . . . . . . . . . . . . . . .6. -. 1 . .2. . . . C a mC h a i nI n s t a l l a t i o n . . . . . . . . . . . . . . . .6. .-.1. .5. . Auto-Tensioner Removal/1nsta11ation ......................... 6-19 ChainCaseOil SealInstallation ........6-21 CyfinderHeadCoverRemoval .......... 6-22 CylinderHeadRemoval ..................... 6-23 WC Actuator.ExhaustCamshaftSorocket R e paf c e m e n t .........6-24 Head Cylinder Inspection for Warpage...................... 6-25 Rocker Arm AssemblyRemoval................................. 6-26 Rocker ArmsandShafts Disassembly/Reassembly .............. 6-27 Rocker ArmsandShaftsInspection............................ 6-28 Camshaft Inspection .......................... 6-29 Valves,Springs,andValveSealsRemoval................ 6-31 ValveInsoection...................... ........... 6-32 ValveStem-to-Guide Clearance Insoection............... 6-32 ValveGuideReolacement ................. 6-33 ValveSeatReconditioning ................ 6-35 Valves,Springs, andValveSealsInstallation............ 6-37 Rocker Arm AssemblvInstallation .... 6-38 C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3 . .9. . . . . . . . . . CylinderHeadCoverInstallation ......6-41

CylinderHead

SpecialTools O .D

o @ o G) E] O tro @ (D

ozoa I oz..rae-oot

07JAB-0010204 07NAB-0010404 07VAE-001010A OTZAJ.PNAAlOO OTZAJ-PNAA2OO I 07ZAJ-PNAA300 07742-0010100 07746-001o4oo 07749-0010000

l-:

,.-/

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r--\ Lq-,

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- 1jr-

..'.,i2

.<:'':'v''

5'r'

..# ..a:-"

- -- -i

'a- ti--

1 1 1 1 1 1 2 1 1

Regulator Air Pressure V a l v eG u i d eR e a m e r5, . 5m m Socket,19 mm H o l d e rH a n d l e HolderAttachment,50 mm Valve Spring CompressorAttachment VTECAir Adapter VTECAlr Stopper Air Joint Adapter V a l v eGu i d eD r i v e r , 5 . 5m m Attachment,52 x 55 mm Driver

OTAAJ.PNAA'IOO OTHAH-PJ7O1OB

Oty

Description

Tool Number

Ref. No.

/":

-- -'''

't'tY-,l

a,/'/'

6-2

ComponentLocationlndex

IGNITIONCOIL COVER

CYLINDER HEAD COVER page6-22 Removal, page6-41 lnstallation,

CAM CHAIN Bemoval,page6-'12 Installation,page6-15

frn "p

CAM CHAINGUIDEB

| ] t J,

CAM CHAINGUIDEA

VALVE VARIABLE TIMINGCONTROL twc) olL soLENotD VALVE

PULLEY CRANKSHAFT R e p l a c e m e npt a , g e6 1 1

TENSIONER ARM

AUTO.TENSIONER page6-'lI Replacement,

O-RING

(cont'd)

6-3

CylinderHead ComponentLocationIndex(cont'd)

CAMSHAFT HOLDER

Y f\ R LI T

fr F]

CAMSHAFTPOSITION ICMP}SENSOR

EEI g-----

CAMCHAIN GUIDEB

-"-oowetew

TOPDEADCENTER (TDC)SENSOR EXHAUSTCAMSHAFT SPROCKET Removal,page6 24 page6-25 Installation,

EXHAUSTCAMSHAFT

ROCKER ARM ASSEMBLY Overhaul,page6 27 Inspection,page 6-28

6-4

.\ ll" --€.i SPRING RETAINER

vALvE

EXHAUSTVALVE SEAL

.""or", uo.u,

>il(

d:l.\

aFl

\ l gg | |

II T1 l l I I

l* I / uo.ur.r","o l l

spntruc

.--

G\-r_

vALVE -/ TNTAKE

^-'--

9E4L Replacement,

Page6-31

U-

H e , tl Y

EI 1.U

|NTAKEVALVE GUIDE page6-33 Replacement,

_-/

2bw 9)

\*""'RArNERcovER wcsrRArNER

HEATSHIELD

HEAD CYLINDER Removal,page6'23 Inspection,page6-25 Installation,page6-39 EXHAUSTVALVE Removal,page6-31 Installation,page6-37 INTAKEVALVE Removal,page6 31 Installation,page6 37

CYLINDER HEAD GASKET

6-5

CylinderHead EngineCompressionInspection 1 . W a r m u p t h e e n g i n et o n o r m a lo p e r a t i n g temperature(coolingfan comes on). 2. Turn the ignition switch OFF. 3. Removethe intakemanifoldcover (seestep 1 on page6-22).

\ 9 . Open the throttlefully, then crankthe enginewith the startermotor and measurethe compression. Compression Pressure Above 930 kpa (9.5 kgf/cm', 135 psi)

1 0 .Measurethe compressionon the remaining cylinders,

4, Disconnectall four injectorconnectors. 5. Startthe engine,and let it run until it stalls. 6 . R e m o v et h e i o u r i g n i t i o nc o i l s( s e ep a g e4 - 1 8 ) . 7. Removethe four spark plugs. 8. Attachthe compressiongaugeto the spark plug note.

Maximum vadation Within 200 kPa (2.0 kgf/cm', 28 psi) 1 1 .lf the compressionis not within specifications, checkthese items,then remeasurethe compressron. . Damagedorworn valvesand seats . Damagedcylinder head gasket . Damagedor worn piston rings . Damagedorworn piston and cylinderbore

6-6

WEC RockerArmsTest Special Tools Required . Air pressureregulator07AAJ-PNAA100 . VTECair adaoter07ZAJ-PNAA100 . WEC air stoDoer07ZAJ-PNAA200 . Air joint adapter07ZAJ-PNAA300 1. Removethe cylinder headcover (seepage 6-22). 2. Set the No. 1 pistonat top dead center(TDC)(see step 1 on page6-12). 3. Verify that the intakeprimary rockerarm (A) moves independentlyof the intakesecondaryrockerarm (B).

Repeatstep 3 on the remainingintakeprimary rockerarms with each piston at TDC.When all the primary rockerarms passthe test, go to step 5. Checkthat the air pressureon the shop air compressorgauge indicatesover 400 kPa (4 kgflcm',57 psi). 6 . Inspectthe valve clearance(seepage 6-9). 7 . Removethe sealingbolt (A)from the relief hole, and installthe VTECair stopper(B). OTAAJ.PNAAlOO

D OTZAJ-PNAA3OO

. lf the intakeprimary rockerarm does not move, removethe primary and secondaryrockerarms as an assemblyand checkthat the pistonsin the secondaryand primary rockerarms move smoothly.lf any rockerarm needs replacing, replacethe primary and secondaryrockerarms as an assemblv,and test. . lfthe intakeprimary rockerarm moves freely,go to step 4.

OTZAJ.PNAAlOO

Removethe No. 2 and No. 3 camshaftholder bolts, and installthe VTECair adapters(C)finger-tight. Connectthe air joint adapter(D),and air pressure regulatorwith a 0-100psi gauge (E).

(cont'd)

6-7

CylinderHead WEC RockerArms Test (cont'dl '10.

Loosenthe valve on the regulator,and apply the specifiedair pressure.

Specified air pressure: 290 kPa 13.0kgt/cm', 42 psi) NOTE:lf the synchronizingpiston does not move after applyingair pressure;move the primary or secondaryrockerarm up and down manuallyby rotatingthe crankshaftclockwise. 1 1 . W i t h t h e s p e c i f i e da i r p r e s s u r ea p p l i e d m , o v et h e i n t a k ep r i m a r yr o c k e ra r m ( A ) f o r t h e N o , 1 c y l i n d e r . The primary rockerarm and secondaryrockerarm ( B )s h o u l dm o v e t o g e t h e r . lf the intakesecondaryrockerarm does not move, removethe primary and secondaryrockerarms as an assembly,and checkthat the pistonsin the primary and secondaryrockerarms move smoothly.lf any rockerarm needsreplacing, replacethe primary and secondaryrockerarms as an assembly,and test.

VTGActuator Inspection '11. Removethe cylinder headcover (seepage 6-22lr. 2. Removethe auto-tensioner(seepage6-19). 3. Loosenthe rockerarm adjustingscrewslsee step 2 on page6-26). 4. Removethe camshaftholder (seestep 3 on page 6-

26t. 5. Removethe intakecamshaft. 6, Checkthat the variablevalve timing control (VTC) actuatoris lockedby turning the VTCactuator clockwiseand counterclockwise. lf the VTC actuator is not locked,replacethe VTCactuator. 7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n the No. 1 camshaftjournal with tape.

Puncha hole through the tape over one of the advanceholes.

1 2 .Removethe specialtools. 1 3 .Tightenthe camshaftholder mounting boltslo 22N m 12.2kgf.m, 16 lbf.ft). 1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m , 14 tbf.ft). t5.

6-8

I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .

ValveGlearanceAdiustment 9. Apply air to the advancehole to releasethe lock.

NOTE:Adjust the valvesonly when the cylinder head temperatureis lessthan 100'F (38'C). 1. Removethe cylinderhead cover (seepage6-22). 2. Set the No. 1 piston at top dead center(TDC).The punch mark (A) on the variablevalve timing control (VTC)actuatorand the punch mark (B)on the exhaustcamshaftsprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaftsprocket.

1 0 .Checkthat the VTCactuatormoves smoothly.lf the VTC actuatordoes not move smoothly, replacethe VTC acluator.

{cont'd)

6-9

GylinderHead ValveClearanceAdjustment (cont'd) 3. Selectthe correctthickness feelergaugefor the valvesyou'regoingto check. Intake: 0.21 0.25mm (0.008-0.010 in.) Exhaust; 0.28 0.32mm (0.011 0.013in.)

\. 5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e locknut(A),and turn the adjustingscrew {B) until the drag on the feelergauge is correct..

Adiustingscrew locations: EXHAUST No. 1

No. 1

N o .2

No.3

N o .4

No.4

Tightenthe locknut,and recheckthe clearance. Repeatthe adjustmentif necessary 7 . Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 ' ) .

4. Insertthe feeler gauge {A) betweenthe adjusting

s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t backand forth; you should feel a slight amount of d rag.

8. Checkand, if necessary,adjustthe valve clearance o n N o .3 c y l i n d e r .

6-10

CrankshaftPulleyRemovaland Installation 9. Rotatethe crankshaft180"clockwise(camshaft pullevturns 90'). Special Tools Required . Holder handle07JAB-001020A . Holderattachment,50 mm 07NAB-001040A . Socket,19 mm 07JAA-001020,4 or a commercially a v a i l a b l e1 9 m m s o c k e t

Removal 1. Removefront tires/wheels. 2. Removethe splashshield (seestep 23 on page 5-5). 3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r attachment(B). B 07NAB-001040A

1 0 .Checkand, if necessary,adjustthe valve clearance on No.4 cylinder. 1 1 .Rotatethe crankshaft180"clockwise(camshaft p u l l e yt u r n s9 0 " ) .

el / f

/ Srroo.oo,oroo (or commercially available)

Removethe bolt with a 19 mm socket(C)and breakerbar.

1 2 .Checkand, if necessary,adjustthe valve clearance o n N o .2 c y l i n d e r . Installthe cylinder headcover (seepage 6-41).

(cont'd)

6-11

CylinderHead CrankshaftPulleyRemovaland Installation(cont'dl

CamChainRemoval

NOTE:Keepthe cam chain away from magneticfields.

Installation 1. Cleanthe crankshaftpulley (A),crankshaft(B),bolt (C).and washer (D).Lubricateas shown below.

1. Turn the crankshaftpulley so ils top dead center ( T D C )m a r k( A )l i n e su p w i t h t h e p o i n r e r( B ) .

. .: Clean O; Lubricate

ll ll

t[] rL -'....-----=a

(-,

5U-1J It t -

2 . Removethe front tires/wheels. I n s t a l l t h ec r a n k s h a fpt u l l e y ,a n d h o l dt h e p u l l e y with holder handle(A) and holder attachment{B).

3 . R e m o v et h e s p l a s hs h i e l d . - , , - - . = . - - - - - _ _ - - _

B 07NAB-0010iroA

A 07JAB-001020A

4. Removethe drive belt (seepage 4-26). Tightenthe bolt to 245 N.m (25.0kgf.m, 181 tbf.ft) with a torque wrench and 19 mm socket(C).Do not use an impactwrench.

5. Removethe cylinder headcover (see page6-22). 6 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .

I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) . 5 . Install front tires/wheels.

6-12

7. Disconnectthecrankshaftposition(CKP)sensor connector{A) and variablevalvetiming control {VTC)oil control solenoidvalve connector(B).

1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .

1 2 . R e m o v et h e c h a i nc a s e .

Removethe VTC oil control solenoidvalve (see s t e p1 o n p a g e1 1 - 1 2 7 ) . 9 . Supportthe enginewith a iack and wood block u n d e rt h e o i l p a n .

1 0 .Removethe ground cable (A).and removethe upper bracket(B).

(cont'd)

6-13

CylinderHead CamChainRemoval(cont'd) Looselyinstallthe crankshaftpulley.

(

\ 16. Removethe auto-tensioner.

1 4 . Turn the crankshaftcounterclockwiseto compress the auto-lensioner,

1 7 . R e m o v et h e c a m c h a i ng u i d eB .

gffi llll t5.

Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e na 1 . 5m m ( 0 . 0 6i n . ) diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe Din.

U U

6- 14

CamChainInstallation 1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r a r m( B ) .

NOTE:Keepthe cam chain away from magneticfields.

1. Set the crankshaftto top dead center(TDC).Align the TDC mark {A) on the crankshaftsprocketwith t h e p o i n t e r( B )o n t h e c y l i n d e rb l o c k .

t./6. | \ {n$1J;

g"'1 9 . R e m o v et h e c a m c h a i n .

Setthe camshaftsto TDC.The punch mark (A) on the variablevalve timing control {VTC)actuatorand t h e p u n c hm a r k( B )o n t h e e x h a u s ct a m s h a f t sprocketshould be at the top. Align the TDC marks (C)on the VTC actuatorand exhaustcamshaft sprocKet.

(cont'd)

6-15

GylinderHead CamChainInstallation(cont'dl 3. Installthecamchainon the crankshaft sprocket with thecoloredpiece(A)alignedwiththe punch mark(B)on the crankshaft sprocket.

{

5 . I n s t a l l t h ec a m c h a i ng u i d eA ( A )a n d t e n s i o n ear r m (B).

6x1.0mm 1 2N . m {1,2kgf.m, 8.7 tbf.ftt

'6I

8 x 1 . 2 5m m 22 N.m 12.2kgt.m, 16tbf.ft)

Installthecam chain on the VTCactuatorand exhaustcamshaftsprocketwith the punch marks (A) alignedwith the two colored pieces(B). B

6. Installthe auto-tensi

a 6x1,0mm 12Nm (1.2kgt.m,8.7 lbf ti)

a 6-16

1 0 .Removeold liquid gasketfrom the chain case

7 , I n s t a ltlh e c a m c h a i ng u i d eB . 8 x 1.25mm 22 N.m (2.2kgf.m,16lbt.ft)

H4 \ilt H g

mating surfaces,bolts,and bolt holes. 1 1 .Cleanand dry the chain case mating surfaces. evenlyto the Apply liquid gasket.P/N 08718-0009, cylinder block mating surfaceofthe chain caseand t o t h e i n n e rt h r e a d so f t h e h o l e s .

8. Removethe Dinfrom the auto-tensioner,

Apply liquid gasket alongthe brokenline.

Apply liquid gasketto the cylinder blockupper surfacecontactareas(A) on the chaincase. evenlyto the 1 4 . Apply liquid gasket,PiN 08718-0009, oil pan mating surfaceof the chain caseand to the innerthreadsof the holes.

9 . Checkthe chain caseoil sealfor damage.lf the oil seal is damaged,replacethe chain case oil seal ( s e ep a g e6 - 2 1 ) .

NOTE:Do not installthe parts it 5 minutesor more have elapsedsinceapplying liquid gasket.lnstead, reapplyliquid gasketafter removing old residue.

Apply liquid gasket alongthe brokenline.

(cont'd)

6-17

GylinderHead CamChainInstallation(cont'd) '15.

Installthe new O-ring(A) on the chain case.Set the edge of the chain case (B)to the edge of the oil pan ( C ) ,t h e n i n s t a ltl h e c h a i nc a s eo n t h e c v l i n d e rb l o c k (D).

{

1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .

NOTE:When installingthe chain case,do not slide the bottom surfaceon the oil pan mounting surface.

rbf.ft)

',.9

17. Installthe upper bracket(A),then tightenthe bolv nuts in the numberedseouenceshown. 6 x 1 . 0m m 12 N.m {1.2kgl m, 8.7 lbf ft}

6x1.0mm 1 2N . m (1.2kgt.m.8.7lbf.ft)

6x1.0mm 12Nm (1.2kgf.m,8.7lbf.ft)

1 2 x 1 . 2m 5m 54 N.m (5.5 kgt m, 40 lbf.ft)

1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .

6-18

Auto-TensionerRemovaU lnstallation 1 9 . lnstallthe variablevalve timing control (VTC)oil c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .

Removal: 20. Connectthe crankshaftposition(CKP)sensor connector{A) and VTC oil control solenoidvalve connector(B).

21. Installthe crankshaftpulley (seepage 6-12).

1 . R e m o v et h e c h a i nc a s ec o v e r .

Turn the crankshaftcounterclockwiseto compress the auto-tensroner.

2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) . 2 3 . I n s t a l l t h ed r i v eb e l t . 2 4 . I n s t a l l t h es p l a s hs h i e l d .

€D@

{cont'd)

6-19

GylinderHead Auto-TensionerRemoval/lnstallation(cont'dl 3. Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . ) diameterpin (C)into the holes.Turn the crankshaft clockwiseto securethe oin.

4. Removethe auto-tensioner.

Installation: 1. Installthe auto-tensioner.

6x1.0mm 12 N.m {1.2kgt.m,8.7 lbt.tt) Remove the pin from the auto-tensioner.

6-20

ChainCaseOil SealInstallation Removeold liquid gasketfrom the chain casecover mating surfaces,bolts,and bolt holes.

SpecialToolsRequired . Driver07749-0010000 . Attachment,52 x 55 mm 07746-0010400

4 . Cleanand dry the chain casecover mating surfaces.

Apply liquid gasket,P/N 08718-0009, evenlyto the chain case mating surfaceof the chain casecover and to the innerthreadsof the holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplyingliquid gasket.Instead, reapplyliquid gasketafter removing old residue.

Apply liquid gasket a l o n gt h e b r o k e nl i n e .

1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l squarelyinto the chain caseto the specified i n s t a l l e dh e i g h t .

07749-0010000

2. Measurethe distancebetweenthe chain case s u r f a c e( A )a n d o i l s e a l1 B ) .

6 . I n s t a l l t h ec h a i nc a s ec o v e r . Oil Seal InstalledHeight: 3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )

6x1.0mm 1 2N . m {1.2kgt.m, 8.7 tbf.ft)

33.0 33.7mm { 1 . 3 0 1 . 3 3i n . l

6-21

GylinderHead CylinderHeadCoverRemoval 1. Removethe intakemanifoldcover.

(

\ 4, Removethe cylinder headcover

V:t :;t 1

|,'.i/ 2. Removethe four ignition coils (seepage 4-'18). 3. Removethe dipstick(A) and breatherhose (B).

(

6-22

GylinderHeadRemoval NOTE: . Usefendercoversto avoiddamagingpainted surfaces. To avoid damage,unplug the wiring connectors carefullywhlle holdingthe connectorportion. To avoid damagingthe cylinderhead,wait until the enginecoolanttemperaturedrops below 100'F(38"C) betore looseningthe cylinder head bolts. Mark all wiring and hosesto avoid misconnection. Also, be sure that they do not contactother wiring or hoses,or interferewith other parts.

' 1 .Drainthe

8. Removethe enginewire harnessconnectorsand wire harnessclampsfrom the cylinder head. . Enginecoolanttemperature(ECT)sensor conneclor . Camshaftposition(Cl\4P)(top dead center(TDC)) sensor B connector . Camshaftposilion (CMP)sensorA connector 9. Removethe upper radiatorhose (A) and heater h o s e( B ) .

enginecoolant(seepage 10-6).

2 . Removethe drive belt (seepage 4-26). 3 . Removethe intakemanifold {seepage 9-3). Removethe air cleanerhousing(seestep 7 on page 5-2t. 5. Removethe water bypasshose (A).

'10.

Removethe harnessholder (A)from the bracket, then removethe connectingpipe mounting boh {B) and brakeboostervacuum line mounting bolts {C).

6 . Removethe exhaustmanifold (seepage9-7) . 7 . Removethe cam chain (seepage 6-12).

11. Removethe water bvpasshose (D).

(cont'd)

6-23

CylinderHead CylinderHeadRemoval(cont'd)

VTCActuator,ExhaustCamshaft

SprocketReplacement Removethe rockerarm assembly(seepage 6-26). tJ.

Removethe cylinderhead bolts.To prevent warpage,unscrewthe bolts in sequence1/3turn at a t i m e ; r e p e a t h e s e q u e n c eu n t i la l l b o l t sa r e loosened. CYLINDERHEADBOLTSLOOSENINGSEQUENGE:

Removal: 1 . R e m o v et h e c a m c h a i n( s e ep a g e6 - 1 2 ) . 2. Hold the camshaftwith an open-endwrench,then loosenthe variablevalve timing control (VTC) actuatormounting bolt and exhaustcamshaft sprocketmounting bolt.

1 4 . R e m o v et h e c y l i n d e rh e a d . I

(

Removethe VTC actuatorand exhaustcamshaft sprocket.

I 6-24

Installation: 1. Installthe VTC actuatorand exhaustcamshaft sprocket.

CylinderHeadInspectionfor Warpage 1 , Removethe cylinder head{see page 6-23).

Inspectthe camshaft(seepage 6-29). 2. Apply engineoil to the th readsof the VTC actuator mounting bolt and exhaustcamshaftmounting bolt, then installthem. 3. Hold the camshaftwith an open-endwrench,then tighten the bolts. Specified torque: VTC actuator mounting bolt: 1 1 3N . m ( 1 1 . 5k g l . m , 8 3l b l . f t ) Exhaust camshaft sprocket mounting bolt: 72 N m (7.3 kgf.m, 53 lbf.ft)

Checkthe cylinder headfor warpage.Measure along the edges,and three ways acrossthe center. . lf warpage is lessthan 0.05mm (0.002in.) cylinder head resurfacingis not required. . lf warpage is between0.05 mm (0.002in.) and 0.2 mm (0.008in.),resurfacethe cylinder head. . Maximum resurfacelimit is 0.2 mm (0.008in,) basedon a height of 104mm (4.09in.). Cylinder Head Height; Standard{New}: 103.95 104.05mm {4.093 4.096in.}

4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .

6-25

CylinderHead RockerArm AssemblyRemoval '1.

Removethe cam chain (seepage 6-12).

4 . Removethe cam chain guide B, camshaftholders, and camshafts.

2 . Loosenthe rockerarm adjustingscrews (A), A

5 . Insertthe bolts (A) Into the rockershaft holder,then removethe rockerarm assembly(B).

3. Removethe camshaftholder bolts.To Drevent damagingthe camshafts,unscrewthe bolts two turns at a time, in a crisscrosspattern. CAMSHAFTHOLDERBOLTS LOOSENING SEOUENCE:

6-26

{

RockerArms and ShaftsDisassembly/Reassembly NOTE: ldentifypartsas they are removedto ensurereinstallationin original location. Inspectthe rockershaftsand rockerarms (seepage 6-28). The rockerarms must be installedin the same positionsif reused. When removing or installingthe rockerarm assembly,do not removethe camshaftholder bolts.The bolts will keep the holders,springsand rockerarms on the shaft. Priorto reassembling,cleanall the parts in solvent,dry them, and apply lubricantto any contactpoints. Bundlethe rockerarms with rubber bandsto keeDthem tooetheras a set. EXHAUSTROCKER SHAFT EXHAUSTROCKER ARM

wASHEB

rffin ,ffif-

\nl I ltnrllln IJI_J;-L,JLI []1_L^|l]

'rl) 70)

.;. ..1

t:l P - l

,,_tl

'l o

INTAKE ROCKER ARM ASSEMBLY

INTAKEROCKERSHAFT

6-27

CylinderHead RockerArms and ShaftsInspection 1 . Removethe rockerarm assembly(seepage 6-26). 2 . Measurethe diameterof the shaft at the first rocker location.

\ 4. Measurethe insidediameterofthe rockerarm, and checkit for an out-of-roundcondition. Rocker Arm-to-Shaflt Clearance: Standard lNew): 0.025 0.052 mm lntake: (0.0010 0.0020in.) Exhaust: 0.018 0.056mm (0.0007 0.0022in.) 0.08 mm (0.003in.) Service Limit:

3. Zero the gauge (A)to the shaft diameter.

5. Repeatfor all rockerarms and both shafts.lfthe clearanceis over the Ilmit. replacethe rockershaft and all overtolerancerockerarms. lf any VTEC rockerarm needs replacement,replacethe rocker arms (primaryand secondary)as a set.

(

6. Inspectthe rockerarm pistons{A}.Pusheach p i s t o nm a n u a l l y . lf it does not move smoothly,replacethe rocker arm set. NOTE:Apply oil to the pistonswhen reassembling.

,,,@@

(

6-28

GamshaftInspection NOTE:Do not rotatethe camshaftduring inspection. 1. Removethe rockerarm assembly(seepage 6-26). and disassembleit (seepage6-27). 2. Putthe rockershaft holders,camshaft,and camshaftholderson the cylinderhead,then tighten the bolts to the specifiedtorque. Specified torque: I mm bolis: 22 N.m {2.2kgt m, 16lbf.ft} 6 mm bolts: 12 N.m {1.2kgf.m,8.7 tbf.ftl 6 mm bolts: @, €0, @

3. Seatthe camshaftby pushing it away from the camshafp t u l l e ye n d o f t h e c y l i n d e rh e a d . 4. Zero the dial indicatoragainstthe end of the camshaft,then push the camshaftbackand forth and read the end play. lf the end play is beyondthe servicelimit, replacethe camshafthead and recheck.lf it is still beyondthe servicelimit, replace thecylinder. CamshaftEnd Play: Standard{New}:0.05 0.20 mm (0.002 0.008in.l ServiceLimit: 0.4 mm (0.02in.)

(cont'd)

6-29

CylinderHead CamshaftInspection(cont'dl Unscrewthe camshaftholder boltstwo turns at a time, in a crisscrosspattern.Then removethe camshaftholdersfrom the cylinder head. Lift the camshaftsout of the cylinder head,wipe them clean.then inspectthe lift ramps.Replacethe camshaftif any lobes are pitted,scored,or excessivelyworn, 1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r head,then set the camshaftsbackin place.Placea plastigagestrip acrosseachjournal. Installthe camshaftholders,then tighten the bolts to the specifiedtorque as shown in step 2.

{

10. Checkthe total runoutwith the camshaftsupported on V-blocks, . l f t h e t o t a l r u n o u to f t h e c a m s h a f its w i t h i nt h e servicelimit, replacethe cylinder head. . lf the total runout is beyondthe servicelimit, replacethe camshaftand recheckthe camshaftto-holderoil clearance.lf the oil clearanceis still beyondthe servicelimit, replacethe cylinder neao. Camshaft Total Runout: Standard(New):0.03mm (0.001in.) max. ServiceLimit: 0.04mm {0.002in.)

9 . Removethe camshaftholders.Measurethe widest portionof plastigageon eachjournal. . lf the camshaft-to-holder clearanceis within l i m i t s ,g o t o s t e p 11 . . lf the camshaft-to-holder clearanceis beyondthe servicelimit and the camshafthas been replaced, replacethe cylinder head. . lf the camshaft-to-holder clearanceis beyondthe servicelimit and the camshafthas not been replaced,go to step 10. Camshaft-to-Holder Oil Clearance: Standard (New): No. 1 Journal: 0.030 0.069mm No.2,3,4,5 Journals: ServiceLimit:

{0.001 0.003in-) 0.060*0.099mm {0.002 0.004in.) 0 . 1 5m m { 0 . 0 0i6n . )

1 1 . M e a s u r ec a m l o b eh e i g h t . Cam Lobe HeiohtStandard(New

INTAKE PRI

3 3 . 9 2 5m m (1.3356 in.)

2 9 . 6 3m 8m ( 1 . 1 6 6i n8 . ) P R IP : rimary C/C:CamChain

EXHAUST 34.092mm \1.3422in.l

SEC

SEC:Secondary

6-30

Valves,Springs,and ValveSealsRemoval Special Tools Bequired Valvespring compressorattachment07VAE-001010A

4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .

ldentifythe valvesand valve springsas they are removedso that each item can be reinstalledin its original position. 1. Removethe cylinder head (seepage 6-23). 2. Using an appropriate-sized socket(A) and plastic mallet {B),lightly tap the valve retainerto loosen the valve keepers.

5 . Removet h e v a l v es e a l . \

Installthe spring compressor.Compressthe spring, and removelhe valve keepers.

6-31

GylinderHead ValveInspection

ValveStem-to-GuideClearance Inspection

1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,

2 . Measurethe valve in these areas. lntake Valve Dimensions A StandardlNewl: 34.85 35.15mm { 1 . 3 7 2 1 . 3 8 4i n . l B Standard{Newl: 108.7- 109.5mm 14.280-4.311in.) C StandardlNew): 5.475 5.485 mm 1 0 . 2 1 5 6 - 0 . 2 1 5i n9 . ) 5.445mm {0.214in.l C ServiceLimit: ExhaustValve Dimensions A Standard(New):29.85-30.15 mm ( 1 . 1 7 5 -1 . 1 8 7i n . ) B Standard(New):108.3 109.1mm (4.264- 4.295 in.l C Standard(New):5.450 5.460mm (0.2146 0.2150in.) C ServiceLimit: 5.42mm (0.213in.)

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

4,.

(

3 . Subtractthe O.D.of the valve stem. measuredwith a micrometer,from the LD. of the valve guide, m e a s u r e dw i t h a n i n s i d em i c r o m e t eor r b a l lg a u g e . Takethe measurementsin three placesalong the v a l v es t e m a n dt h r e ep l a c e si n s i d et h e v a l v eg u i d e . The differencebetweenthe largestguide m e a s u r e m e nat n dt h e s m a l l e s st t e m m e a s u r e m e n t should not exceedthe servicelimit lntake Valve Stem-to-GuideClearance: Standard(New):0.030 0.055mm {0.0012 0.0022in.) ServiceLimit; 0.08mm (0.003in.l ExhaustValve Stem-to-GuideClearance: Standard{Newl: 0.055 0.080mm (0.0022-0.003rin.l ServiceLimit: 0.11mm (0.004in.)

6-32

ValveGuideReplacement SpecialToolsRequired . Valveguidedriver,5.5mm 07742-0010100 . Valveguidereamer,5.5mm 07HAH-PJ7o108 1 . Inspectvalve stem-to-guideclearance(seepage 6-

32t. As illustratedbelow, use a commerciallyavailable air-impactvalve guide driver (A) modifiedto fit the diameterof the valve guides.In most cases,the same procedurecan be done usingthe specialtool and a conventionalhammer.

Working from the camshaftside. usethe driver and an aarhammerto drive the guide about 2 mm (0.1 in.)towardsthe combustionchamber.This will knockoff some of the carbon and make removal easier.Hold the air hammer directlyin line with the valve guide to preventdamagingthe driver. Turn lhe head over, and drive the guide out toward the camshaftside of the head.

tT -_|Jfillr-.-4fi'11., 10.8mm {0.,|2in.)

3. Selectthe proper replacementguides,and chill lhem in the freezersectionof a refriqeratorfor about an hour. 4. Use a hot plate or oven to evenly heatthe cylinder headto 300'F (150"C).Monitor the temperature with a cookingthermometer.Do not getthe head hotterthan 300'F (150"C);excessiveheat may loosenthe valve seats. 7 . lf a valve guide won't move, drill it out with a I mm ( 5 / 1 6i n c h )b i t .t h e nt r y a g a i n .D r i l lg u i d e so n l y i n extremecases;youcould damagethe cylinder head if the guide breaks. Removethe new guide(s)from the freezer,one at a time, as vou needthem.

(cont'd)

6-33

CylinderHead ValveGuideReplacement(cont'dl Apply a thin coat of clean engineoil to the outside of the new valve guide. Installthe guide from the camshaftside of the head;usethe specialtool to drive the guide in to the specifiedinstalledheight ( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o , you may have to reheatthe head.

\ 1 0 .Coat both reamerand valve guide with cutting oil. 1 1 .Rotatethe reamerclockwisethe full length of the v a l v eg u i d eb o r e .

O7HAH.PJ7O1OB

Valve Guide Installed Height: 15.2 16.2mm (0.598-0.638in.) Intake: Exhaust: 15.5 16.5mm (0.610-0.650in.)

' - \

Continueto rotatethe reamerclockwisewhile removing it from the bore. Thoroughlywash the guide in detergentand water to remove any cutting residue. s i t h a v a l v e( s e ep a g e6 3 2 ) . 1 4 . C h e c kt h e c l e a r a n c ew Verifythat a valve slidesin the intakeand exhaust valve guideswithout exening pressure.

6-34

ValveSeat Reconditioning 1. Inspectvalve stem-to-guideclearance(seepage 632).lf the valve guidesare worn, replacethem (see page6-33)beforecuttingthe valve seats.

5. Make one more very light passwith the 45" cutter to removeany possibleburrs causedby the other cutters.

2 . R e n e wt h e v a l v es e a t si n t h e c y l i n d e rh e a du s i n ga valve seat cutter.

Valve Seat Width: Standard(New): 1.25 1.55mm {0.049 0.061in.) ServiceLimit: 2.00 mm (0.079in.) 6. After resurfacingthe seat,inspectfor even valve s e a t i n gA: p p l y P r u s s i a nB l u ec o m p o u n d( A )t o t h e v a l v ef a c e .I n s e r t h e v a l v ei n i t s o r i g i n a l o c a t i o ni n the head,then lift it and snap it closedagainstthe seat severaltrmes.

3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h materialto ensurea smooth and concentricseat. 4 . Bevelthe upper and lower edgesat the angles shown in the illustration. Checkthe width of the seat and adjustaccordingly. INTAKE:35" EXHAUST:30' - 45' , { 67.5'

1 . The actualvalve seatingsurface(B),as shown by the blue compound,should be centeredon the seat. . lf it is too high (closerto the valve stem),you must make a secondcut with the 67.5' cutterto move it down, then one more cut with the 45" cutterto restoreseatwidth. . lf it is too low (closeto the valve edge),you must make a secondcut with the 35'cutter (intake sidel or the 30" cutter (exhaustside)to move it up, then make one more cut with the 45" cutterto restoreseatwidth. N O T ET : h e f i n a lc u t s h o u l da l w a y sb e m a d ew i t h the 45'cutter.

(cont'd)

6-35

CylinderHead ValveSeat Reconditioning(cont'dl

(

8 . Insen the intakeand exhaustvalves in the head, and measurevalve stem installedheight (A). Intake Valve Stem Installed Height: Standard{New):40.8 41.0mm ( 1 . 6 0 6 1 . 6 1 4i n . ) Exhaust Valve Stem Installed Height: Standard(New):54.6-54.8 mm |'2.150-2.157 in.l

L lf valve stem installedheight is over the standard, replacethe valve and recheck.lf it is still over the standard,replacethe cylinder head;the valve seat in the head is too deeD.

6-36

Valves,Springs,and Valve SealsInstallation Special Tools Required Valve spring compressorattachment07VAE-00101 0A 1. Coatthe valve stemswith engine oil. lnstallthe valves in the valve guides. 2. Checkthat the valves move up and down smoothly. Installthespring seatson the cylinder head.

l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e spring with closelywound coils toward the cylinder ne a o . 6 . Installthe valve retainer. 7 . Installthevalve spring compressor,Compressthe spring, and installthe valve keepers.Removethe valve spring compressor.

Installthe new valve seals(A) usingthe valve guide s e a li n s t a l l e(rB ) . NOTE:The exhaustvalve seal (C)has a blackspring (D),and the intakevalve seal (E)has a white spring (F).They are not interchangeable.

Lightlytap the end of each valve stem two or three times with a plasticmallet (A)to ensureproper seatingof the valve and valve keepers.Tap the valve stem only along its axis so you do not bend the stem.

6-37

CylinderHead RockerArm AssemblyInstallation :,ean and dry the No. 5 rockershaft holder mating surfaces.

\ 5 . Removethe bolts from the rockershaft holder. 6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e

eeassemblethe rockerarm assembly(seepage 62 1t . Apply liquid gasket,P/N 08718-0009, evenlyto the :ylinder head mating surfaceofthe No. 5 rocker shaft holder. \OTE: Do not lnstallthe partsif 5 minutesor more r a v e e l a p s e ds i n c ea p p l y i n gl i q u i dg a s k e tI.n s t e a d , 'eapply liquid gasketafter removingold residue.

timing control (VTC)actuatorand exhaustcamshaft sprocketare facing up. then set the camshafts(A) in the holder.

fl c

Apply liquid gasket alongthe brokenline.

Insertthe bolts (A) into the rockershaft holder,then installthe rockerarm assembly(B)on the cylinder head.

\7 . Set the camshaftholders(B) and cam chain guide B ( C )i n p l a c e . Tightenthe bolts to the specifiedtorque. Specified torque: 8 mm bolts: 22 N.m (2.2 kgf.m, 16 lbl.ft) 6 mm bolts: 12 N.m {1.2kgf.m,8.7 lbf.fil 6 mm bolts: @),@.@

lnstallthe cam chain (seepage 6-15).and adjustthe valve clearance(seepage 6-9).

6-38

{

CylinderHeadInstallation Installthe cylinder head in the reverseorder of removat:

5. Measurethe diameterof each cylinder head bolt at ooint A and DointB. a 50mm (2.0in.l

1. Cleanthe cylinderhead and blocksurface. f.f

2. Installthe new cylinder headgasket(A) anddowel pins (B)on the cylinderblock.Always use a new cylinder headgasket.

)>-

A '15mm {'1.8in.) " < > .

l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) , replacethe cvlinder head bolt. Set the crankshaftto top dead center{TDC).Align the TDC mark (A) on the crankshaftsprocketwith the pointer(B)on the cylinderblock.

4. Installthe cylinderhead on the block.

( c o n td )

6-39

CylinderHead CylinderHeadlnstallation(cont'd) 7 . Apply engine oil to the bolt threadsand under the b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .

8 . Tightenthe cylinder head bolts in sequenceto 39

{

10. Installthe rockerarm assembly{seepage6-38).

1 ' .t Installthe water bypasshose (A).

N.m {4.0 kgf.m,29 lbf.ft).Use a beam-typetorque wrench.When using a preset-typetorque wrench, be sure to tighten slowly and do not overtighten.lf a bolt makesany noisewhile you are torquing it, loosenthe bolt and retightenit from the first step.

---l.-.

B 6 x1.0mm 'r2 N.m c (1.2kgl.m,8.7lbf.ftl 6 x l . 0 m m '12N,m(1.2kgt.m,8.7 lbf.ft) 9 . After torquing,tighten all cylinderhead bolts in two steps(90" per step).lf you are using a new cylinder head bolt,tighten the bolt an extra 90..

1 2 .Tightenthe connectingpipe mounting bolt (B)and brakeboostervacuum line mounting bolts (C),then i n s t a l l t h eh a r n e s sh o l d e r( D )o n t h e b r a c k e t .

't3. Installthe (B).

upper radiatorhose {A) and heaterhose

FIRSTSTEP

SECOND STEP

6-40

GylinderHeadCoverlnstallation 1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e .

1. Thoroughlycleanthe headcover gasketand the groove. 2. Installthe head cover gasket(A) in the groove of t h e c y l i n d e rh e a dc o v e r( B ) .

1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e 5-15). 1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) . 1 7 . I n s t a l l t h ee x h a u s tm a n i f o l d( s e ep a g e9 - 7 ) .

Checkthat the mating surfacesare clean and dry.

'18. I n s t a l l t h ec a m c h a i n ( s e ep a g e6 - 1 5 ) .

on the chain Apply liquid gasket.P/N 08718-0009, caseand the No.5 rockershaft holder mating areas.

1 9 . A d j u s tt h e v a l v ec l e a r a n c e( s e e p a g e 6 - 9 ) . 2 0 . I n s t a l l t h ed r i v eb e l t( s e ep a g e4 - 2 6 ) .

NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

21. Cleanthe batterypostsand cableterminalswith s a n d p a p e rt h , e n a s s e m b l et h e m a n d a p p l yg r e a s e to preventcorrosion. 2 2 . A f t e ri n s t a l l a t i o nc ,h e c k t h a t a ltl u b e s ,h o s e s a n d connectorsare installedcorrectly. . u r nt h e i g n i t i o ns w i t c hO N 2 3 . I n s p e c t f o r f u elle a k sT {ll) {do not operatethe starter)so that the fuel pump runs for about 2 secondsand pressurizesthe fuel line. Repeatthls operationtwo or three times, then c h e c kf o r f u e l l e a k a g ea t a n y p o i n ti n t h e f u e l l i n e . 24. Refillthe radiatorwith enginecoolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10-6). 2 5 . I n s p e ctth e i d l es p e e d( s e ep a g e1 1 - ' 1 3 8 ) . 2 6 . I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .

(cont'd)

6-41

GylinderHead CylinderHeadGoverInstallation(cont'd) Set the spark plug seals(A) on the spark plug tubes. O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r head,slide the cover slightly backand forth to seat the head cover gasket.

7. Tightenthe bolts in two or three steps.In the final s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 9 . 8 N . m ( 1 . 0 kgf.m,7.2 lbf.ft).

8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .

Inspectthe cover washers(C).Replaceany washer that is damagedor deteriorated.

\l 6-42

9 . Installthe four ignition coils (seepage 4-'18). 1 0 . Checkthat all tubes, hoses,and connectorsare installedcorrectly. 1 1 .lnstallthe intakemanifoldcover. 6 x 1 , 0m m '12 N.m{1.2kgf m. 8.7tbf.ftl

12. After assemblv,wait at least30 minutesbefore f i l l i n gt h e e n g i n ew i t h o i l .

6-43

EngineMechanical EngineBlock

. . . . . . . . . .7.-.2. S o e c i aTl o o l s C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .-.3. . . . . . . . . . . EndPlay RodandCrankshaft Connecting 7-5 .............. InsDection 7-6 ...................... Replacement Main Bearing Crankshaft 7-8 RodBearingReplacement...................... Connecting . . . . . . . .7. .- 1 1 O i lP a nR e m o v a .l . . . . . . . . . . . . . . . . . . . . . . ........7-12 Piston Removal and Crankshaft 7-14 ........................ Inspection Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . .7.-. 1. .5. . . . . . . . . B l o c ka n dP i s t o nI n s o e c t i o n . " . . . . . . . . . . . . .7. -. .' 1. .7. . C y f i n d eHr o n i n g. . . . . . . . . . . . 7-18 .......... RodReplacement Piston,PinandConnecting 7 -21 ................... PistonRingReplacement 7-23 ........... Pistonlnstallation.................... 7 -24 .......' Inspection Rod Bolt Connecting 7-24 .....................'. lnstallation Crankshaft . . . . . . . . .7.-.2 7 O i lP a nl n s t a l l a t i o .n. . . . . . . . . . . . . . . . . Seal EndCrankshaft Transmission ........'7-28 Car ................... lnstallation-ln

EngineBlock SpecialTools Ref.No.

6 @

Tool Number OTZAD-PNAAlOO 07746-0010700 07749,0010000

Description Oil Seal DriverAttachment96 Attachment,24 x 26 mm Driver

{

Oty 1 1 1

I o

{

7-2

ComponentLocationIndex BAFFLEPLATE

LOWERBLOCK

fr "

fi E

-4 I MAINBEARINGS O i l c l e a r a n cpea,g e7 - 6 page7-6 Selection,

FLYWHEEL

CRANKSHAFT OILSEAL. END TRANSMISSION Installation, step21on page7-26

THRUSTWASHERS

CRANKSHAFT End play,page7-5 R u n o u t p, a g e7 - 1 4 page7-14 Out-of-Round, Removal,page7-12 lnstallation,page7-24

(cont'd)

7-3

EngineBlock ComponentLocationIndex(cont'd)

/^.,

D->< Y1

rkrej,

ffil

| l-"t

nrrucs _,-ersroru Benlacement. 7-21

rG\ AalQ [=l ^oJ PISTON Removal,page7-'12 Measurement,page7-15

CONNECTINGROD End play, page7-5 Small end measurement,page7-19

Page

PISTONPIN Removal,page7-18 I n s p e c t i o np ,a g e7 - 1 9 Installation,page7,20

ENGINEBLOCK Cylinderbore inspection,page7-'15 Warpageinspection,page7-15 C y l i n d e br o r eh o n i n g ,p a g e1 - 1 1 Ridgeremovai,step 13 on page7-13 CONNECTINGROD

CONNECTINGROD BOLT page7 24 lnspectaon,

7- 4

(

ConnectingRod and CrankshaftEnd PlayInspection 1 . Remove the oil pump(seepage8-9).

Removethe baffleplates(seestep6 on page1 -12). 3. Measurethe connectingrod end play with a feeler gauge betweenthe connectingrod and crankshaft. ConnectingRod End Play Standard{New):0.15 0.30mm (0.006-0.012in.l 0.40mm (0.016in.l ServiceLimit

4 . lf the connectingrod end play is out-of-tolerance,

installa new connectingrod, and recheck.lf it is replacethe crankshaft(see still out-of-tolerance, page 7 -12],.

5. lnstalla dial indicatoras shown. Pushthe crankshaftfirmly away from the dial indicator,and zerothe dial againstthe end of the crankshaft.Then pull the crankshaftfirmly backtoward the indicator; the dial readingshould not exceedthe servicelimit. Crankshaft End Plav StandardlNew): 0.10-0.35 mm { 0 . 0 0 4 - 0 . 0 1 4i n . l ServiceLimit: 0.45mm {0.018in.)

replacethe thrust lf the end play is out-of-tolerance, washersand recheck.lf it is still out-of-tolerance, replacethe crankshaft.

7-5

EngineBlock CrankshaftMain BearingReplacement MainBearingClearance Inspection 1. To checkmain bearing-to-journaI oil clearance. removethe lower block and bearinghalves(see page 1 -12).. 2 , C l e a ne a c hm a i nj o u r n a la n d b e a r i n gh a l fw i t h a cleanshop towel. 3. Placeone strip of plastigageacrosseach main l o ur n a l . 4. Reinstallthe b e a r i n g sa n d l o w e rb l o c k t, h e nt o r q u e the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'.

6. lf the plastigagemeasurestoo wide or too narrow, removethe crankshaft.and removethe upper half ofthe bearing.Installa new, completebearingwith the same color code{s),and recheckthe clearance. Do not file, shim, or scrapethe bearingsor the caps to adjustclearance. 7. lf the plastigageshows the clearanceis still incorrect,try the next largeror smaller bearing(the color listedabove or below that one),and check again.lf the proper clearancecannot be obtained b y u s i n gt h e a p p r o p r i a t e l a r g e ro r s m a l l e rb e a r i n g s , replacethe crankshaftand start over.

NOTE:Do not rotatethe crankshaftduring Inspeclton. 5 . R e m o v et h e l o w e rb l o c ka n d b e a r i n g sa g a i n ,a n d measurethe widest part of the plastigage. Main Bearing-to-Journal Oil Clearance N o . 1 , 2 ,4 , 5 J o u r n a l s : Standard(New):0.017 0.041mm Service Limit: No.3 Journal:

10.0007 0.0016in.l 0.050mm {0.0020 in.)

Standard{Newl:0.025- 0.049mm (0.0010 0.0019in.) ServiceLimit: 0.055mm (0.0022 in.l

7-6

Main BearingSelection

Main Journal Code Location

Crankshaft Bore Code Location

2. The main journal codesa{e stampedon the cran kshaft.

1. Numbersor lettersor bars have been stampedon the end of the block as a code for the sizeof each of the five main journal bores.Write down the crank bore codes.lf you can't readthe codes becauseof accumulateddirt and dust, do not scrub them with a wire brush or scraper.Cleanthem only with solventor detergent. No. 5 JOURNAL END) {FLYWHEEL

No. 1 JOURNAL IPULLEYEND}

No. 1 JOURNAL

No. 5 JOURNAL

(cont'd)

7-7

EngineBlock CrankshaftMain Bearing Replacement(cont'd)

ConnectingRodBearing Replacement

3. Usethe crank bore codes and crankjournal codes to selectthe appropriatereplacementbearings from the following table.

RodBearingClearance lnspection

NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors.it does not matterwhich color is used in the top or bottom.

Main iournsl cooe 1

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

2ot Borll

Lalgercrankbore 3or c oi__-l C o r l l l D o r t t t It

--> Smaller bearing {Thickerl

Pink f!1f;* v"rro* c,""n l

v"no*c,""" $;;fl f111f;,," cr""n $ffi

ero-n

ffi#Tr,.*" i.,""* '---l-'o"*,

Creen ; g=jiff;i Brown Black

;;lT]*Brown Black

6il;

Brack !l;kr

ar*

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

(Thicker)

{

7-8

8 . lf the plastigagemeasurestoo wide or too narrow, removethe upper half of the bearing,installa new, completebearingwith the same color code(s),and recheckthe clearance.Do not file. shim, or scrape the bearingsor the capsto adjustclearance.

RodBearingSelection 1. Inspecteach connectingrod for cracksand heat damage. Connecting Rod Big End Eore Code Locations

9 . lf the plastigageshows the clearanceis still incorrect,try the next largeror smaller bearing(the color listedabove or below that one),and check clearanceagaln.lf the proper clearancecannot be obtainedby usingthe appropriatelarger or smaller bearing,replacethe crankshaftand stan over.

2 . E a c hr o d h a sa t o l e r a n c er a n g ef r o m 0 0 . 0 2 4m m (0.0009in.),in 0.006mm (0.0002in.) increments, dependingon the sizeof its big end bore. lt's then s t a m p e dw i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l l l l l )i n d i c a t i n g t h e r a n g e .Y o u m a y f i n d a n y c o m b i n a t i o no f n u m b e r sa n d b a r si n a n y e n g i n e . ( H a l ft h e n u m b e ro r b a r i s s t a m p e do n t h e b e a r i n g cap,the other half on the rod.) lf you can't readthe code becauseof an accumulationof oil and varnish.do not scrub it with a wire brush or scraper.Cleanit only with solventor detergent. Normal Bore Size: 48.0 mm 11.89in.l

(cont'd)

7-9

EngineBlock ConnectingRod BearingReplacement(cont'dl Connecting Rod Journal Code Location 3. The connectingrod journalcodesare stampedon the crankshaft. Connecting Rod Journal Code Location (Letters or Bars)

{

4. Use the big end bore codes and rod journalcodes to selectappropriatereplacementbearingsfrom the followingtable. NOTE: . Color code is on the edge of the bearing. . When using bearinghalvesof differentcolors,it does not matter which color is used in the top or bottom. Big end ----------> bore codo lorl

Rod

Largerbig end bore

2oJll

3 ol lll

4 orllll

---------> Smallsrb.aring {Thickerl Pink

Pink/ Yollow/ Yellow Grecn

Green

Green/ Brown Brown

Yellow Yellow/ Green

Green

Green/ Erown/ Brown Black

Black

Brown

Brown/ Black

Blue

Black/ Blue

(Thicker)

No.l JOURNAL No.4 JOURNAL

{

7-10

OilPanRemoval 1 . Drainthe engineoil (seepage8-5).

5 . C u tt h eo i l p a n s e abl y s t r i k i n g t h e s i d e o f t h e c u t t e r to slidethecutteralongthe oil pan.

lf the engine is still in the vehicle,removethe subframe. -1 Attachthe chain hoistto the engine (seestep 35 on page 5-6). -2 Disconnectthesuspensionlower arm ball joints (seestep 3 on page 18-19). -3 Removethe rear mounl mounting bolts (see step 39 on page 5-7). -4 Removethe front mount mounting bolt (see step 40 on page 5-7). -5 Use a markerto make alignmentmarks on the referencelinesthat align with the centersof the rear subframemounting bolts.Removethe front subframe(seestep 43 on page 5-8). 6 . R e m o v et h e o i l p a n . Removethe bolts/nutssecuringthe oil pan. Drivean oil pan seal cutter betweenthe oil pan and cylinderblock.

7-11

EngineBlock Crankshaftand PistonRemoval 1 . R e m o v et h e e n g i n ea s s e m b l y( s e ep a g e5 - 2 ) . 2 . R e m o v et h e t r a n s m i s s i o (ns e ep a g e1 3 - 4 ) .

8. Removethe bearingcap bolts.To preventwarpage, unscrewthe bolts in sequence1/3turn at a time: repeatthe sequenceuntil all bolts are loosened.

3 . R e m o v et h e o i l p a n ( s e ep a g e7 - 11 ) . 4. Removethe oil pump {seepage8-9). 5. Removethe cylinderhead (seepage 6-23). 6. Removethe baffle plates. E

7. Removethe 8 mm bolts.

L Removethe lower blockand bearings,Keepall bearingsin order.

(

7-12

1 0 .Removethe rod caps/bearings.Keepall caps/ b e a r i n g si n o r d e r .

14. Use the wooden handleof a hammer (A)to drive out the pistons(B).

1 1 .Liftthe crankshaftout ofthe engine,being careful n o t t o d a m a g et h e j o u r n a l s .

1 5 . Reinstallthe lower block and bearingson the engine in the proper order, t o . R e i n s t a l l t hc e o n n e c t i n gr o d b e a r i n g sa n d c a p s

after removingeach piston/connectingrod assembly. 1 7 .To avoid mixup on reassembly.mark each piston/ connectingrod assemblywith its cylinder number. Removethe upper bearinghalvesfrom the connectingrods.and set them asidewith their respectivecaps. t.J.

NOTE:The existingnumber on the connectingrod does not indicateits positionin the engine,it indicatesthe rod bore size.

lf you can feel a ridge of metal or hard carbon aroundthe top of eachcylinder,remove it with a r i d g er e a m e r{ A ) .F o l l o w t h er e a m e rm a n u f a c t u r e r ' s instructions.lf the ridge is not removed,it may damagethe pistonsas they are pushedout.

7-13

EngineBlock Crankshaftlnspection

\ Straightness

Out-ol-Round and Taper 1. Removethe crankshaftfrom the cylinder block(see page7-121. 2. Cleanthe crankshaftoil passageswith pipe c l e a n e r so r a s u i t a b l eb r u s h .

6. Placethe cylinder blockon the surfaceplate. 7 . C l e a na n d i n s t a l l t h eb e a r i g n so n t h e N o . 1a n d N o . 5 j o u r n a lo f t h e c y l i n d e rb l o c k . 8. Lowerthe crankshaftinto the block.

3. Cleanthe keywayand threads. 4. Measureout-of round at the middle of each rod and main journal in two places.The differencebetween measurementson each journal must not be more than the serviceIimit. Journal Out-ot-Round Standard(New):0.005mm (0.0002in.) max. ServiceLimit; 0.010mm (0.0004in.)

. o t a t et h e 9 . M e a s u r er u n o u to n a l l m a i nj o u r n a l sR crankshafttwo completerevolutlons.The differencebetweenmeasurementson eachjournal must not be more than the servicelimit. Crankshaft Total Runout Standard(New):0.03mm 10.0012 in.l max. ServiceLimit: 0.04mm (0.0016in.l

(

I_JJ fl 5. Measuretaper at the edgesof each rod and main journal.The differencebetweenmeasurementson eachjournal must not be more than the service limit. JournalTaper StandardlNewl: 0.005mm (0.0002in.) max. ServiceLimit: 0.010mm {0.0004in.)

{

7- 14

Blockand PistonInspection 1 . Removethe crankshaftand pistons(see pageT -121. Checkthe pistonfor distortionor cracks, M e a s u r et h e p i s t o nd i a m e t e ra t a p o i n t I 1 m m { 0 . 4 in.)from the bottom of the skirt.There are two pistons(No Letteror A, and B).The standard-size letteris stampedon the top of the piston.Letters are also stampedon the blockas cylinder bore stzes. Piston Diameter: Standard(Newl: No Letter {or A): 85.980 85.990 mm (3.3850 3.3854in.) B: 85.970-85.980mm (3.3846-3.3850in.)

4. Measurewear and taper in directionX and Y at t h r e el e v e l si n e a c hc y l i n d e ra s s h o w n .l f measurementsin any cylinder are beyondthe oversizebore servicelimit. replacethe block.lf the block is to be rebored,referto step 7 after reboring. CylinderBore Size Standard(New): A or l: 86.010 86.020mm 13.3862 3.3866in.) B or ll: 86.000 86.010mm (3.3858 3.3862in.) Service Limit: 86.070 mm (3.3886in.) Oversize: O.25t 96.250 86.260 mm (3.3957 3.3961 in.) Reboringlimit: 0.25mm (0.01in.l max.

Service Limit: No Lefter lor A): 85.930mm (3.3831in.) B: 85.920mm 13.3827in.)

Bore Taper: Limit: (Differencebetween first and third measurement)0.05mm (0.002in.) 6 mm {0.2in.} First Measurement Second Measutement Third Measurement 6 mm {0.2in.}

Oversize Piston Diameter: 0.25: 86.230-85.240mm (3.3949-3.3953 in.l

(cont'd)

7-15

EngineBlock Blockand PistonInspection(cont'd) Scoredor scratchedcylinderbores must be honed. Checkthe top of the blockfor warpage.Measure along the edgesand acrossthe centeras shown. Engine Block Warpage StandardlNew): 0.07mm (0.003in.) max. ServiceLimit: 0.10mm (0.004in.l

\ 7. Calculatethe differencebetweenthe cylinder bore diameterand the plstondiameter.lf the clearance is near or exceedsthe servicelimit, inspectthe pistonand cvlinder blockfor excessivewear. Piston-to-Cylinder Clearance StandardlNew): 0.020 0.040mm {0.0008 0.0016in.) ServiceLimit: 0.05mm (0.002in.l

PISTON-TO-CYLINDER CLEARANCE

PRECISION STRAIGHT EDGE

(

7-16

CylinderHoning Only a scoredor scratchedcylinderbore should be noneo. 'L

M e a s u r et h e c y l i n d e rb o r e s{ s e ep a g e7 - 1 5 ) . lf the block is to be reused,hone the cylindersand remeasurethe bores. H o n et h e c y l i n d e rb o r e sw i t h h o n i n go i l a n d a f i n e (400grit) stone in a 60 degreecross-hatchpattern (A).Use only a rigid hone with 400 grit or finer stone such as Sunnen,Ammco, or equivalent.Do not use stonesthat are worn or broken.

3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l yc l e a nt h e engine blockof all metal particles.Wash the cylinder boreswith hot soapywater,then dry and oil them immediatelyto preventrusting.Never use solvent,it will only redistributethe grit on the c y l i n d e rw a l l s . lf scoringor scratchesare still presentin the cylinderboresafter honing to the servicelimit, reborethe cylinder block.Some light vertical scoringand scratchingis acceptableif it is not deep enoughto catchyour fingernailand does not run the full length of the bore.

7-17

EngineBlock Piston,Pin,and ConnectingRod Replacement Disassembly

4 . Heatthe piston and connectingrod assemblyto about 158'F(70"C),then removethe piston pin.

1. Removethe pistonfrom the cylinderblock (see page7 -12). 2 . A p p l ye n g i n eo i l t o t h e p i s t o np i n s n a p r i n g s( A ) , and turn them in the ring grooves until the end gaps are lined up with the cutoutsin the piston pin b o r e s( B ) . NOTE;Takecare not to damagethe ring grooves.

\ Removeboth snap rings (A).Start at the cutout in t h e p i s t o np i n b o r e .R e m o v et h e s n a pr i n g s carefullyso they do not go flying or get lost.Wear eve protection.

7-18

(

Inspection NOTE:Inspectthe piston,piston pin, and connecting rod when they are at room temperature. 1. Measurethe diameterof the piston pin.

3. Checkthe differencebetweenthe DistonDin d i a m e t e ra n d p i s t o np i n h o l ed i a m e t e ri n t h e p i s t o n . Piston Pin-to-Piston Clearance Standard(Newl: -0.005 to +0.002 mm (-0.00020 to +0.00008 in.) ServiceLimit: 0.005mm (0.0002in.)

Piston Pin Diameter Standard(New):21.961 21.965mm (0.8646-0.8648in.) ServiceLimit: 21.953mm 10.8643 in.l

4 . Measurethe piston pin-to-connecting rod clearance.

2. Zerc the dial indicatorto the piston pin diameter.

Piston Pin.to-Connecting Rod Clearance Standard(New):0.005 0.015mm {0.0002 0.0006in.} ServiceLimil: 0.02mm (0.0008in.l

v (cont'd)

7-19

EngineBlock (cont'd) Piston,Pin,and ConnectingRodReplacement Reassembly 1 . I n s t a l al p i s t o np i n s n a pr i n g ( A ) .

4. Installthe piston pin (A).Assemblethe piston (B) and connectingrod (C)with the arrow (D)and the e m b o s s e dm a r k ( E )o n t h e s a m es i d e . -

Coatthe piston pin bore in the piston,the bore in the connectingrod, and the piston pin with engine oil.

3 . Heatthe pistonto about 158"F(70'C).

(

5 . I n s t a ltlh e r e m a i n i n gs n a pr i n g ( F ) . 6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e end gaps are positionedat the bottom of the piston.

7 -20

PistonRing Replacement 1. Removethe piston{rom the cylinder block(see page 7 -121.

4. Using a piston,push a new ring (A) into the c y l i n d e rb o r e 1 5 - 2 0 m m { 0 . 6 - 0 . 8 i n . )f r o m t h e bottom.

2. Using a ring expander(A),removethe old piston r i n g s( B ) .

15 20 mm (0.6 0.8 in.)

I B 3. Cleanall ring groovesthoroughlywith a squaredoff brokenring or ring groovecleanerwith a blade to fit the pislon grooves.The top and 2nd ring g r o o v e sa r e 1 . 2m m ( 0 . 0 5i n , ) w i d e T . h eo i l r i n g groove is 2.0 mm (0.08in.) wide. Filedown a blade lf necessary.Do not use a wire brush to cleanthe ring grooves,or cut the ring groovesdeeperwith t h e c l e a n i n gt o o l s . NOTE:lf the piston is to be separatedfrom the connectingrod, do not installnew rings yet.

Measurethe piston ring end-gap(B)with a feeler g au g e : . l f t h e g a p i s t o o s m a l l ,c h e c k t os e ei f y o u h a v e t h e p r o p e rr i n g sf o r y o u r e n g i n e . . l f t h e g a p i s t o o l a r g e ,r e c h e c k t h e c y l i n d ebro r e diameteragainstthe wear limits (seeslep 4 on p a g e7 - 1 5 ) . . l f t h e b o r e i s o v e r t h es e r v i c el i m i t ,t h e c y l i n d e r block must be rebored. PistonRing End-Gap Top Fing Standard(Newl: 0.20 0.35 mm (0.008 0.014in.l ServiceLimit: 0.60mm (0.024in.. SecondRing Standard(New):0.40-0.55 mm {0.016 0.022in.) ServiceLimit: 0.70mm (0.028in.) Oil Ring REKENmanufacturedring Standard(Newl: 0.25 0.65 mm (0.010 0.026in.l ServiceLimit: 0.75mm (0.030in.) FEDERALMOGUL manufacturedrino StandardlNew): 0.20 0.70mm {0.008 0.028in.} ServiceLimit: 0.80mm (0.031in.)

(cont'd)

7-21

EngineBlock PistonRing Replacement(cont'd) 6. Installthe top ring and secondring as shown.The t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e s e c o n dr i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e marks must be facing upward.

{

8. Positionthe ring end gaps as shown:

OIL RINGGAP

About 90' SECONDRINGGAP

About 45"

TOP RINGGAP and SPACER RINGGAP

=:-=2

V" 12-) V P'ffi+a \aq*-pogd

.ZR, V PistonRingoimensions: | |

| |

A-

t J

o -

ToPRing{Standardl: A :3 . 1m m { 0 . 1 2 in.l in.) B : 1 . 2m m { 0 . 0 5 SocondRing{Standard): A : 3 . 4m m { 0 . 1 3 in.} B:'1.2mm (0.05in.i

7, Rotatethe rings in their groovesto make sure they do notbind.

7-22

PISTONPIN

9. After installinga new set of rings,measurethe ring-to-grooveclearances:

o\,"16. s

OIL RINGGAP

Top RingClearance Standard {New}: mm {0.0014-0.0024 in.) 0.035-0.060 ServiceLimit: 0.13mm (0.005in.) SecondRing Clearance StandardlNew): REKENmanutactured ring in.) 0.030-0.055 mm (0.0012-0.0022 FEDERALMOGUL manulactured ring 0.025-0.060mm (0.0010-0.0024in.) 0.13 mm (0.005in.) ServiceLimit:

{

PistonInstallation lf the crankshaftis alreadyinstalled 1. Setthe crankshafttobottom dead center(BDC)for e a c hc y l i n d e r . 2. Removethe connectingrod caps,then installthe ring compressor,and checkthat the bearingis securelyin place,

lf the crankshaftis not installed 1 . Removethe connectingrod caps.then installthe r i n g c o m p r e s s o ra, n d c h e c kt h a tt h e b e a r i n gi s s e c u r e l yi n p l a c e .

2. P o s i t i o nt h e a r r o w( A ) f a c i n gt h e c a m c h a i ns i d eo f Ineengrne.

3. Positionthe arrow {A) facingthe cam chain side of r n ee n g t n e .

\--lno

Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) . N4aintain downward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.

^ un\-.--l.

Positionthe piston in the cylinder,and tap it in u s i n gt h e w o o d e nh a n d l eo f a h a m m e r( A ) , Maintaindownward force on the ring compressor (B)to preventthe rings from expandingbefore enteringthe cylinder bore.

>-*/zi .,.'_\pf{

(( 'V,/:

Stop afterthe ring compressorpops free, and checkthe connectingrod-to-crankjournal alignmentbeforepushingthe piston into place.

4. Positionall pistonsattop dead center.

6 . Checkthe connectingrod bearingclearancewith plastigage(seepage7-8). 7 . lnspectthe connectingrod bolts (seepage 7 241. Apply engine oil to the bolt threads,then installthe rod capswith bearings.Torquethe bolts to 20 N.m {2.0kgf m, 14 lbf ft) + 90'.

7-23

EngineBlock ConnectingRod Bolt Inspection 1 . Measurethe diameterof each connectinqrod bolt at DointA and ooint B. 35 mm

CrankshaftInstallation

(

Special Tools Bequired . Driver07749-0010000 . Attachment,24 x 26 mm 07746-0010700 . Oil seal driver attachment96 o7ZAD-PNAAl00 1 . I n s t a ltl h e c r a n k s h a fet n d b u s h i n gw i t h t h e s p e c i a l tools when replacingthe crankshaft.Drive in the c r a n k s h a fet n d b u s h i n gu n t i lt h e s p e c i atl o o l s bottom aqainstthe crankshaft.

07749-0010000

07746-00'l

Calculatethe differencein diameterbetweenpoint A a n d p o i n tB . Point A-Point B = Difference in Diameter Diflerence in Diameter: Specification:0 0.1 mm (0 0.004in.)

(

3 , lf the differencein diameteris out of tolerance, replacethe connectingrod bolt. e ith C h e c kt h e c o n n e c t i n gr o d b e a r i n gc l e a r a n c w plastigage{seepage7-8). C h e c kt h e m a i n b e a r i n gc l e a r a n c w e ith plastigage ( s e ep a g e7 - 6 ) . 4 . lnspecttheconnectingrod bolts (seepageT-241.

7-24

5 . I n s t a l l t h eb e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d conneclrngrods.

12. Tightenthe connectingrod bolts to 20 N.m (2.0kgf.m, 14 lbf.ft).

6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g sa n d rod bearings.

13. Tightenthe connectingrod bolts an additional90".

7 . H o l dt h e c r a n k s h a fsto r o d j o u r n a lN o . 2 a n d r o d journal No. 3 are straightup, and lower the crankshaftinto the block. 8 . l n s t a l l t h et h r u s tw a s h e r s( A )i n t h e N o . 4 j o u r n a lo f the cylinder block.

14. Removeold liquid gasketfrom the lower block mating surfaces,bolts and bolt holes. 15. Cleanand dry the lower block mating surfaces. 16. Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the lower block a n dt o t h e i n n e r t h r e a d o s f t h e b o l th o l e s . NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

,i, \-1

Apply liquid gasket alongthe broken line.

9 . Apply engine oil to the threadsot the connecting rod bolts,

1 0 .Seatthe rod journals into connectingrod No. 1 and connectingrod No. 4. Line up the mark (B)on the connectingrod and cap,then installthe caps and bolts finger-tight. '11. Rotate the crankshaftclockwise,and seatthe j o u r n a l si n t oc o n n e c t i n g r o d N o . 2 a n dc o n n e c t i n g rod No. 3. Line up the mark on the connectingrod and cap, then installthe caps and bolts finger-tight.

(cont'd)

7-25

EngineBlock CrankshaftInstallation(cont'd) '17 . Putthe lower blockon lhe cylinderblock. 1 8 . Tightenthe bearingcap bolts in sequenceto 29 N.m (3.0kgf m, 22 lbf.ft).

{ 2'1. Use the specialtoolsto drive a new oil seal squarelyinto the blockto the specifiedinstalled height.

07749-0010000

07zAo-PNAA100 Measurethe distancebetweenthe crankshaft(A) a n d o i l s e a l( B ) . Oil Seal InsialledHeight:

1 9 . Tightenthe bearingcap bolts an additional56". 20. Tightenthe I mm bolts in sequenceto 22 N.m 12.2 kgf m, 16 lbf.ft).

7-26

5.5 6.5 mm |10.22 0.26 in.l 5.5-6.5 mm {0.22 0.26in.l

{

OilPanlnstallation 23. Installthe baffle plates. 6x1.0mm 1 2N . m (1.2ksf m, 8.7lbf ft)

1 . Removeold liquid gasketfrom the oil pan mating surfaces,bolts,and bolt holes. 2 . Cleanand dry the oil pan mating surfaces. 3 . Apply liquid gasket,P/N 08718-0009, evenlyto the cylinderblock mating surfaceof the oil pan and to the innerthreadsof the bolt holes. NOTE:Do not installthe parts if 5 minutesor more have elapsedsinceapplying liquid gasket.Instead, reapplyliquid gasketafter removing old residue.

2 4 . I n s t a l l t h eo i l p u m p ( s e ep a g e8 - 1 4 ) . 25. Installtheoil pan (seepage7-27). Apply liquid gasket alongthe brokenline.

26. Installthecylinderhead (seepage 6-39). 27. Installthetransmission(seepage 13-8).

4. I n s t a l l t h eo i l p a n .

28. Installtheengine assembly(seepage 5-9).

5. Tightenthe bolts in two or three steps.In the final

s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 1 2 N . m ( 1 . 2 kgf m, 8.7 lbf.ft). ( } @

(cont'd)

7-27

EngineBlock Oil PanInstallation(cont'dl

TransmissionEndGrankshaftSeal Installation- In Car

6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l tl h e subframe, - 1 I n s t a l l t h es u b f r a m eA. l i g nt h e r e f e r e n c e lines on the subframewith the bolt head center,then tighten the bolts (seestep 5 on page 5-10). -2 Tightenthe front mounting bolt (seestep 6 on p a g e5 - 1 0 ) . -3 Tightenthe rear mount mounting bolts (see s t e p7 o n p a g e5 - 1 1 ) . -4 Connectthe suspensionlower arm ball joints (seestep 6 on page 18-19). 7. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n ew i t h o i l .

Special Tools Required . Driver07749-0010000 . Oil seal driver attachment 96 07ZAD-PNAA100 '1.

D r y t h e c r a n k s h a fot i l s e a lh o u s i n g .

2. Use the specialtools to drive a new oil seal squarelyinto the blockto the specifiedinstalled height. 07749-0010000

/$rRfr4T

tr*W(r -]t fl\ a OTZAD.PNAAlOO

Measurethe distancebetweenthe crankshaft(A) a n d o i l s e a l( B ) . Oil Seal InstalledHeight: 5.5 6.5 mm 10.22-0.26in.l 5.5 6.5 mm l0.22- O.26in .l

v 7-28

EngineMechanical t--l

r_::::-l

EngineLubrication SpecialTools Ref. No.

Tool Number 07HAA-PJ70100

\ Descriotion

Otv

Oil FilterWrench

I \-

8-2

ComponentLocationIndex WASHER

DRAINBOLT

OILPAN R e m o v apl ,a g e7 1 1 page7-27 Installataon,

OILPUMP page8-8 OverhaLrl,

HL]

BAFFLEPLATE

OILPUMP CHAINTENSIONER

OILCONTROL ORIFICE

-&\JrI --t

ksrarr cKEr

OIL FILTERFEEDPIPE Replacement,page8-7

lN-? dczt$)

# 1 \

OIL PUMP CHAINGUIDE

OILFILTER page8-6 Replacement, OIL PRESSURESWITCH SwitchTest,page8 4 Oil Pressuretest, page8'4 R e p l a c e m e npt a, g e8 1 6

8-3

EngineLubrication Oil PressureSwitch Test 1 . R e m o v et h e Y E U R E Dw i r e ( A ) f r o mt h e e n g i n eo i l pressureswitch (B).

Oil PressureTest

{

lf the oil pressureindicatorstayson with the engine r u n n i n g c. h e c kt h e e n g i n eo i l l e v e l .l f t h e o i l l e v e li s correct: '1.

Connecta tachometer. Removethe engine oil pressureswitch,and install a n o i l p r e s s u r eg a u g e{ A ) .

2. Checkfor continuitybetweenthe positiveterminal ( C )a n d t h e e n g i n e( g r o u n d )T. h e r es h o u l db e continuitywith the engine stopped.There should be no continuitywith the engine running. lf the switch fails to operate,checkthe engineoil l e v e l .l f t h e e n g i n eo i l l e v e li s O K .c h e c kt h e e n g i n e oil pressure.lf the oil pressureis OK, replacelhe oil Dressureswitch.

(

Start the engine.Shut it off immediatelyif the gauge registersno oil pressure.Repairlhe problem beforecontinuing. 4. Allow the engineto reachoperatingtemperature (fan comes on at leasttwice),The pressureshould be: EngineOil Temperature: 176'F (80'Cl EngineOil Pressure: At ldle: 70 kPa (0.7kgf/cm', 10 psi) mtntmum At 3,000rpm: 300 kPa (3.1kgf/cm',44 psi) minimum lf the oil pressureis NOT within specifications, inspectthese items: . C h e c kt h e o i l s c r e e n f o r c l o g g i n g . . Checkthe oil pump (seepage8-8). . Checkcrankshaftand connectingrod bearing clearances.

I 8-4

EngineOil Replacement 1 . Warm up the engine. 2 . R e m o v et h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l .

A 44 N.m {i1.5kgf.m,33lbf.ft) Donotovertighten.

3 . Reinstallthe drain bolt with a new washer (B). R e f i l l w i t ht h e r e c o m m e n d e o d i l ( s e ep a g e3 - 2 ) . Capacity 4.0 0 (4.2US qt) at oilchange. 4.2 014.4US qt) at oilchange includingfilter. 5.3 015.6US $) after engineoverhaul. 5 . Run the enginefor more than 3 minutes.then check for oil leakage.

8-5

EngineLubrication EngineOil FilterReplacement Special Tool Fequired Oil filter wrench 07HAA-PJ70100

EngineOil Filter(3/4-turntype) 1 . R e m o v et h e o i l f i l t e r w i t h t h e s D e c i at ol o l . 2. Inspectthe threads{A) and rubber seal (B)on the new filter. Wipe off the seat on the engine block, then apply a light coat of oil to the filter rubber seal. Use only filterswith a built-inbypasssystem.

5. lf 4 numbersor marks (1 to 4 or V to VVVV) are printedaroundthe outsideof the filter, usethe following procedureto tighten the filter. . Spin the filter on until its seal lightly seatsagainst t h e b l o c k ,a n d n o t ew h i c h n u m b e ro r m a r ki s a t the bottom. . Tightenthe filter by turning it clockwise3 numbersor marksfrom the one you noted.For example,if number 2 is at the bottom when the seal is seated,tightenthe filter until the number 1 comes around the bottom.

Number when rubber seal is seated.

Number aftertightening.

N u m b eor r M a r kw h e n r u b b esr e a li s

1 or V

2 or VV

3 or VVV

4 or VVVV

N u m b e ro r Mark after tightening

2 or VV

3 or VVV

\..

I n s t a l l t h eo i l f i l t e rb y h a n d . After the rubberseal seats,tightenthe oil filter clockwisewith the specialtool. Tighten: Tighteningtorque:

3/4 turn clockwise. 12 N.m (r.2 kgf.m,8.7 lbf.ft)

vvvv. v

6 . A f t e ri n s t a l l a t i o nf i,l l t h e e n g i n e w i t ho i l u p t o t h e specifiedlevel,run the enginefor more than 3 m i n u t e st,h e n c h e c kf o r o i l l e a k a g e .

07HAA-PJ70100

8-6

(

Oil FilterFeedPipeReplacement 1 . Removethe oilfilter (seepage8-6). Removethe oil filter feed pipe.

3 . l n s t a l l t h e t w o 2 x0 1 . 5 m m n u t s ( Ao) n t o t h e n e w oil filter feed pipe. Holdthe nut with a wrench,then tighten the other nut.

4 . T i g h t e n t hoei lf i l t e r f e e p d i p e t o t h eb l o c k t o4 9N . m {5.0kgf.m,36 lbf ft),thenremovethe nutsfrom the oil filterfeedoiDe.

8-7

EngineLubrication OilPumpOverhaul ExplodedView 6x1.0mm 1 2N . m {1.2kgfm,8.7lbf.ft)

BAFFLEPLATE

x 1 . 2 5m m 27 N.m

6x1.0mm 12 N.m 11.2kgf.m,8.7 lbt ft)

(2.8kst m, 20 lbt ft) A p p l ye n g i n o eilto the boltthreads.

Ptr

P UI" I EU

UPPERBALANCER SHAFTHOLDER

$--."Dowetem BALANCERSHAFT BEARINGS

DOWELPIN

REAR BALANCER SHAFT -

/=.---'n

fs/

t w

SEALINGBOLT 39 N.m {4.0kgf.m,29lbf.ftl

FRONT BALANCER SHAFT

LOWERBALANCER SHAFTHOLDER

8-8

Oil PumpRemoval

6. Removethe oil pump sprocket(A),then removethe oil pump(B).

1. Setthe No. 1 piston attop deadcenter{TDC){see s t e p 1 o n p a g e6 - 1 2 ) . 2 . R e m o v et h e o i l p a n ( s e e p a g e T - 1 1 ) . 3 . R e m o v ea n d d i s c a r dt h e o i l p u m p c h a i n t e n s i o n e r .

4. To hold the rear balancershaft,inserta 6 mm pin driver (A) into the maintenancehole in the lower balancershaft holderand through the rear balancer shaft.

5. Loosenthe oil pump sprocketmounting bolt.

(cont'd)

8-9

EngineLubrication Oil PumpOverhaul{cont'dl Oil PumpInspection 1 . R e m o v et h e p u m p h o u s i n g .

{ 3. Checkth e h ousing-to-roto r axiaI clearancebetween t h e r o t o r( A )a n d p u m p h o u s i n g( B ) .l f t h e h o u s i n g to-rotoraxial clearanceexceedsthe servicelimit. r e p l a c et h e o i l p u m p . Housing"to-Rotor Axial Clearance Standard(New):0.02 0.07 mm (0.001-0.003 in.l ServiceLimit: 0.12mm (0.005in.l

Checkthe inner-to-outerrotor radialclearance betweenthe inner rotor (A) and outer rotor {B).lf the inner-to-outerrotor radialclearanceexceeds the servicelimit, replacethe oil pump. Inner Rotor-to-Outer Botor Radial Clearance Standard{New):0.02 0.16mm (0.001-0.006 in.) ServiceLimit: 0.20mm (0.008in.,

4 . Checkthe housing-to-outer rotor radialclearance

betweenthe outer rotor (A) and pump housing(B). lf the housing-to-outerrotor radialclearance exceedsthe servicelimit, replacethe oil pump.

Housing-to-Outer Rotor Radial Clearance StandardlNewl: 0.15 0.21mm (0.006-0.008in.l ServiceLimit; 0.23mm (0.009in.)

1'[1e-\1.-,-2 1

'a -

:.:

,-'r'

Inspectboth rotors and the pump housingfor scoringor other damage.Replaceparts if necessary.

8- 10

BalancerShaft Inspection 1 . Seatthe balancershaft by pushingit away from the o i l p u m p s p r o c k eet n d o f t h e o i l p u m p .

3. Removethe baffle plate (A) and upper balancer shaft holder {with bearings)(B),then removethe front balancershaft (C)and rear balancershaft (D). 9

2 . Zero the dial indicatoragainstthe end of the balancershaft,then push the balancershaft back and forth and readthe end olav. Balancer Shaft End Play: Fronl Balancer Shaft: Standard{Newl: 0.070 0.135mm {0.0028 0.0053in.} ServiceLimit: 0.15mm (0.006in.) Rear Balancer Shaft: Standard{New):0.070-0.135 mm (0.0028 0.0053in.l ServiceLimit: 0.15mm (0.006in.)

''/

L=]

Rfl|] 3B eI ]U U +-

(cont'd)

8-11

EngineLubrication Oil PumpOverhaul(cont'dl 4. Measure the innerdiameterof the No. 1 bearingfor thefrontbalancer shaftholeandthe rearbalancer shafthole. BearingInnerDiameier: Front: Standard(New):20.000-20.020 mm (0.7874 0.7882in.) ServiceLimit; 20.03mm (0.789in.) Rear: Standard(New):24.000-24.020mm in.) 10.9/t49-0.9457 ServiceLimit: 24.03mm (0.946in.)

( 5 . Measurethe diametersof the No. 1 journalson the front balancershaft and rear balancershaft. NO.1Journal Diameter: Front: StandardlNew): 19.938 19.950mm (0.7850 0.7854in.) ServiceLimit: 19.92mm {0.784in.) Rear: StandardlNewl: 23.938 23.950mm in.) {0.9424-0.9/129 ServiceLimit: 23.92mm (0.942in.) Front:

Front:

a Rear:

8-12

6. Cleanboth balancershaft No. 2 journalsand bearinghalveswith a cleanshop towel. 7. Placeone strip of plastigageacrosseach No.2 journal.

1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c esr h a f t with the centerof the two punch marks on the front balancershaft,then install'thebalancershaftsin the lower balancershaft holder

8 . Reinstallthe bearingsand upper balancershaft holder,then torque the bolts. NOTE;Do not rotatethe balancershaft durinq insDection. 9 . Removethe uooer balancershaft holder and bearingsagain,and measurethe widest part of the plastigage.lf the balancershaft No. 2 journal oil installthe new clearanceis out-of-tolerance. bearings,and recheck.lf it is still out-of-tolerance, replacethe balancershafts. No. 2 Journal Oil Clearance: StandardlNewl; 0.060 0.120mm ServiceLimit:

(0.0024 0.0047in.l 0.15mm {0.006in.) 1 1 .Apply engine oil to the threads of the 8 mm bolts (A). 6 x1.0mm '12 N.m (1.2kgt.m,8.7 lbt ft)

1 2 . I n s t a l l t h eu p p e rb a l a n c esr h a f th o l d e r( B )a n d bafile plate (C).

(cont'd)

8-13

EngineLubrication Oil PumpOverhaul(cont'd) 1 3 . l n s t a l l t h ep u m p h o u s i n g .

Oil PumpInstallation 1. Make sure the No. 1 piston is at TDC (seestep 1 on p a g e6 - 1 2 ) . 2. Align the dowel pin{A} on the rear balancershaft with the mark (B)on the oil pump.

9%ttrc 6x1,0mm 1 2N . m (1.2kgt.m,8.7lbf.ft)

+:.:4.4

o/.-lY\

To hold the rear balancershaft, inserta 6 mm pin driver {A) into the maintenancehole in the lower balancershaft holder and through the rear balancer shaft.

\,-

-rrdv

:aa:'

f,o-;

8- 14

4. Apply engine oil to the threadsof the oil pump sprocketmounting bolt (A).

8. Squeezethe new oil pump chain tensioner(A),then installthe set clip (B)on it as shown. N O T ET : h e s e tc l i p i s s u p p l i e dw i t h t h e o i l p u m p chain tensioner.

A 10x 1.25mm {4 N.m (a.5kg{ m, 33 rbf.ftl

9. Installthe oil DumD chain tensioner. 6x1.0mm 12N.m(1.2kgf.m, 8.7rbf.ft)

1 0 x1 . 2 5m m ,l,t N.m {4.5kgf.m, 33 tbt.ftl

8 x 1 , 2 5m m 22N m l2.2kot m.

r6 tbt.fti

5 . L o o s e l yi n s t a l l t h eo i l p u m p( B ) t, h e ni n s t a l l t hoei l pump sprocket(C). Removethe pin driver (D). 7 . Tightenlhe oil pump mounting bolts.

(cont'd)

8-15 I

EngineLubrication Oil PumpOverhaul(cont'dl

I Oif PressureSwitch Replacement

1 0 . R e m o v et h e s e tc l i pf r o m t h e o i l p u m p c h a i n tensioner.

1. Disconnectthe oil pressureswitchconnector,then removethe oil pressureswitch.

1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) .

2. Apply liquid gasketto the oil pressureswitch threads,then installthe oil pressureswitch.

(

8-16

EngineMechanical IntakeManifoldand ExhaustSystem lntakeManifoldRemovaland Installation................. 9-2 ExhaustManifoldRemovalandInstallation.............. 9-7 ExhaustPipeand MufflerReplacement ..................... 9-8

r-!i!1

IntakeManifoldand ExhaustSystem lntakeManifoldRemovaland Installation

Exploded View:

8 x 1 , 2 5m m 22 N.m {2.2kgf.m, 16 lbf ft}

I INTAKEMANIFOLD Replaceif crackedor if mating surfaceis

GASKET Replace.

'e) w)

INTAKE MANIFOLDPLATE Replaceif crackedor if matingsurfaceis damaged.

(

t9 \

8 xx1.25 . 2 5mm 222 N' mm 2 kgf.m, 1 6 12.2ksf

6x1.0mm 1 2N . m {1.2kgf.m,8.7lbf.ft)

8 x 1 . 2 5m m 22 N.m (2.2kgf m. 16 lbt.ft)

9-2

Removal: '1.

Removethe intakemanifoldcover.

3. Disconnecttheintakeairtemperature(lAT)sensor connector(A),and removethe breatherhose (B), then removethe air cleanerhousingcover/intake a i r d u c ta s s e m b l y( C ) .

2 . Removethe evaporativeemission(EVAP)canister hose (A),brakeboostervacuum hose (B),and vacuum hoses{C).

4. Fully open the throttle link and cruisecontrol link by hand,then removethe throttlecable (A) and cruisecontrol cable(B)from the links.Loosenthe locknuts{C).and removethe cablesfrom the bracket.

(

(cont'd)

9-3

IntakeManifoldand ExhaustSystem IntakeManifoldRemovaland Installation(cont'dl 5. Be preparedto catch and clean up spilledcoolant. Removethe water bypasshoses,then plug the water bypasshoses.

(

9 . Removethe enginewire harnessconnectorsand w i r e h a r n e s sc l a m p sf r o m t h e i n t a k em a n i f o l d . . Four injectorconnectors . ldle air control (lAC)valve connector . Throttleposition(TP)sensorconnector . fvlanifoldabsolutepressure{lvlAP)sensor connector . Evaporativeemission(EVAP)canister purge valve connector

'10. Removethe bolt securingthe intakemanifoldand bracket.

6 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) . 7 . R e m o v et h e f u e l l i n e ( s e e p a g e l l - 1 4 9 ) . 8. Removethe positivecrankcaseventilation(PCV) hose (A),harnessholder mounting bolt (B)and h a r n e s sc l a m pm o u n t i n gb o l t ( C ) .

1 1 .Removeallthe intakemanifold mounting bolts/ nuts.

1'>

Removethe two stud bolts (A),then removethe i n t a k em a n i f o l d( B ) .

9-4

1. Installthe intakemanifold (A)with a new gasket(B), then installand tighten the two stud bolts (C).

4 . Installthe PCVhose {A), harnessholder mounting b o l t ( B ) ,a n d h a r n e s sc l a m pm o u n t i n gb o l t( C ) .

e-li*h,r

*& \ 8 x 1.25mm 22 N.m |.2.2k91.m. 16 tbt.ft) 8 x 1.25mm 22 N.rn (2.2kgf m. 16 lbf.ttl

2. Tightenall intakemanifold mountlng bolts/nutsin a crisscrosspatternin two or three steps,beginning with the inner bolt. ?

Tightenthe bolt securingthe intakemanifold and bracket.

8 x 1.25mm 22 N.m (2.2ksf m, 16lbf.ft)

6x1.0mm 12N.m(1.2kgf.m,8.7lbf.ft) 5 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) . 6 . Installthewater bypasshoses.

7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 )t ,h e n a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) . 8 . Installthe cruisecontrol cable (seepage 4-44).then adjustthe cable (seepage 4-45).

(cont'd)

9-5

lntake Manifoldand ExhaustSystem IntakeManifoldRemovaland Installation(cont'd) 9 . l n s t a l l t h ea i r c l e a n e rh o u s i n gc o v e r( A ) ,a n d connectthe IAT sensorconnector(B).

1 2 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r . 6x1.0mm 1 2N . m l.1.2k91.m, 8.7 tbf.ftl

C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .

1 0 .Installthebreatherhose(C). 1 1 .lnstalltheEVAPcanisterhose(A),brakebooster

After installation,checkthat all tubes,hoses,and connectorsare installedcorrectly.

, n dv a c u u mh o s e s{ C ) . v a c u u mh o s e( B ) a Inspectfor fuel leaks.Turn the ignition switch ON (ll) (do not operatethe starter)so that the fuel pump runs for about 2 secondsand pressurizesthe fuel line. Repeatthis operationtwo or three times,then checkfor fuel leakageat any point in the fuel line.

t o . Refillthe radiatorwith enginecoolant,and bleed

air from the cooling systemwith the heatervalve open (seepage 10-6).

9-6

ExhaustManifoldRemovaland Installation 1 . Removethe VTECsolenoidvalve (seepage 1'1-128). 2 . Removethe driveshaftheat shield(seepage 16-19). 3 . Removethe cover and exhaustmanifold bracket,then removethe exhaustmanifold. 8 x 1 . 2 5m m 22 N.m (2.2kgf.m, 16lbt.ftl

SELF-LOCKING NUT 10x 1.25mm 44 N.m {4.5ksf.m, 33lbt.ftl Beplace.

#'-.-

1 0x 1 . 2 5m m 44 N.m (4.5kgt.m, 33 lbl ftl Replace. GASKET Replace.

WASHEB 10x 1.25mm 14 N.m {4.5kgl.rn, 33lbf.ft)

8 x 1-25mm 22 N.m (2.2kgI m, 16lbf.ft) Replace. Tightenthe boltsin steps, alternating sideto side.

Installthe exhaustmanifoldand tighten the bolts/nutsin a crisscrosspatternin two or three steps,beginningwith the inner bolt. 5 . Installtheother parts in the reverseorder of removal.

9-7

lntake Manifoldand ExhaustSystem ExhaustPipeand Muffler Replacement

NOTE:Use new gasketsand self-lockingnuts when reassembling.

8 x 1 . 2 5m m 22 N.m (2.2kst.m. 16lbf.ftl Replace. Tightenthe bolts in steps, alternatingside'to side. EXHAUSTPIPEB HEATSHIELD

6x1.0mm 9.8 N.m {1.0kgt.m,7.2 lbf ft}

GASKET Replace.

SECONDARY HEATED OXYGEN SENSOR HO2SI {SECONDARY

NUT SELF-LOCKING 1 0x 1 . 2 5m m 33N.m{3.4kgf.m, 25 rbf.ft) Beplace.

8 x 1.25mm 22 N.m {2.2kgf m, 16lbf.ft) Replace. Tightenthe bolts in steps, alternatingside to-side.

il4Nm (4.5 ksf.m,33 lbf.ftl

AIR FUELRATIO {A/F) SENSOR 44 N.m (it.s kgf.m, 33 lbf ftl

\-.

9-8

EngineCooling CoolingSystem Component Location Index ......................................... 10-2 Radiator CapTest ..................... .......... 10-3 RadiatorTest ............. 10-3 FanMotorTest ..........l0-4 Thermostat Test ...................... ........... 10-4 WaterPumpInspection ..................... 10-5 WaterPumpReplacement ................. 10-5 C o o l a nCt h e c k. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. .0. .- .6. . CoolantReplacement ......................... 10-6 Thermostat Replacement .................. 10-8 WaterPassage Installation ................ 10-9 WaterOutletInstallation .................... 10-9 Radiator andFanReplacement ................................... 10-10

FanControls C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .0. .-.1. .1. . . . . . . SymptomTroubleshooting Index ............................... 10-12 CircuitDiagram .........10-13 Radiator FanCircuitTroubleshooting ........................ 10-14 Radiator FanSwitchCircuitTroubleshooting ( O p e n ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6 Radiator FanSwitchCircuitTroubleshooting ( S h o r t ). . . . . . . . . . . . . . . . . . .1. 0 - 1 6 Radiator FanSwitchTest ................... 10-17 Radiator FanSwitchReolacement .............................. 10-17

CoolingSystem ComponentLocationIndex

WATER OUTLET, I n s t a l l a t i opna,g e ' 1 0 - g

\\f

WATERPUMP page10-5 Inspection, page10-5 Replacement. PIPE CONNECTING RESERVE TANK WATERPASSAGE page10-9 Installation,

THERMOSTAT Test,page10 4 page108 Replacement,

RADIATOR CAP

RAOIATORFAN SWITCH Test,page 10-17 page 10'17 Replacement,

RADIATOR page 10-'l0 Replacement,

A/C CONDENSER FAN ASSEMBLY Replacement,page 10'10-4 10 Fan Motor Test,page

RADIATORFAN ASSEMgLY R e p l a c e m e npta, g e1 0 - 1 0 Fan MotorTest,page 10 4

\J 10-2

RadiatorCapTest

RadiatorTest

1. Removethe radiatorcap {A),wet its sealwith engine coolant,then installit on the pressuretester ( B )( c o m m e r c i a l layv a i l a b l e ) .

1 . Wait untilthe engine is cool, then carefullyremove the radiatorcap and fill the radiatorwith engine coolantto the top of the filler neck. Attachthe pressuretester (A) (commercially a v a i l a b l et)o t h e r a d i a t o r .

Apply a pressureof 93 kgf/cm', l4 18 psi).

'123 kPa{0.95 1.25

3 . Checkfor a drop in pressure. 4 . lf the pressuredrops, replacethe cap. 3 . Apply a pressureot 93 '123kPa(0.95 1.25 kgf/cm',

'14

18 psi).

4 . I n s p e cfto r e n g i n ec o o l a n tl e a k sa n d a d r o p i n

pressure. Removethe tester,and reinstallthe radiatorcap.

10-3

CoolingSystem FanMotor Test

ThermostatTest

1. Disconnectthe 2P connectorsfrom the radiatorfan motor and condenserfan motor.

Replacethe thermostatif it is open at room remperalure.

To test a closedthermostatl 1. Suspendthe thermostat(A) in a containerof water. Do not let the thermometer{B)touch the bottom of t h e h o tc o n t a i n e r .

Testthe motor by connectingbatterypower to the B terminaa l n d g r o u n dt o t h e A t e r m i n a l . lf the motor fails to run or does not run smoothly, r e p t a c er L

2. Heatthe water, and checkthe temDeraturewith a thermometer.Checkthe temperatureat which the thermostatfirst opens,and at which it is fully open.

3 . Measurethe lift height of the thermostatwhen it is f u l l vo o e n . STANDARDTHERMOSTAT Lift height; above 8.0 mm (0.31in.) Starts opening: 169 176"F(76 80"C) Fullyopen: 194"F{90'Cl

10- 4

(

Water Pump Inspection

Water Pump Replacement

1 . Removethe drive belt (seepage 4-26),

1. Removethe drive belt (seepage 4-26).

2 . Turn the water pump pulleycounterclockwise. Checkthat it turns freely.

2 . D r a i nt h e e n g i n ec o o l a n t{ s e ep a g e1 0 - 6 ) . 3 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .

Checkfor signs of seal leakage.A small amount of "weeping" from the bleed holes(A) is normal.

4. Removethe six bolts securingthe water pump, then removethe water pump (A).

6x1.0mm 1 2 N m { 1 . 2k g t m , 8.7 rbf.ft)

Inspectand cleanthe O-ring groove and mating surfacewith the water passage. I n s t a l l t h ew a t e r p u m pw i t h n e w O r i n g si n t h e reverseorder of removal. 7 . C l e a nu p a n y s p i l l e de n g i n ec o o l a n t . 8 . I n s t a l l t h ec r a n k s h a fpt u l l e y( s e ep a g e6 - 1 2 ) . L R e f i l tl h e r a d i a t o w r i t h e n g i n ec o o l a n t a, n d b l e e d air from the cooling system with the heatervalve o p e n{ s e ep a g e1 0 - 6 } .

10-5

CoolingSystem GoolantCheck 1. Look at the coolantlevel in the reservetank. Make sure it is betweenthe MAX mark (A) and MIN mark (B),

CoolantReplacement

1 . Startthe engine.Set the heatertemperaturecontrol dial to maximum heat.then turn off the ignition switch.Make surethe engine and radiatorare cool to the touch. Removethe radiatorcap. Removethe splashshield(seestep 23 on page5-5). Loosenthe drain plug (A),and drain the coolant.

lf the coolantlevel in the reservetank is at or below the MIN mark, add coolantto bring it up to the l\4AX mark, and inspectthe cooling system for leaks.

\ Removethe reservetank drain cap (A),and drain the coolant.

10-6

After the coolanthas drained,tighten the radiator drain plug securely.and installthe reservetank drain cap securely.

Type 2 8. Pour HondaAll SeasonAntifreeze/Coolant into the radiatorup to the baseof the filler neck. NOTE: . Always use HondaAll SeasonAntifreeze/Coolant Type 2 {P/N01999-9001).Using a non-Honda c o o l a n tc a n r e s u l ti n c o r r o s i o nc, a u s i n gt h e cooling systemto malfunctionor fail. . HondaAll SeasonAntifreeze/Coolant Type 2 is a mixture of 50% antifreezeand 507owater. Prem i x i n gi s n o t r e q u i r e d .

1 . Fillthe reservetank to the MAX mark (A) with Tvpe 2 HondaAll SeasonAntifreeze/Coolant (P/NO1999-9001).

EngineCoolant RefillCapacity includingthe reserve tank capacity of 0.53 4 (0.56 US gtl : 5.0 0 (s.3US qt)

L I n s t a l l t h er a d i a t o cr a p l o o s e l y .

1 0 .Startthe engine,and let it run until it warms up (the radiatorfan comes on at leasttwice). 1 1 .Turn off the engine.Checkthe level in the radiator, Type and add HondaAll SeasonAntifreeze/Coolant 2 if needed. P u tt h e r a d i a t o cr a p o n t i g h t l y ,t h e n r u n t h e e n g i n e a g a i na n d c h e c kf o r l e a k s . tJ.

lnstallthe splashshield(seestep 22 on page 5-12).

10-7

GoolingSystem

ThermostatReplacement 1 . D r a i nt h e e n g i n ec o o l a n t( s e ep a g e1 0 - 6 ) . 2. Removethe splashshield (seestep 23 on page 5-5). 3. Removethe lower hose,then removethe thermostat. 6 x 1 . 0m m 9.8N.m ( 1 . 0k g f . m , 7 . 2 l bf ft )

i* -

THERMOSTAT

LOWERHOSE

4. Installthethermostatwith a new O-ring,then installthe lower hose. 5 . I n s t a l l t h es p l a s hs h i e l d( s e es t e p2 2 o n p a g e5 - 1 2 ) . 6. Refillthe radiatorwith engine coolant,and bleed air from the cooling systemwith the heatervalve open (seepage 10_6).

10-8

Water PassageInstallation

Water Outlet lnstallation

1 . Cleanand dry the water passagemating surfaces.

I n s t a l l t hw e a t e ro u t l e (t A ) w i t ha n e wO - r i n g{ B ) ,

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

1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )

3 . I n s t a l l t h ew a t e rp a s s a g e( A ) w i t ha n e w O - r i n g( B ) .

.t':.:

1 0x 1 . 2 5m m 44N m {4.5kgtm.33 lbf.ft} 4. After assembly,wait at least30 minutes before f i l l i n gt h e e n g i n ew i t h o i l .

10-9

CoolingSystem Radiatorand FansReplacement

{

1. Drainthe enginecoolant(seepage 10-6). 2. Removethe front bumper {seepage 20,85). 3. Removethe bulkhead. 4. Removethe upper radiatorhose and lower radiatorhose. DRAINPLUG

O.RING

RADIATOR CAP

UPPERBADIATORHOSE BADIATOB BAOIATOAFAN ASSEMBLY

\LOWERCUSHION RADIATOR FAN

swtTcH 24Nm

{ 2 . 1kt g l m . 1 7 l b l h l

LOWERFADIATOR HOSE

RESERVETANK A/C CONDENSER FANASSEMBLY 9 . 8N m { 1 . 0k g f m , 7 . 2l b ff t ) CONNECTORS

RADIATOBFANSWITCH CONNECTOB

5. Disconnectthe fan motor connectorsand radiatorfan switch connector,then pull the radiatorup and out. 6. Removethe fan shroud assembliesand other partsfrom the radiator. 7 . I n s t a l l t h er a d i a t o ri n t h e r e v e r s eo r d e ro f r e m o v a l M . a k es u r et h e u p p e ra n d l o w e rc u s h i o n sa r e s e t s e c u r e l V . 8 . I n s t a ltlh e b u l k h e a di n t h e r e v e r s eo r d e ro f r e m o v a l A . p p l y b o d y p a i n tt o t h e b u l k h e a dm o u n t i n gb o l t s . 9 . F i l lt h e r a d i a t o w r i t h e n g i n ec o o l a n ta n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) .

10-10

FanControls ComponentLocationIndex UNDER.HOOD FUSE/RELAY BOX

RADIATORFAN RELAY

RADIATOBFAN SWITCH Test,page 10'17 R e p l a c e m e npt a, g e ' 1 0 - 1 7

RADIATORFAN ASSEMBLY Motor Test,page 10 4 CONDENSER FAN ASSEMBLY Motor Test,page 10-4

10-11

FanControls Symptom TroubleshootingIndex

{

Beforeperformingany troubleshootingprocedurescheck: . Fuses . Grounds . Cleanlinessand tightnessof all connectors

SYMPTOM

PROCEDURE

Radiatorfan does not run at all

RadiatorFanCircuilTroubleshooting(seepage 1O-14).

Radiatorfan does not run for enginecooling, but it runs with A,/CON

RadiatorFan Switch CircuitTroubleshooting(Open) ( s e ep a g e1 0 - 1 6 ) .

Radiatorfan runs with ignition switch ON (ll),Ay'COFF, and enginetemperaturebelow 199"F(93"C)

RadiatorFan Switch CircuitTroubleshooting(Short) (seepage 10-'16).

\ , 4

10-12

CircuitDiagram '

No.20loA): USA modd : Cm.de mod.l No.20l50A) UNDEN DASX FUSE/RELAY BOX

BOX UIIDEFHOOD FJSE/NILAY

lG2H0TiiAClill, 0N{lllrndSTABI llll)

10-13

FanGontrols RadiatorFanCircuitTroubleshooting 1. Checkthe No. 4 (20A)fuse in the under-hood fuse/relaybox, and the No. 14 (10A)fuse in the under-dashfuse/relaybox. ls the tuse (s) OK?

( 4 . C o n n e ct th e N o . l a n d N o . 2 t e r m i n a l s o f t h e radiatorfan relay 4P socketwith a jumper wire.

RADIATORFAN RELAY4P SOCKET

YES-Go to step 2. NO- Replacethe fuse (s) and recheck.l

JUMPER WIRE

2. Removethe radiatorfan relayfrom the under-hood fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 3.

T e r m i n asli d eo f I e m a l tee r m i n a l s

NO Replacethe radiatorfan relay.t Does the radiatot fan run? 3. Measurethe voltage betweenthe No. 2 terminal of the radiatorfan relay 4P socketand body ground.

YES Go to step 5. NO Go to step 6.

RADIATORFAN RELAY4PSOCKET

Disconnectthe jumper, and turn the ignition switch ON {ll}. Checkfor voltage betweenthe No. 3 terminal of the radiatorfan relay 4P socketand b o d yg r o u n d .

BADIATOB FANRELAY4PSOCKET

Terminalside of femaleterminals

ls therebatteryvoltage? YES Goto step4. NO Replace the under-hood fuse/relay box.I

Termlnalsideof femaleterminals

ls there battety voltage? YES-Go to step 9. NO Checkfor an open in the wire betweenthe under-hoodfuse/relaybox and under-dashfuse/ relay box.l

10-14

Disconnectthe radiatorfan motor 2P connector. 7 . Checkfor continuitybetweenthe No. 1 terminal of the radiatorfan relay 4P socketand the No. 2 terminal of the radiatorfan motor 2P connector.

RAOIATOR FANREI-AY 4PSOCKET

9 . Reinstallthe radiatorfan relay. 1 0 .Disconnectthe radiatorfan switch 2P connector. 1 1 .Connectthe No. 1 and No. 2 terminals,of the radiatorfan switch 2P connectorwith a jumper wire. RAOIATOR FANSWITCH 2P CONNECTOR

5\-'fl \ \r--

Terminalsideof femaleterminals

f-;

IJUMPER

I wrRE

Wiresideof femaleterminals RADIATORFAN MOTOR2P CONNECTOR

Does the radiator fan run?

ls thete continuity? YES- Replacethe radiatorfan switch.l

YES-Go to step8. N O - G o t o s t e p1 2 .

NO Repairopenin the wire betweenthe underhoodfuse/relay boxandthe radiatorfan motor2P terminalNo.2,I connector 8. Checkfor continuitybetweenthe No, 1terminal of the radiatorfan motor 2P connectorand bodv g round.

Removethe jumper wire, and measurethe voltage betweenthe No, 2 terminal of the radiatorfan switch connectorand body ground, RADIATOR FANSWITCH 2P CONNECTOR

RADIATORFAN MOTOR2P CONNECTOR

rftr

T-

ls there battery voltage?

Wire side of femaleterminals

ls there continuity? YES Replacethe radiatorfan motor.l NO Checkfor an open in the wire between radiatorfan motor 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1

YES Checkfor an open in the wire between radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1 NO Repairopen in the wire betweenthe radiator fan switchterminal No. 2 and the under-hood fuse/relaybox.l

10-15

FanControls RadiatorFanSwitch Circuit Troubleshooting(Openl 1. Disconnectthe radiatorfan switch 2P connector. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 3 . M e a s u r ev o l t a g eb e t w e e nt h e N o . 2 t e r m i n a lo f t h e radiatorfan switch 2P connectorand body ground. RADIATORFAN SWITCH2P CONNECTOR

RadiatorFanSwitch Circuit Troubleshooting(Short)

NOTE:After troubleshooting,perform the engine c o n t r o lm o d u l e( E C M ) i d l el e a r np r o c e d u r e( s e ep a g e 11 , 1 3 9 ) . 1 . R e m o v et h e r a d i a t o fra n r e l a yf r o m t h e u n d e r - h o o d fuse/relaybox, and test it (seepage 22-51). ls the relay OK? YES Go to step 2. NO

Replacethe radiatorfan relay.I

2. Removethe radiatorfan switch,and test it (see p a g e1 0 - 1 7 ). Is the radiatot tan switch OK? YES Go to step 3. ls there battety voltage?

YES-Go to step 4.

Disconnectthe batterynegativecablefrom the battery.

NO- Repairopen in the wire betweenthe radiator fan switch 2P connectorterminal No. 2 and underhood fuse/relaybox.l Turn the ignition switch OFF,and checkfor continuitybetweenthe No. '1terminal of the radiatorfan switch 2P connectorand body ground. RADIATOBFAN SWITCX2P CONNECTOR

Replacethe radiatorfan switch.I

4 . Disconnectenginecontrol module {ECM)connector ) n d t h e u n d e r h o o df u s er e l a yb o x 1 4 P B ( 2 4 Pa connector. Checkfor continuitybetweenthe No. 2 terminal of the radiatorfan switch 2P connectorand body grouno. RADIATORFAN SWITCH 2P CONNECTOR

ls there continuity?

lstnere continuity?

YES Replacethe radiatorfan switch.t

YES Repairshort in the wire betweenthe radiator f a n s w i t c h2 P c o n n e c t otre r m i n a lN o . 2 a n d u n d e r hood fuse/relaybox.l

NO Checkfor an open in the wire betweenthe radiatorfan switch 2P connectorterminal No. 1 and body ground. lf the wire is OK, checkfor a poor g r o u n da t G 3 0 1 . 1

10-16

NO Replacethe under-hoodfuse/relaybox.t

RadiatorFanSwitch Replacement

RadiatorFanSwitch Test NOTE:Bleedair from the cooling system after installing the radiatorfan switch (seepage 10-6). 1, Removethe radiatorfan switchfrom the radiator ( s e ep a g e1 0 - 1 7 ) .

1 . Disconnectthe radiatorfan switch connector,then removethe radiatorfan switch (A). A 24 N m (2.4kgt.m,17lbt.ftl

2 . S u s p e n dt h e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r of water as shown.

2. Installthe radiatorfan switchwith a new O-ring(B).

3. Heatthe water, and checkthe temperaturewith a thermometer.Do not let the thermometer(B)touch the bottom of the hot conlainer. 4. Measurethe continuitybetweenterminal No. 1 and terminal No. 2 accordingto the table. Termina

\ Operation

lTemperature 203'F ON 196" (91" gs"C) swtTcH 5' 15'F {3' 8'C) lowel OFF than the temoerature when it goes on

10-17

Fueland Emissions Fueland EmissionsSystems SpecialTools 1't-2 General Troubleshooting Information I I-J DTCTroubleshooting lndex .... 11-7 SymptomTroubleshooting 1ndex............... 11 - 1 0 SystemDescriptions ................ 11-12 Howto SetReadiness Codes.. 11-46

PGM-FlSystem Component Location Index .... 11-49 D T CT r o u b l e s h o o t i n. .g. . . . . . . . .11-52 ... MILCircuitTroubleshooting ... 11-97 DLCCircuitTroubleshooting .. 1 1 - 1 0 9 InjectorReplacement ............... 11-111 A,/FSensorReplacement .........1 1 - 1 1 3 HO2S Secondary Replacement 11-113 ECTSensorReolacement.......1 1 - 1 1 4 CMPSensorB {TDCSensor) Replacement 11-114 I A TS e n s oR r e p l a c e m e.n. t. . . . . 1. .1 - 1 1 5 KnockSensorReplacement .... 1 1 - 1 1 5 CKPSensorReolacement .......1 1 - 1 1 6

VTEC/VTC LocationIndex .... 11-117 Comoonent D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 11 8 VTCOil ControlSolenoid ValveRemoval/Test ............. 11-127 CMPSensorA Replacement ... 11-128 VTECSolenoid Valve R e m o v a l / l n s o e c t.i .o. n. . . . . . .11-128 ...

ldle ControlSystem Location Index Component

11-129 . . . . . . . . . . .1. .I.- 1 3 0 D T CT r o u b l e s h o o t i n g A,/CSignalCircuit T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .I .t.-. t.5 5 AlternatorFRSignalCircuit T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1. 1. .-. 1 3 4 EPSSignalCircuit T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1.1. .-1. 3 5 Brake PedalPosition SwitchSignal Troubleshooting ............. Circuit 11 - 1 3 7 ldle SpeedInspection 11 - 1 3 8 E C Ml d l el e a r nP r o c e d u r e. . . . . . .11 - 1 3 9

FuelSupplySystem ComponentLocationIndex 11 - 1 4 0 FuelPump Circuit Troubleshooting 1 1 - 1 4 1 F u e lP r e s s rue R e l i e v i n g. . . . . . . . .1. .1 - 1 4 4

F u eP l r e s s u r e T e s. .t. . . . . . . . . . . .1. 1. .-.1. 4 5 FueL l i n e sI n s p e c t i o.n. . . . . . . . . .1. .1. .- 1 4 6 FuelLine/Ouick-Connect FittingsPrecautions............. 11-148 FuelLine/Ou ick-Con nect F i t t i n gR s e m o v a l. . . . . . . . . . . . .1. 1. .-.1. 4 9 FuelLine/Ou ick-Con nect F i t t i n glsn s t a l l a t i o.n. . . . . . . . . .1. .1. .- 1 5 0 FuelPressure Regulator R e p l a c e m e .n.t. . . . . . . . . . . . . . . 1 . .1. .-.1. .5. 2 FuelFifterReplacement ........... 11-152 FuelPump/Fuel GaugeSending . .1. .-.1 5 3 U n i t R e D l a c e m e. .n. t. . . . . . . . . 1 F u eP l u l s a t i oDna m o e r R e p 1 a c e m e. n . .t. . . . . . . . . . . . . . 1 . .1. .-.1. .5. 4 F u eT l a n kR e o l a c e m e n . .t. . . . . . .1. 1. - 1 5 5 F u eGl a u g e S e n dUi n igt T e s. .t . . . .1. 1 - 1 5 6 11-158 LowFuellndicatorTest .................

IntakeAir System C o m o o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 5 9 T h r o t t l eB o d y T e s t . . . . . . . . . . . . . . 1 . .1. .-.1 6 0 IntakeAir BypassControl T h e r m aV l a l v eT e s t . . . . . . . . . . .1. .1. - 1 6 1 A i r C l e a n eR r e o l a c e m e n .t . . . . . .1. 1 - 1 6 2 A i r C l e a n eE r lement R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1 . .1. .-.1. .6 2 ThrottleCableAdjustment ...... 11-163 ThrottleCable Removal/lnstallation ............ 11-164 Th rottleBody Removal/ Installation .. 11-165 Th rottleBody Disassembly/ R e a s s e m b l v. . . . . . . . . . . . . . . . . . .1. .1. .- .1. 6. 6

CatalyticConverterSystem D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 1 6 7

PCVSystem D T CT r o u b l e s h o o t i n g. . . . . . . . . . .1. .1.- 1 6 8 PCVValveInsDection a n dT e s t . . . . . .11 -1 6 9 P C VV a l v eR e o l a c e m e n.t. . . . . . . .1.1 - 1 6 9

EVAPSystem C o m p o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 7 0 D T C T r o u b l e s h o o t i n.g. . . . . . . . . .1. .1. - 1 7 1 EVAPTwo Way ValveTest ......11-186 FuelTank VaoorControl ValveTest ... 11-187 E V A PC a n i s t eR r e p l a c e m e n.t. . 1 1 - 1 8 9 FuelTank VaoorControl V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .1.- 1 8 9

Fueland EmissionsSystems SpecialTools Rel. No.

(L) @

@ @ @

@-t @-2 O-3 @-4 @ (iD

Tool Number

ffi

--1

a=:t=' (F

(

otv

Description V a c u u mP u m p / G a u g e0, 3 0 i n . H g Vacuum/Pressure Gauge.0 4 in.Hg BackprobeSet Fuel PressureGaugeAdapter PressureGaugeAdapter FuelSenderWrench Hose,Oil Pressure A,/TPressureHose A,/TLow PressureGaugeW/Panel A,/TPressureHose,2,210 mm A,/TPressureHoseAdapter F u e lP r e s s u r eG a u g e FuelPressureGauoeSet

A973X-041-XXXXX 07JAZ-0010008 07sAz-001000A 07vAJ-0040100 07NAJ-P07010A 07xAA-001010A 07zAJ-S5AA200 07406-0020201 07406-0070300 OTMAJ-PY4O11A 07MAJ-PY40120 07406-004000A 07zAJ-S5A0100

1 1

2 1 1 1

/6\ l\r )l

/'r';-:'-;--' \7 At-'' \-,/

UtB o

-'-,---=---1,-'.

ut/t 'jt' o

(i)

)

i-==.€ *==-.2'l -1,40-2, -3,@-4

\\h

*.'l€) \\:

\\d o

11-2

GeneralTroubleshooting Information IntermittentFailures The term "intermittentfailure" means a svstem mav have had a failure.but it checksOK now. lf the MalfunctionIndicatorLamp (MlL)on the dash does not come on, checkfor Doorconnectionsor looseterminals at all connectorsrelatedto the circuitthat Vou are troubleshooting.

2. lf the MIL stayson, connectthe HondaPGM Tester (A) or an OBD ll scantool to the Data Link Connector{DLC)(B) locatedunderthe driver'sside o f t h ed a s h b o a r d .

Opensand Shorts "Ooen" and "Short" are common electricalterms.An open is a breakin a wire or at a connection.A short is an accidentalconnectionof a wire to ground or to anotherwire. In simple electronics,this usuallymeans somethingwon't work at all. With complex electronics ( s u c ha s E C M s ) t h i sc a n s o m e t i m e sm e a ns o m e t h i n g works, but not the way it's supposedto.

How to Usethe PGMTesteror a ScanTool 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . lf the MIL {Malfunction Indicator Lamp} has come on '1. S t a r tt h e e n g i n ea n d c h e c kt h e M I L { A ) . N O T E l: f t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d the engine is not started,the MIL will stay on for 1 5 2 0 s e c o n d s( s e ep a g e1 1 - 4 6 ) .

K->;"PN/.- -:::--d V-: !

w:ix&K#

Checkthe DiagnosticTroubleCode (DTC)and note it. Also checkthe freezedata.Referto the DTC T r o u b l e s h o o t i nIgn d e x ,a n d b e g i nt h e a p p r o p r i a t e troubleshootingprocedure. 5 . lf you do not find any DTCS,go to MIL circuit t r o u b l e s h o o t i n(gs e ep a g e1 1 - 9 7 ) . NOTE: . Freezedata indicatesthe engineconditionswhen the first malfunction,misfire,or fuel trim malfunction was detected. . The scantool and the Honda PGM Testercan readthe DTC,freezedata,currentdata,and other Engine Controll\4odule{EClvl)data. . For specificoperations,referto the user's manual that came with the scantool or HondaPGl\4Tester. lf the MIL did not stay lf the MIL did not come on but there is a driveability problem,referto the Symptom TroubleshootingIndex i n t h i ss e c t i o n . lf you can't duplicate the DTC Some of the troubleshootingin this sectionrequires you to resetthe ECM and try to duplicatethe DTC.lf rhe problem is intermittentand you can't duplicatethe code, d o n o t c o n t i n u et h r o u g ht h e p r o c e d u r eT. o d o s o w i l l o n l y r e s u l ti n c o n f u s i o na n d ,p o s s i b l ya, n e e d l e s s l y r e p l a c e dE C M .

(cont'd)

11-3

Fueland EmissionsSystems

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

How to Removethe ECMfor Testing 1. Removethe passenger'sdashboardlower cover {seepage 20-63),the passenger'skick panel (see page 20-63),and the glove box (seepage 20-63). 2. Removethe ECM mounting bolts (B)and the ECM

(c),

9.8 N.m {1.0kgf.m,7.2lbt.ft} 3 . R e m o v et h e E C M ( B ) .

How to Enda TroubleshootingSession (requiredafterany troubleshootingl

4. Installthe ECM in the reverseorder of removal.

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

\- ta 11-4

How to TroubleshootCircuitsat the ECM Special Tools Required . DigitalMultimeterKS-AHM-32-003 (1) or a commerciallyavailabledigital multimeter . BackprobeSet 07SAZ-0010004 (2) 1. Connectthe backprobeadapters(A) to the stacking patchcords (B),and connectthe cords to a digital m u l t i m e t e (r C ) .

2 . U s i n gt h e w i r e i n s u l a t i o n a s a g u i d ef o r t h e contouredtip ofthe backprobeadapter,gently slide the tip into the connectorfrom the wire side until it touchesthe end of the wire terminal. 3. lf you cannot get to the wire side of the connector or the wire side is sealed(A),disconnectthe connectorand probe the terminals(B)from the terminal side. Do not force the Drobeinto the connector.

Do not puncturethe insulationon a wire. Puncturescan causeDooror intermittent electricalconnections.

07sAz-001000A

(cont'd)

11-5

Fueland EmissionsSystems Information(cont'd) GeneralTroubleshooting ECMUpdatingand Substitutionfor Testing Special Tools Bequired HondaInterfaceModule (HlM) EOS05435570

(

How to Substitute the ECM '1.

Removethe ECMf rom the vehicle.

2. Installa known-goodECM in the vehicle. Usethis procedurewhen you haveto substitute a known-goodECM in a troubleshootingprocedure. does not alreadyhave U pdatethe ECMonly if the ECN4 the latestsoftwareloaded, NOTE; . lMakesure the batteryis fully chargedbeforeyou updatethe ECN4. . To preventECMdamageduring the update,do not turn the ignition switch OFF,and do not use any of the vehicle'selectricaldevices(light,horn, radio,etc. ).

3 . R e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e E C M replacementprocedurefrom the Honda PGM Tester.lt allows you to startthe engine. 4. After completingyour tests,reinstallthe original E C Ma n d r e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e E C Mr e p l a c e m e nptr o c e d u r e o n t h e H o n d aP G M T e s t e ra g a i n .

How to Update the ECM 1. Turn the ignition switch ON (ll).Do not startthe e n gI n e . 2. Connectthe HondalnterfaceModule (HlM)to the Data Link Connector{DLC)(A) locatedunderthe d r i v e r ' ss i d eo f d a s h b o a r d .

EOS05A35570

Do the ECM updateprocedureas describedon the HlN4label and in the ECM updatesystem.

11-6

DTCTroubleshootingIndex DTC Temporary DTC Detection ltem {MlLindication*) P 0 0 1 (05 6 ) VariableValveTiming Control{VTC)Oil Control P 0 0 1 (15 6 )

P0011

P 0 1 0 (73 ) P 0 1 0 (83 ) P 0 1 1 2( 1 0 )

(10) P01r3 P 0 1 1 6{ 8 6 )

P0116

S o l e n o i dV a l v eM a l f u n c t i o n VariableValveTiming Control(WC) System Malfunction

{ s e ep a g e11 ' 11 8 ) ( s e ep a g e1 1 -11 9 )

(MAP)SensorCircuit ManifoldAbsolutePressure LowVoltaqe (MAP)SensorCircuit ManifoldAbsolutePressure HiqhVoltaqe

( s e ep a g e1 ' l - 5 2 1

IntakeAir Temperature(lAT)SensorCircuitLow Voltaoe IntakeAir Temperature(lAT)SensorCircuitHigh Voltaoe EnglneCoolantTemperature(ECT)Sensor Range/ PerformanceProblem

(seepage 11-55)

(ECT)SensorCircuit EngineCoolantTemperature LowVoltaqe

P0117 {6)

Note

( s e ep a g e1 1 - 5 3 )

(seepage '11-56) { s e ep a g e1 1 - 5 7 ) ( s e ep a g e1 1 - 5 8 )

EngineCoolantTemperature(ECT)SensorCircuit { s e ep a g e1 1 - 5 9 ) Hiqh Voltaqe P 0 1 2 t27 \ ( s e eD a q e1 1 - 6 0 ) Throttle Position(TP)SensorCircuitLow Voltaqe P 0 1 2 {37 ) ( s e ep a q e1 1 - 6 2 ) Throttle Posltion(TP)SensorCircuitHiqh Voltaoe ( s e eD a q e1 1 - 6 4 ) P 0 1 2 8( 8 7 ) P0128 CoolinqSVStemMalfunction ( s e ep a g e1 1 - 6 5 ) P 0 1 3 4( 4 1 ) Air Fuel Ratio(Ay'F) Sensor(Sensor1) No Activity Detected P 0 1 3 (76 3 ) P0137 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 5 ) (Sensor2) CircuitLow Voltaqe P 0 1 3 8( 6 3 ) P0138 SecondaryHeatedOxygen Sensor (SecondaryHO2S) ( s e ep a g e1 1 - 6 6 ) ( S e n s o2 r ) C i r c u i tH i q hV o l t a q e P 0 1 3 (96 3 ) P0139 SecondaryHeatedOxygen Sensor (SecondaryH02S) ( s e ep a g e1 1 - 6 7 ) ( S e n s o2 r )SlowResDonse P 0 1 4 1( 6 5 ) SecondaryHeatedOxygen Sensor(SecondaryH02S) ( s e ep a g e1 1 - 6 8 ) (Sensor2) HeaterCircuitMalfunction ( 4 5 ) ( s e ep a q e1 1 - 7 0 ) P0171 PO\11 FuelSvstemToo Lean ( s e eo a o e1 1 - 7 0 ) PO112l'45) PO\l2 FuelSystemToo Rich ( s e ep a g e1 1 - 7 1 ) P0300andany P0300andany R a n d o mM i s f i r e

P 0 1 1{86 )

of P 0 3 0 (17 1 ) (721 PO302 P0303(73) P0304(74) P0301(7'1)

of P0301 P0302 P0303 P0304 P0301

No. 1 Cyl n d e rM i s f i r e

P0302(721

P0302

No.2 Cvl n d e rM i s f i r e

{ s e ep a g e1 1 - 7 2 ) { s e ep a q e11 - 7 2 ) ( s e eo a q e1 1 - 7 2 ) P0303(73) P0303 N o . 3 C v l nder Misfire P0304{74) P0304 N o . 4 C v l nder Misfire {seeDaqe11-72) " ; T h e s e D T C sa r e i n d i c a t e db y a b l i n k i n gm a l f u n c t i o ni n d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c es i g n a l i n e i s jumped with the Honda PGM Tester.

{cont'd)

11-7

Fueland EmissionsSystems DTCTroubleshootingIndex(cont'd)

(

KnockSensorCircuitN4alfunction

PO4i{ P 0 4 5 1( 9 1 )

TU45I

P0452

CrankshaftPosition(CKP)SensorIntermittent

( s e ep a g e1 1 - 7 8 )

CamshaftPosition(CMP)SensorA No CamshaftPosition(CMP)SensorA Intermiftent

( s e eo a q e1 1 - 1 2 1 i s e ep a g e1 1 - 1 2 1 )

Phqse G Yetrgb-le VelyeTiTing_controlll/T!)

s e eo a o e1 1 - 1 2 2 CqJalystSystemElficie-ncy Below Threshold s e eo a q e11 -1 6 7 ( F T PS ) e n s o rR a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 ) F u e lT a n kP r e s s u r e SensorCircuitLow V FuelTank Pressure(FTP)SensorCircuitHigh V V e h i c l eS D e e dS e n s o r C i r c u i tM a l fu n c t i o n E n g i n eC o n t r o M l o d u l e( E C N 4P)o w e rS o u r c eC i r c u i l

11-172

s e eD a q e1 1 - 1 3 0 ) ( s e ep a g e11 - 8 1 )

SeriaC l o m m u n i c a t i o Ln i n kM a l f u n c t i o n

Referto the l\4ultiplex ControlSystem T r o u b l e s h o o t i n{gs e e

P 1 1 0(61 3 )

(BARO) Barometric Pressure SensorRange/ PerformanP c er o b l e m

( s e ep a g e11 - 8 3 )

P 1 1 0(?1 3

( B A R OS ) e n s o rC i r c u i tL o w BarometriP c ressure

( s e ep a S e11 ' 8 3 )

P 11 0 8( t s '

( B A R OS ) e n s o rC i r c u i tH i g h BarometriP c ressure

{ s e ep a g e1 1 - 8 3 )

P112111)

P't121

T h r o t t l eP o s i t i o n{ T P iS e n s o rS i g n a lL o w e rT h a n

( s e ep a g e1 1 - 6 3 )

P1122ll J

Pl122

T h r o t t l eP o s i t i o n( T P )S e n s o rS i g n a lH i g h e rT h a n

tsee page I r-oJ,

i j 1 1 2 8( 5 )

P11f,.8

Pr 158 (48)

(l\,4AP M a n i { o l dA b s o l u t eP r e s s u r e S }e n s o rS i g n a l G;tp"s" 1154) Loqer Than Expected ( * " p a S e11 5 4 ) ManifoldAbsolutePreisure (MAP)SeiiioiSgnul H i q h e rT h a nE x ( s e ep a g e1 1 - 8 4 ) A i r F u e lR a t i o( A V FS) e n s o r( S e n s o r1 ) R a n g e / R e r f o r m a n cP eroblem A i r F u e lR a t i o { A " FS) e n s o r{ S e n s o 1 r ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 )

P 11 5 9( 4 8 )

'l) A i r F u e lR a t i o1 A V FS)e n s o ri s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 )

P 1 1 6 3( 6 1 P 1 1 6 4( 6 1 )

Air FuelRatio{A,/F)Sensor{SensorI ) Slow Response ( s e ep a g e 11 - 8 8 ) A i r F u e lR a t i o( A / F )S e n s o r( S e n s o r1 ) R a n g e /

P 11 2 9( 5 ) P 1 1 5 7( 4 8 )

l\."

P 11 6 6( 4 1 )

( s e ep a g e1 1 - 8 9 ) Air Fuel Ratio(4,/F)Sensor(Sensor1) HeaterCircuit Malfunction Air Fuel Ratio(A,/F)Sensor(Sensor1) HeaterSystem ( s e ep a g e1 1 - 9 1 ) P 11 6 7( 4 1 )' Malfunction " : T h e s eD T C Sa r e i n d i c a t e db y a b l i n k i n gM I L w h e n t h e S C Ss e r v l c es i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M Tester. * 1 r' 0 2 m o d e l

11-8

DTC Temporary DTC Detectionltem {MlLindication*l P1259t22J VTECSystem l\4alfunction P1291t20\ ElectricalLoad Detector(ELD)CircuitLow Voltaqe P1298(20) ElectricalLoad Detector(ELD)CircuitHiqh Voltaqe P 1 3 6 1( 8 )

P 1 3 6 (28 ) P'r456(90)

P1456

(90) P14s7

P1457

P 1 5 0 (51 0 9 )

P1505

(14) P1519 P 1 6 0 7( )

CamshaftPosition(CMP)SensorB (Top DeadCenter (TDC)Sensor)IntermittentSional InterruDtion CamshaftPosition(CMP)Sensor B (Top DeadCenter ( T D C )S e n s o r N ) o Siqnal EvaporativeEmissions(EVAP)ControlSystem Leakaqe(FuelTank Svstem) EvaporativeEmissions(EVAP)ControlSystem Leakaqe(EVAPCanisterSvstem) PositiveCrankcaseVentilation(PCV)Air Leakaqe ldle Air Control(lAC)ValveCircuitMalfunction

EnginC e o n t r oM l o d u l e( E C MI)n t e r n aCl i r c u i t Malfunction

Page ( s e eD a q e1 1 - 1 2 3 ) ( s e eD a q el 1 - 9 2 ) ( s e eo a o e1 1 - 9 3 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 9 5 ) ( s e ep a g e1 1 - 1 7 5 ) ( s e ep a g e1 ' l - 1 8 0 ) ( s e eo a q e1 1 - 1 6 8 1 { s e ep a q e1 1 - 1 3 1 ) ( s e ep a g e11 - 9 6 )

" : TheseDTCSare indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM Tester.

11-9

Fueland EmissionsSystems Symptom TroubleshootingIndex

When the vehiclehas one of these symptoms,checkthe diagnostictrouble code (DTC)with the scantool. lf there is no DTC,do the diagnosticprocedurefor the symptom, in the sequencelisted,until you find the cause. Svmotom E n g i n ew i l l n o t s t ar t (MlL works OK, no DTCSset)

Diaqnostic procedure 1. Testthe battery{seepage 22-50). 2. Testthe starter(seepage 4-8). 3. Troubleshootthe fuel pump circult(seepage 11 141).

E n g i n ew i l l n o t s t a r t( M l L comes on and stayson, or n e v e rc o m e so n a t a l l ,n o DTCSset) Enginewill not start (immobilizerindicatorstays on or flashs)

Troubleshootthe l\4lLcircuit(seepage 1

Hardstarting (MlLworksOK,no DTCS set)

1. Testthe battery(seepage22-50). 2 . C h e c k t h ef u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .

Coldfast idle too low (MlL works OK. no DTCSset) Coldfast idle too high (MlL works OK, no DTCSset)

1 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . 2 . C h e c k t h ei d l e s D e e d( s e ep a q e1 1 - 1 3 8 ) . ' ] D o t h e E C I \ 4i d l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) . 2. C h e c k t h ei d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) . '1-'163). the throttlecable (seepage 1 3 . Inspect/adjust Inspectand test the throttle body {seepage 11-160}. ( s e ep a g e1 1 - ' 1 3 9 ) .I n t a k ea i r l e a k s 1 . D o t h e E C Mi d l e l e a r np r o c e d u r e 2 . C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) . 3, Inspecvadjustth e throttlecable (seepage 11''163). 4. Insoectand test the throttle bodv (seepaqe 11-160) 1 . D o t h e E C I Vi d I l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) . Vacuum hose clogged/ cracked/poor 2. TroubleshootthealternatorFRsignalcircuit (see p a g e1 1 - ' 1 3 4 ) . connectron 3. InsDectand test the throttle bodv {seepaqe 11-160). 1 . D o t h e E C Mi d l e l e a r np r o c e d u r e { s e ep a g e1 ' j - 1 3 9 ) . t e a l t e r n a t oFr Rs i g n a lc i r c u i t ( s e e 2 . T r o u b l e s h o ot h p a g e1 1 - 1 3 4 ) .

ldle speedfluctuates (MlL works OK, no DTCSset)

After warming up, idle speed is below specificationswith no load {MlL works OK, no DTCSset) After warming up, idle speed is above specificationswith no toao (MlL works OK. no DTCSset) Low power (MlL works OK, no DTCSset)

E n g i n es t a l l s (MlL works OK. no DTCSset)

'1-97).

Also check lor Low compressron N o i g n i t i o ns p a r k l n t a k ea i r l e a k s L o c k e du p e n g i n e B r o k e nt i m i n gc h a i n Contaminatedfuel

Troubleshootthe immobilizersystem (seepage 22-165).

1 . C h e c kt h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 5 ) . 2. Inspectand test the th roftle body (seepage 11-160). 3 . I n s p e c v a d j u tsht e t h r o t t l ec a b l e( s e ep a g e1 1 - ' 1 6 3 ) .

1. 2. 3. 4.

D o t h e E C Mi d l el e a r np r o c e d u r e( s e ep a g e1 ' l ' 1 3 9 ) . C h e c kt h e f u e l p r e s s u r e { s e e p a g e l l - 1 4 5 ) . C h e c kt h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) . Troubleshootthebrakepedal positionswitch signal c i r c u i t( s e ep a q e1 1 - 1 3 7 ) .

Low compression I n t a k ea i r l e a k s Contaminatedfuel

Low compressron C a m s h a ftti m i n g problem E n g i n eo i l l e v e l prootem l n t a k ea i r l e a k s F a u l t yh a r n e s sa n d sensorconnections

11-10

Symptom Difficultto refuel (MlL works OK. no DTCSset)

Fueloverflowsduring refueling (No DTCSset)

Diagnosticprocedure 1 . T e s t t h e f u e lt a n kv a p o rc o n t r o lv a l v e { s e e p a g e1 ' l 2. 1471. I n s p e ctth e f u e lt a n kv a p o rc o n t r o ls i g n a lt u b e 3. betweenthe fuel pipe and the fuel tank vapor control valve. 4. Inspectthe fuel tank vapor vent tube betweenthe EVAPcanisterand the fuel tank vapor control valve. Checkthe EVAPcanister. Replacethe fuel tank vapor control valve (seepage '11 189).

Also checktor M a l f u n c t i o n i ngga s s t a t i o nf i l l i n gn o z z l e .

Malfunctioninggas stationfilling nozzle.

11-11

Fueland EmissionsSystems SystemDescriptions

{

ElectronicControl System The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM). Fail-safeFunction When an abnormalityoccursin the signalfrom a sensor,the ECI\4ignoresthat signaland assumesa pre-programmed value for that sensorthat allowsthe enqineto continueto run. Back-up Function When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependentof the systemto p e r m i tm i n i m a ld r i v i n g . Self-diagnosis When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp {MlL) and storesthe diagnostictrouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl suppliesground to the l\4lLfor 15 to 20 secondsto checkthe M lL bulb condition. Two Driving Cycle Detection Method "two driving cycle detectionmethod" is usedfor some self-diagnostic functions. To preventfalse indications,the When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n ,t h e E C Mt u r n so n t h e M l L .

11-12

ECMData You can retrievedata from the ECI\4by connectingthe OBD ll scantool or the Honda PGM Testerto the data link connector(DLC).The items listedin the table below conform to SAE recommendedpractice.The HondaPGM Tester also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems. The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual vehicle. Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition, and the A,/Cand all Diagnostic Trouble Code (DTC}

lf the ECM delectsa problem, it will store it as a code consistingof one letterand four numbers.Dependingon the problem,an SAE-definedcode (Poxxx)or a Honda, definedcode {P1xxx)will be output to the tester.

l f n o p r o b l e mi s detected,there is no ourpul.

YES

TheECI\4 computesenginespeedfromthe signalssent N e a r l yt h e s a m ea s position(CKP)sensor.Thisdatais fromthe crankshaft tachometerindication usedfor determining thetimeandamountof injectedfuel. At idle speed;

Manifold Absolute Pressure (MAP)

The ECMconvertspulsesignalsfrom the vehiclespeed sensor(VSS).

N e a r l yt h e s a m ea s speedometer indication

The absolutepressurecausedin the intakemanifold by e n g i n el o a da n d s p e e d .

Withenginestopped:

YES

Nearlythe same as almospnencpressure. At idle speed:about 20 4'1kPa ( 1 5 0 3 1 0m m H g , 6 - 1 2 i n . H q ) . 0 . 71 . 3V The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e : and signalsthe ECM.The sensor is a thermistorwhose S a m ea s a m b i e n t internalresistancechangeswith coolanttempetature.The temperatureand IAT ECM usesthe voltagesignalsfrom the ECTsensorto With enginewarmed determinethe amount of injectedfuel. u p ; a b o u t1 1 6 2 ' 1 2 " F

1 0 0 ' c ) . 0 . 5 - 0 .v8

Air Fuel Ratio ( A y ' FS)e n s o r . (Sensor1)

Secondary Heated Oxygen Sensor (Secondary H02S, Sensor2)

The A,/Fsensordetectsthe oxygen content in the exhaust 0.0- 1.25 V g a s a n d s e n d sv o l t a g es i g n a l st o t h e E c l v l ,B a s e d o n t h e s e 8 . 0 1 1 . 0 m A ( P G M signals,the ECMcontrolsthe airlfuel ratio.When the I Tester) oxygen contentis high (that is, when the ratio is leaner At idle speed: than the stoichiometricratio),the voltagesignal is Iower. about 0.1 0.9 V When the oxygencontent is low (that is, when the ralio is richerthan the stoichiometricratio).the voltagesignal is higher.The A'lFsensorsignalsare electricalcurrentthat are indicatedas voltaqe on the The HO2Sdetectsthe oxygen contentin the exhaustgas 0 . 0 1 . 2 5V a n d s e n d sv o l t a g es i g n a l st o t h e E C M .B a s e do n t h e s e At idle speed: signals,the ECMcontrolsthe airlfuel ratio.When the a b o u t0 . 1 0 . 9V oxygen contentis high (that is, when the ratio is leaner than the stoichiometricratio),the voltagesignal is lower. When the oxygen content is low (that is, when the ratio is r i c h e rt h a nt h e s t o i c h i o m e t r irca t i o ) t, h e v o l t a g es i g n a li s

(cont'd)

11-13

Fueland EmissionsSystems

r a

SystemDescriptions(cont'd) ECMData(cont'd) Description "open" or "closed". Fuelsystem statusis indicatedas Closed:Basedon the A,/FSensoroutput,the ECM determinesthe airlfuel ratio and controlsthe amount of injectedfuel. Open: lgnoringAy'FSensoroutput,the ECM refersto signalsfrom the throttle position{TP),manifoldabsolute pressure(MAP),intakeair temperature(lAT),barometric pressure(BARO),and enginecoolanttemperature(ECT)) sensorsto controlthe amount of iniectedfuel. The airlfuel ratio correctioncoefficientfor correctingthe Short Term amount of injectedfuel when the fuel system status FuelTrim is "closed." When the ratio is leanerthan the sloichiometricratio,the ECM increasesshort term fuel trim gradually,and the amount of iniectedfuel increases. The airlfuel ratio graduallygets richer,causinga lower oxygen content in the exhaustgas. Consequently,the short term fuel trim is lowered,and the ECM reducesthe amount of injectedfuel. This cvcle keepsthe airlfuelratio closeto the stoichiometricratio when in closed loop status. Long term fuel trim is computedfrom short term fuel trim LongTerm and indicateschangesoccurringin the fuel supply system F u eT l rim over a long period. l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f injectedfuel must be increased.lf it is lower than 1.00,the amount of injectedfuel must be reduced. The IAT sensorconvertsintakeair temperatureinto IntakeAir Temperature v o l t a g ea n d s i g n a l st h e E C M .W h e n i n t a k ea i r temperatureis low, the internalresistanceofthe sensor {IAT) increases,and the voltagesignal is higher. Basedon the acceleratorpedal position,the opening Throttle anole of the throttlevalve is indicated. Position lgnitiontiming is the ignition advanceangle set by the lgnition ECM.The ECM matchesignitiontiming to driving Timing conditions.

Data FuelSystem Status

Calculated L o a dV a l u e (cLV)

cLV is the enoine load calculatedfrom IMAPdata.

Opera'tingValue At idle speed:closed

FreezeData

YES

o.7 1.5

YES

0.8 1.2

YES

w W i t h c o l de n g i n e : S a m ea s a m b i e n t a n dE C T temperature

YES

At idle speed: a b o u t1 0% At idle speed:8" t 5" | ' t u L w n e nr n e > L ) s e r v i c es i g n a l i n e i s jumped with the Honda PGM Tester At idle speed: 12 34% At 2.500rpm with no toao: 't4- 34%

YES NO

YES

\.,

11-14

J/-\ -1\_/

BEIAY2

A/C CLUTCHRELAY

I )

RAOIATOR

T UNDER.HOOD FUSE/RELAY BOX: (8oA) ONo. 19BATTERY ONo.6 ECU(ECM)(15A1 (3)No.20lG {40A1 {Canada:50A} ONo.l4 OPTION {40A1 €)No.9 BACKuP (7.5A1 lo)No.7 HORN,STOP{15A} UNDER.DASH FUSE/RELAY BOX: ONo. 17FUELPUMP {15A} @No.,t ACG{10A) ONo.1 IGNCOIL(1sA) q)No.10METER (7.5A) 0)No.14A/C CLUTCH RELAY IlOA) @No.2+B LAF(A/F) (2OA) HEATER

(cont'd)

11-15

Fueland EmissionsSystems SystemDescriptions(cont'dl

ECMElectricalConnections

MAPSENSON No. INJECTOR

No,2INJECTOR TPSENSOR

No.3 INJEC]OB

No./tINJECTOF

IATSENSOR

ECTSENSOB

CMP SENSORB (TDCSENSOSJ

CKPSENSOR

F€VERSELOCK SOLENOIDVAIVE

11-16

A/FSENSOR

EVAPCANISTE6 PURGEVAIVE

EVAPCANISTER VENTSHUTVATVE

A/FSENSOR (sENSOn 1)

sotENotovAtvE

CMP SENSOFA

VIC OIL CONTROL SO!ENOIDVALVE No. 1 IGNITIONCOIL

wEcorl N o . 2 l G N l l l O NC O I L

No. 3 IGNITIONCOIL

PRESSUSESWTICH

VTEC SOLENOID

No. a IGNITIONCOIL

{cont'd)

11-17

Fueland EmissionsSystems SystemDescriptions(cont'd)

ECMElectricalConnections

ARAKEPEDAL POStTtONSWTTCH

GAUGEASSEMBLY

IMMOBILPENUN|T

EPSCONTROTUNIT

TERMINALLOCATIONS

11-18

ECMInputsand Outputsat ConnectorA (31P)

2 1 AFS]TC ]GP2 '10 SG2

3 IGPl

^:^ I -:,

12 ACV

23 HTC+ LG2

6 AFS+

15 T6 TPS AFS_ 26 25 CMPB CMPA(rDc)

I KS

1 CKP

18 1 9 2A 21 V S S IVAP vcc2 vccl 27 28 29 30 tGPts,lrcPts3tGPts2GPLS 1

Wire side ol femaleterminals NOTE:Standardbatteryvoltageis 12V. Terminal Who color numb€r ELKAVHT

forminal name

Description

Signal

YEUBLK

AFSHTC(AIRFUELRATIO (4./F)SENSOR HEATER CONTROL} IGP2(POWEB SOURCE)

YEUBLK

IGPl {POWER SOURCE)

4 5 6

PG2(POWER GROUND Groundforthe ECMcircuit PG1(POWER GROUND Groundforthe ECMcircuit AFS+ (AIRFUELRATIO DetectsAy'Fsensor (A,/F}SENSOR, SENSOR1 {sensor1)signal + stDE) 8LU CKP(CRANKSHAFT Detects CKPsensorsignal Withenginerunning:pulses POSITION SENSOR) BED/BLU ) KS E N S O B ) pulses Detectsknocksensorsiqnal Withenqineknocking: YEL 2 {SENSOR; R O U N D ) Sensorqrounr Lessthan1.0Vat elltimes ; R O U N D ) Sensorqroun( G 1{ S E N S O R L e s s t h a 1n . 0 Va t a l l t i m e s BLIVRED IACV(IDLEAIRCONTROL DrivesIACvalve Withenginerunningrdutycontrolled (IAC)VALVE) RED/BLK TPS(THROTTLE POSITION Detects TPsensorsignal Withthrottlefullyopen:about4.8V SENSOR) Withthronlefullvclosed:ahout0-5V REDI/EL AFS (AIRFUELRATIO Detects!y'Fsensor (4,/F)SENSOR, ( s e n s o1r) s i g n a l SENSOB1 SIDE) WHT/GRN V S S ( V E H I C L ES P E E D Detects VSSsignal WathignitionswitchON (lli andfrontwheels SENSOR) rotating: cyclesfrom about0 V to about5 V or

1 9 10 12

BLK

BLK RED

DrivesAy'Fsensorheater

Withignit'onswitchON {ll):batteryvoltage Withfullywarmedup enginerunnang: 0V

Powersourcefor the ECM circuit Powersourcefor the ECM

Withthe ignitionswitchON 1ll):batteryvoltage Withthe ionitionswitchOFF:about0 V Withthe ignitionswatch ON {ll):batteryvoltage Withthe ionitionswitchOFF:about0 V Lessthan 1.0V at all times Lessthan 1.0V at all times

(cont'd)

11-19

Fueland EmissionsSystems

\. il

SystemDescriptions{cont'd) ECMInputsand Outputsat ConnectorA (31P)

1 AFS]TC

2 GP2

3 IGPl

4 PG2

12 10 11 SG2 sG1 IACV 22 23 AFS LG2 HTC+

5 6 PG.1 AFS+ '15 1 6 TPS AFS_

26 25 CMPB Ct\.4PA (rDc)

I KS

1 CKP

18 1 9 20 21 V S S IVAP vcc2 vccl 29 30 27 28 IGPLS,I IGPLS4 IGPLS3 IGPLS2

Wire side of femaleterminals NOTE:Standard batteryvoltageis 12V. [€rminal namo Description Jorminal Wirecolor number DetectsMAPsensorsignal 19 GRN/RED MAP(MANIFOLD PRESSURE ABSOLUTE SENSOR) YEUBLU VCC2(SENSOR VOLTAGE) P r o v i d e ss e n s o r v o l t a g e 20

YEURED VCC](SENSOB VOLTAGE) Provides sensorvoltage

AFSHTC- (AIRFUEL Detectsa,/Fsensorheater RATIO(A"iFiSENSOR voltage + SIDE) HEATER CONTROL BRN?ryE L LG2(LOGIC GROUND roundfor the ECMcircu 1(L roundfor the ECMcircu BRN?ryE L (CAMSHAFT D e t e c t sC M P s e n s o r A BLU,^/VHT CMPA A) stonal POSITION SENSOR Detects CMPsensor8 (TDc GRN CMPB CAMSHAFT (CMP)SENSOB sensor) POSITION B (TDC(TOPDEADCENTER SENSORi) I G P L S 4{ N o .4 I G N I T I O N DrivesNo, 4 ignitioncoi BRN

23 24 25 26

COILPULSE) I G P L S 3{ N o . 3 I G N I T I O N COILPULSE)

WHT/BLU

GNITION BLU/RED l G P L S 2 l N o .I 2 COILPTJLSE) YEUGRN IGPLSI(No.1 IGNITION co PlltsF)

Signal With ignitionswitchON (ll):about3 V A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )

With ignitionswitchON {ll):about5 V WithionitionswitchOFF:about0V WithignitionswitchON {ll):about5 V With ionitionswitchOFF:about0V W i t h i g n ; t i o ns w i t c h O N l l l ) : b a n e r y v o l t a g e

\. Lessthan1.0V at alltimes L e s st h a n

'1.0 V at alltimes

Withenginerunning:pulses Withenginerunning:pulses

WithignitionswitchON (ll)rabout0 v Withenginerunning:pulses

O r i v e s N o . 3 r g n i t i o nc o i DrivesNo.2 ignitioncoil

DrivesNo. I ignitioncoil

11-20

Wire side o{ femaleterminals

NOTE:Standardbafteryvoltageis 12V. Terminal numo€t

Wirecolor

[erminal name

Description

BLUAvHT VTC+ lVTCOILCONTBOL DrivesVTCoilcontrol 2 3 4 5 6 7 8 9

'17

18 21

VALVE+SIDE) SOLENOID lNJa{No.4INJECTOR) Jo.3INJECTORI BL )TOR) R1 lNJl 1No.I INJECTOR) BRN FAN FANC(RAOIATOR GRN CONTROL) LOCK GRN/vVHT RVS(REVERSE VALVE) SOLENOID

Drives o. 4 iniector Drives o.3 iniector Drives o . 2 i n i e c t o r DrivesNo. 1 iniector Drivesradiatorfan relay

Signal WithignitionswitchON (ll):0 V At idle:dutycontrolled

With radiatorfan running:about0 V With radiatorfan stopped:battervvoltaoe Drivesreverselocksolenoid Withvehiclespeedbelow9.4mph (15km/h): batteryvoltage Withvehiclespeedabove12.5mph (20km/h):0 V Withthe ignitionswitchON (ll):about0.1 4.8V DetectsECTsensorsignal COOLANT REDAVHT ECT(ENGINE ideoendino on enoinecoolanttemDerature) TFMPFRATURE SENSOR) VTEcoil pressure Withengineat low enginespeed:about0 . Detects BLU/BLK VTPSW(VTECOIL Wirhenoineat hiohenoinesoeed:battervvoltaqe PRFSSTIRF SWITCH) switch sional L signal With ignitionswit'chON (ll):about0 V L Detects alternator WHT/BLU ALTL(ALTEBNATOR Whh enoinerunnino:battervvoltaqe SIGNAII FBsignal Withenginerunning:about0 V- 5 V FR Deteclsalternator WHT/RED ALTF(ALTERNATOR load) on electrical S I GN A L I {deoendinq DrivesVIECsolenoidvalve A t i d l e : a b o u t 0 V GRN/YEL VTS {VTECSOLENOID With ignitionswitchON {ll):about0.1V 4.8v l.lcnen.iino on intakeairtemoerature) Withenginerunning:about0 V 5 V control Sendsalternator (.lcocn.lino on electrical ioad) purge Withenginerunning,enginecoolantbelow149'F DrivesEVAPcanister batteryvoltage 165'C): valve Withenginerunning,enginecoolantabove149'F 165"C): dutvcontrolled W i t h t h e i g n i t i o n s w i t c h O N ( l l ) :0 V BLK/Vr'HT VTC (VTCOILCONTROL DrivesVTCoilcontrol SOIFNOIDVALVE SIDE)

IAT(INTAKE AIR TEMPERATURE SENSOR) WHT/GRN ALTC(ALTERNATOR CONTROL) YEUBLU PCS{EVAPORATIVE EMISSION CANISTER PURGE VALVE)

REDI/EL

DetectsIATsensorsignal

(confd)

11-21

Fueland EmissionsSystems L

SystemDescriptions(cont'dl ECMlnputsand Outputsat ConnectorE (31P}

1 iMo FPR

sr-{]zsLG3

22 23 24 BKSWK-LINESEFMJ

6 1 $1025 MRLY HTC 16 14 15 18 FTP ELD EPS ACC LD 21 26 rMo NEP CD

8 AFS HTCR

4 SG3

20 21 Z/VBS VSV 29

scs WEN MIL

Wire side of femaleterminals NOTE:Standardbatteryvoltageis '12V. Terminal Wire color number GRNI/EL 2

3 4 5 6

(SECONDARY Drivessecondary BLKATr'HT SO25HTC HO2S HEATED OXYGENSENSOR heater (SECONDARY H02S) HEATER CONTROL) REDA/EL MRLY(PGM.FI MAIN DrivesPGM-Flmain relay1 RELAY} Powersourceforthe DTC ORN

YEUBLK

'18

Description

IMOFPR(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2 FLJEL PUMPRELAYI WHT/RED SHO2S(SECONDARY DetectssecondaryHO2S HEATED OXYGENSENSOR {sensor2) signal (SECONDARY HO2S), SENSOR 2r BRN/YEL LG3(LOGIC GROUND) cround forthe ECM/PCM controlcircuit PNK SG3{SENSOR GBOUND) Sensororound YEUELU VCC3{SENSOR VOLTAGE) Providessensorvoltage

't4

ferminal name

0Vfor2 secondsafterturningignitionswitchON {ll).then battervvoltaoe WiththrottleJullyopenedfrom idlewith fully warmedup engine:above0.6V Withthrottlequicklyclosed:below0.4V Lessthan1.0V at all times Lessthan 1.0V at all times With ignitionswitchON (ll):about5 V With ionitionswitchOFF:about0 V With ignitionswitch ON (ll):bafteryvoltage Wilh fullvwarmedup enginerunning:dul, controlled

WithignitionswirchON {ll):0 V

IGl (IGNITION SIGNAL)

With ignition switch ON (ll): battery voltage With iqnition switch OFF: about 0 V

D e t e c r si g n i t i o n s i g n a l

FIP lFUELTANK DetectsFTPsensorsignal (FTP)SENSOR) PRESSURE GRN/RED ELD(ELECTRICAL LOAD DetectsELDsignal DETECTOF) LTGRN/8LK EPSLD(ELECIRICAL DetectsPowersteeringload POWEBSTEEBING LOAD srgnal DETECT) ACC(Ay'C CLUTCH RELAY) DrivesP,/Cclutch relay

WithignitionswitchON (ll):about0 V With ignitionswitchOFF:batteryvoltage

AFSHTCR {AIRFUELBATIO Drivesairfuel ratiosensor (Iy'F)SENSOR HEATER heaterrelay CONTROLRELAY)

LT GRN

RED

Signal

WithignitionswitchON (ll)andfuelfill capopen: about2.5V WithignitionswjtchON itt):aOoutO.t V l-gV (deDendino on electrical load) At idlewith steeringwheelin straightahead position:about0 V At idlewith steeringwheelatfulllock:momentary Withcompressor ON:about0 V With comoressorOFF:battervvoltaoe

11-22

ECMInputsand Outputsat ConnectorE (31P)

2 t M o $.c2s FPR

14 FTP

22 23 24 BKSWK LINESEFMJ

I AFS HTCR

6 1 SFIO2S IV RLY HTC

15 ELD

16 EPS LD

26 NEP

21 20 2,4/BS VSV

21 lvo CD

9 tGl

scs WEN MIL

Wire side of femaleterminals

NOTE:Standardbatteryvoltageis 12V. Terminal Wire color 20 21

22 23

21 29

Description

BLU/RED 2WBS(EVAPORATIVE

DrivesEVAPbypass (EVAP)BYPASSsolenoidvalve EMISSION SOLENOID VALVE) DrivesEVAPcanistervent LT GRN/RED VSV (EVAPORATIVE shutvalve EI\4ISSION iEVAP) VENTSHUT CANISTEB VALVE) Detects brake pedal WHT/BLK BKSWlBRAKEPEDAL POSITION SWITCH) o o s i t i o ns w i t c h s i o n a l scan LT BLU K-LIN E Sendsand receives YEL

Terminalname

SEFMJ

N E P( E N G I NSEP E E D PULSE) RED/BLU \40CDfl\4MOBTLTZER CODE) BRN S C S ( S E R V I C EC H E C K

BLU

ENABLE RED,A/VHT WEN(WRITE SIGNALi GRN/ORN MIL(MALFUNCTION LAMP) INDICATOR

WithignitionswitchON (ll):bafteryvoltage W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e

With brakepedalreleased: about0 V With hrake nedal nresse.l: batterv voltaoe

With ignitionswitchON (li)rpulsesor battery

With ignitionswitchON (ll):about5 V Withenoinerunninounderload:DUlses Outputsenginespeedpulse Withenginerunning:pulses

C o m m u n i c a t e sw i t h mrltinleYeontrolunit

D e t e c t si m r n o b i l i z e rs i g n a l

checksignalshortedwith the PGM O e t e c t ss e r v i c ec h e c k s i g n a l Withthe service Tester:about0 V Wiih rheservicechecksionalooened:about5 V

SIGNAL)

Signal

D e t e c t sw r i t e e n a b l e s i g n a l

W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V

DrivesN4lL

WithMILturnedON:about0 V WithMILturnedOFF:battervvoltaqe

(cont'd)

11-23

Fueland EmissionsSystems !

SystemDescriptions(cont'dl VacuumHoseRouting

INTAKEAIR BYPASSCONTROL THERMALVALVE

FRONTOF VEHICLE EVAPORATIVEEMISSION {EVAP}CANISTERPURGEVALVE

11-24

VacuumHoseRouting

1} {SENSOR O AIRFUELRATIOIA/F)SENSOR HEATED OXYGENSENSOR O SECONDARY 2} HO2S}{SENSOR ISECONDARY (MAPISENSOR PRESSURE ABSOLUTE O MANIFOLD {ECT)SENSOR O ENGINECOOLANTTEMPERATURE (IAT)SENSOR O INTAKEAIRTEMPERATURE (CKP)SENSOR POSITION O CRANKSHAFT O KNOCKSENSOR (CMPISENSOR B POSITION O CAMSHAFT ITDC)SENSOR) ITOPDEADCENTER A POSITION O CAMSHAFT ICMPISENSOR (IACIVALVE @ IDLEAIRCONTROL O THRONLEBODY .OINJECTOR OAMPER @ FUELPULSATION [I FUELFILTER REGULATOR @ FUELPRESSURE @ FUELPUMP @ FUELTANK

@ RESONATOR (9 AIRCLEANER VENTILATION{PCVIVALVE @ POSITIVECRANKCASE CONVERTER WAYCATALYTIC @ THREE EMISSION {EVAPICANISTER @ EVAPORATIVE EMISSION {EVAP)CANISTER @ EVAPORATIVE PURGE VALVE (EVAPICANISTER EMISSION {} EVAPORATIVE VENTSHUTVALVE EMISSION {EVAP)TWOWAYVALVE {' EVAPORATIVE EMISSION IEVAPIBYPASS @ EVAPORATIVE VALVE SOLENOID (FTP)SENSOR @ FUELTANKPRESSURE EMISSION IEVAP}VALVE @ EVAPORATIVE VALVE @ FUELTANKVAPORCONTROL VALVE 60)FUELTANKVAPORRECIRCULATION VALVE THERMAL CONTROL O INTAKEAIRBYPASS

(cont'd)

11-25

Fueland EmissionsSystems SystemDescriptions(cont'd) PGM-FISystem The ProgrammedFuel Injection(PGM-Fl)system is a sequentialmultiport fuel injectionsystem.

CamshaftPosition(CMPISensorB (TopDeadCenter (TDCISensor) TheCMPsensorB (TDCsensor)detectsthe positionof the No.1 cylinderasa reference for sequential fuel injectionto eachcylinder.

Air Conditioning {A/C) Compressor Glutch Relay When the ECfMreceivesa demandfor coolingfrom the Ay'Csystem,it delaysthe compressorfrom being energized,and enrichesthe mixture to assuresmooth transitionto the AVCmode. Air Fuel Ratio lA/Fl Sensor The Ay'FSensoroperatesover a wide airlfuel range.The Ay'FSensoris installedupstreamof the TWC, and sends signalsto the ECMwhich variesthe durationof fuel injectionaccordingly.

ztRcoNta ELEMENT

HEATER

MAGNET

SENSOR TERMINALS

Crankshaft Position (CKPISensor The CKPsensordetectscrankshaftsoeedand determinesignitiontiming and timing for fuel injection of each cylinderas well as detectingengine misfire.

HEATER TERMINALS

Barometric Pressure {BAROI Sensor The BAROsensoris insidethe ECM.lt convens atmosphericpressureinto a voltagesignalthat the ECM usesto modify the basicdurationof the fuel injection discharge.

Engine Coolant Temperature (ECT)Sensor The ECTsensoris a temperaturedependentresistor (thermistor).The resistanceof the thermistordecreases as the enginecoolanttemperatureincreases. TERMINAL

11-26

lgnition Timing Control The ECMcontainsthe memory for basicignitiontiming at variousengine speedsand manifold absolute pressure.lt also adjuststhe timing accordingto engine coolanttemperature. Iniector Timing and Duration The ECM containsthe memory for basicdischarge d u r a t i o na t v a r i o u se n g i n es p e e d sa n d m a n i f o l d pressures.The basicdischargeduration,after being read out from the memory, is further modified by signalssent from varioussensorsto obtain the final d i s c h a r g ed u r a t i o n . By monitoring long term fuel trim, the ECMdetectslong term malfunctionsin the fuel systemand sets a DiagnosticTrouble Code{DTC). Intake Air Temperature (lAT) Sensor The IAT sensoris a temperaturedependentresistor {thermistor).The resistanceof the thermistor decreases as the intakeair temDeratureincreases.

MalfunctionIndicatorLamp lMlLl Indication{ln relation to ReadinessCodes) "readinesscodes" that are part The vehiclehas certain of the on-boarddiagnosticsfor the emissionssystems. lf the vehicle'sbafteryhas been disconnectedor gone dead.if the DTCShave been cleared,or if the ECM has been reset.these codesare set to incomplete.In some states,part of the emissionstesting is to make sure these codes are set to comDlete.lf all of them are not set to complete,the vehiclemay fail the test and the test cannot be finished. To checkif the readinesscodes are set to complete, turn the ignition switch ON (ll). but do not startthe e n g i n e . T h e M I L w ci lol m e o n f o r l S 2 0 s e c o n d sl f. i t then goes off, the readinesscodesare set to complete, lf it blinksseveraltimes,one or more readinesscodes are not set to comolete.To set each code, drive the v e h i c l eo r r u n t h e e n g i n ea s d e s c r i b e di n t h e proceduresto set them in this section(seepage 11-46). Manifold Absolute Pressure {MAP) Senso] The MAP sensorconvertsmanifoldabsolutepressure i n t oe l e c t r i c asl i g n a l st o t h e E C M . SENSOR UNIT

Knock Sensor The knockcontrol system adjuststhe ignitiontiming to minimizeknock.

PIEZO CERAMIC

(cont'd)

11-27

Fueland EmissionsSystems SystemDescriptions(cont'dl Secondary Heated Oxygen Sensor (Secondary HO2S) The secondaryHO2Sdetectsthe oxygen content in the exhaustgas downstreamof the three way catalytic converter(TWC)and sendssignalsto the ECMwhich checksthe efficiencyof the TWC.To stabilizeits output, the sensorhas an internalheater.The secondarvHO2S i s i n s t a l l e di n t h e T W C .

( Vehicle Speed Sensor (VSS) The VSS is driven by the differential.lt generatesa pulsedsignalfrom an input of 5 volts.The number of pulsesper minute increases/decreases with the speed of the vehicle. BEARING

SENSOR TERMINALS

ztRcoNta ELEMENT

HEATER TERMINALS

Starting Control When the engine is started,the ECM providesa rich mixture by increasinginjectorduration.

( Throttle Position ITP)Sensor The TP sensoris a potentiometerconnectedto the throttlevalve shaft.As the throttle positionchanges,the sensorvariesthe signalvoltageto the ECM.The TP sensoris not replaceableapart from the throftle body.

ELEMENT

BRUSHHOLDER

gRUSH

(

11-28

wEc/wc The i-WEC has a VTC (VariableValveTiming Control)mechanismon the intakecamshaftin additionto the usual VTEC. This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed. a n d e n g i n el o a d . The VTECmechanismchangesthe valve lift and timing by using more than one cam profile. The VTCchangesthe phaseof the intakecamshaftvia oil pressure.lt changesthe intakevalve timing continuously. HIGH

LOW<-

ENGINESPEED

DrivinoCondition Qr Light-load

VTC Control B a s eP o s i t i o n

?l M edium/high-load

AdvanceControl

€) High speed

Advance-BasePosition

DescriDtion Cam angle is retardedto reducethe entry of exhaust gas into the intakeport and to achievestablefuel c o n s u m D t i o dn u r i n ql e a nb ur n . Cam angle is advancedfor EGReffectand to reduce this pumping loss.The intakevalve is closedquickly to help reducethe entry of airlfuel mixture into the intakeport and improve the chargingeffect. C a m p h a s ea n g l ei s c o n t r o l l e df o r o p t i m u mv a l v e t i m i n qa n d m a x i m u me n o i n eo o w e r .

{cont'd)

11-29

Fueland EmissionsSystems SystemDescriptions(cont'dl

(

VTC system . The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions. . Intakevalve timing is optimizedto allow the engineto producemaximum power. 'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect. . Cam angle is reducedat idle to stabilizecombustionand reducesenginespeed. ' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r iosl d i s a b l e da n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e dp o s i t i o n . TDC MAXIMUM VTCADVANCE50'

MAXIMUM VTC ADVANCE50'

l(-4

'+-|l

sHoRToVERLAP LoNGoVERLAP

VTEC system ' The VTECsystemchangesthe cam profileto correspondto enginespeed.lt maximizestorque at low enginespeed and output at high engine speed. . The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.

LOWSPEEDVALVETIMING

11-30

HIGHSPEEDVALVETIMING

System Diagram CMPSENSORA From No. il ACC{10A)fuse

INTAKE CAMSHAFT

BRN/YEL -:-

BLU/WHT BLU/WHT

VARIOUS SENSORS

BLK/WHT GRN/YEL BLU/BLK

BLK

:5i.T,""

Camshaft Position {CMP}Sensor The CMP sensordetectscamshaftangle positionfor the VTC system.

{cont'd}

11-31

Fueland EmissionsSystems (

SystemDescriptions(cont'd) ldle Control System

FuelSupply System

When the engine is cold, the Ay'Ccompressoris on, the transmissionis in gear,the brakepedal is pressed.the power steeringload is high, or the alternatoris charging,the ECIMcontrolscurrentto the ldle Air Control(lAC)valveto maintainthe correctidle speed. Referto the System Diagramto seethe functional layout of the system.

Fuel Cut-off Control Duringdecelerationwith the throttle valve closed, currentto the injectorsis cut off to improve fuel economy at enginespeedsover 1,030rpm. Fuelcut-off actionalso occurswhen enginespeedexceeds 6,900rpm, regardlessof the positionof the throttle valve,to protectthe enginefrom over-rewing. When the vehicleis stopped.the ECMcuts the fuel at engine speedsover 6,500rpm.

Brake Pedal Position Switch The brakepedal positionswitch signalsthe ECMwhen the brakepedal is oressed. Electrical Power Steering (EPS)Senser The EPSsensorsignalsthe ECMwhen the power s t e e r i n gl o a di s h i g h . ldle Air Control llACl Valve To maintainthe proper idle speed,the IACvalve changesthe amount of air bypassingthe throttle body in responseto an electricalsignalfrom the ECM. From AIR CLEANER

IAC VALVE

11-32

To INTAKE MANIFOLD

Fuel Pump Control When the ignition is turned on, the ECMgroundsthe PGM-Flmain relay which feeds currentto the fuel pump for 2 secondsto pressurizethe fuel system,With the e n g i n er u n n i n gt.h e E C Mg r o u n d st h e P G M - Fm l ain relay and feeds currentto the fuel pump. When the engine is not running and the ignition is on, the ECI\4 cuts ground to the PGM-Flmain relaywhich cuts currentto the fuel pump. PGM-FIMain Relay1 and 2 The PGM-Flmain relay consistsof two separaterelays. Relay1 is energizedwheneverthe ignition switch is ON (ll)to supply batteryvoltageto the ECM power to the injectors,and power for relay,Relay2 is energizedto supply power to the fuel pump for 2 secondswhen the i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) ,a n d w h e n t h e e n g i n ei s runnrng.

{

IntakeAir System Referto the SystemDiagramto seethe functional layout of the system.

Throttle Body The throttle body is a single-barrelside draft type. lt housesthe TP senserand the IACvalve.The lower portion of the IAC valve is heatedby enginecoolant f r o m t h e c y l i n d e rh e a d .

Intake Air Bypass Control Thermal Valve W h e nt h e e n g i n ei s r u n n i n g t, h e i n t a k ea i r b y p a s s controlthermal valve sendsair to the iniectors,

IACVALVE

INJECTOR

{cont'd)

11-33

Fueland EmissionsSystems SystemDescriptions(cont'dl

{

GatalyticConverterSystem

PositiveCrankcaseVentilation (PCVISystem

ThreeWay CatalyticConverter(TWC) (HC),carbon TheTWCconvertshydrocarbons monoxide{CO),andoxidesof nitrogen(NOx)in the exhaustgasto carbondioxide(C02),dinitrogen(N2), andwatervaDor.

The PCVvalve preventsblow-by gassesfrom escaping into the atmosphereby ventingthem into the intake manifold.

BREATHERPIPE

THREEWAY CATALYST

FRONTOF VEHICLE

:: €:

BLOW-BY VAPOR FRESH AIR

11-34

Evaporative Emission(EVAPIControl System Referto the SystemDiagramto see the functional layout of the system. EVAPCanister The EVAPcanistertemporarilystoresfuel vapor from the fuel tank until it can be purged back into the engine a n db u r n e d . EVAP Canister Purge Valve When the enginecoolanttemperature is below 149'F (65'C),the ECMturns off the EVAPcanisterpurge valve which cuts vacuum to the EVAPcanister.

EVAP Two Way Valve and EVAP Eyp8s Solenoid Valve The EVAPtwo way valve is installedbetweenthe fuel tank and the EVAPcanisterline. The EVAPtwo way valve sendsfuel vapor to the EVAP canistercorrespondingto the pressureinsidethe tuel tank. lt also relievesexcessvacuum in the tank by allowingfresh air to be drawn into the tank through the EVAPcanister. The EVAPbypasssolenoidvalve opensto bypassthe two way valve during the EVAPleakcheck. EVAP BYPASS SOLENOID VALVE

FuelTank Pressure (FTP)Sensor The FTPsensorconvertsfueltank absolutepressure into an electricalinputto the ECMduring the EVAPleak cnecK.

VALVE

SENSOR UNIT

To FUELTANK

(cont'd)

11-35

Fueland EmissionsSystems SystemDescriptions(cont'dl

ldle Control System Diagram The idle speedof the engine is controlledby the ldle Air Control(lAC)varve: 'Aftertheenginestarts,theIACvalveopensforacertainamountoftime.Theamountofairisincreasedtoraisethe i d l es D e e d . . When the engine coolanttemperatureis low, the IACvalve is openedto obtain the properfast idle speed.The amount of bypassedair is controlledin relationto enginecoolanttemperature. INTAKE MANIFOLD

IACVALVE

AKEAIR DUCT CLEANER

YEL/BLK ---<

From PGM.FI MAIN RELAY

BLK/ REO

THROTTLEAODY

VARIOUS SENSOnS

BLK

IntakeAir SystemDiagram This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is drawn into the svstem.

THROTTLEAODY

VARIOUS SENSORS

BLK

11-36

{

Evaporative Emission(EVAPIControlDiagram The EVAPcontrolsminimizethe amount of fuel vapor escapingto the atmosphere.Vapor from the fuel tanKrs temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.

. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold. The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant temperatureis above 149'F(65"C). 'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan regulatesthe flow of fuel vapor to the EVAPcanister. ' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rvoal l v eo p e n sw i t h t h e p r e s s u r ei n t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r to the EVAPcanister.

FUELTANK VAPOR RECIRCULATION VALVE

FUELTANK VAPOR SIGNAL TUBE BLU/RED

BLK FUELFILLCAP

FUELTANK VAPOR RECIRCULATION TUBE

EVAP + CANISTER VENTSHUT VALVE From BLK/YEL --<No. 4 Acc

FUELTANK

{ 1 0A } f u s e

EVAP CANISTER EVAPTWOWAY VALVE

(cont'd)

11-37

Fueland EmissionsSystems

SystemDescriptions(cont'd) ECM Circuit Diagram CONNECTOi

mrrrrn

CMP SENSORB (TDCSENSOn)

I-BRN/YEr-

11-38

wEc solENorD

_YEL/aLU -RED/aLK |-GFN/YEL I

__f -----l _l

F=-1 Hi I t_r I I?SCNSOn

L!l

I I I

croz

ff:l_l *'*"_-ll-t -KnocK lSENSOn

l I

-l-

Ll]

wcoLcoNTnoL SoLENO|OVAIVE

(cont'd)

11-39

Fueland EmissionsSystems SystemDescriptions(cont'dl

ECMCircuitDiagram{cont'd)

-{ffi]

---1t-|

IATSENSOR

-{El ------l ECTSENSOS

T_""",,.. I-BFN/YEL

CMPSENSOAA

L-

IJUNCTION I CONNECTOR

ft^--l , " , " . , J | t -' : I I

I +

t!j]]

11-40

REVERSE LocK

soleloto vaLvE

_1ffi1 -'----1 | |Fahdl G8N

'--r-

I | Tl -r l

'8r-K-L-|

HcoNNEcroR

BLU/

-l

J.L9l

.lurcrroru

EVAPCANISTEB

ALK/YEL WHT/ALU WHT/NED WHI/GRN

JUNCTION CONNECTOR

rrrn

tcM

PLUG

N o . 2 I G N I T I O NC O l t

PLUG No.3IGNITION COIL

(cont'd)

11-41

Fueland EmissionsSystems

SystemDescriptions(cont'd) ECMCircuitDiagramlcont'dl

YEI/BLK IGP2

VET/BLK

---rF-rl -lF-forl --JliD\l --t-l

MAIN BETAV2

t_,",

:t l-,r'l r, -,u-

f-"'*'o""

I SENSOS

IMMOAIL|zERUNIT

a 11-42

SECONDAFY H02S (s€NsoR2l

m tlil

TPS€NSOR

'--{=l

-{r

CANISTERVEAIT SHUTVALVE

t-_]

--lti l EVAP EYPASS

solENorD

To€PS CONTROLUNIT

CPU

GAUGE ASSEMBTY

(cont'd)

11-43

Fueland EmissionsSystems SystemDescriptions(cont'dl

ECMCircuitDiagram(cont'd)

UNDER.HOOD FUSE/RELAY9OX

CONN€CTOF

CONNECTOi

WHI/NED BLK/YET

lalLREllY_ _l

a 11-44

CONNECTOR E

""rr"a*J r''lHr/cnN 1

CONNECTOiK

IGNITIONSWITCH lG2

' I

CONNECTOFJ /GRN

TEST TACHOMETER CONNECTO8

UNDER.HOOD

UNDER.DASH FUSE/FELAYBOX

UNDER.DASH FUSE/RELAY BOX: 4 ACG (1oAt 1 tGN CO|Lt15A) 2 A/F HEATER{2OA) 17 FUELPUMPI15A} 1OMETER{7.5AI 14 A/C CLUTCHRELAY{1OA}

POStTtONSWTTCH

,or"-9J3{51 "_.rl re* _{F Brake pedal pressed: closed Brake pedal releasedropen

11-45

Fueland EmissionsSystems How to Set ReadinessCodes

MalfunctionlndicatorLamp(MlL)Indication (ln relationto Readiness Codesl

CatalyticConverterMonitorand Readiness Code

The vehiclehas certain"readinesscodes" that are part of the on-boarddiagnosticsfor the emissionssystems. lf the vehicle'sbatteryhas beendisconnectedor gone dead,if the DTCShave beencleared,or if the ECM has been reset,these codesare set to incomplete.In some states,part of the emissiontesting is to make sure these codesare set to complete.lf all of them are not set to complete,the vehiclemay fail the emissiontest, or the test cannot be finished.

NOTE: . Do not turn the ignition switch off during the procedure. . All readinesscodes are clearedwhen the batteryis disconnectedor when the ECM is clearedwith the OBD ll scantool or HondaPGlvlTester. . Low ambienttemperaturesor excessiveslop-and-go traffic may increasethe drive time neededto switch the readinesscode from incompleteto complete. ' The readinesscode will not switchto com Dleteuntil a l l t h e e n a b l ec r i t e r i aa r e m e t . . lf a fault in the secondaryHO2Ssystemcausedthe MIL to come on. the readinesscode cannot be set to comDleteuntil vou correctthe fault.

To checkifthe readinesscodesare complete,turn the ignitionswitch ON (ll), but do not startthe engine.The MIL will come on for 15 20 seconds.lf it then goes off, the readinesscodesare complete.lf it blinksseveral times, one or more readinesscodes are not complete. To set readlnesscodesfrom incompleteto complete. do the procedurefor the appropriatecode.

EnableCriteria

. E C Ta t 1 5 8 " F( 7 0 ' C )o r h i g h e r . . I n t a k ea i r t e m p e r a t u r e ( l A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r . . Vehiclespeed is steady,and vehiclespeedsensor ( V S S )r e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) .

Procedure 1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' sd a t al i n k c o n n e c t o(rD L C i a, n d b r i n gu p t h e t o o l ' sg e n e r i c O B Dl l m o d e .

2 . Startthe engine. 3 . Test-drivethe vehicleunder stop-and-goconditions with short periodsof steadycruise.After about 5 miles (3 km),the readinesscode should switch from incompleteto complete. lf the readinesscode is still set to incomplete,check for a temporary DTC.lf there is no DTC,one or more of the enablecrlteriawere probablynot met;

11-46

\ \"

EvaporativeEmissions(EVAP)Control SystemMonitor and Readinesscode

Air FuelRatio(A/FlSensorMonitorand Readiness Code

NOTE:

NOTE: . Do not turn the ignitionswitch off during the orocedure. . All readinesscodesare clearedwhen the bafteryis disconnectedor when the ECM is clearedwith the OBD ll scantool or Honda PGM Tester.

All readinesscode are clearedwhen the batterVis disconnectedor when the ECM is clearedwith the OBD ll scantool or HondaPGM Tester. The enablecriteriamust be repeatedif the intakeair temperature(lAT)drops lower than 36'F (20"C)from i t s v a l u ea t e n g i n e$ a n u p .

EnableCriteria At enginestart up, ECTand IAT are higherthan 32'F (0"C), but lower than 95'F (35"C). At enginestart up, the ECTand IAT are within 12'F (7'C)of each other.

Procedure 1. Connectthe scantool to the vehicle'sdata link connector(DLC),and bring up the tool's generic O B Dl l m o d e . 2. Startthe engine. 3. Test-drivethe vehicleunder stop-and-goconditions with short periodsof steadycruise.After about 2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e scso d es h o u l d switchf rom incompleteto complete. 4. lf the readinesscodeisstill setto incomplete,check for a temporaryDTC.lf there is no DTC,one or more of the enablecriteriawere probably not met; repeatthe procedure.

EnableCriteria ECTat 140'F(60"C)or higher.

Procedure 1. Connectthe scantoolto the vehicle'sdata link connector(DLC),and bring up the tool's generic O B Dl l m o d e . 2. Start the engine. 3. Test-drivethe vehicle under stop-and-goconditions with short periodsof steadycruise.Duringthe drive, decelerate(wirh the throttlefully closed)for 5 seconds.After about 3.5 miles (2.2km).the readinesscode should switch from incomDleteto complete. 4 . l f t h e r e a d i n e s s c o d e i s s t isl le tt o i n c o m p l e t ec,h e c k for a temporary DTC.lfthere is no DTC,the enable criteriawas probablynot meU repeatthe procedure.

Air/FuelRatio(A/FlSensorHeaterMonitor Readiness Code NOTE;All readinesscodes are clearedwhen the battery is disconnectedor when the ECM is clearedwith the OBD ll scantool or HondaPGM Tester,

Procedure '1.

Connectthe scantool to the vehicle'sdata link connector{DLC),and bring up the tool's generic O B Dl l m o d e .

2. Startthe engine,and let it idle for 1 minute.The readinesscode should switch from incompleteto comDlete. 3. lf the readinesscode is still set to incomplete,check for a temporary DTC.lf there is no DTC,repeatthe proceoure.

(cont'd)

11-47

Fueland EmissionsSystems How to Set ReadinessCodes(cont'd)

Code MisfireMonitorand Readiness . This readinesscode is alwaysset to available becausemisfiring is continuouslymonitored. . l\4onitoringpauses,and the misfirecounterresets,if the vehicleis driven over a rough road. . Monitoringalso pauses,and the misfire counter holds at its currentvalue.if the throttle position changesmore than a predeterminedvalue,or if driving conditionsfall outsidethe rangeof any relatedenablecriteria,

Code FuelSystemMonitorand Readiness . This readinesscode is always setto available becausethe fuel system is continuouslymonitored during closedloop operation. . Monitoringpauseswhen the catalyticconverter, EVAPcontrol system,and Ay'Fsensor monitorsare active. . Monitoringalso pauseswhen any relatedenable criteriaare not being met. Monitoring resumeswhen lhe enablecriteriais again being met.

ComponentMonitorand Comprehensive Readiness Code This readinesscode is always set to availablebecause the comprehensivecomponentmonitor is continuously r u n n i n gw h e n e v e tr h e e n g i n ei s c r a n k i n go r r u n n i n g .

a 11-48

PGM-FISystem ComponentLocationIndex

CAMSHAFTPOS]TION{CMP)SENSORB (TOPDEAD CENTER(TDC} SENSORI Troubleshootina. oaoe 11-95 p;ge 1-1.1 Replacement, 14

ii'- r'1

ELECTRICAL LOAD DETECTOR {ELDI Troubleshooting, page1'l-92

.I11---:,I ''.!,i(..,.?:fir-J-

.....,..:--.

INTAKEAIRTEMPERATURE {IATISENSOR Troubleshooting, page'l'l-55 page11-'l15 Replacement, f -

ENGINECOOLANTTEMPERATURE (ECTISENSOR page11-57 Troubleshooting, R e p l a c e m epnat ,g e1 11 1 4 MANIFOLD ABSOLUTE PRESSURE (MAP)SENSOR page11-52 Troubleshooting,

CRANKSHAFTPOSITION ICKPISENSOR page'l1-78 Troubleshooting, page 11-'l16 Beplacement,

THROTTLE POSITION ITP}SENSOR page11-60 Troubleshooting, KNOCKSENSOR page11-77 Troubleshooting, B e p l a c e m epnat ,g e1 11 1 5 AIR FUELRATIO{A/F) SENSORISENSOR1} page 11-84 Trorrbleshooting, page 11-113 Replacement,

{cont'd)

11-49

PGM-FlSystem ComponentLocationIndex(cont'd)

\.,

v 11-50

DATALINKCONNECTOR IDLCI GeneralTroubleshooting Information,page 1l 3

PGM.FIMAINRELAY1 page11-97 Troubleshooting,

ENGINECONTROLMODULE g Information, GeneralTroubleshootin p a g e1 1 3 page I 1-96 Troubleshooting,

11-51

PGM-FISystem DTCTroubleshooting

DTCP0107: MAPSensorCircuitLowVoltage 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .

(

ls there about 5 V? YES-Repair open in the wire betweenthe Eclvl ( A 2 1 ) a n dt h e M A P s e n s o r . l

2. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg)or 2.9 V indicated? YES Intermittentfailure, system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e M A P s e n s o ra n d a t t h e E C M . I

NO Updatethe ECMif it does not havethe latest software,or substitulea known-goodECM,then recheck(seepage 'l1-6).lf the symptom/indication goes away with a known-goodECfvl,replacethe originaE l CM.I 8 . Checkthe MAP with the scantool. ls 2 kPa (15 mmHg,0.6 in.Hg) ot lessor 0 V indicated?

N O - G o t o s t e p3 . 3. Turn the ignition switch OFF.

YES-Go to step 9. 4. Disconnectthe MAP sensor3P connector. NO Replacethe lvlAPsensor.l 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l l .

9 . Turn the ignitionswitch OFF. 6. lvleasurevoltage betweenMAP sensor3P c o n n e c l o tre r m i n a l sN o . 1 a n d N o . 3 .

'10.Disconnect

ECMconnectorA (31P).

1 1 .Checkfor continuitybetweenMAP sensor

MAP SENSOR3P CONNECTOF

connectorterminal No. 2 and body ground.

(

MAP SENSON3P CONNECTOA

sGl {GRN/WHTI

Wires de of femaleterminais

ls there about 5 V? YES Go to step8. ls therc continuity? N O - G o t o s t e p7 . 1 . Measurevoltage betweenEClvlconnector t e r m i n a l s4 1 1 a n d 4 2 ' 1 . ECM CONNECTOR A 13'IP}

vccr {YEL/BED)

YES-Repair short in the wire betweenthe ECM ( A 1 9 )a n d t h e M A P s e n s o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

sGr {GRN/WHT}

Wire side of female terminals

11-52

(

DTCP0108:MAPSensorCircuitHighVoltage '1.

Startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle.

2. Checkthe MAP with the scantool. le about 101kPa (780 nmHg, 30 in.Hg)ot highet, or about2.9 V or higher indicated?

9. Measure voltagebetweenMAPsensor3P connector terminalsNo.1 andNo.3. MAP SENSOR3PCONNECTOF

vccl { Y E L / Rl E , lD o) cl l . l . r l I lsct d) l{GRN/wHrr

YES Go to step 3.

W i r es i d eo f f e m a l el e r m i n a l s

NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the MAP sensorand at the ECM.I

ls there about 5 V?

3. Turn the ignitionswitch OFF.

YES Go to step 10.

4. DisconnecttheMAP sensor3P connector.

NO Repairopen in the wire betweenthe ECM (A11) and the MAP sensor.I

5, ConnectMAP sensor3P connectorterminalsNo. 2 and No. 3 with a jumper wire. MAP S€NSOR3P CONNECTOR

1 0 .Turn the ignitionswitch OFF. 1 1 .C o n n e c E t C Mc o n n e c t otre r m i n a l sA 1 1 a n d A 1 9 with a jumper wire.

1 2 3 MAP {GRN/REO}

A {31PI ECMCONNECTOR

SG1(GRN/WHTI

JUMPER WIRE J U M P E RW I A E

Wiresideof femaleterminals

Wire side of fema e te.minals

6. Turn the ignition switch ON (ll). T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 7. Checkthe MAP with the scantool. Checkthe MAP with the scantool. ls about 101kPa (760 mmHg,30 in.Hg) ot higher, or about2.9 V or higher indicated?

ls about 101kPa (760 mmHg,30 in.Hg)or higher, or about2.9 V ot higher indicated?

YES-Go to step 8. NO Replacethe MAP sensor.I 8 . R e m o v et h e j u m p e rw i r e .

YES Updatethe ECM if it does not have the lalest software,or substitutea known-goodECM,lhen recheck(seepage 11-6).lf the symptom/indication goes away with a known good ECM,replacethe originaE l CM.I NO-Repair open in the wire betlveenthe ECI\il ( A 1 9 )a n dt h e M A P s e n s o r . I

11-53

PGM-FISystem DTCTroubleshooting(cont'dl DTCPl128:MAPSensorSignalLowerThan Expected 1. Turn the ignition switch ON (ll). 2. Checkthe MAP with the scantool. ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or higher indicated? YES- Intermittentfailure.system is OK at this time.I NO Replacethe MAP sensor.l

DTCPl129:MAPSensorSignalHigherThan Expected 1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then Iet it idle. 2. Checkthe MAP with the scantoot. ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less indicated? YES- lntermittentfailure,system is OK at this time.l NO Replacethe MAP sensor.l

11-54

DTCP0112: IATSensorCircuitLowVoltage 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 2. Checkthe IAT with the scantool. ls 302'F (150'C) or highet (or H-Limit in Honda node of PGM Tester),ot 0 V indicated?

8. Checkthe temperaturereadingon the scantool. Be aware that if the engine is warm, the reading w i l l b e h i g h e rt h a n a m b i e n t e m p e r a t u r el I. t h e engine is cold, the IAT and ECTwill have the same v al u e . ls the correct ambient temperatureindicated? YES lntermittentfailure,system is OK at this time Checkfor poor connectionsor looseterminalsat t h e I A Ts e n s o ra n d a t t h e E C M . I

VES-Go to step 3. NO Go to step 8.

NO Replacethe IAT sensor.l Disconnectthe IAT sensor2P connector. 4 . Checkthe IAT with the scantool.

ls 302'F(150'C)or higher (or H-Limit in Honda mode of PGM Testet),ot 0 V indicated? YES-Go to step 5. NO- Replacethe IAT sensor.I 5 . Turn the ignition switch OFF. 6 . DisconnectECMconnectorB (24P). 7 . Checkfor continuitybetweenIAT sensor2P c o n n e c t otre r m i n a lN o . 2 a n d b o d y g r o u n d , IAT SENSOR2PCONNECTOR

,^\ , l r 2 l t

-----Tr---

l IAT _t{RED/YELI

W i r es i d eo f f e m a l et e r m i n a i s

ls there continuity? YES Repairshon in the wire betweenthe ECM ( B ' 1 7a) n d t h e I A Ts e n s o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-55

PGM-FISystem DTCTroubleshooting(cont'dl DTCP0113: IATSensorCircuitHighVoltage 1. Turnthe ignitionswitchON (ll).

{

7. Checkthe IAT with the scantool. ls - 4"F ( 20'C) or less(or L-Limitin Honda mode ot PGM Tester) or 5 V indicated?

2. Checkthe IATwith the scantool. YES Go to step 8.

ls 4'F (-20'C) or less(or L-Limitin Honda modeot PGM Tester)or 5 V indicated?

NO - Replacethe IAT sensor.l

YES-Go to step 3.

8. Turn the ignition switch OFF.

NO Intermitentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the IAT sensorand at the ECM.I

9 . R e m o v et h e j u m p e rw i r e . 1 0 . C o n n e cE t C Mc o n n e c t otre r m i n a l sA 1 0 a n d 8 1 7 w i t h a j u m p e rw i r e .

3 . Turn the ignitionswitch OFF. ECM CONNECTORS

4. Disconnectthe IAT sensor2P connector. ConnectIAT sensor2P connectorterminalsNo. 1 a n d N o . 2 w i t h a j u m p e rw i r e .

A (31 P)

B {24 P)

IATSENSOR 2PCONNECTOR

rJ--

:---

JUMPERWIRE

l ' l L l -'_-l--_----r--_

sG2 rAT I {GRN/YEL) IRED/YEL) I L ] WIRE JUMPER

Wiresideof femaleterminals 1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 12. Checkthe IAT with the scantool.

Wiresideof femaleterminals

ls - 4"F ( 20"C) or less (or L-Limitin Honda mode of PGM Tester) or 5 V indicated?

6 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECI\4then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaE l C M !. NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I

11-56

(

DTCP0116:ECTSensorRange/Performance Problem NOTE:lf DTCP0117and/or P0118are storedat the same time as DTCP0116,troubleshootthose DTCSfirst, then recheckfor DTCP0116, 1. Stanthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on, then let it idle. 2. Checkthe ECTwith the scantool. ls 176- 212'F (80 indicated?

100"C)or0.5 0.8V

YES Intermittentfailure.system is OK at this time. Checkthe thermostatand the cooling system.l NO-Checkthe thermostatand the cooling system. lf they are OK, replacethe ECTsensor.l

11-57

PGM-FISystem DTCTroubleshooting(cont'dl DTCP0117:ECTSensorCircuitLow Voltage 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 2. Checkthe ECTwith the scantool.

(

7. Checkfor continuitybetweenthe ECTsensor2P connectorterminal No. 1 and bodv oround. ECTSENSOR2PCONNECTOR

ls 150'C (302'F)or higher (ot H-Limit in Honda mode of PGM Tester) or 0 V indicated? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the ECTsensorand at the ECM.t Wire side of femaleterminals

3. Disconnectthe ECTsensor2P connector. 4. Checkthe ECTwith the scantool.

ls there continuity?

ls 150'C (302"F)or higher (ot H-Limit in Honda mode ot PGM Tester) or 0 V indicated?

YES-Repair short in the wire betweenthe ECM ( B 8 )a n d t h e E C Ts e n s o r . l

YES-Go to step 5.

NO-Update the ECMif it does not havethe latest software,orsubstitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodEClvl,replacethe originaE l CM.I

Replacethe ECTsensor.!

5. Turn the ignition switch OFF.

(

6. DisconnectECMconnectorB (24P).

(

11-58

DTCP0118: ECTSensorCircuitHighVoltage 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

1 . Checkthe ECTwith the scantool. ls 20"C ( 4"F)or less (or L-Limitin Honda mode ot PGM Tester) or 5 V indicated?

2. Checkthe ECTwith the scantool. YES-Go to step 8. ls 20'C ( 4'F)or less(or L-Limitin Honda mode of PGM Tester) or 5 V indicated?

NO Replace t h e E C Ts e n s o r . I

YES Go to step 3.

8 . Turn the ignition switch OFF.

NO lntermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the ECTsensorand at the ECM.I

9 . R e m o v et h e j u m p e rw i r e .

Turn the ignitionswitch OFF.

1 0 . ConnectECMconnectorterminalsA10 and Bg with a j u m p e rw i r e . ECM CONNECTORS

Disconnectthe ECTsensor2P connector. 5 . Connectthe ECTsensor2P connectorterminals N o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .

a {31P}

B {24P)

ECTSENSOR2P CONNECTOR

JUMPERWIRE

lt tt .l t l l -I-l*,

Ecr (RED/WHT)

Wiresideof femaleterminals

{GRN/YEL)

t l WIRE JUMPER

1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 1 2 . Checkthe ECTwith the scantool.

wire sideoI Iemaleterminals ls 20"C ( 4"F) or less (or L-Limitin Honda mode of PGM Tester) ot 5 V indicated? 6 . T u r nt h e l g n i t i o ns w i t c hO N ( l l ) .

YES- Updatethe ECM if it does not havethe latest then software,or substitutea known-goodECI\4, recheck(seepage 11-6).If the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I NO Repairopen in the wire betweenthe ECM ( A 1 0 ,8 8 ) a n d t h e E C Ts e n s o r . l

11-59

PGM-FISystem DTCTroubleshooting(cont'dl DTCP0122:TP SensorCircuitLowVoltage 1 . T u r nt h e i g n i t i o ns w i t c ho N ( 1 1 1 . 2. Checkthe throttle positionwith the scantool.

8. At the sensorside, measureresistancebetweenthe TP sensor3P connectorterminalsNo. 1 and No. 2 with the throttlefully closed. TP SENSOR3P CONNECTOR

ls there about 10./.or 0.5 V when the thrcttle is fully closed and about 90% or 4.5 V when the throttle is fully opened? YES Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the TP sensorand at the ECM.t NO Go to step 3. 3. Turn the ignition switch OFF,

T e r m i n as li d eo f m a l et e r m i n a l s

4. Disconnectthe TP sensor3P connector.

Is there about 0.5 0.9 kQ ?

5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

YES Go to step 9.

6. Measurevoltagebetweenthe TP sensor3P connectorterminals No. 1 and No. 3.

NO Replacethe throttle body (theTP sensoris not a v a i l a b l es e p a r a t e l yI) .

TP SENSOR3P CONNECTOR

9 . Measureresistancebetweenthe TP sensor3P connectorterminalsNo. 2 and No. 3 with the throttlefully closed. TPSENSOR 3PCONNECTOB

Wire side of femaleterminals

ls thereabout5 V? Terminalsideof maleterminals

YES-Go to step7. N O G ot o s t e p1 4 . 1 . Turnthe ignitionswitchOFF.

ls there about 4.5k{l ? YES Go to step 10. NO Replacethe throttle body (theTP sensoris not a v a i l a b l es e p a r a t e l yI) . 1 0 . D i s c o n n e cEt C Mc o n n e c t oA r (31P).

11-60

11. At thewire harnessside,checkfor continuity terminalNo,2 betweenTPsensor3Pconnector a n db o d yg r o u n d . TP SENSOR3P CONNECTOR

11 2 1 3

13. At thewire harnessside,checkfor continuity terminalNo.2 betweenTPsensor3Pconnector a n db o d yg r o u n d . TP SENSOR3PCONNECTOR

1 2 3 TPS (RED/BLX}

'PS REO/BLKI

Wire sideof female terminals

Wire side ot Iemaleterminals

ls there continuity?

ls thetecontinuity? YES-Repairshortin the wire betweenthe ECM { A 1 5a) n dt h eT Ps e n s o r . l l N O - G o t o s t e p1 2 . terminalA15to body 12. ConnectECMconnector groundwith a jumperwire. A 131P) ECMCONNECTOR

9 1 1 2 1 34 5 6 7 19 t c 6 10 1 1 1 1 2 8 t2021

23124

YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO- Repairopen in the wire betweenthe ECM ( A 1 5 )a n d t h e T P s e n s o r . l 14. lvleasurevoltage betweenECMconnector t e r m i n a l s4 1 0 a n d A 2 0 . A 131P} ECMCONNECTOB

28129130

wrne ,tf$,rr*, ];uueen vcc2

(YEL/8LU)

Wire side oJ.femaleterminals

Wire side of female terminals

ls there about 5 V? YES Repairopen in the wire betlveenthe ECM ( A 2 0 )a n d t h e T P s e n s o r . I NO Updatethe ECM if it does nor have the latest software,or substilutea known-goodECM,then r e c h e c k( s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n goes away with a known-goodECM.replacelhe originaE l CM.I

11-61

PGM-FISystem DTCTroubleshooting(cont'd) DTCP0123: TPSensorCircuitHighVoltage 1 . T u r nt h e i g n i t i o ns w i t c ho N ( l l ) 2. Checkthe throttle positionwith the scantool.

( 7. Measurevoltage betweenECMconnector terminalsA10 and A20. ECMCONNECTOR A 131PI

ls there about 10%or 0.5 V when the throttle is fully closed and about 90% or 4.5 V when the throttle is f ully opened? YES lntermittentfailure.system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e T P s e n s o ra n d a t t h e E C M I, NO Go to step 3.

Wiresideof femaleterminals

3. Turn the ignition switch OFF. Is there about 5 V? 4. Disconnectthe TP sensor3P connector. 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 6. At the wire harnessside, measurevoltage between the TP sensor3P connectorterminalsNo. 1 and No.3. TP SENSOR3P CONNECTOR

W;resideof femaleterminals

ls thete about 5 V? YES-Replace the throttle body (theTP sensor is not availableseparately). I NO Go to step 7.

11-62

YES- Repairopen in the wire betweenthe ECM (A10)and the TP sensor.t NO Updatethe ECMif it does not havethe latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

(

DTCPl121:TPSensorSignalLowerThan Expected

DTCP1122:.fP SensorSignalHigherThan Expected

1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

2. Checkthe throttle positionwith the scantool.

ls 12.9'/.,0.6 V, or higher indicated when the throttle is tully opened?

ls 12.9%,0.6 V, or lessindicated when the throttle is f ully closed?

YES- Intermittentfailure,system is OK at this time.I

YES Intermittentfailure,system is OK at this time.l

NO-Replace the TP sensor(the TP sensor is not availableseparately). I

NO Replacethe TP sensor(theTP sensoris not availableseparately). I

11-63

PGM-FISystem (cont'dl DTGTroubleshootang DTCP0128:CoolingSystemMalfunction

\ 3. Checkthe radiatorfan. Does the tadiator fan keep running?

NOTE;lf the DTCSlistedbelow are stored at the same time as DTCP0128.troubleshootthose DTCSfirst, then recheckfor P0128. P 0 1 0 7P, 0 1 0 8P, 1 1 2 8P , 1 1 2 9N : 4 a n i f o ladb s o l u t e pressure(MAP)sensor P] I06, P1107,P1108:Barometricpressure(BARO) sensor P1259:VTECsystem P0116,P0117, P0118:Enginecoolanttemperature(ECT) sensor P0112,P0113: Intakeair temperature(lAT)sensor P0500:Vehiclespeedsensor{VSS) P0335,P0336:Crankshaftposition(CKP)sensor P0300:Randommisfire P 0 3 0 1P , 0 3 0 2P, 0 3 0 3P , 0 3 0 4N : o . 1 ,N o .2 , N o . 3 o r N o . 4 cylinder misfire P0505:ldle control system malfunction P 1 5 1 9l:d l ea i r c o n t r o l( l A C ) v a l v e DTCP0128can occasionallyset when the hood is o p e n e dw h i l e t h e e n g i n ei s r u n n i n g . 1. Checkthe enginecoolant level Is the engine coolantlevel low? VES Refillthe enginecoolant.lf necessary,repair t h e c o o l a n tl e a k a g e . l NO Go to step 2. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d m a k es u r et h e A,/Cis off.

11-64

YES Checkthe radiator fan circuit(seepage 1014),the radiatorfan switch circuit(Short)(seepage 10-'16), and the radiatorfan switch (seepage 10-17). Also, inspectthe ECTand IAT circuitsand terminal connections.lf the circuits,the switch,and the connectionsare OK, updatethe ECI\4if it does not have the latestsoftware.or substitutea knowngood ECM,then recheck(seepage 11-6).lf the symptom/indicationgoes away with a known-good E C M ,r e p l a c et h e o r i g i n a E l CM.I NO Replacethe thermostat(seepage 10-8).1

DTCP0134:Ay'FSensor(Sensor1) No Activity Detected 1. Checkthe attachmentstateof the A,/Fsensor ( S e n s o r1 ) .

DTCP0137: Secondary HO2S(Sensor 2) CircuitLowVoltage 1 . R e s e t h e E C M( s e ep a g eI 1 - 4 )

ls it slacked f rom the exhaust pipe?

2. Start the engine.Holdthe engine at 3,000rpm wilh no load (in neutral)until the radiatorfan comes on.

YES- Reinstallthe Ay'Fsensor(Seneor1) (seepage 11-113).t

3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool.

NO-Go to step 2.

ls there 0.3 V or less?

2 . R e s e t h e E C M( s e ep a g e11 - 4 ) .

YES Go to step 4.

3 . S t a nt h e e n g i n e H . o l dt h e e n g i n es p e e da t 3,000rpmwith no load (in neutral)until the radiator fan comes on, then let it idle for 2 minute.

NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the secondaryHO2S(Sensor2) and at the ECM.I

ls DTC PO134 indicated?

4. T u r nt h e i g n i t i o ns w i t c hO F F .

YES-Replacethe Ay'Fsensor{Seneor1) (seepage 11-113).t

5 . Disconnectthe secondaryHO2S(Sensor2) 4P

NO - Intermittentfailure, sistem is OK at this time. Checkfor poor connectionsor looseterminalsat the Ay'Fsensor(Seneor1) and the ECM.I

6 . Turn the ignition switch ON (ll).

connector.

7 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 0.3 V or less? YES Go to step 8. r ).1 NO Replace t h e s e c o n d a r yH O 2 S( S e n s o 2 8 . Turn the ignition switch OFF. r (31P). 9 . D i s c o n n e cEt C Mc o n n e c t oE

icont'd)

11-65

PGM-FISystem

DTCTroubleshooting(cont'dl 10. Checkfor continuitybetweenthe secondaryHO2S (Sensor2) 4P connectorterminal No. 2 and body ground. SECONDARY H02S 2) 4PCONNECTOR ISENSOR

DTCP0138: Secondary HO2S(Sensor 2) CircuitHighVoltage 1 . R e s e t t h eE C M{ s e ep a g e ' 1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Checkthe secondaryHO2S(Sensor2) output voltageat 3,000rpm with the scantool. ls thete 1.0 V or morc? YES Go to step 4.

Terminalside of male terminals

NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the secondaryHO2S(Sensor2) and at the ECM.I

ls there continuity? 4. Turn the ignition switch OFF. YES-Repair shon in the wire betweenthe ECM (E2)and the secondaryHO2S(Sensor2).t NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I|

5. Disconnectthe secondaryHO2S(Sensor2) 4P connector. ConnectsecondaryH02S (Sensor2) 4P connector t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e . SECONDARY HO2S {SENSOR2) 4P CONNECTOR JUMPERWIRE

SG3 (PNKI

SHO25(WHT/RED)

T e r m i n asl i d eo Jm a l et e r m i n a l s 7. Turn the ignitionswitch ON (ll).

11-66

8 . Checkthe secondaryH02S (Sensor2) output voltagewith the scantool, ls there 1.0 V ot mote? YES-Go to step 9.

DTCP0139:SecondaryHO2S(Sensor2l Slow Response 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . Start the engine.Holdthe engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on.

NO Replacethe secondaryHO2S(Sensor2).1

3 . Checkthe secondaryHO2S(Sensor2) output 9 . Turn the ignitionswitch OFF.

voltageat 3,000rpm with the scantool.

1 0 . ConnectECMconnectorterminalsE2 and E4 with a J U m p ew r rre.

ls thete 0.3- 0.8 V, fot 2 minutes?

E 131PI ECMCONNECTOR

JUMPERWIRE

YES Replacethe secondaryHO2S(Sensor2).! NO- lntermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminaisat the secondaryHO2S(Sensor2) and at the ECM.I

Wiresideof femaleterminals 1 1 .Turn the ignition switch ON (ll). 1 2 . Checkthe secondaryHO2S(Sensor2) output voltagewith the scantool. ls there 1.0 V or more? YES Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaE l CM.I NO Repairopen in the wire betweenthe ECM (E2, E4)and the secondaryHO2S{Sensor2).I

11-67

PGM-FISystem DTCTroubleshooting(cont'dl DTCP0141: Secondary HO2S(Sensor 2l HeaterCircuitMalfunction 1. Resetthe ECM(seepage 1 l-4)

6. Checkfor continuitybetweenbody ground and secondaryH02S (Sensor2) 4P connectorterminals N o . 3 a n d N o .4 i n d i v i d u a l l y . SECONDARY HO2S{SENSOR 214PCONNECTOR

2. Startthe engine. ls DTC P0141indicated? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the secondaryHO2S(Sensor2) and at the ECM.I

Wire side of femaleterminals

3 . Turn the ignitionswitch OFF. Disconnectthe secondaryH02S (Sensor2) 4P connecror.

ls therecontinuity? YES- Replace the secondary HO2S(Sensor2).1

5 . At the secondaryHO2S(Sensor2) side, measure resistancebetweenH02S 4P connectorterminals N o . 3 a n d N o .4 .

NO-Go to step7. 7 . Turnthe ignitionswitchON (ll).

HO2S(SENSOR 214PCONNECTOR SECONDARY

voltagebetweensecondary H02S4P 8 . Measure connector terminalsNo.3 andNo.4, SECONDARYHO2S (SENSOR2l ilP CONNECTOR

s02sHTc {BLK/WHTI

IG1(BLK/ORN}

Wire side ol lemale terminals

ls thereabout3.3 Q ?

T e r m i n asli d eo f m a l et e r m i n a l s

YES Goto step6. NO- Replace the secondary HO2S(Sensor 2).t

ls there battery voltage? YES Go to step 9. NO Go to step 12. 9 . Turn the ignition switch OFF. 1 0 . DisconnectECMconnectorE {31P)

11-68

11. Checkfor continuitybetweenECMconnector terminalE6andbodyground. ECM CONNECTORE {31PI

1 3 .Turn the ignitionswitch OFF. 1 4 . Reconnectthe secondaryHO2S(Sensor2) 4P connector. t5.

DisconnectECMconnectorE (31P).

to.

Turn the ignition switch ON (ll).

1 7 . Measurevoltage betweenECMconnectorterminal E 6a n d A 5 . ECMCONNECTORS Wire side o{fIemaleterminals

A (31 P)

ls therc continuity? YES-Repair short in the wire betweenthe ECM r ).1 ( E 6 )a n d t h e s e c o n d a r yH O 2 S( S e n s o 2 NO-Update the ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I MeasurevoltagebetweensecondaryHO2S (Sensor2) 4P connectorterminal No. 4 and body g round. HO2S{SENSOR 2I 4PCONNECTOR SECONDARY

tFff I

E {31P}

Wire side ot femaleterminals

Is there 0-1 V or less? YES-Repair open in the wire betweenthe ECM (E6)and the secondaryHO2S(Sensor2).! NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe . o r i g i n aE l CMa

l[faJl--ro' 14 |

IBLK/OFN)

Y I Terminal sideof maleterminals ls there battety voltage? YES Go to step 13. N O - C h e c k t h e N o . 4 A C G ( 1 0 A )f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repair open in the wire betweenthe secondaryHO2S(Sensor2) a n d N o . 4 A C G ( 1 0 A )f u s e . l

11-69

PGM-FISystem DTCTroubleshooting(cont'dl FuelSystemToo Lean DTCP0171:

3. Turn the ignition switch OFF.

DTCP0172:FuelSystemToo Rich

4. With a vacuum pump, apply vacuum to the evaporativeemission(EVAP)canisterpurge valve (A) from the evaporativeemission(EVAP)canister side.

NOTE:lf some of the DTCSlistedbelow are storedat the same time as DfC PO17'land/ot PO172, troubleshootthose DTCSfirst, then recheckfor P0171 andlot P0112. P 0 1 0 7P, 0 1 0 8P. 11 2 8 .P 11 2 9 :M a n i f o l da b s o l u t e p r e s s u r e( M A P )s e n s o r P1162.P1166,P 1167:4,,/Fsensor(Sensor1) heater r) P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH O 2 S( S e n s o 2 P014'l:SecondaryHO2S(Sensor2) heater P1259:VTECsystem 1 . C h e c kt h e f u e l p r e s s u r e( s e ep a g e1 1 - ' 1 4 5 ) .

' ls luel pressure OK?

A973AX-041-XXXXX

YES Go to step 2. Does it hold vacuum? NO Checkthese items: . lf the pressureis too high, replacethe fuel p r e s s u r er e g u l a t o(rs e ep a g e1 1 - 1 5 2 ) . 1 . l f t h e p r e s s u r ei s t o o l o w . c h e c k t h e f u epl u m p , the fuel feed pipe,the fuel filter, and replacethe f u e l p r e s s u r er e g u l a t o (r s e ep a g e1 1 - 1 5 2 ) . I 2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on.

11-70

YES-Check the enginevalve clearancesand adjust if necessary,lf the valve clearancesare OK, replace t h e i n j e c t o r s( s e ep a g e11 - 111 ) . 1 NO-Replace the EVAPcanisterpurge valve.l

DTCP0300: RandomMisfireandAny Combination of the Following: DTCP0301: No.1 CylinderMisfire DTCP0302:No.2 CvlinderMisfire DTCP0303: No,3 CvlinderMisfire DTCP0304:No. 4 CvlinderMisfire NOTE: . lfthe misfiring is frequentenoughto trigger detectionof increasedemissionsduring two consecutivedriving cycles. the MIL will come on, and DTCP0300(and some comlrinationof P0301through P0304)will be stored. . lf the misfiring is frequentenoughto damagethe catalyst,the MIL will blink wheneverthe misfiring occurs,and OTC P0300(and some combinationof P0301through P0304)will be stored.When the misfirlng stops,the MIL will remain on. 1. Troubleshootthe following DTCsfirst if any of them were stored along with the random misfire DTC(s): P 0 ' 1 0 7P,0 1 0 8P, 1 1 2 8P , 1 1 2 9N r 4 a n i f o ladb s o l u t ep r e s s u r e( M A P )s e n s o r P0111.P0'172t Fuelsvstem P0335.P0336:Crankshaftposition(CKP)sensor P0505:ldle control system sensor P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F) P1259:VTECsystem P1361,P1362:Camshaftposition(CMP)sensorB {Top dead center(TDC)sensor) P 1 5 1 9l:d l ea i r c o n t r o l( l A C )v a l v e 2. Test-drivethe vehicleto verify the symptom. 3. Findthesymptom inthechart below, and dothe relatedproceduresin the order listeduntil you find the cause. Symptom R a n d o mm i s f i r eo n l y at low RPMand under load R a n d o mm i s f i r eo n l y du ring acceleration Randommisfire at h i g h R P M ,u n d e r l o a d ,o r u n d e r random conditions

Procedure(sl

Also check foi:

Checkfuel pressure(seepage 11-145).

. Lowcompressron. . Lowqualityfuel.

Checkfuel pressure(seepage 11-145).

in the Malfunction VTECsystem(seepage 1' t-123).

C h e c kf u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .

Correctenginevalve clearances(seepage 691.

11-71

PGM-FISystem

DTCTroubleshooting(cont'dl No.1 CylinderMisfire DTCP0301:

1 . Determinewhich cylinder(s)had the misfire.

DTCP0302:No.2 CylinderMisfire

Does the misf ire occur in the cylinder where the ignition coil was exchanged?

DTCP0303:No.3 CylinderMisfire YES Replacethe faulty ignitioncoil.!

DTCP0304:No. 4 CylinderMisfire NO-Go to step 8. 1. After checkingand recordingthe freezedata,reset the ECM (seepage 11-4).lf there is no freezedata of the misfire,just clearthe DTC. 2. Startthe engine,and listenfor a clickingsound from the injectorat the problemcylinder.

8 . Turn the ignition switch OFF. 9 . Exchangethe spark plug from the problemcylinder with one from anothercylinder.

1 0 .Test-drivethe vehiclefor severalminutes in the rangeof the freezedata or under various conditionsif there was no freezedata.

Does the injector click? YES-Go to step 3.

1 1 .Checkfor a DTCor TemporaryDTCwith the scan Tool. ls DTC ot Tempotary DTC P0301, P0302, P0303 or P0304indicated?

NO-Go to step 30. 3. Turn the ignition switch OFF.

YES Go to step 12. 4. Exchangethe ignition coil from the problem cylinderwith one from anothercylinder,

NO Intermittentmisfiredue to spark plug fouling, e t c .( n o m i s f i r ea t t h i st i m e ) . 1

5. Test-drivethe vehiclefor severalminutesin the range of the freezedata or under va rious conditionsif there was no freezedata.

Determine w h i c h c y l i n d e r ( sh)a dt h e m i s f i r e . Does the misl ire occur in the cylinder where the spark plug was exchanged?

6. Checkfor a DTCor a TemporaryDTCwith the scan root.

YES Replace t h e f a u l t ys p a r kp l u g . l ls DTC or Tempotaty DTC P0301, P0302, P0303 or P0304 ind icated?

NO Go to step 13.

YES Go to step 7.

Turn the ignition switch OFF.

NO Intermittentmisfire due to poor contactat the i g n i t i o nc o i l c o n n e c t o r {sn o m i s f i r ea t t h i st i m e ) . Make sure the coil connectionsare secure.l

1 4 . Exchangethe lnjectorfrom the problemcylinder w i t h o n ef r o m a n o t h e rc y l i n d e r . t5.

11-72

L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .

1 6 .Test-drivethe vehiclefor severalminutesin the rangeof the freezedata or under various conditionsif there was no freezedata.

't7. Checkfor a DTCor a TemporaryDTCwith the scan

22. Measurevoltage betweenignition coil 3P connectorterminal No. 3 and body ground. IGNITIONCOIL3P CONNECTOR

Tool. ls DTC or TemporaryDTC P0301,P0302, P0303 or P0304 indicated? YES Go to step 18. NO lntermittentmisfire due to bad contactat the injectorconnector(no misfireat this time). Make surethe injectorconnectionis secure.Checkfor poor connectionsor looseterminalsat the injector.l

Wire side ol femaleterminals

ls there battery voltage?

1 8 .Determinewhich cylinder(s)had the misfire. YES-Go to step 23. Does the misf ire occur in the cylinder where the i njector w as exchanged ?

NO Repairopen in the wire betweenthe No. 1 I G NC O I L( 1 5 A ) f u s ea n dt h e i g n i t i o nc o i l . I

YES- Replacethe faulty injector.I

2 3 . Turn the ignitionswitch OFF. NO-Go to step19.

24. Checkfor continuitybetweenignitioncoil 3P 1 9 .Turn the ignitionswitch OFF. 20. Disconnectthe ignitioncoil 3P connectorfrom the

connectorterminal No. 2 and body ground. IGNITIONCOIL3PCONNECTOR

problemcylinder. Turn the ignition switch ON (ll).

Wire side ot femaleterminals

ls there continuity? YES Go to step 25. NO Repairopen in the wire betweenthe ignition c o i l a n dG 1 0 1 . 1 DisconnectECMconnectorA {31P)

(cont'd)

11-73

PGM-FISystem

DTCTroubleshooting(cont'dl 26. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).

28. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).

ECMCONNECTOR A {31PI

PROBLEIVI CYLINDER

DTC

ECM WIRE TERMINAL COLOR

N o .1 No.2 No.3 No,4

P0301 P0302 P0303 P0304

430 A.29 428 421

YEUGRN BLU/RED WHT/BLU BRN

ECMCONNECTOR A {31P}

PROBLEM CYLINDER

DTC

No.1 N o .2 N o .3 N o .4

P0301 P0302 P0303 P0304

ls there continuity?

YES Repairshon in the wire betweenthe EClvl a n dt h e i g n i t i o nc o i l . l

YES-Go to step 29.

ECM WIRE TERI\4INAL COLOR A30 YEL/GRN 429 BLU/RED A.28 WHT/BLU A.21 BRN

NO Repairopen in the wire betweenthe ECMand t h e i g n i t i o nc o i l . l

NO-Go to step 27. 2 7 . C o n n e c itg n i t i o nc o i l 3 P c o nn e c t o rt e r mi n a l N o . 1 t o body ground with a jumper wire (seetable). IGNITIONCOII 3PCONNECTOR

29. Checkthe engine compression

ls the compression OK? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CI\4.I N O - R e p a i tr h e e n g i n e . l

Wire s de of femaleterminals

3 0 . DisconnectECMconnectorB (24P). PROBLEM CYLINDER

DTC

WIRECOLOR

No.1 N o .2 N o .3 N o .4

P0301 P0302 P0303 P0304

YEUGRN BLU/RED WHT/BLU

11-74

T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

BRN

32. fvleasure voltagebetweenbodygroundandECM connector terminal(seetable). ECMCONNECTOR B (24P)

36. Exchangethe injectorfrom the problemcylinder w i t h o n e f r o m a n o t h e rc y l i n d e r .

3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s . 3 8 . Test-drivethe vehiclefor severalminutes in the r a n g eo I t h e l r e e z ed a t ao r u n d e rv a r i o u s condilionsif there was no freezedata.

39. Checkfor a DTCor TemporaryDTCwith the scan tool. ls DTC or TemporaryDTC P0301,P0302, P0303, or P0304 indicated? W i r e s i d e o f f e m a l et e r m r n a l s

YES Go to step 40. PROBLEM CYLINDER No. 1 No.2 No.3 No.4

DTC P0301 P0302 P0303 P0304

ECt\4 TERMINAL B5 B4 B3

WIRE COLOR BRN RED BLU YEL

NO Intermittentmisfiredue to injector malfunction,etc. Make sure the injector connectionsare secure.Checkfor poor connections or looseterminalsat the injectorconnector.l D e t e r m i n ew h i c hc y l i n d e r { sh}a d t h e m i s f i r e .

ls there battery voltage? YES-Go to step 33,

Does the mislirc occur in the cylinder whete the i nj ector w as exchanged ?

N O G o t o s t e p4 1 .

YES Replacethe faulty injector.l

33. Turn the ignitionswitch OFF,and removethe engine cover.

34. Disconnectthe injector2P connectorfrom the p r o b l e mc y l i n d e r .

3 5 , Measurethe resistancebetweeninjector2P

NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodEClvl,replacethe originaE l CM.I

4 1 .Turn the ignition switch OFF.

c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .

42. Removethe enginecover. INJECTOB2P CONNECTOR

43. Disconnectthe injector2P connectorfrom the p r o b l e mc y l i n d e r . 4 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )

Terminal side of male terminals

l s t h e r e 1 0Q

13A?

YES-Go to step 36. NO Replace t h e i n j e c t o r( s e ep a g e11 -1 1I ) .t (cont'd)

11-75

PGM-FISystem DTCTroubleshooting(cont'dl 45. Measure voltagebetweeninjector2Pconnector t e r m i n aNl o .1 a n db o d yg r o u n d .

48. Connectinjector2PconnectorterminalNo.2to bodygroundwith a jumperwire {seetable).

INJECTOR 2P CONNECTOR

INJECTOR2P CONNECTOR

tll-z] -lt,o,,"=rrrr*, oI

tll-Z-l -]_r-l_rNJ IJUMPER

IwrBE

Wiresideof femaleterminals Wire side of {emaleterminals

ls there battery voltage? YES-Go to step 46. NO-Repair open in the wire betweenthe injector l a i n r e l a yl . l a n d t h e P G M - Fm

PROBLEM CYLINDER No.1 No.2 N o .3 N o .4

DTC

WIRECOLOR

P0301 P0302 P0303 P0304

BRN RED BLU YEL

46. Turn the ignitionswitch OFF. 4 7 .Checkfor continuitybetweenbody ground and

49. Checkfor continuitybetweenbody ground and ECMconnectorterminal (seetable).

ECMconnectorterminal (seetable).

ECM CONNECTORB I24P)

B {24P) ECMCONNECTOR

Wire side oJtemaleterminals W i r es i d eo f f e m a l et e r m i n a l s

PROBLEM CYLINDER N o .1 No.2 No.3 N o .4

ECM TERMINAL P030'1 B5 B4 P0302 P0303 B3 P0304 82 DTC

WIRE COLOR BRN

RED BLU YEL

PROBLEM CYLINDER No.1 N o .2 N o .3 N o .4

DTC P0301 P0302 P0303 P0304

ECM TERMINAL B5 B4 B3 82

WIRE COLOR BRN RED BLU YEL

ls therc continuity? ls there continuity? YES Replacethe injector,then recheck.l YES-Repair short in the wire betweenthe ECM a n dt h e ; n j e c t o r . I N O - G o t o s t e p4 8 .

11-76

NO Repairopen in the wire betweenthe ECM and the injector.I

DTGP0325:Malfunctionin KnockSensor Circuit 1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .

7. Connectstanersubharness 6Pconnector terminal r ire. N o .5 t o b o d yg r o u n dw i t ha j u m p e w STARTER SUAHARNESS 6P CONNECTOR

2. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 3. Holdthe engineat 3,000-4,000 rpm for at least 60 seconds.

l1l213l l._, / l 5 l 6 l

KS IJUMPER |RED/BLU) IW|RE I

ls DTC P0325 indicated? Wiresideof femaleterminals

YES-Go to step 4. NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the knocksensorand at the ECM.I

8 . Checkfor continuitybetweenbodygroundand ECMconnector terminalA9. ECMCONNECTOR A {31PI

4. Turn the ignition switch OFF. 5. Disconnectthe startersubharness6P connector. 6. Checkfor continuitybetweenECMconnector terminalAg and body ground. ECMCONNECTOR A 131P) Wire side of female terminals

ls there continuity? YES-Go to step 9. NO Repairopen in the wire betweenthe ECM (A9) and the startersubharness6P connector.l Wire side of lemaleterminals

9 . Checkthe startersubharnessbetweenthe 6P ls therecontinuity? YES-Repairshortin thewire betweenthe ECM (A9)andthe startersubharness 6Pconnector.l NO Goto step7.

connectorand the knocksensorfor an open or short. lf it's OK, substitutea known-goodknock sensorand recheck. ls DTC P0325 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck{seepage '11-6). lf the sym ptomlindication goes away with a known good ECM,replacethe originaE l CM.I NO Replace t h e o r i g i n a kl n o c ks e n s o ra n d / o r starter subharness.l

11-77

PGM-FISystem DTCTroubleshooting(cont'd) DTCP0335:CKPSensorNo Signal DTCP0336:CKPSensorIntermittent Interruption

7. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o , 1 a n d b o d y g r o u n d CKPSENSOR3P CONNECTOR

'1-4). '1. Reset the ECM (seepage 1 2. Start the engine. ls DTC P0335 and/or P0336 indicated? YES Go to step 3. Wire side of female tefminals

NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e C K Ps e n s o ra n d a t t h e E C M . I

ls thereabout5 V?

3. Turn the ignition switch OFF.

YES Goto stepL

4. Disconnectthe CKPsensor3P connector.

N O G ot o s t e p1 0 .

5. Turn the ignitionswitch ON {ll). 6. Measurevoltage betweenCKPsensor3P connector t e r m i n a lN o . 3 a n d b o d y g r o u n d .

voltagebetweenCKPsensor3Pconnector 8. Measure t e r m i n a lN s o . 2a n dN o .3 . CKPSENSOR3PCONNECTOR

CKPSENSOR3PCONNECTOF ,llYtL

IGP

1 2 3

(YEL/BLK}

L " l LGl {BRN/YELI

(

W i r e s i d eo f f e m a l et e r m i n a l s

Wiresadeof femaleterminals

ls there battery voltage? YES Go to step 9.

Is therebattery voltage? YES- Goto step7. NO Repairopenln thewire betweenPGM-Flmain r e l a y1 a n dt h eC K Ps e n s o r . !

NO Repairopen in the wire betweenthe CKP s e n s o ra n d G 1 0 1. I 9. Substitutea known-goodCKPsensorand recheck. ls DTC P0335 and/or P0336 indicated? YES Updatethe ECM if it does not have the latest software.or substitutea known good ECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I t h e o r i g i n aC l K Ps e n s o r . l NO Replace

11-78

'10.l\4easure voltagebetweenECMconnector terminal A7 andbodyground, ECMCONNECTOR A 13lPI

Wiresideot femaleterminals

ls there about 5 V? YES-Repair open in the wire betweenthe ECM (A7)and the CKPsensor.t N O - G o t o s t e p1 1 . 1 1 .Turn the ignitionswitch OFF. DisconnectECMconnectorA (31P) 1 3 . Checkfor continuitybetweenECMconnector terminal 47 and body ground. ECMCONNEfiORA (31P)

Wiresideof femaleterminals

ls there continuity? YES-Repair short in the wire betweenthe ECM (A7)and the CKPsensor.t NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECI\4,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.t

11-79

PGM-FlSystem DTCTroubleshooting(cont'dl DTCP0500:VSSCircuitMalfunction

9. Turn the ignitionswitch OFF.

1. Test-drivethe vehicle.

10. DisconnectECMconnectorA (3'1P).

2. Checkthe vehiclespeedwith the scantool.

11 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .

ls the correct speed indicated? YES-lntermiftent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e V S Sa n d a t t h e E C M . I NO Go to step 3.

12. Blockthe right front wheel. and slowly rotatethe left front wheel. '!3.

lMeasurevoltage betweenECMconnector t e r m i n a l sA 1 8 a n d A 2 4 . A I31PI ECMCONNECTOR

3. Turn the ignition switch OFF. 4. Blockthe rearwheels,and set the parkingbrake. 5. Raisethe front ofthe vehicle,and make sure it is securelysupported, 6 . Turn the ignition switch ON (ll). 1 . Blockthe right front wheel, and slowly rotatethe left front wheel. 8. Measurevoltage betweenECMconnector t e r m i n a l sA 1 8 a n d A 2 4 . A {31P) ECMCONNECTOR

Wiresideof femaleterminals

Does the voltage pulse between 0 V and 5 V ol between0V and battety voltage? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe origlnaE l CM.I NO Checkthese items: . A short or an open in the wire betweenthe ECM ( A 1 8 )a n d t h e V S S . I . l f t h e w i r e i s O K , t e s t t h e V S S( s e ep a g e2 2 7 1 ) . 1

Wiresideof femaleterminals

Does the voltage pulse between 0 V and 5 V or between 0V and battery voltage? YES-Update the ECM if it does not havethe latest software,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CN4.l NO Go to step 9.

11-80

DTCP0563:ECMPowerSourceCircuit Unexpected Voltage

9 . Removethe glove box (seepage20-63). 1 0 .Removethe PGM-FImain relay 1 (A7.

1 . R e s e t h e E C I \ {4s e ep a g el 1 - 4 } . 2. Turn the ignitionswitch OFF. 3. Wait 5 seconds. 4 . T u r nt h e i g n i t i o ns w i t c hO N { l l l . ls DTC P0563 indicated? YES Go to step 5. NO-lntermiltent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e N o . 6 E C U( E C M ){ 1 5A ) f u s e i n t h e u n d e r - h o o d fuse/relaybox and at the ECM.I

1 1 .Checkfor continuitybetweenECMconnector terminal E7 and body ground.

Turn the ignitionswitch OFF. ECMCONNECTOR E 131P)

6 . DisconnectECI\4connectorE {31P).

MRLY {RED/YEL)

7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 8 . lvleasurevoltagebetweenECMconnectorterminal E7 and body ground. ECMCONNECTOR E {31P} MRLY

Wiresideof {emaleterminals

ls there continuity? YES-Repair short in the wire betweenthe ECM l a i n r e l a y1, I { E 7 )a n d t h e P G M - Fm Wiresideol remaleterminals

NO Replace t h e P G M - Fm l a i n r e l a y1 . 1 tt.

ls there battery voltage?

Turn the ignition suitchOFF.

'13.R e c o n n e cEt C M

c o n n e c t oE r (31P).

YES Go to step 12. NO Go to step 9.

(conl'd)

11-81

PGM-FISystem DTCTroubleshooting(cont'dl 14. Measurevoltage betweenECMconnectorterminal E7 and body ground.

1 8 .Removethe glove box (seepage 20-63). 1 9 .Removethe PGM-FImain relay '1{A).

ECMCONNECTORE 13lPI MRLY IBEO/YEL)

W i r es i d eo f f e m a l et e r m i n a l s

ls there battery voltage? YES Go to step 15. NO-Update the ECM if it does not have the latest software,or substitutea known-goodEClvl,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I 1 5 . DisconnectECI\4connectorA (31P).

20. Measure voltage between body ground and ECM connector terminals A3 and A2 individually. ECMCONNECTOR A {31PI IGP2 (YEL/BLK)

IGP1 (YEL/BLK)

t o . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

1 7 . Measurevoltage betweenbody ground and ECIM c o n n e c t otre r m i n a l s4 3 a n d4 2 i n d i v i d u a l l y . ECMCONNECTOR A {3.IP) IGP2 (YEI./BLX)

IGP1 (YEL/BLKI

Wiresideof femaleterminals

I s there battery v oltage? YES Repairshortto power in the wire between ( A 2 . A 3a) n d t h e P G M - Fm the ECI\4 l a i n r e l a y1 . 1 W i r es i d eo f f e m a l el e r m i n a l s

ls there battery voltage? YES-Go to step 18. NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originalECM/PCl\4.1

11-82

N O R e p l a c e t h eP G M F l m a i n r e l a y1 . !

DTGPl106:BAROSensorRange/Perfomance Problem 1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Holdthe engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle.

DTCPl107:BAROSensorCircuitLowVoltage DTCPl108:BAROSensorCircuitHigh Voltage 1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) . 2. Turn the ignition switch ON (ll).

Test-drivewith the transmissionin 4th gear.

l s D T C P 1 1 0 7o r P 1 1 0 8i n d i c a t e d ?

Acceleratefor 5 secondsusingwide open throttle.

YES-Update the ECM if it does not havethe iatest software,or substitutea known-goodECI\4, then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CI\4.I

Checkfor a TemporaryDTCwith the scantool. Is TemporaryDTC Pl106 indicated? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l C M !.

NO- Intermittentfailure,system is OK at this trme.l

NO Intermittentfailure,system is OK at this time.I

11-83

PGM-FISystem DTGTroubleshooting(cont'dl DTCPl157:Ay'F Sensor(Sensor1)Range/ Performance Problem 1 . R e s e t t h eE C I M( s e ep a g e1 1 - 4 ) .

L 6. Checkfor continuitybetweenECMconnector t e r m i n a l4s6 a n dA 1 6 . ECMCONNECTOR A {3IP)

2. Startthe engine. ls DTC Pl157 indicated? YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the Ay'Fsensor(Sensor1) and at the ECN4.I Wire side of femaleterminals

3 . Turn the ignitionswitch OFF. Disconnectthe Ay'Fsensor(Sensor1) 4P connector a n d E C Mc o n n e c t oA r (31P). ConnectA,/Fsensor(Sensor1) 4P connector t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .

ls therecontinuity? YES Goto step9. NO Goto step7.

(SENSOR A/F SENSOR 1) 4PCONNECTOR

7 . Connect A/Fsensor(Sensor1)4Pconnecror

r ire. t e r m i n aNl o .1 t o b o d yg r o u n dw i t ha j u m p e w AFS+ {BLU)

(

A/F SENSOR{SENSOR1I 4P CONNECTOR

JUMPERWIRE

Wire side of femaleterminals

Wire side ot femaleterminals

(

11-84

8. Checkfor continuitybetweenECMconnector terminals46 andbodyground. A 131P} ECMCONNECTOR

DTCPl158:Ay'F Sensor(Sensor1)AFSTerminalLowVoltage 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1158 indicated? YES Go to step 3. NO-lntermittent failure,system is OK at this time Checkfor poor connectionsor loosetermanalsat the Ay'Fsensor(Sensor1) and at the ECIMI

Wire side ol lemaleterminals

3. Turn the ignition switch OFF. ls there continuity? YES-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM(416).1 NO-Repair open in the wire betweenthe Ay'F sensor(Sensor1) and the ECM (46).1

4, DisconnecttheAy'Fsensor(Sensor1) 4P connector, r (31P). a n d E C Mc o n n e c t oA 5. Checkfor continuitybetweenECMconnector termina4 l 1 6 a n d b o d yg r o u n d . A (31P) ECMCONNECTOR

9 . Substitutea known-goodAy'Fsensor(Sensor1) and recheck. ls DTC P1157 indicated? YES- Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe original ECM.!

Wire side oJfemaleterminals

NO- Replacethe Ay'Fsensor{Sensor1).! ls thete continuity? YES-Repair shon in the wire betweenthe A,/F s e n s o r( S e n s o r1 ) a n dt h e E C M( A 1 6 ) . 1 NO Go to step 6.

' c o n td )

11-85

PGM-FISystem DTCTroubleshooting(cont'd) 6. Substitutea known-goodAy'Fsensor(Sensor1)and recheck.

(

DTCPl159:A,/FSensor(Sensor1)AFS + TerminalLowVoltage

Is DTC P1158 indicated?

1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .

YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

2. Start the engine.

NO- Replacethe Ay'Fsensor(Sensor1).t

ls DTC P1159 indicated? YES-Go to step 3. NO-lntermiftent failure.system is OK at this time. Checkfor poor connectionsor looseterminaisat the A,/Fsensor(Sensor1) and at the ECM.I 3. Turn the ignition switch OFF. 4. Disconnectthe Ay'Fsensor(Sensor1) 4P connector a n d E c M c o n n e c t oA r (31P). 5. Checkfor continuitybetweenECMconnector terminal 46 and body ground. ECMCONNECTOR A {31PI

Wire side of femaleterminals

ls therecontinuity? YES-Repairshortin thewire between the Ay'F s e n s o(rS e n s o1r )a n dt h eE C M( A O ) . I NO Goto step6.

11-86

6. Substitutea known-goodAy'Fsensor(Sensor1i and recnecK. l s D T C P 1 1 5 9i n d i c a t e d ? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).if the symptom/indication goes away with a known-goodECN4, replacethe o r i g i n aE l CM.I NO Replace t h e A y ' Fs e n s o r( S e n s o r1 ) . 1

11-87

PGM-FISystem DTCTroubleshooting(cont'dl DTCPl163:Ay'FSensor(Sensor1) Slow Response

DTCPl164:A,/FSensor(Sensor1)Circuit Range/Performance Problem

NOTE:lf DTCP1162is storedat the same time as DTC P1163.troubleshootDTCP1162first, then recheckfor D T CP 1 1 6 3 .

( s e ep a g e1 t - 4 ) . 1 . R e s e t t h eE C I \ 4

1 . R e s e t h e E C M( s e ep a g e11 - 4 ) . 2. Startthe engine.Hold the engine at 3,000rpm with no load (in neutral)until the radiatorfan comes on. 3. Test-driveunderthe following conditions: . 55 mph (89 km/h) steadyspeed ' Transmissionin sth gear ' Until the Ay'Fsensorreadinesscode or TemporaryDTCPl163 comes on 4. Checkfor a TemporaryDTCwith the scantool. ls Temporary DTC P 1163indicated? YES Replacethe Ay'Fsensor(Sensor1).I NO Intermittentfailure, system is OK at this time. Checkfor poor connectionsor looseterminalsat the A'lFsensor (Sensor1) and at the ECM.t

11-88

2 . S t a r tt h e e n g i n e .H o l d t h e e n g i n e a t 3 , 0 0r0p m w i t h no load (in neutral)until the radiatorfan comes on, 3. Test-drivein 3rd gear.Startingat 1,600rpm, accelerateusing wide open throttlefor at least 5 seconds.Then deceleratefor at least5 seconds with the throttle completelycloseduntil the A,/F sensorreadinesscode is set to completeor TemporaryDTCP1164comes on. 4. Checkfor a TemporaryDTCwith the scantool. ls TemporaryDTC P1164indicated? YES- Replacethe A,,/F sensor(Sensor1).I NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the Ay'Fsensor relay,at the Ay'Fsensor(Sensor1), a n da t t h e E c M . l

Sensor(Sensor1)Heater DTCPl166:Ay'F CircuitMalfunction 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.

Is therc battery voltage? YES-Update the ECM if it does not have the latest soflware,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

ls DTC P1166indicated? NO-Go to step 5. YES-Go to step 3. NO-lntermittent failure,system is OK at this lime. Checkfor poor connectionsor looseterminalsat the Ay'Fsensorrelay,the A,/Fsensor(Sensor1),and t h e E c M .!

5. MeasurevoltagebetweenECMconnector terminalsA22 and A24. A {31P} ECMCONNECTOR

3. Checkthe following fuse: . No. 14 OPTION(30A)fusein under-hoodfuse/ rerayDox. . No. 2*B LAF (Ay'F) HEATER(20A)fuse in underdash fuse/relaybox. . No. 4 ACG (10A)in underdash fuse/relaybox. Are any of the fuses blown?

Wire side of femaleterminals

YES Repairshort in the wire betweenthe Ay'F sensorrelay and the fuses.I

ls therebattery voltage?

NO Go to step 4.

YES Goto step6.

4. MeasurevoltagebetweenECMconnector terminalsA1 and A24. 30 secondsafter the ignition s w i t c hi s t u r n e dO N ( l l ) . A I31P) ECMCONNECTOR

N O - G o t o s t e p1 0 . 6. Turnthe ignitionswitchOFF. E (31P). 7. Disconnect ECMconnector s w i t c hO N{ l l ) . 8 . T u r nt h ei g n i t i o n

W i r es r d eo f l e m a l et e r m i n a l s

(cont'd)

11-89

PGM-FISystem DTCTroubleshooting(cont'dl 9. ConnectECMconnectorterminal EStobody ground with a jumper wire, then measurevoltage betweenECMconnectorterminalsA1 and 424. ECMCONNECTORS

ls there continuity? YES Repairshort in the wire betweenthe A|/F sensorrelay,A,/Fsensor{Sensor1) and ECM lA22J.a NO Go to step 13. t 5 . Turn the ignition switch ON (ll).

1 4 . Measurevoltage betweenECMconnector terminalsE8 and A24. ECM CONNECTORS

Wire side of femaleterminals

E {31P)

ls there battery voltage? YES- Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l C M t.

a {31P)

Wiresideof femaleterminals NO Repairopen in the wire betweenthe Ay'F r ) a n d E C M( A 1 ) t. s e n s o r( S e n s o 1

1 0 .Turn the ignitionswitch OFF. 1 1 .Disconneclthe ECfMconnectorA (31P)and the Ay'F sensor(Sensor1) 4P connector. 1 2 . Checkfor continuitybetweenthe Ay'Fsensor ( S e n s o r1 ) 4 Pc o n n e c t otre r m i n a lN o . 3 a n d b o d y ground.

ls there battety voltage? YES-Repair open in the wire betweenthe ECM (A22)and the IVF sensor(Sensor1).I N O - G o t o s t e p1 5 . Checkfor continuityin the wires betweenthe Ay'F sensorand the fuses. ls there continuity?

(SENSOR A/F SENSOR 1)4PCONNECTOR

YES-The wires are OK. Replacethe A,/Fsensor relay.l NO Repairopen in the wire betweenthe Ay'F sensorrelay and the fuses.l

Wire side ot Iemaleterminals

11-90

Sensor(Sensor1)Heater DTCPl167:Ay'F CircuitMalfunction NOTE:lf DTCP1162is storedat the same time as DTC P1167,troubleshootDTCP1162first, then troubleshoot D T CP 1 1 6 7 . 1 . R e s e t t h eE C I \ (4s e ep a g e1 1 - 4 )

6. Checkfor continuitybetweenECMconnector t e r m i n a l s, 4 6a n d 4 1 6 . A {31P) ECMCONNECTOR AFS- {RED)

trTzTil,ilsl l t

9 2C21

l?rlzsIels

2. Startthe engine.Wait for at least80 seconds.

AFS

ls DTC P01167 indicated?

IRED/YEL)

YES Go to step 3. Wire side of lemale terminals

NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the Ay'Fsensorrelay,at the Ay'Fsensor(Sensor1), a n da t t h e E C M . I ?

Turn the ignitionswitch OFF. Disconnectthe A,/Fsensor4P connectorand ECM connectorA (31P).

ls thetecontinuity? h eA / Fs e n s o(rS e n s o1r ) . 1 Y E S - R e p l a ct e NO-Repairopenin thewire betweenthe Ay'F s e n s o(rS e n s o1r) a n dt h eE C M( 4 6o r A 1 6 ) . I

5 . Connectthe Ay'Fsensor(Sensor1) 4P connector t e r m i n a l sN o . 2 a n d N o . 1 w i t h a j u m p e rw i r e . A/F SENSOR(SENSOR1) 4P CONNECTOR JUMPERWIRE

Wire side of f e m a l et e r m i n a l s

11-91

PGM-FISystem

DTCTroubleshooting(cont'dl DTCPl297:ELDCircuitLowVoltage

8. Turn the ignition switch OFF.

1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) .

9. DisconnectECMconnectorE {31P).

2. Startthe engine.

10. Checkfor continuitybetweenbody ground and E C Mc o n n e c t otre r m i n a lE 1 5 .

3 . T u r no n t h e h e a d l i g h t s . ECMCONNECTOR E 131PI

ls DTC P1297 indicated?

I l 2 l 34 5 6 1 7

YES Go to step 4.

NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e E L Da n d a t t h e E C M . I

,2 2al2/

7\'

8 I

/ 12021 31

ELD (GRN/RED}

4. Turn the ignition switch and the headlightsOFF. 5. DisconnecttheELD3P connector.

Wire side of femaleterminals

6. Turn the ignition switch ON {ll). ls there continuity? 7. Measurevoltage betweenbody ground and ELD3P connectorterminal No. 3. ELO3P CONNECTOB

ELD{GRN/REDI

Wire side of femaleterminals

ls thereabout5 V? YES Replace the ELD.t N O - G o t o s t e p8 .

11-92

YES-Repair short in the wire betweenthe ECM ( E1 5 )a n d t h e E L D r. NO- U pdatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

DTCPl298:ELDCircuitHighVoltage 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 )

8. T u r nt h e i g n i t i o ns w i t c hO F F . 9 . ConnectELD3P connectorterminal No. 3 to body g r o u n dw i t h a j u m p e rw i r e .

2. Stan the engine. ELD3P CONNECTOR

3. Turn on the headlights.

---F-------

ls DTC P1298 indicated?

l 1 l 2: r l

ELD (GRN/RED)

YES-Go to step 4.

wrRE IJUMPER

NO- Intermittentfailure.system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e E L Da n d a t t h e E C M . I 4. Turn the ignition switch and headlightsOFF. 5. DisconnecttheELD3P connector.

Wire side of temaleterminals

1 0 .DisconnectECMconnectorE (31P).

6. Turn the ignition switch ON (ll).

1 1 .Checkfor continuitybetweenbody ground and 7. Measurevoltagebetweenbody ground and ELD3P connectorterminal No. 1. ELD3PCONNECTOR

ECMconnectorterminal E15. E 131PI ECMCONNECTOR

1 2 1 34 5 IG1IBLK/ORNI

I I 1 8 2C 21 21./ 2Q 30 J

o t /

1 4 L C 6l/

22123 24

ELD i1' IGRN/RED)

Wire side of femaleterminals Wire side ot {emaleterminals

Is thetecontinuity? ls there battery voltage?

Y E S - G ot o s t e p1 2 . YES-Go to step 8. N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in the wire betweenthe No. 4 ACG (10A)fuse and the ELD.I

NO Repairopenin thewire betweenthe ECM ( E 1 5a) n dt h eE L D .

(cont'd)

11-93

PGM-FISystem DTCTroubleshooting(cont'dl 12, Checkfor continuitybetweenELD3P connector t e r m i n a lN o . 2 a n d b o d y g r o u n d . E L D 3 PC O N N E C T O R

W i r e s i d eo f f e m a l et e r m i n a l s

ls there continuity? YES Go to step 13. NO- Repairopen in the wire betweenthe ELDand G 2 0 1I. Reconnectthe ELD3P connectorand ECM connectorE (31P). 1 4 . Startthe engineand let it idle. t 5 _ While measuringvoltage betweenECMconnector

t e r m i n a l s4 2 4 a n d E 1 5 ,t u r n t h e h e a d l i g h t os n t hi g h ) . ECM CONNECTORS

W i . e s i d eo f f e m a l et e r m i n a l s

Does the voltage drop? YES-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO Replace the ELD.I

11-94

DTCPl361:CamshaftPosition(CMP)Sensor B (TDCSensor)Intermittent Interruption DTCPl362:CamshaftPosition(CMP)Sensor B (TDCSensor)No Signal

7. l\4easure voltage betweenCMP sensorB {TDC sensor)3P connectorterminal No. 1 and body ground. CMP S€NSOR 8 ITDCSENSOR)3P CONNECTOR

1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P1361and/or P1362 indicated? YES Go to step 3.

Wlres de ollemaleterminals

NO- Intermittentfailure.system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e C M Ps e n s o rB ( T D Cs e n s o r a ) n da tt h e E C M . I

ls thereabout5 V? YES-Go to step8.

3 . Turn the ignitionswitch OFF. N O - G o t o s t e p1 0 . 4 . DisconnecttheCMP sensorB (TDCsensor)3P

voltagebetweenCl\ilPsensorB (TDC 8. Measure s e n s o r3)Pc o n n e c t ot er r m i n a lN s o .2 a n dN o ,3 .

connector.

5 . Turn the ignitionswitch ON (ll). CMPSENSON B llOC SENSOfi)3P CONNECTOF

6 . Measurevoltage betweenCMP sensorB (TDC sensor)3P connectorterminal No. 3 and body grouno. B {TDCSENSOR) CMPSENSOR 3PCONNECTOR IGP

1 2 3

{YEL/BLK}

Wire s de olfema etefminals

ls there battery voltage? Y E S - G o t o s t e p9 . NO Repairopen in the wire betweenthe CMP ) n dG 1 0 1 . 1 s e n s o rB ( T D Cs e n s o r a

Wiresideol temaleterminals

9. Substitutea known-goodCMP sensorB (TDC sensor)and recheck.

ls there battety voltage?

ls DTC P1361and/or P1362 indicated?

YES Go to step7.

YES Updatethe ECMif it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

NO-Repair open in the wire betweenthe PGM-Fl m a i n r e l a y1 a n dt h e C M Ps e n s o rI ( T D Cs e n s o r ) . I

NO Replace theoriginaC l MPsensorB(TDC sensor).1

(cont'd)

11-95

PGM-FISystem (cont'd) DTCTroubleshooting 10. MeasurevoltagebetweenECI\4 connectorterminal A26andbodyground. ECMCONNECTOR A (31P)

1 2 3 4 5 6 1 7 I 0 1 11 2 1 . / 61,/18 I 2C2l 2324 21m 30 TDC {GRN}

Wire side oI temaleterminals

ls thereabout5 V ? YES- Repairopenin thewire betweenthe ECM (426)and CMPsensorB (TDCsensor).1

DTCPl607:Malfunction in ECMInternal Circuit 1. ResettheEC|\illsee page 11-4). 2 , T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 40 seconds. ls DTC P 1607 indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11 6). lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I NO Intermittentfailure,system is OK at this time. A low batterycan causethis problem . Ask the customerif there has been any recenttrouble s t a r t i n gt h e e n g i n e . l

N O - G o t o s t e p1 1 . 1 1 .Turnthe ignitionswitchOFF.

ECIM A (31P) 1 2 . Disconnect connector Checkfor continuitybetweenECMconnector terminal426 andbodyground. ECMCONNECTOR A {31PI

Wiresideof femaleterminals

ls there continuity? YES Repairshort in the wire betweenthe ECM (426)and the CMP sensor B (TDCsensor).1 NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-96

MIL CircuitTroubleshooting 1. Connectan OBD ll scantool/HondaPGM Tester ( s e ep a g e1 1 - 3 ) . 2. Turn the ignition switch ON (ll) and readthe OBD ll scantool/HondaPGM Tester. Does the OBD ll scan tool/Honda PGM Tester communicatewith the ECM? YES Go to step 3. " NO Go to troubleshooting DLCCircuit T r o u b l e s h o o t i n g (" s e ep a g e1 1 - 1 0 9 ) .

. A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s ei n t h e under-dashfuse/relaybox. . A p o o rc o n n e c t i o n l 31. a t E C Mt e r m i n a E . An intermittentopen in the GRN/ORNwire ) n d t h e g a u g ea s s e m b l y . b e t w e e nt h e E C M( E 3 1 a . An intermittentshort in the wire betweenthe ECM(A21)and the manifold absolutepressure ( M A P )s e n s o r . . An intermittentshort in the wire betweenthe ECI\4(A20)and the throttle posilion (TPisensor. . An intermittentshort in the wire betweenthe ECM (E5)and the fuel tank pressure(FTP)sensor. 6. Turn the ignition switch OFF.

3. Checkthe OBD ll scantool/HondaPGM Testerfor DTCs.

7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

Are any DTCs indicated?

ls the low oil pressure light on?

YES Go to the DTCTroubleshootingIndex.

YES Go to step 10.

NO-Go to step 4.

N O - G o t o s t e p8 .

4. Turn the ignitionswitch OFF. 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) a n dw a t c ht h e l M a l f u n c t i oIn d i c a t oLr a m p( M l L ) .

8 . I n s p e c t t h eN o . 1 0 l \ 4 E T E(R7 . 5 A ) f u s ei n t h e u n d e r dash fuse/relaybox. ls the luse OK?

Does the MIL come on and stay on for more than 20 secondsaftet turning the ignition switch

YES Go to step L

oN (tr)?

N O R e p a i rs h o n i n t h e w i r e b e t w e e nN o . 1 0 M E T E R( 7 . 5 A ) f u s e a n d t h e g a u g ea s s e m b l yA. l s o r e p l a c e t h eN o . 1 0 M E T E R{ 7 . 5 A f) u s e . l

YES lf the MIL alwayscomes on and stayson, go to step 76. But if the lMlLsometimesworks normally,first checkfor these problems. . An intermittentshort in the wire betweenthe ) n dt h e d a t al i n kc o n n e c t o(rD L C ) . E C I M( E 2 9 a . An intermittentshort in the wire betweenthe ) n dt h e g a u g ea s s e m b l y . E C M( E 3 1 a NO lf the MIL is alwaysoff, go to step 6. But if the lvllLsometimesworks normally,first checkfor these problems. . A l o o s eN o . 1 0 M E T E R( 7 . 5 A f)u s ei n t h e u n d e r dash fuse/relaybox. . A l o o s eN o . 2 0 l G ( 4 0 A )( C a n a d a5: 0 A ) I u s ei n t h e under-hoodfuse/relaybox. . A i o o s eN o . 6 E C U( E C M )( 1 5 A )f u s ei n t h e u n d e r hood fuse/relaybox.

9. Inspectthe No. 20 lG1 (40A)(Canada:50A)fuse in the under-hoodfuse/relaybox. ls the f use OK? YES Repairopen in the wire betweenthe No. 20 l G ( 4 0 A ){ C a n a d a5r0 A ) f u s ea n d t h e g a u g e assembly.lf the wire is OK, test the ignition switch {seepage 22 53). N O R e p a i rs h o r ti n t h e w i r e b e t w e e nN o . 2 0 l G ( 4 0 A )l C a n a d a5: 0 A ) f u s ea n d t h e u n d e r ' d a s h fusel r e l a yb o x .A l s o r e p l a c et h e N o . 2 0 l G ( 4 0 A i ( C a n a d a5: 0 A )f u s e . I

(conr'd)

11-97

PGM-FISystem MIL CircuitTroubleshooting(cont'dl 1 0 .Tryto startthe engine.

t o . Removethe blown No. 6 ECU{ECfU)(154)fuse

from the under-hoodfuse/relaybox.

Doesthe enginestart? 1 7 . Removethe glove box (seepage 20-63)and the P G M ' F Im a i n r e l a y1 .

Y E S - G ot o s t e p1 1 . N O - G o t o s t e p1 4 . 1 1 .Turnthe ignitionswitchOFF.

12. ConnectECMconnector terminalE31to body groundwith a jumperwire. ECMCONNECTOR E 13lPI

l l 2 l 34 5 6 1 7 l1 8I 4 1 5161,/118 2( 2t 2' 23 24 z7l/ 129 31 JUMPER MIL (GRN/ORN} WIRE

1 8 . Checkfor continuitybetweenbody ground and P G M - Fm l a i n r e l a y1 4 P c o n n e c t otre r m i n a l sN o . 2 a n d N o .4 i n d i v i d u a l l v . PGM-FIMAIN RELAY1 4P CONNECTOR

Wire side of femaleterminals

Turn the ignition switch ON (ll). ls the M lL on? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECIM,replacethe o r i g i n aE l CM.I NO-Check for an open in the wire betweenthe ) n d t h e g a u g ea s s e m b l yA. l s o c h e c kf o r E C M( E 3 1 a a b l o w nM I L b u l b .l f t h e w i r e sa n d t h e b u l b a r e O K , replacethe gauge assembly.l

't4. Turn the ignltion switch OFF,

f V (wHr/ B v) BLK)( IA W r r es r d eo l l e m a l et e r m r n a l s

ls there continuity? Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e N o . 6 ) 5 A )f u s ea n d t h e P G M - Fm E C U( E C l \ 4( 1 l a i n r e l a y1 . A l s o r e p l a c et h e N o . 6 E C U( E C M )( 1 5 A )f u s e . l N O - G o t o s t e p1 9 .

(15A)fuse in the 1 5 . Inspectthe No. 6 ECU (ECIM) under-hoodfuse/relaybox. ls the f use OK? YES-Go to step 22. N O - G o t o s t e p1 6 .

11-98

19. Disconnecteach of the componentsor the connectorsbelow, one at a time, and checkfor continuitybetweenPGM-FImain relay 1 4P connectorterminal No. 1 and body ground.

21. Checkfor continuitybetweenPGM-FImain relay 1 4P connectortermlnal No. 1 and body ground. PGM-FIMAIN RELAY1 4P CONNECTOR

. PGfvl-Flmain relay 2 . ECMconnectorA (31P) . Eachinjector2P connector . ldle air control (lAC)valve3P connector . CamshaftPosition(CMP)sensorB (Topdead center(TDC)sensor)3P connector . Crankshaftposition(CKP)sensor3P connector PGM-FIMAIN RELAY1 4PCONNECTOR Wire side of femaleterminals

ls there continuity? YES Repairshort in the wire betweenthe PGM-Fl main relay 1 and each item. Also replacethe No. 6 E C U{ E C M )( 1 5 A )f u s e . l l a i n r e l a y1 .A l s o r e p l a c e N O - R e p l a c et h e P G M - Fm t h e N o 6 E C U{ E C I M()1 5 A )f u s e .I Wire side of femaleterminals

( 1 5 A ) f u s ei n t h e 22. I n s p e c t t h eN o . 1 7 F U E LP U I \ 4 P ls thete continuity?

under-dashf use/relaybox.

YES Go to step 20.

ls the tuse OK?

NO- Replacethe componentthat made continuity to body ground go away when disconnected.lf the item is the ECM,updatethe ECM if it does not have the latestsoftware.or substitutea known-good ECM,then recheck(seepage 11-6).lf the symptom/ indicationgoes away with a known'good ECM, r e p l a c et h e o r i g i n a E l CM. Also replacethe No. 6 ECU(ECM)(15 A) fuse,

YES Go to step 34. NO Go to step 23.

23. R e m o v et h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A )f u s e from the under-dashfuse/relaybox.

2 4 . DisconnectECfvlconnectorE (31P).

20. Disconnectthe connectorsof all these components. . P G M - Fm l a i n r e l a y2 . E C Mc o n n e c t oA r (31P) . lnjectors . l d l ea i r c o n t r o l( l A C ) v a l v e . CamshaftPosition{CMP)sensorB (Top dead center(TDC)sensor) . Crankshaftposition(CKP)sensor

(conr'd)

11-99

PGM-FISystem MIL CircuitTroubleshooting(cont'dl 25. Checkfor continuitybetweenECMconnector terminal E9 and body ground.

27. Checkfor continuitybetweenECIVI connector terminalEgandbodyground.

ECMCONNECTOR E (31P)

ECMCONNECTOR E 131P)

Wire side o{ {emaleterminals

Wire side oI Jemaleterminals

ls therc continuity?

ls there continuity?

YES-Go to step 26.

YES Repairshort in the wire betweenthe No. 17 ,r F UE LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) o betweenthe No. 17 FUELPUMP (15A) fuse and the P G M - Fm I a i n r e l a y2 . A l s o r e p l a c et h e N o . 1 7 F U E L P U M P( 1 5 A ) f u s e . l

N O R e p l a cteh e N o . l T F U E L P U M P ( 1 5 A ) f u s e , and updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM.replacethe originaE l CM.I

NO Go to step 28.

28. Removethe rear seatcushion (seepage 20-80). 26. Removethe PGM-Flmain relay 2 (A).

29. Removethe accesspanelfrom the floor. 30. Disconnectthe fuel pump 5P connector.

11-100

31. Checkfor continuitybetweenfuel pump5P connector terminalNo.5 andbodyground. FUELPUMP5PCONNECTOR

33. Checkfor continuitybetweenfuel pump5P connector terminalNo.5 andbodyground. FUELPUMP5P CONNECTOR

= Wire side ol lemal€ rerminals

Wire side of temaleterminals

ls there continuity?

ls therc continuity? YES Repairshortin thewire betweenthefuel p u m pa n dt h eP G M - Fml a i nr e l a y2 .A l s or e p l a c e t h EN O .1 7F U E LP U M P( 1 5 Af)U S E . T

YES Replacethe PGM-Flmain relay 2. Also r e p l a c et h e N o . 1 7 F U E LP U M P( 1 5 A )f u s e . l NO Checkthe iuel pump, and replaceil if necessary.Also replacethe No. 17 FUELPUMP ( 1 5 A )f u s e . !

NO-Go to step32. 32. Reinstallthe PGM-Flmainrelay2 (A).

34. DisconnectECMconnectorE (31P). 3 5 . T u r nt h e i g n i t i o ns w i r c hO N { 1 1 1 . 36. Measurevoltage betweenECMconnectorterminal E9 and body ground. ECfl CON|{CCIORE (3rPt

Wire side ol female lerminals

ls there battery voltage? YES Go to step 37. NO Repairopen in the wire betweenthe No. 17 F U E LP U M P( 1 5 A ) f u s ea n d t h e E C M( E 9 ) . 1

(cont'd)

11-101

PGM-FISystem (cont'dl MIL CircuitTroubleshooting 37. lvleasure voltagebetweenECM/PCM connector t e r m i n aEl 7a n db o d yg r o u n d .

40. lvleasurevoltage betweenPGN4-Fl main relay 1 4P c o n n e c t otre r m i n a lN o . 4 a n d b o d vq r o u n d . PGM-FIMAIN RELAY1 ilP CONNECTOR

ECM CONNECTORE {31PI MRLY

Wire side of femaleterminals Wire side ot lemale terminals

ls there battery voltage?

YES Go to step 42.

Y E S - G o t o s t e p4 1 .

NO Go to step38.

NO Repairopen in the wire betweenthe No. 6 E C U( E C M )( 1 5 A )f u s ea n d t h e P G f M - Fml a i n r e l a y1 . I

38. Turn the ignitionswitch OFF. 3 9 . Removethe PGM-FImain relay 1 {A} -A

4 1 . Checkfor continuitybetweenPGM-FImain relay 1

4P connectorterminal No. 3 and ECMconnector t e r m i n a lE 7 . PGM.FIMAIN RELAY1 4P CONNECTOR

MRLY(RED/YEL) ECMCONNECTOR E 131PI

MRLY(RED/YEL)

Wire side of femaleterminals

ls there continuity? YES-Testthe PGM-Flmain relay 1 (seepage2251). lf the relay is OK, updatethe ECM if it does not have the latestsoftware,or substitutea knowngood ECM,then recheck{seepage 11'6).lf the symptom/indicationgoes away with a known-good E C M ,r e p l a c et h e o r i g i n a E l CM.I NO*Repair open in the wire betweenthe PGM-FI m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1

11-102

42. ReconnectECI\4connectorE {31P).

48. MeasurevoltagebetweenPGM-FI mainrelay1 4P connector terminalNo.2 andbodyground.

4 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

PGM.FIMAIN RELAY1 4PCONNECTOR

44. Measurevoltage betweenbody ground and ECM connectorterminals42 and 43 individually. ECMCONNECTOR A {31PI

Wire side of temaleterminals

ls there battery voltage? Wire side of femaleterminals

YES Go to step 49. ls there battery voltage?

N O R e p a i ro p e ni n t h e w i r e b e t w e e nt h e N o . 6 E C U{ E C M )( 1 5 A } f u s ea n d t h e P G M - Fm l ain r e l a y1. !

YES Go to step 51. NO Go to step 45.

4 9 . T u r nt h e i g n i t i o ns w i t c hO F F .

4 5 . T u r nt h e i g n i t i o ns w i t c hO F F . 46. R e m o v et h e P G M ' F lm a i n r e l a y1 {A)

5 0 . Checkfor continuitybetweenPGM-Flmain relay 1 4P connectorterminal No. 1 and ECMconnector t e r m i n a l s4 2 a n d 4 3 i n d i v i d u a l l y .

PGM.FI MAIN RELAYI ilP CONNECTOR

IGPl (YEL/BLK)

W i r es i d eo f f e m a l et e r m i n a l s

4 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

ls there continuity? YES Replace t h e P G M - Fm l a i n r e l a y1 . 1 NO Repairopen in the wire betweenthe PGM-FI '1 m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1

{cont'd}

11-103

PGM-FISystem MIL CircuitTroubleshooting(cont'dl 51. MeasurevoltagebetweenbodygroundandECM connector terminals44, A5,423,and424 individuallv. ECMCONNECTOR A 131P) PG2(BLK)

PG1IBLKI

53. Turn the ignitionswitch OFF. 54. Disconnectthe manifoldabsolutepressure(MAP) sensor3P connector. 55. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 56. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a A l 21. ECMCONNECTOR A {31P)

W i r es i d eo f f e m a l et e r m i n a l s

ls there morc than 1.0 V ? YES Go to step 52. N O - R e p a i r o p e ni n t h e w i r e ( s )t h a t h a d m o r et h a n 1.0V betweenG 10'l and the ECM (A4,A5, A23, A24l.a Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a 4 l 21. ECMCONNECTOR A 131P)

Wiresideof femaleterminals ls there about 5 V? YES Replacethe MAP sensor.l NO Go to step 57. 5 7 . Turn the ignition switch OFF. 5 8 . D i s c o n n e cEt C Mc o n n e c t oA r (31P).

Wiresideof femaleterminals ls there about 5 V? YES-Go to step 60. N O - G o t o s t e p5 3 .

11-104

59. Checkfor continuitvbetweenECIM connector t e r m i n a4l 2 1a n db o d yg r o u n d .

t t , Turn the ignition switch OFF.

o z , Disconnectthe throttle position(TP)sensor3P connector.

ECM CONNECTORA {3,IPI

6 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 64. Measurevoltage betweenbody ground and ECM connectorterminal 420, ECMCONNECTOR A 131P)

Wire side of femaleterminals

ls there continuity? YES*Repair short in the wire betweenthe ECM ( 4 2 1 )a n d t h e M A P s e n s o r . l NO Updatethe ECM it it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 1'l-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

Wiresideof femaleterminals ls there about 5 V? YES Replacethe thronle body (theTP sensoris not availableseparately). I

6 0 . Measurevoltagebetweenbody ground and ECM connectorterminal 420.

NO Go to step 65.

ECMCONNECTOR A {3TP}

65. Turn the ignition switch oFF. 66. DisconnectECMconnectorA (31P).

1 1 2 1 43 5 o t / I 1 0 11112 5 6 / 1189 2t 21 2' 231?4 ? q Tln 29

vcc2

IYEL/ BLU)

W i r es i d eo t f e m a l tee r m i n a l s ls there about 5 V? YES-Go to step 68. N O - G o t o s t e p6 1 .

conlo

11-105

PGM-FISystem MIL CircuitTroubleshooting(cont'd) 6 7 . Checkfor continuitybetweenECIM connector t e r m i n aAl 2 0a n db o d yg r o u n d .

68. Measurevoltage betweenbody ground and ECM c o n n e c t otre r m i n a lE 5 .

ECMCONNECTOR A (31P)

r l 2 l 3 1 54 o t / 10 t1 121,/1,/ 1516 22 '3 241 12526

ECMCONNECTOR E (31PI 9

ta, 9 2A21

vcc2

o {YEL/ BLU} Wire side of femaleterminals Wire side of femaleterminals

ls there continuity?

Is there about 5 V?

YES Repairshon in the wire betweenthe ECN4 {A20)and the TP sensor,or repairshort in the wire betweenthe ECM (A8) and the knocksensor.t

YES U pdatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodEClvl,replacethe o r i g i n aE l CM.t

NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage l1-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.t

NO-Go to step 69. 6 9 . Turn the ignition switchOFF.

7 0 . Disconnectthe fuel tank pressure(FTP)sensor3P connector. 1 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

11-106

72. MeasurevoltagebetweenbodygroundandECM connector terminalE5.

7 6 . T u r nt h e i g n i t i o ns w i t c hO F F . 7 7 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

ECMCONNECTOR E 131P}

7 8 . Measurevoltage betweenECMconnectorterminal E 2 9a n d b o d y g r o u n d . ECMCONNECTOR E (31P)

r l 2 l 3 1 4 5 6 1 15 6 ,/1,/114

2 2 23 241

l,/

8 9 2A21 2930 scstBRN)

Wire side of femaleterminals

ls there about 5 V? Wiresideof femaleterminals YES Replacethe FTPsensor.t NO Go to step 73.

ls there about 5 V (or battery voltage)?

1 3 . Turn the ignitionswitch OFF.

YES-Go to step 82.

7 4 . DisconnectECMconnectorE (3'lP).

NO Go to step 79.

7 5 .Checkfor continuitybetweenECMconnector

7 9 . Turn the ignitionswitch OFF.

t e r m i n a lE 5 a n d b o d y g r o u n d .

8 0 . DisconnectECMconnectorE (31P). ECMCONNECTOR E {31PI

Wire side of femaleterminals

Is there continuity? YES Repairshort in the wire betweenthe ECM ( E 5 )a n dt h e F T Ps e n s o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I (cont'd)

11-107

PGM-FISystem MIL GircuitTroubleshooting(cont'd) 81. Checkfor continuitybetweenECMconnector t e r m i n a lE 2 9a n d b o d y g r o u n d . ECMCONNECTOR E 131P}

r l 2 l 34 5 14 t c

22123124

61,/118 2A21 271./ 3031

scs(BRN)

Wire side of femaleterminals

ls there continuity? YES-Repair short in the wire betweenthe data link connector(DLC)and the ECM(E29).1 NO Updatethe ECM if it does not havethe latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CI\4,I Turn the ignition switch OFF. DisconnectECMconnectorE (31P). T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the MIL stay on? YES-Repair short in the wire betweenthe gauge a s s e m b l ya n dt h e E C M( E 3 1) . l f t h e w i r e i s O K , r e p l a c et h e g a u g ea s s e m b l y . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-108

DLCCircuitTroubleshooting lf the ECMdoes not communicatewith the OBD ll scan tool, HondaPGfMTester,or l/M test equipment,do this troubleshootingprocedure. 1. Measurevoltage betweenDLCterminal No. 16 and body ground.

3. Measurevoltage betweenDLCterminalsNo. 5 and No. 16. DATALINKCONNECTOR {DLC)

DATALINKCONNECTOR {DLCI

(WHT/RED)

Terminalside of femaleterminals

ls there battery voltage? Terminal sideof lemaleterminals YES Go to step 4. ls therc battery voltage?

NO- Repairopen in the wire betweenDLCterminal N o . 5 a n dt h e E C M( E 3 )t.

YES-Go to step 2. 4 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . NO-Repair open in the wire betweenDLCterminal N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5A ) f u s ei n t h e under-hoodf use/relaybox.I Measurevoltage betweenDLCterminalsNo. 4 and No.16.

5 . M e a s u r ev o l t a g eb e t w e e nD L Ct e r m i n a l sN o . 5 a n d No.7. DATA LINKCONNECTOR {DLCI

DATA LINK CONNECTOR(DLCI

T e r m i n asli d eo f l e m a l et e r m i n a l s

Terminalsideof Jemale terminals

ls there 8.5 V or more? YES Go to step 10.

Is there battery voltage? NO Go to step 6. YES Go to step 3. 6. Turn the ignition switch OFF. NO Repairopen in the wire betweenDLCterminal N o . 4 a n d b o d yg r o u n d . l

(cont'd)

11-109

PGM-FISystem DLCCircuitTroubleshooting {cont'dl 7. DisconnectEClvlconnectorE (31P).Make sure the O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s disconnectedfrom the DLC.

ls there continuity? YES U pdatethe ECMif it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CI\4.I

8. Checkfor continuitybetweenDLCterminal No. 7 a n d b o d yg r o u n d . DATALINKCONNECTOR IDLC)

NO Repairopen in the wire betweenDLCterminal N o . 7 a n dt h e E C M{ E 2 3 )A. f t e rr e p a i r i n gt h e w i r e , checkthe DTCwith the OBD ll scantool/Honda PGl\4Tester,and go to the DTCTroubleshooting Index.l

1 0 .T u r nt h e i g n i t i o ns w i t c hO F F . 1

' I.

Ierminal side of femaleterminals

DisconnectECI\4connectorE (31P).l\4akesure the O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s disconnectedfrom the DLC. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

ls there continuity? tJ.

YES-Repair short to ground in the wire between DLCterminal No. 7 and the ECM {E23).After r e p a i r i n gt h e w i r e ,c h e c kt h e D T Cw i t h t h e O B Dl l scantool/HondaPGM Tester,and go to the DTC Troubleshootingindex.I

Measurevoltage betweenDLCterminalsNo. 5 and No.7. DATALINKCONNECTOR {DLC}

NO Go to step 9.

9 . Checkfor continuitybetweenDLCterminal No. 7 a n d E C Mt e r m i n a lE 2 3 , ECMCONNECTOR E {31PI Terminalside of femaleterminals

K-LINE{LTBLU) DATA LINK CONNECTOR

Is there 0 V? YES Updatethe ECMif it does not havethe latest then software,or substitutea known-goodECI\4, recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

Terminalside of femaleterminals

NO Repairshort to power in the wire betweenthe D L Ct e r m i n a lN o . 7 a n d t h e E C M( E 2 3 )A. f t e r repairingthe wire, checkthe DTCwith the OBD ll scantool/HondaPGMTester,and go to the DTC T r o u b l e s h o o t i ni g n d e x I.

11-110

InjectorReplacement (seepage1l-144). fuel pressure 1 . Relieve 2 . Disconnect the connectors fromthe injectors(A),disconnect the groundcable(B),andremovethe bracket(C).

(2.2 kgf.m, l6 lbf.ftl

ffi\t\

3. Disconnectthe quick-connectfittings (D). 4 . R e m o v e t h e f u erl a i lm o u n t i n g n u t s ( Ef)r o m t h e f u e l r a i l( F ) t h e nr e m o v e t h e f u e rl a i la n d i n j e c t o r sa s a n a s s e m b l y . 5. Removethe injectorclip (G)from the injector. 6. Removethe injectorfrom the fuel rail.

(cont'd)

11-111

PGM-FISystem InjectorReplacement(cont'd) 7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o risn(tBo)t h e f u e lr a i l( C ) .

8 , l n s t a ltl h e i n j e c t o cr l i p { D ) . 9. Coatthe injectoro-rings(E)with cleanengine oil. 1 0 . I n s t a l l t h ei n j e c t o r si n t o t h e f u e lr a i l ,t h e n i n s t a l tl h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) . 1'1. Installthe fuel rail mounting nuts,ground cable.and bracket. 12. Connectthe connectorsto the injectors. 13. Connectthe quick-connectfittings. 1 4 . T u r n t h ei g n i t i o ns w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h es t a r t e rA. f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e fuel pressurein the fuel line rises.Repeatthis two or three times. then checkfor fuel leakage.

11-112

A/F SensorReplacement

SecondaryHO2SReplacement

Special Tools Required O2 sensorwrench,Snap-onYA8875.SPTools 93750, o r e q u i v a l e n ct ,o m m e r c i a l l a yvailabre

Special Tools Fequired 02 sensorwrench,Snap-onYA8875,SP Tools 93750, o r e q u i v a l e n tc,o m m e r c i a l l a Vv a i l a b l e

1. Disconnectthe A,/Fsensor4P connector(A),then removethe A,/Fsensor{B).

1. Disconnectthe secondaryHO2S4P connector(A), then removethe secondaryH02S (B).

ffi

B 44N.m

InstalltheIVF sensorin the reverseorder of removal.

2 . InstallthesecondaryHO2Sin the reverseorder of removal.

11-113

PGM-FlSystem ECTSensorReplacement '1.

CMPSensorB (TDCSensorl Replacement

R e m o v et h e a i r c l e a n e r{ s e ep a g e1 1 - 1 6 2 ) .

2. Disconnectthe ECTsensor2P connector.

' t . R e m o v et h e a i r c l e a n e r( s e ep a g e1 1 - 1 6 2 ) .

3. Removethe ECTsensor(A).

2. Disconnectthe CN4PsensorB (TDCsensor)3P conneclor. Removethe CMP sensorB (TDCsensor)(A).

{1.2kgt m.8.7 lbt.ft}

l n s t a l l t h es e n s o ri n t h e reverse order of removal with a new o-ring {B).

11-114

---r, ".- ,',',.,*nr...

8.7tbf.ftl

4 . lnstallthe sensorin the reverseorder of removal with a new o-ring {B).

IAT SensorReplacement 1, Dlsconnectthe IAT sensor2P connector.

KnockSensorReplacement 1. Removethe intakemanifold bracket(A).

2. Removethe clip (A) and the IAT sensor(B).

3. lnstallthe sensorin the reverseorder of removal.

24Nm (2.4kgt.m,17lbt.ftl

2. Disconnectthe knocksensor 1Pconnector. 3 . R e m o v et h e k n o c ks e n s o r( B ) . 4 . Installthesensorin the reverseorder of removal.

11-115

PGM-FISystem GKPSensorReplacement 1. Disconnect the CKPsensor3Pconnector. 2. RemovetheCKPsensor{A). 12 N.m (1.2kgt m. 8.7 tbf.ftl

3. lnstallthe sensorin the reverseorder of removal with a new o-ring (B).

11-116

VTEC/VTC ComponentLocationIndex

-gl :1

r-:

@'-;'

--tl

;'l--i

lt i..,,

€)

',..

VTCOILCONTROL VALVE SOLENOID page11-118 Troubleshooting, 11-'l27 Test,page

'--'-

CAMSHAFTPOSITION ICMPISENSORA Troubleshooting,page 11-121 Replacement, Pagel'!-128

VALVE VTCSOLENOID page11-123 Troubleshooting, page11-128 Removal/lnspection,

11-117

VTEC/VTC DTGTroubleshooting DTCP0010:WC Oil ControlSolenoidValve Malfunction

8. MeasureresistancebetweenVTCoil control s o l e n o i dv a l v e2 Pt e r m i n a l sN o . 1 a n d N o . 2 .

1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .

VTC OIL CONTAOLSOLENOID VAI"VE2P CONNECTOB

2. Start the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, t h e nl e t i t i d l e . 3. Test-driveat a steadyspeed between20-40mph (30-60km/h)for 10 minutes. ls DTC P0010indicated?

T e r m i n a s i d 6 o t m a t e t e r m i n as

YES Go to step 4.

ls there 6.75 8.25 Q ?

NO- Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the VTC oil control solenoidvalve and at the ECM.I

YES-Go to step L

4. Turn the ignition switch OFF. 5. Disconnectthe ECMconnectorB {24P). 6. MeasureresistancebetweenECrUconnector t e r m i n a l sB 1 a n d 8 2 3 .

NO-Replace the VTC oil control solenoidvalve (seepage 11-1271.a 9 . C o n n e cV t T Co i l c o n t r o ls o l e n o i d v a l v e 2 P connectorterminalsNo. 1 and No. 2 to body g r o u n dw i t h a j u m p e r w i r ei n d i v i d u a l l y . wc otl coNTBoL sotENoto VALVE 2P CONNECTOR

-4t 1 t 2 l

ECMCONNECTOR B I24P)

lwc*

tBr-K/wHT) | liELU/WHT) JUMPER WTREI IJUMPEnW|RE

W i r e s i d eo f 1 6 m a l et e . m i n a t s

10. Checkfor continuitybetweenECMconnector t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y . Wiresideof femaleterminals

ls there 6.75 8.25 Q ? YES Go to step 11. NO Go to step7. 7. Disconnectthe VTC oil control solenoidvalve2P connector.

ls there continuity? Y E S G o t o s t e p1 1 . NO- Repairopen in the wire betweenthe ECM (B1, B23)and the VTCoil control solenoidvalve.I

11-118

11. Checkfor continuitybetweenECMconnector t e r m i n a l sB 1 a n d B 2 3a n d b o d y g r o u n di n d i v i d u a l l y .

DTCP0011:VTCSystemMalfunction 1. Resetthe EClvl(seepage 11-4). 2 . S t a r tt h e e n g i n e .H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n .

VTC (BtK/WHT)

3. Test-driveat a steadyspeed between20 40 mph (30 60 km/h)for 10 minutes. 4 . Checkfor TemporaryDTCP0011with the scantool

ls Tempotaty DTC P0011indicated? ls there continuity?

YES-Go to step 5.

YES Go to step 12.

NO- Intermittentfailure, system is OK at this time. Checkfor poor connectionsor loosewires at the V T Co i l c o n t r o ls o l e n o i dv a l v ea n d a t t h e E C M . I

NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe original EClvl.!

Watch the low oil pressurelight with the engine r un n i n g . ls the low oil pressute light on?

12. Disconnectthe VTC oil control solenoidvalve 2P connector.

YES- Checkthe oil pressure(seepage 8-4).I

1 3 .Checkfor continuitybetweenECMconnector

N O - G o t o s t e p6 .

t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y . 6 . Turn the ignition switch OFF. 7 . Removethe auto-tensioner(seepage 4-28).

vfc

(8LK/WHT)

W i r e s i d eo f f e m a l er e r m i n as

ls there continuity? Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e E C M( B 1 , B23)and the VTCoil control solenoidvalve.l NO Replacethe VTC oil control solenoidvalve (seepage 11-1211.a

(cont'd)

11-119

VTEC/VTC DTCTroubleshooting(cont'dl Removethe VTC strainer(A).Checkthe WC s t r a i n e fro r c l o g g i n g .

13. ConnectECM connectorterminalsA3 and 81 witha j u m p e rw i r e m o m e n t a r i l y . NOTE:Do not jump for more than 1 minute, ECM CONNECTORS

ls the strainet OK? Wire side of femaleterminals

YES Go to step g. NO-Clean the VTC strainer,then replacethe e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l 9. Checkthe VTCoil control solenoidvalve{seepage 11-127 ). ls the VTC oilcontrol solenoid valve OK? YES Go to step 10. NO Cleanthe ports of the WC oil control solenoid valve,or replacethe VTCoil control solenoidvalve {seepage 11-127).a

1 0 .InstalltheVTCoil control solenoidvalve. 1 1 .Startthe engine.Hold the engine at 700 1,000rpm. 1 2 . C o n n e cE t C Mc o n n e c t otre r m i n a lB 2 3 t o b o d v g r o u n dw i t h a j u m p e rw i r e . ECMCONNECTOR B {24PI

213415 8 e l1a,/1,/ 1 181./l l./ 21

6 7 15

23 vTc JUMPER (BLK/WHT} WIRE

Wire side of temaleterminals

11-120

Did the engine stall or run rough? YES Test-driveat a steadyspeedbetween 20 40 mph (30 60 km/h)for 10 minutes. lf temporaryDTCP00'l1 is indicated,updatethe ECIVIif it does not have the latestsoftware,or substitutea known-goodECM,then recheck(see page 11-6).lf the symptom/indicationgoes away with a known-goodECM,replacethe original E C M !. NO Go to step 14. 1 4 . Checkthe VTC actuator(seepage6,8). ls the VTC actuatot OK? YES Removethe auto-tensioner(see page 4-281, and clean or replacethe VTC oil strainer.Update the ECI\4if it does not have the latestsoftware,or substitutea known-goodECM,then recheck(see page 11-6).lf the symptom/indicationgoes away with a known-goodECM,replacethe original ECM. T NO Replacethe VTC actuator.t

DTCP0340: CMPSensorA No Signal DTGP0344:CMPSensorA Intermittent Interruption

7. MeasurevoltagebetweenCMPsensorA 3P terminalNo. 1 andbodyground. connector CMP SENSORA 3P CONNECTOR

'11-4). 1 . R e s e t h e E C M( s e ep a g e 2. Startthe engine. ls DTC P0340and/or P0344indicated? YES-Go to step 3.

W i r e s i d eo l f e m a l e t e r m i n as

NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e C M Ps e n s o rA a n d a t t h e E C M . I

ls thercabout5 V? YES-Go to step8.

3. Turn the ignition switch OFF.

NO-Go to step10. 4. Disconnectthe CMPsensorA 3P connector. 5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 6. Measurevoltage betweenCMPsensorA 3P connectorterminal No. 3 and body ground. CMPSENSORA 3P CONNECTOR tG1

1 2 3

voltagebetweenCMPsensorA 3P 8. Measure s o .2 a n dN o .3 . c o n n e c t ot er r m i n a lN CMP SENSORA 3P CONNECTOF

;f-;-1 J ,o,,r.*,"r., I l1 l-t ,-or---T--I {8RN/YEL) ni-

(BLK/YEL}

ls there battety voltage? YES Go to step 9. Wiresideof femaleterminals

NO-Repair open in the wire betweenthe Cl\4P s e n s oA r a n dG 1 0 1 . 1

ls there battety voltage? YES Go to step7. N O C h e c kt h e N o . 4 A C G { 1 0 A )f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in the wire betweenthe CN4PsensorA and No. 4 ACG ( 1 0 A )f u s e . I

9. Substitutea known-goodCMPsensorA and recheck. ls DTC P0340and/ot P0344indicated? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I t h e o r i g i n aC l M Ps e n s o rA { s e ep a g e NO Replace 11-128).t (cont'd)

11-121

VTEC/VTC DTCTroubleshooting(cont'd) 1 0 .Measurevoltage betweenECMconnectorterminal A25 and body ground. ECMCONNECTORA 131P)

DTCP0341:WC PhaseGap 1 . R e s e t t h eE C M{ s e ep a g e1 1 - 4 ) . 2. Startthe engine. ls DTC P0341indicated? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e C M Ps e n s o rA a n d a t t h e E C M . I

Wiresideof femalete.minals

3. Checkthe VTC oil control solenoidvalve (seepage 11_127]-.

ls there about 5 V? YES-Repair open in the wire betweenthe ECM ( A 2 5 )a n d C M Ps e n s o rA . I N O - G o t o s t e p1 1 .

Isthe VTC oil control solenoid valve OK? YES-Go to step 4. NO-CIean the VTCoil control solenoidvalve,or r e p l a c ei t ( s e ep a g e1 1 - ' l 2 7 l . a

1 1 .Turn the ignition switch OFF. 't2.

DisconnectECMconnectorA (31P) Checkfor continuitybetweenECMconnecror terminal A25 and body ground. ECMCONNECTONA 131P}

4. Removethe head cover,and checkthe cam chain {seepage 6-12). ls the cam chain OK? YES Go to slep 5. NO Replace t h e c a m c h a i n( s e ep a g e6 - 1 2 ) . 1 5. Checkthe VTC actuator(seepage 6-8). ls the VTC actuator OK?

Wiresideof femaleterminals

ls tnere continuity? YES-Repair short in the wire betweenthe ECM (A25)and the CMP sensorA. t NO Updatethe ECt\4if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-122

YES- U pdatethe ECM if it does not have the tatest soflware,or substitutea known-goodECI\4, then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO- Replacethe VTC actuator.l

DTCPl259:WEC SystemMalfunction SpecialToolsRequired . Pressuregaugeadapter07NAJ P07010A . A/T low pressuregaugew/panel 07406-0070300 . A/T pressurehose 07406-0020201 . Av/Tpressurehose,2,210mm 07IMAJ-PY4o11A . l"/T pressureadapter07MAJ-PY40120 . Oil pressurehose 07ZAJ-S54,4200

6. Disconnectthe VTECoil pressureswitch2P connector. 7. Checkfor continuitybetweenVTECoil pressure switch 2P connectorterminals No. 1 and No. 2 SWITCH VTECOILPRESSURE 2PCONNECTOR

1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2 . C h e c kt h e e n g i n eo i l l e v e l ,a n d r e f i l li f n e c e s s a r y . 3. Startthe engine.Hold the engineat 3,000rpm with no load {in neutral)until the radiatorfan comes on. 4. Roadtestthe vehicle: Acceleratein the 1stgear to an engine speedover 4.000rpm. Holdthe speedfor at least2 seconds.lf DTCP1259is not repeatedduring the first road test, repeatthe test two more times. ls DTC P1259 indicated? YES Go to step 5. NO-lntermittent failure,system is OK at this time Checkthe oil consumptionif oil was added in step 2. Checkfor poor connectionsor looseterminalsat the VTECsolenoidvalve,the VTECoil pressure I switch,and at the ECI\4. 5, Turn the ignitjon switch OFF.

T e r m i n asl i d eo f m a l et e r m i n a l s

Is therecontinuity? YES-Go to step8. switch.l theVTECoil pressure NO Replace s w i t c hO N( l l ) . 8 . T u r nt h ei g n i t i o n switch voltagebetweenVTECoil pressure 9. Measure terminalNo.1 andbodyground 2Pconnector SWITCH VTECOILPRESSURE 2PCONNECTOR VTPSW /T\ {BLU/BLK}

{.--rr-l'--.l

\rJ

oI W i r es i d eo f f e m a l et e r m i n a l s

ls there battety voltage? Y E S G o t o s t e P1 4 . NO-Go to step 10.

(cont'd)

11-123

VTEC/VTC DTCTroubleshooting(cont'd) 10. Measurevoltage betweenECMconnectorterminal 89 and body ground.

14. fMeasure voltagebetweenVTECoil pressure switch 2 Pc o n n e c t ot er r m i n a lN s o .1 a n dN o .2 ,

ECMCONNECTOR B (24P)

VTECOILPRESSURE SWITCH 2P CONNECTOR 213415 o 1 8 I a t / t / n 3 15

VTPSW (BLU/BLK) (BRN/YELI

WPSW {BLU/BLK}

WiresideofIemale terminals

Wire side of Iemaleterminals

ls there battery voltage? ls there battery voltage? YES Repairopen in the wire betweenthe VTECoil pressureswitch and the ECM(89).t N O - G o t o s t e p1 1 .

Y E S - G o t o s t e p1 5 . NO Repairopen in the wire betweenthe VTECoil p r e s s u r es w i t c ha n d G 1 0 1 . 1

1 1 .Turn the ignition switch OFF. Turn the ignition switch OFF. DisconnectECMconnectorB {24P). t o . Disconnectthe VTECsolenoidvalve 2P connector.

Checkfor continuitybetweenECMconnector t e r m i n a lB g a n d b o d y g r o u n d . ECMCONNECTOR B {24P)

2 3 415 I 9 ol./ ./ 13

6 7 15

1 7 . Checkfor resistancebetweenVTECsolenoidvalve 2 Pc o n n e c t otre r m i n a l sN o , 1 a n d N o . 2 . VTECSOLENOIDVALVE 2PCONNECTOR

VTPSW{BLU/BLK}

Wrre side of femaleterminals

T e r m i n as li d eo f m a l et e r m i n a l s ls there continuity? YES Repairshort in the wire betweenthe VTECoil pressureswitch and the ECM (89).I

ls there 14- 30 Sl ? YES Go to step 18.

NO Updatethe ECM if it does not have the latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l C N 4! .

11-124

NO Replacethe VTECsolenoidvalve (seepage 11-128).t

1 8 . Removethe VTECoil pressureswitch (A) and i n s t a l l t h es p e c i a l t o o l a s s s h o w n ,t h e n r e i n s t a ltlh e VTECoil pressureswitch.

07406-0070300

07406-0020201 ot 07MAJ-PY,lo11A and 07MAJ-PY40120

\lsl

24. Disconnectthe VTECsolenoidvalve 2P connector. 25. Aftachthe batterypositiveterminalto VTEC s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 .

26. Startthe engine,then connectthe batterynegative

t:={

23. Turn the ignitionswitch OFF.

A 22 N.m l2.2kgt.m, 16rbf.ft) 07NAJ-P07010A

t e r m i n a l t oV T E Cs o l e n o i dv a l v e2 P c o n n e c t o r t e r m i n a lN o . 1 , a n d c h e c kt h e o i l p r e s s u r ea t a n engine speedof 3,000rpm. ls the oil pressure above 390 kPa (4.0 kgt/crtf , 57 psi)? YES Go to step 27. NO InspecttheVTECsolenoidvalve (seepage I112Al.a

1 9 .Reconnectthe VTECsolenoidvalve 2P connector and VTECoil pressureswitch 2P connector.

20. Connecta tachometeror OBD ll scantool/Honda PGM Testerto the DLC.

2 1 . Startthe engine.Holdthe engine at 3,000rpm with

27. With the batteryterminalsstill connectedtothe VTECsolenoidvalve connector,measurevoltage betweenECMconnectorterminal 89 and bodv oround. B {24P) ECMCONNECTOR

no load (in neutral)until the radiatorfan comes on.

22. Checktheoil pressureat enginespeedsof 1,000 and 2.000rpm. Keepthe measuringtime as shon a s p o s s i b l e{ l e s st h a n 1 m i n u t e )b e c a u s et h e e n g i n e i s r u n n i n gw i t h n o l o a d . ls the oil ptessure below 49 kPa (0.5 kgf/cnf, 7 psi)? YES Go to step 23. NO Inspectthe VTECsolenoidvalve (seepage 11't28l.a

Wire side of femaleterminals

ls there battery voltageabove 4,000 tpm? YES Go to step 28. NO-Replace the VTECoil pressureswitch (see p a g e1 1 ' 1 2 8 ) . 1

28. Turn the ignitionswitch OFF. 29. Disconnectthe batteryterminalsfrom the VTEC solenoidvalve terminal connector.

(cont'd)

11-125

WEC/VTC DTCTroubleshooting(cont'd) 30. DisconnectECMconnector B (24P) Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d . ECM CONNECTORB {24P)

32. ConnectVTECsolenoidvalve 2P connector terminal No. 2 to body ground with a jumper wire. VTEC SOLENOIDVALVL 2P CONNECTOR

r-.'-r.---.1

t 1 t 2 l

JUMPERI VtS WIRE I IGRN/YEL)

Wiresideof femaleterminals

Wire side of femaleterminals

Checkfor continuitybetweenECMconnector t e r m i n a l8 1 5 a n d b o d y g r o u n d .

ls therecontinuity? ECM CONNECTORB {24PI

YES-Repairshortin thewire betweentheVTEC s o l e n o ivda l v ea n dt h eE C M( 8 1 5 ) . 1 NO Goto step32.

Wiresideof femaleterminals ls thete continuity? YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO Repairopen in the wire betweenthe VTEC s o l e n o i dv a l v ea n dt h e E C M( 8 1 5 ) . I

11-126

WC OilControlSolenoidValveRemoval/Test 1 . R e m o v et h e W C o i l c o n t r o ls o l e n o i dv a l v e( A ) . NOTE:lnstallthe valve in the reverseorder of removalwith a new o-ring (B),then checkthese tlems:

Connectthe batterypositiveterminal to VTC oil control solenoidvalve 2P connectorterminal No. 2. VTCOILCONTROLSOLENOID VALVE2PCONNECTOR

Cleanand dry the VTCoil control solenoidvalve mating surface. Coatthe O-ringwith engineoil. Do not installthe VTC oilcontrol solenoidvalve while wearingfibrous gloves, Be carefulnot to contaminatethe cylinder head openrng.

Terminalside oJ m a l et e r m i n a l s

BATTERY Connectthe batterynegativeterminalto VTC oil c o n t r o ls o l e n o i dv a l v e2 Pc o n n e c t otre r m i n a lN o . 1 , t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y .

Checkthe VTC oil control solenoidvalve filter for clogging.lf it is clogged,replacethe VTC oil control solenoidvalve. Checkthe clearancebetweenthe port (advance side)and the valve.The clearance(A) should be at l e a s t2 . 8m m ( 1 / 8i n . ) .

11-127

VTEC/WC CMPSensorA Replacement

WEC SolenoidValveRemoval/ Inspection

1 . R e m o v et h e a i r c l e a n e r( s e ep a g e11 - 1 6 2 ) . Disconnectthe CMP sensorA 3P connector.

1 . Disconnectthe VTECsolenoidvalve 2P connector.

Removethe CMPsensorA (A).

MeasureresistancebetweenVTECsolenoidvalve c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 . Resistance:14-30 Q

B-'-----'-l:,",14* Installthe sensorin the reverseorder of removal with a new o-ring (B). 3. lf the resistanceis within specifications,removethe VTECsolenoidvalve assemblv(A)from the cylinder head,and checkthe VTECsolenoidvalve f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r, e p l a c et h e solenoidvalve filter,the engine oilfilter, and the e n g i n eo i l .

6x1.0mm 9.8 N.m (1.0kgf.m, 7,2 lbf.ftl

11-128

ldleGontrolSystem ComponentLocationIndex

TE'

IDLEAIRCONTROL{IAC)VALVE page11-'131 Troubleshooting,

11-129

ldle ControlSystem (

DTCTroubleshooting DTCP0505:ldle ControlSystemMalfunction

7 . P u ty o u r f i n g e r so n t h e l o w e rp o n ( A )i n t h e t h r o t t l e oooy.

NOTE:lf DTCP1519is storedatthe same time as DTC P0505,troubleshootDTCP1519first, then recheckfor DTCP0505. 1. Startthe engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle, 2. Checktheengine speedat idle with no,load conditions:headlights,blower fan, rear defogger, radiatorfan, and air conditioneroff. Is the engine running at 750t50 rpm? YES- Intermittentfailure,system is OK at this trme.I

Does the enginestall?

NO lf the idle speed is lessthan 700 rpm, go to step 3; if it's 800 rpm or higher,go to step 4.

Y E S C h e c k t h ei d l es p e e d( s e ep a g e1 1 - 1 3 8 )l f. i t ' s out of specification,replacethe IACvalve.l

3 . D i s c o n n e ct h t e i d l e a i r c o n t r o l{ l A C )v a l v e 3 P connector. Does the engine speed increase or fluctuate? YES- Checkthe idle speed{seepage 1 1-138).lf the idle will not adjust properly,cleanthe passagein the throttle body, and then adjustthe idle.I NO- Replace t h e I A Cv a l v e . I 4. Turn the ignition switch OFF. 5. Removethe intakeair duct from the throttle body. 6. Startthe engine,and let it idle.

11-130

NO With the throttlevalve completelyclosed, c h e c kf o r v a c u u ml e a k sa, n d r e p a i ra s n e c e s s a r y . l

DTCPl519:IACValveCircuitMalfunction 1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .

8, Checkfor continuitybetweenbody ground and IAC v a l v e3 Pc o n n e c t otre r m i n a lN o . 1 . IACVALVE3PCONNECTOR

2. Turn the ignition switch ON (ll) ls DTC P 1519indicated?

YES Go to step 3.

PG1{BLK}

NO-lntermittent failure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the IACvalve and at the ECM.I 3. Turn the ignition switch OFF.

a. Wire side of lemaleterminals

4. Disconnectthe IACvalve 3P connector. Is there continuity? 5. Turn the ignitionswitch ON (ll). Y E S - G o t o s t e p9 . 6. Measurevoltage betlveenIACvalve 3P connector terminal No. 2 and body ground. IACVALVE3PCONNECTOR

NO Repairopen in the wire betweenthe IACvalve a n dG ' 1 0 1 . 1 9 . DisconnectECMconnectorA (31P)

IGP{YEL/BLK)

1 0 . Checkfor continuitybetweenbody ground and l 12. E C Mc o n n e c t otre r m i n a A ECM CONNECTORA 131P)

r l 2 l 3 l 45 6 1 7

r0 1l 12./ / 115 6 ./118192C21 da Wire side of femaleterminals

ls therebattery voltage?

25126 l27ln2930

IACV{BLK/RED}

1,)

YES Goto step7. NO-Repairopenin thewire betweenthe IACvalve a n dt h eP G M - Fml a i nr e l a y1 . 1

terminals WiresideoJJemale ls there continuity?

7 . Turnthe ignitionswitchOFF. YES-Repair short in the wire betweenthe IAC v a l v ea n dt h e E C M( A 1 2 ) . 1 N O G o t o s t e p 11 .

LCOnIOl

11-131

ldle ControlSystem (

DTCTroubleshooting(cont'd) 11. ConnectIACvalve3Pconnector terminalNo.3to bodygroundwith a jumperwire. IACVALVE3PCONN€CTOR

IACVIBLK/REO} JUMPERWIRE

15. Measurevoltagebetweenbody ground and ECM c o n n e c t otre r m i n a A l 12. ECMCONNECTOR A 131P}

r l 2 l 3 1 54 6 1 7 9 t 0 1tl12l,/l/ t c 6 ,/ 118 2C21 2 2 231?4l| zil28 30 12. IACVIBLK/RED)

Wire side of femaleterminals Wire side ol femaleterminals

Checkfor continuitybetweenECMconnector t e r m i n a l A l 2 a n d b o d yg r o u n d . ECMCONNECTOR A 131P)

I s there battery voltage? YES-Update the ECI\4if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CI\4.1 N O - R e p l a c et h e I A Cv a l v e . I

Wire side of femaleterminals

ls therecontinuity? YES Goto step13. NO-Repairopenin thewire betweenthe IACvalve a n dr h eE c M( A 1 2 ) . r 1 3 .Reconnect the IACvalve3Pconnector. 1 4 .Turnthe ignitionswitchON (ll).

11-132

A/G SignalCircuitTroubleshooting 1 . Turn the ignitionswitch ON (ll). 2 . MomentarilyconnectECMconnectorterminals424 and E18with a jumper wire severaltimes.

6. Momentarilyconnectunder-hoodtuse/relaybox 14Pconnectorterminal No. 10 to body ground with a jumper wire severaltimes. UNDER.HOOD FUSE/RELAY BOX I4P CONNECTOR

1 2 3 1 8 9 10 11

5 6 I J

ACC (RED) JUMPERWIRE

Wiresideof femaleterminals Wire side of femaleterminals

ls there a clicking noise I rom the NC compressor clutch?

ls there a clicking noise f rom the NC compressor clutch?

YES Go to step 3.

YES- Repairopen in the wire betweenthe ECM (E'18)and the Ay'Cclutch relay.l

NO-Go to step 6.

NO- Checkthe A/C systemfor other symptoms.l

Start the engine. Turn the blower switch ON.

5. Turn the Ay'Cswitch ON. Does the NC operate? Y E S - T h e a i r c o n d i t i o n i n sg i g n a li s O K . I NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n a€ l CM.l

11-133

ldle GontrolSystem AlternatorFRSignalCircuitTroubleshooting ' t . Disconnectthe alternator4P

connectorfrom the

alternalor.

2. T u r nt h e i g n i t i o ns w i t c hO N { l l ) .

'11. Connectalternator4P connector term inal No.4 to body ground with a jumper wire. ALTERNATOR4P CONNECTOR

3 . Measurevoltage betweenECMconnector t e r m i n a l s4 2 4 a n d 8 1 3 . ECM CONNECTORS

A l31Pl

ALTFIWHT/RED)

1 2 1 3 4 5 6 1 1| 1 . , 'I 10 1 1 1 1 2 , / 5 6 , / r8119l2C21 23124 28129130 L

JUMPERWIRE

(BRN/Y EL) ALTF (WHT/REDI

213 4t5 8

9ltal,/l/

6 1 15

Wiresideof femaleterminals

1 2 .Checkfor continuitybetweenbody ground and EClvlconnectorterminal 813.

Wire side of femaleterminals

ECMCONNECTOB B (24PI

ls there about 5 V? YES Go to step 4.

N O - G o t o s t e p1 3 . 4. Turn the ignition switch OFF. 5. Reconnectthe alternator4P connector. 6. Slan the engine.Hold the engineat 3,000rpm with no load (in neutral)until the radiatorfan comes on, then let it idle. 7. lvleasurevoltagebetweenECMconnector t e r m i n a l sA 2 4 a n d B 1 3 . Does the voltage decrease when the headlights and rear window defogger arc tutned on?

Wire side of femaleterminals

ls there continuity? YES-Testthe alternator(seepage 4-22).1 NO Repairopen in the wire betweenthe ECM ( B1 3 )a n dt h e a l t e r n a t o r . l

1 3 .Turn the ignitionswitch OFF. Y E S T h e a l t e r n a t oFr Rs i g n a li s O K . l N O - G o t o s t e p8 . 8. Turn the ignition switch OFF. 9. DisconnectECMconnectorB (24P). 10. Disconnectthe alternator4P connector.

11-134

't4. DisconnectECMconnectorB (24P).

ElectricalPowerSteering(EPSI SignalCircuitTroubleshooting 15. Checkfor continuitybetweenbody ground and ECIMconnectorterminal 813. ECM CONNECTORB I24P}

1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 2 . l\4easure voltage betweenECMconnector t e r m i n a l s4 2 4 a n d E 1 6 .

Wire side of femaleterminals

ls there continuity? Wire side of femaleterminals

YES Repairshort in the wire betweenthe ECM ( 8 1 3 )a n dt h e a l t e r n a t o r . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then rechecklsee page 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

ls there battery voltage? YES Go to step 6. NO Go to step 3.

3 . Startthe engine. 4 . Turn the steeringwheel lo the full lock position. 5 . l\4easurevoltage betweenECMconnector t e r m i n a l sA 2 4 a n d E 1 6 . ls there momentatybattery voltage? Y E S T h e E P Ss i g n a li s O K . t N O G o t o s t e p1 0 . 6 . T u r nt h e i g n i t i o ns w i t c hO F F . 7. Disconnectthe EPScontrol unit 20Pconnector. 8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

(cont'd)

11-135

ldle ControlSystem ElectricalPowerSteering(EPSISignalCircuitTroubleshooting(cont'd) 9. Measure voltagebetweenEPScontrolunitterminal N o . l 7a n db o d yg r o u n d .

'13.

l\4easure voltagebetweenEPScontrol unitterminal N o . 1 7a n d t h e b o d y g r o u n d . EPSCONTROLUNIT2OPCONNECTOR

EPSCONTROLUNIT2OPCONNECTOR

Wire side of femaleterminals

ls there battery voltage? ls there battety voltage? YES-Substitute a known-goodEPScontrol unit a n dr e c h e c k . I NO- Repairopen in the wire betweenthe ECM ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l

YES Substitutea known-goodEPScontrol unit andrecheck.l N O - G o t o s t e p1 4 , 1 4 . Turn the ignition switch OFF. t 5 _ D i s c o n n e c t t hE e C Mc o n n e c t oE r {31P).

1 0 .Turn the ignitionswitch OFF. I ' I. Disconnectthe EPScontrol unit 20Pconnector.

1 6 .Checkfor continuitybetweenbody ground and E C I \ c4o n n e c t otre r m i n a E l 16. ECMCONNECTOR E {31PI

12. Turn the ignitionswitch ON (ll). 1 2 3 4 5 6 1 7 l1 89 5 6 . / 1 8 2A21 22 23 zi ./ 2930 o l EPSLD {LTGRN/BLK)

Wiresideot Iemaleterminals lsthere continuity? YES Repairshort in the wire betweenthe ECN4 ( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-136

BrakePedalPositionSwitch SignalCircuitTroubleshooting 1. Checkthe brakelights. Are the brake lights on without pressing the brake pedal? YES Inspectthebrakepedal positionswitch ( s e ep a g e1 9 - 6 ) . I NO Go to step 2. 2. Pressthe brakepedal. Do the brake lights come on?

4 . I n s p e ctth e N o . 7 H O R N S , T O P( 1 5 A )f u s el n t h e under-hoodfuse/relaybox. ls the tuse OK? YES- Repairopen in the wire betweenthe brake pedal positionswitch and the No.7 HORN,STOP ( l5A) fuse, Inspectthe brakepedal positionswitch ( s e ep a g e1 9 - 1 0 ) . 1 NO Repairshort in the wire betweenthe ECM ( E 2 2 )a n dt h e N o . 7 H O R N ,S T O P( 1 5 A ) f u s e . Replace the No.7 HORNS , T O P( 1 5 A ) f u s e . t

YES-Go to step 3. NO Go to step 4. 3. MeasurevoltagebetweenECMconnector terminalsA24 and E22with the brakepedal presseo.

Wire side of lemaleterminals

ls there battery voltage? YES-The brakepedal positionswitch signal is

oK,I NO Repairopen in the wire betweenthe Eclvl (E22)and the brakepedal positionswitch.l

11-137

ldle ControlSystem ldle Speedlnspection NOTE: ' Leavethe idle air control (lAC)valve connecled. . Beforecheckingthe idle speed,checkthese items: - T h em a l f u n c t i o n i n d i c a t o lra m p ( M l L )h a s n o t b e e n reportedon. - l g n i t i o nt i m i n g - S p a r kp l u g s - Aircleaner - PCVsystem . P u l l t h ep a r k i n gb r a k el e v e ru p . S t a r tt h e e n g i n e a , nd make sure the headlightsare off. 1. Disconnectthe evaporativeemission(EVAP) canisterpurge valve 2P connector.

3 . Startthe engine.Holdthe engineat 3,000rpm with n o l o a d ( i n n e u t r a l u) n t i lt h e r a d i a t ofra n c o m e so n , t h e nl e t i t i d l e . 4 . Checkthe idle speedwith no-loadconditions; headlights,blower fan, radiatorfan, and air conditioneroff. ldle speedshould be: 750 t 50 rpm 5 . Let the engine idle for 1 minute with the heaterfan switch on Hl and air conditioneron, then checkthe i d l es p e e d . ldle speedshould be: 750 t 50 rpm

2. Connecta tachometer(A)to the test tachometer connector(B),or connectthe HondaPGM Tester(C) or an OBD ll scantool to the data link connector (DLC)(D) locatedunder the driver'sside of the dashboard.

11-138

NOTE:lf the idle speed is not wilhin specification, go to the Symptom TroubleshootingIndex, 6 . Reconnectthe EVAPcanisterpurgevalve 2P connector.

ECMldle LearnProcedure The idle learn proceduremust be done so the ECMcan learnthe engine idle characteristics. Do the idle learn procedurewheneveryou do any of these actions: . Disconnectthe battery. Replacethe ECMor disconnectits connector. Resetthe ECM. NOTE:ErasingDTCSwith the HondaPGM Tester does not requireyou to do the idle learn procedure. Removethe No.6 ECU{ECM)( 15A)fuse from the under-hoodfuse/relaybox. Removethe No.19baftery(80A)fuse from the underhood fuse/relaybox. R e m o v eP G M - Fm I a i n r e l a y1 . Removeany of the wires from the under-hoodfuse/ retayDox. Disconnectany of the connectorsfrom the under hood fuse/relaybox. Disconnectthe connectorbetweenthe engine compartmentwire harnessand ECMwire harness. Disconnectthe G2 terminal from the transmission h ous r n g . DisconnecttheG'l terminal from the body. D i s c o n n e c t t hG e 1 0 1t e r m i n a fl r o m t h e c y l i n d e rh e a d cover.

Procedure: To completethe idle learn procedure,do this: 1. Make sure all electricalitems (Ay'C, audio, rear defogger,l:ghts,etc.,)are off. 2. Startthe engine,and hold it at 3,000rpm with no l o a d{ i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n , o r u n t i lt h e e n g i n ec o o l a n t t e m p e r a t u r e a c h e s1 9 4 " F

(90'c).

3. Let the engine idle for about 5 minuteswith the throttlefully closed. NOTE:lf the radiatorfan comes on, do not includeits r u n n i n gt i m e i n t h e 5 m i n u t e s .

11-139

FuelSupplySystem ComponentLocationIndex

{

PUMP

T e s t ,p a g e1 1 - 1 4 1 page 11'153 Fleplacement, FUELFILTER page 11-152 Replacement, FUELGAUGESENDINGUNIT T e s t ,p a g e1 1 - 1 5 6 page 11-153 Replacement, FUELPRESSUN REGULATOR page'11-'152 Replacement,

FUELFILLCAP

FUELTANK R e p l a c e m epnat ,g e '1l - 1 5 5 FUELTUBE/OUICK.CONNECT FITTINGS page 11-148 Precautions, p a g e Removal, 11-'149 Installation,page 11-'l50

FUELFEEDLINE

FUELVAPORLINE

FUELPULSATIONDAMPER page11'154 Replacement,

PGM.FIMAIN RELAY1

PGM.FIMAINRELAY2 T r o u b l e s h o o t ipnagg, e ' l ' l - 1 4 1

11-140

FuelPumpCircuitTroubleshooting lf you suspecta problemwith the fuel pump, checkthat the fuel pump actuallyruns;when it is on, you will hear some noise if you listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignition switch is first turned on. lf the fuel pump does not make noise,checkas follows:

5. N4easure voltage betweenPGM-Flmain relay 2 5P connectorterminal No. 1 and body ground. PGM.FI MAIN RELAY2 5P CONNECTOR

1. Turn the ignition switch OFF. 2. Removethe glove box {seepage 20-63),then removethe PGM-FImain relay 2 (A).

Wire side oJfemaleterminals

ls there battery voltage? YES Go to step 6. NO Repairopen in the wire betweenthe underd a s hf u s e / r e l a yb o x a n d P G M - Fm l a i n r e l a y2 . 1 6. Turn the ignition switch OFF.

3 . Turn the ignitionswitch ON {ll). Measurevoltage betweenPGM-Flmain relay 2 5P connectorlerminal No. 5 and body ground. PGM.FIMAIN RELAY2 5P CONNECTOR

7. DisconnectECMconnectorE (31P). 8. Checkfor continuitybetweenPGM-FImainrelay2 5P connectorterminal No. 3 and ECMconnector t e r m i n a lE 1 . PGM-FIMAIN RELAY2 5PCONNECTOB

E t 2 l

Ftxm

IGPl (YEL/BLK}

7 -

z IMOFPR (GBN/ YEL)

ECMCONNECTOR E 131P}

Wiresideof femaleterminals Wire side of femaleterminals

ls there battery voltage?

ls therecontinuity? YES-Go to step 5.

YES-Go to step9. NO Repairopen in the wire betweenthe PGM'Fl m a i n r e l a y1 a n dt h e P G M - Fm l a i n r e l a y2 . t

NO-Repairopenin thewire betweenthe PGMFl m a i nr e l a y2 a n dt h eE C M( E 1 ) . 1

(cont'd)

11-141

FuelSupplySystem FuelPumpCircuitTroubleshooting(cont'dl

(

l a i n r e l a y2 . L R e i n s t a l l t hP e G M - Fm

ls there battery voltage?

1 0 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

YES U pdatethe ECM if it does not havethe latest so{1ware,or substitutea known-goodECM.then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

connector 1 ' ] .Measurevoltage betweenECI\4/PCM t e r m i n a lE 1a n d b o d y g r o u n d . ECMCONNECTOB E {31P)

NO Go to step 15. t 5 . Turn the ignition switch OFF. t o . Removethe rear seat cushion (seepage 20-80).

1 1 . Removethe accesspanelfrom the floor.

Wiresideof femaleterminals

ls there battety voltage?

1 8 . Measurevoltage betweenfuel pump 5P connector terminal No. 5 and body ground within the first 2 secondsafter the ignition switchwas turned ON (ll). FUELPUMP5P CONNECTOR

YES Go to step 12. l a i n r e l a y2 . 1 N O - R e p l a c et h e P G M - Fm

( Turn the ignition switch OFF.

1 3 .ReconneclECMconnectorE (31P). 1 4 .Turn the ignitionswitch ON (ll),and measure voltagebetweenECMconnectorterminal E1 and body ground within the first 2 secondsafterthe i g n i t i o ns w i t c hw a s t u r n e dO N ( l l ) .

wire sideoI femaleterminals

ls there battery voltage? E (31PI ECMCONNECTOR

YES Go to step 24. N O - G o t o s t e p1 9 . 1 9 . Turn the ignition switch OFF. 20. R e m o v et h e P G M - Fm l a i n r e l a y2 .

Wiresideof femaleterminals

11-142

21. ConnectPGM-Flmain relay 2 5P connector terminalsNo. 1 and No. 2 with a iumDerwire. PGM.FIMAIN RELAY2 5P CONNECTOR

FUEL PUMP (YEL/ GRN) JUMPER WIRE

FNI

tri

rcr fv {YEL/BLK) A

25. Checkfor continuitybetweenfuel pump 5P connectorterminal No. 4 and body ground. FUELPUMP5P CONNECTOR

dffi

Wiresideof {emaleterminals

Wire side of femaleterminals

22. Turn the ignitionswitch ON (ll).

ls therecontinuity?

23. Measurevoltagebetweenfuel pump 5P connector

Y E S R e p l a cteh ef u e lp u m p . l

terminal No. 5 and body ground. FUELPUMP5PCONNECTOR

NO-Repairopenin thewire betweenthefuel p u m p5 Pc o n n e c t oarn dG 5 5 1 . 1

Wiresideol femaleterminals

ls there battery voltage? Y E S R e p l a c e t h eP G M - Fm l a i nr e l a y 2 . t NO-Repair open in the wire betweenthe PGM-Fl main relay 2 and the fuel pump 5P connector.l

24. Turn the ignitionswitch OFF.

11-143

FuelSupplySystem FuelPressureRelieving Beforedisconnectingfuel lines or hoses,relieve pressurefrom the system by disconnectingthe fuel tube/quickconnectfitting in the enginecompartment.

9. Placea rag or shop towel over the quick-connect fitting (A).

1 . T u r nt h e i g n i t i o ns w i t c hO F F , 2 . R e m o v et h e P G M - Fm l a i n r e l a y2 ( A ) .

1 0 .Disconnectthe quick-connectfifting (A):Hold the connector(B)with one hand and squeezethe retainertabs (C)with the other handto release them from the lockingpawls {D).Pullthe connector off.

3 . S t a r t t h ee n g i n e a, n d l e t i t i d l e u n t i li t i s s t a l l s . NOTE:The DTCSor TemporaryDTCSP0301.P0302, P0303,P0304may come on during this procedure. lf any DTCSare stored,ignorethem. 4 . Turn the ignitionswitch OFF.

Removethe fuel fill cap, and relievefuel pressure inthefueltank. 6 . Removethe enginecover.

NOTE: . P r e v e ntth e r e m a i n i n gf u e l i n t h e f u e lf e e d l i n e o r hosefrom flowing out with a rag or shop towel. . Be carefulnotto damagethe line (E)or other parts. . Do not use tools. . l f t h e c o n n e c t o r d o e ns o t m o v e ,k e e p t h er e t a i n e r tabs presseddown, and alternatelypull and push the connectoruntil it comes off easily. . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one.

7 . Disconnectthe negativecablefrom the battery. 8 . Checkthe fuel quick-connectfitting for dirt, and cleanit if necessary.

1 1 After disconnectingthe quick-connectfifting, check i t f o r d i r t o r d a m a g e( s e ep a g e11 - 1 4 9 ) .

11-144

FuelPressureTest Special Tools Required . Fuel pressuregauge 07406-0040004 . Fuel pressuregaugesel 07ZAJ-S5A0100 1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 ' 1 - 1 4 4 ) . 2. Disconnectthe quick-connectfitting (A).Aftachthe fuel pressuregaugeset and fuel pressuregauge.

Startthe engineand let it idle. . lf the enginestarts,goto step 5. . lf the enginedoes not start,goto step 4. Checkto see if the fuel pump is running:listento the fuel fill port with the fuel fill cap removed.The fuel pump should run for 2 secondswhen the ignitionswitch is first turned on. . lf the pump runs,go to step 5. . l f t h e p u m p d o e sn o t r u n ,d o t h e f u e l p u m pc i r c u i t t r o u b l e s h o o t i n(gs e ep a g e11 - 14 1) . 5 . Readthe pressuregauge.The pressureshould be 320-370 kpa (3.3-3.8 kgf/cm',a7-52 psi) . lf the pressureis OK, the test is complete. . lf the pressureis out of specification,replacethe fuel pressureregulatorand the fuel filter (see p a g e1 1 - 1 5 2 t) h, e n r e c h e c kt h e f u e l p r e s s u r e .

11-145

FuelSupply System FuelLineInspection Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration.Replaceany damagedparts.

Make surethe connectionis secureand the quick-connect fitting cover is firmly lockedinto place.

11-146

Checkall clampsandretightenif necessary. A: Do notdisconnect the hosefromthe lineat theseioints.

Settheboltflange T h e r es h o u l d b e n o

W.W C l a m pi n t h e m i d d l e .

Setthispart

C l a m pi n t h e m i d d l e .

t h e f u e l { i l lt u b e , a l i g nt h e m a r k s on the tubeand t h el i n e .

11-147

FuelSupply System FuelLine/Ouick-Connect FittingsPrecaution The fuel tube/quick-connect fittings connectthe fuel rail (A)to fuel feed hose (B),the fuel feed hose (B)to the f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p a s s e m b l y( E ) .W h e n r e m o v i n go r i n s t a l l i n g t h ef u e l f e e d hose,fuel pump assembly,or fuel tank, it is necessary to disconnector connectthe quick-connectfittings. Pay attentionto the following: . T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k be careful connectfittings (F)are not heat-resistanU not to damagethem during welding or other heatgeneralrngproceoures. . T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k connectfittings (F)are not acid-proof;do not touch them with a shop towel which was used for wiping batteryelectrolyte.Replacethem if they came into contactwith electrolyteor somethingsimilar. . When connectingor disconnectingthe fuel feed hose (B),fuel tube (D),and quick'connectfittings (F).be carefulnot to bend or twist them excessivelv.ReDlace them it they are damaged. A disconnectedquick-connectfitting can be reconnected,but the retaineron the mating line cannot be reusedonce it has been removedfrom the line. Replacethe retainerwhen . replacingthe fuel rail. . replacing t h ef u e ll i n e . . replacingthe fuel pump. . replacingthe fuel filter, . replacingthe fuel gaugesendingunit. . it has been removedfrom the line. . it isdamaged.

PART

I\4ANUFACTUREB RETAINER COLOR EN GI N E TOKAI GREEN COI\4PARTMENT ( F U EF LEED H O S EF; UE L L I N ES I D E ) E NGI N E TOKAI BLU COIVIPARTMENT ( F U EF LEED H O S EF: U E L R A I LS I D E ) WHITE FUELTANK SANOH UNIT

11-148

FittingsRemoval FuelLine/Ouick-Gonnect 1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e1 ' l - 1 4 4 ) .

2 . Checkthe fuel quick-connectfiftingsfor din, and clean if necessary. Hold the connector(A) with one hand and squeeze the retainertabs(B)with the other hand to release them from the lockingpaws (C).Pullthe connector off. NOTE: . B e c a r e f u ln o t t o d a m a g et h e l i n ei D ) o r o t h e r parts.Do not usetools. . lf the connectordoesnot move, keepthe retainer tabs presseddown, and alternatelypull and push the connectoruntil it comes off easily. . Do not removethe retainerfrom the line; once removed,the retainermust be replacedwith a new one.

4. Checkthe contactarea (A) of the line (B)for dirt and d am a g e . . lf the surfaceis dirty, clean it. . if the surfaceis rusty or damaged,replacethe f u e l p u m p ,f u e l f i l t e r f, u e l f e e dl i n e .

=k To preventdamagedand keepforeign matter out, cover the disconnectedconnectorand line end with plasticbags (A). NOTE: . The retainercannot be reusedonce it has been r e m o v e df r o m t h e l i n e . Replacedthe retainerwhen - replacing t h e f u e lr a i l . - r e p l a c i n gt h e f u e lf e e dI i n e . - r e p l a c i n gt h e f u e l p u m P . - replacingthe fuel filter. - replacing t h e f u e l g a u g es e n d i n gu n i t - it has been removedfrom the line. - it is damaged.

11-149

FuelSupply System FuelLine/Ouick-Connect Fittingslnstallation 1. Checkthe contacta rea (A) of the line (B)for dirt and damage,and clean if necessary.

Inserta new retainer(A) into the connector(B) if the retaineris damaged,or after . r e p l a c i n gt h e f u e l r a i l . . replacingthe fuelfeed line. . replacingthe fuel pump. . replacingthe fuel filter. . r e p l a c i n gt h e f u e l g a u g es e n d i n gu n i t . removingthe retainerfrom the line.

11-150

3. Beforeconnectinga new fueltube/quick-connect fitting assembly(A),removethe old retainerfrom t h e m a t i n ol i n e ,

4. Align the quick-connectfittingswith the line (A). a n d a l i g nt h e r e t a i n e (r B )l o c k i n gp a w l sw i t h t h e connector{C)grooves.Then pressthe quickconnectfittings onto the line until both retainer p a w l sl o c kw i t h a c l i c k i n gs o u n d .

5. lvlakesure the connectionis secureand that the p a w l sa r ef i r m l y l o c k e di n t o p l a c e c; h e c kv i s u a l l y and by pullingthe connector.

N O T E ;l f i t i s h a r dt o c o n n e c tp, u t a s m a l la m o u n to f n e w e n g i n eo i l o n t h e l i n ee n d . Connectionwith new retainer:

6. Reconnectthenegativecableto the battery,and t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .T h e f u e l p u m p w i l l run for about 2 seconds,and fuel pressurewill rise Repeat2 or 3 times, and checkthat there are no fuel leaks.

Reconnectionto existing retainer:

11-151

FuelSupply System FuelPressureRegulator Replacement 1 . R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) . 2 . Removethe fuel pressureregulator(A).

FuelFilterReplacement The fuel filter should be replacedwheneverthe fuel pressuredrops belowthe specifiedvalue {270 320 kpa, 2.8 3.3 kgflcm', 40 47 psi),after makingsure that the fuel pump and the fuel pressureregulatorare OK. 1 . R e m o v et h e f u e l p u m p ( s e e p a g e l l - ' 1 5 3 ) . 2. Removethe fuel filter (A).

@-to

Re IJ

e"^ ^e

g s

...\

@n-)

s g Installthe part in the reverseorder of removalwith a n e w o - r i n g( B ) .

Installin the reverseorder of removalwith a new basegasket(B)and a new o-ring (C),then check these items: ' When connectingthe wire harness,make sure the connectionis secureand the terminal (D) is firmly lockedinto place. . W h e ni n s t a l l i n g t h e f u e l g a u g es e n d i n gu n i ti E ) , make sure the connectionis secureand the connectoris firmly lockedinto place.Be careful not to bend or twist it excessively.

11-152

{

FuelPump/FuelGaugeSendingUnit Replacement SpecialToolsRequired F u e ls e n d e rw r e n c h0 7 X A A - 0 0 1 0 1 0 A

8 . R e m o v et h e l o c k n u (t A )a n d t h e f u e lt a n k u n i t .

1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 1 - 1 4 4 ) . Removethe fuel fill cap. Removethe seat cushion(seepage 20-80). Removethe accesspanel (A)from the floor.

5 . D i s c o n n e ct h t e f u e l p u m p 5 Pc o n n e c t o(rB ) . Disconnectthe quick-connectfitting {C)from the f u e lt a n ku n i t . 7 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t locknut(A).

t h e h o o k ( P )a n d 9 . R e m o v et h e s t o p p e r{ O ) .R e l e a s e r e m o v et h e f u e lf i l t e r( B ) ,t h e f u e l g a u g es e n d i n g u n i t ( C ) .t h e c a s e( D ) ,t h e w i r e h a r n e s s( E ) ,a n d t h e fuel pressureregulator(F). t h e f u e lt a n ku n i t ,m a k es u r et h e 1 0 . W h e nc o n n e c t i n g i s s e c u r ea n d t h e s u c t i o nf i l t e r( G )i s connection t o t h e f u e lp u m p ( H ) . f i r m l yc o n n e c t e d 1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s eo r d e ro f r e m o v aw l i t h a n e w b a s eg a s k e t( l ) a n dn e w o - r i n g s ( J ) ,t h e nc h e c kt h e s ei t e m s :

93 N.m 19.5kgf.m,69 lbf.ftl

. W h e nc o n n e c t i n tgh e w i r e h a r n e s sm , a k es u r e t h e c o n n e c t i o ni s s e c u r ea n d t h e c o n n e c t o(rK )i s f i r m l y l o c k e di n t ot h e p l a c e . . W h e n i n s t a l l i n gt h e f u e l g a u g es e n d i n gu n i t , make sure the connectionis secureand the c o n n e c t oirs f i r m l y l o c k e di n t o p l a c e .B e c a r e f u l not to bend or twist the connectorexcessively. . W h e ni n s t a l l i n g t h e f u e l t a n ku n i t ,a l i g nt h e m a r k s ( L )o n t h e f u e lt a n k ( M ) a n d t h e f u e lt a n ku n i t( N i

11-153

FuelSupply System FuelPulsationDamperReplacement 1 . R e l i e v et h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) . 2. Removethe enginecover. 3. Removethe fuel rail mounting nuts from the fuel rail. 4 . R e m o v et h e g r o u n dc a b l e( G1 0 1 . 5 . R a i s et h e f u e l r a i l . 6 . P l a c ea w r e n c h( A )o n t h e f u e l r a i l( B ) .

7 . P l a c ea w r e n c h( C )o n t h e f u e l p u l s a t i o nd a m p e r( D ) . 8. Removethe pulsationdamper. 9. Installthefuel pulsationdamper in lhe reverse order of removalwith new washers. NOTE: . Replaceall washerswhenever the fuel pulsation damper is loosenedor removed, . l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r cover does not face bottom, reinstallit as shown.

11-154

FuelTank Replacement 1 . R e l i e v e t h e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) . 2 . D r a i nt h e f u e lt a n k :R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U. s i n ga h a n dp u m p ,h o s e ,a n d c o n t a i n esr u i t a b l ef o r gasoline.draw the fuel from the fuel tank.

3 . Jack up the vehicle,and suppon it with safetystands. Removethe fuel pipe cover (A).Disconnectthe fuel vapor hose and quick-connectfittings. Disconnectthe hoses.Slide backthe clamps (B),then twist the hosesas you pull to avoid damagingthem.

(}

38N.m (3.9ksf.m,28lbfft)

5. Placea jack or other supportunder the tank. 6 . R e m o v e t h es t r a pb o l t s ,a n d l e t t h e s t r a p( C )h a n g f r e e . 7 . R e m o v et h e f u e lt a n k ( D ) .l f i t s t i c k s t o t h eu n d e r c o a t o ni t s m o u n t ,c a r e f u l l yp r y i t o f f t h e m o u n t 8. Installthe parts in the reverseorder of removal.

11-155

FuelSupply System FuelGaugeSendingUnit Test Special Tools Required Fuelsenderwrench 07XAA-001010A NOTE;For the fuel gauge system circuitdiagram,refer to the GaugesCircuitDiagram(see page 22-58||. 1 . C h e c k t h eN o . 1 0 f U E T E R { 7 . 5 A ) f u s ei n t h e u n d e r dash fuse/relaybox beforetesting.

7. Measurevoltage betweenfuel pump 5P connector terminalsNo. 1 and No. 2 with the ignition switch ON (ll).There should be batteryvoltage. . lf the voltage is as specified,go to step 8. . l f t h e v o l t a g ei s n o t a s s p e c i f i e d , c h e c k f o r : - a n o p e n i n t h e Y E U B L Ko r B L Kw i r e . - p o o r g r o u n d( G 5 5 1 ) .

2. Do the gauge drive circuitcheck(see page 22-56|l. ' lf the fuel gauge needlesweepsfrom minimuni to maximum positionand then returnsto the m i n i m u mp o s i t i o nt.h e g a u g ei s O K .G o t o s t e p3 . . lf the fuel gauge needle does not sweep from m i n i m u mt o m a x i m u mp o s i t i o np o s i t i o na n d then returnto the minimum position,replacethe gauge assemblyand retest.

FUELPUMP5PCONNECTOR

3 . T u r nt h e i g n i t i o ns w i t c hO F F . 4. Removethe rear seat cushion{seepage 20-80).

Wiresideof femaleterminals

5. Removethe accesspanel (A)from the floor.

-ztr

Turn the ignition switch OFF.Removethe No. 9 BACKUP (7.5A)fusefrom the under-hoodfuse/ relay box for at least 10 seconds,lhen reinstallit. Installa 2 Q resistorbetweenfuel pump 5P connectorlerminals No. 1 and No. 2, then turn the i g n i t i o ns w i t c hO N ( l l ) . FUELPUMP5P CONNECTOR

-VVV{Y {YEL/BLK) 2 9 RESISTOR,

=-a

//,

\ 4

5 /

(elrt \

Wire side of femaleterminals

6. Disconnectthe fuel pump 5P connector{B).

11-156

1 0 . C h e c k t h a t t h ep o i n t e r o ft h e f u e lg a u g ei n d i c a t e s "F". . lf the pointerdoes not indicate"F", replacethe g au g e . . lf the pointerindicates"F", inspectthe fuel gauge sendingunit. NOTE:The pointerof the fuel gauge returns to the bottom of the gaugedial when the ignition switch is OFF,regardlessof the fuel level.11. Relievethe fuel pressure(seepage 11-144\. 1 2 . R e m o v et h e f u e l f i l l c a p .

1 5 . M e a s u r er e s i s t a n cbee t w e e nt h e N o . 1 a n d N o . 2 'l12 terminalswith the float at E (EN4PTY), \HALF F U L L )a, n d F { F U L L p ) ositions. lf you do not get the following readings,replacethe f u e l g a u g es e n d i n gu n i t{ s e ep a g e1 ' 1 - 1 6 3 ) . F Float Position Resistance 1 1 {0) to 13

'U2 68,5 to 74.5

LOW

114.4 130 to 126.6 to 132

NOTE:Removethe No. 9 BACKUP (7.5A)fuse from the under-hoodfuse/relaybox for at least 10 secondsafter completingtroubleshooting, otherwiseit may take up to 20 minutesfor the fuel gaugeto indicatethe correctfuel level.

13. Disconnectthe quick-connectfittingsfrom the fuel pump. 1 4 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t locknut(A).

A 93Nm {9.5ksf.m,69 lbf.ft}

11-157

FuelSupply System Low FuelIndicatorTest 1 . Do the fuel gauge sendingunit test (seepage 11, rcol. . lf the system is OK, go to step 2. . lf the system has any malfunction,repair it. Turn the ignition switch OFF.Removethe No. 9 BACKUP (10A)fuse from the under-hoodfuse/ relay box for at least30 seconds,then reinstallit. Turn the ignition switch ON (ll)with the float at the E (EMPry) position. . lf the low fuel indicatoris on, go to step 4. . lf the low fuel indicatoris not on, referto the low fuel indicatorCircuitDiagram(seepage 22-58) and checkthe circuit. 4, Turn the ignition switch OFF.Removethe No. 9

BACKUP (10A)fuse from the under-hoodfuse/ relay box for at least30 seconds,then reinstallit. Lift the float above the LOW position. . l f t h e l o w f u e li n d i c a t o r g o eo s f f , t h es y s t e mi s O K . . lf the low fuel indicatoris still on, referto the low fuel indicatorCircuitDiagram{seepage 22-58), and checkthe circuit.

11-158

IntakeAir System ComponentLocationIndex

INTAKE AIR BYPASSCONTROL THERMALVALVE Test,page 1'1-161

THROTTLEBODY Test,page l'l-160 page 11-165 Removal/lnstallation, page 11 166 Disassembly/Reassembly,

l .

AIR CLEANER R e p l a c e m e npt a, g e11 ' 1 6 2 AIR CLEANERELEMENT R e p l a c e m e npta, g e11 - 1 6 2

THROTTLE CABLE page11-163 Adjustment, R e m o v a l / l n s t a l l apt a i ogne1, 1 - 1 6 4

11-159

IntakeAir System Throttle BodyTest NOTE: . Do not adjustthe throttlestop screw. lt is presetat the factory. . lfthe malfunction i n d i c a t o lra m p ( M l L )h a sb e e n reportedon, checkfor diagnostictrouble codes ( D L C S()s e ep a g e1 1 3 ) . 1. With the engine off, checkthe throttle cable movement.The cableshould move without binding or sticking. . lf lhe cable moves OK, goto step 2. . lf the cable binds or sticks,checkit and its routing. . l f t h e c a b l ei s f a u l t y ,r e r o u t ei t o r r e p l a c ei t a n d a d j u s ti t ( s e ep a g e1 1 - 1 6 3 )t h , e ng o t o s t e p2 . 2. l\4ovethe throttle lever by hand to see if the throftle valve and/or shaft are too looseor too tight. . lf there is excessiveplay in the throttlevalve shaft,or any binding in the throttlevalve at the fully closedposition,replacethe throttle body. . l f t h e t h r o t t l e v a l v ea n d s h a f ta r e O K ,g o t o s t e p 3 . 3. Connectthe scantoolto the DLC. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 5 . Checkthe throttle positionwith the scantool. The readingshould be about 10%when the throttle is fully closedand about 90% when the throttle is fully openeo. . lf the throttle positionis correct,the throttle body is OK. . lf thethrottle positionis notcorrect,replacethe throttle body.

11-160

Test IntakeAir BypassGontrolThermalValve Special Tools Required Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX

, n d m a k es u r e 5 . R a i s ea n d l o w e rt h e e n g i n es p e e d a the vacuum gauge readingdoes not changeas the rpm cnanges.

1 . S t a nt h e e n g i n e T . h e nl e t i t i d l € . NOTE:The enginecoolanttemperaturemust be b e l o w1 4 9 ' F ( 6 5 ' C ) . 2 . R e m o v et h e v a c u u mh o s e( A ) f r o mt h e i n t a k ea i r duct, and connecta vacuum pump/gaugeto the nose.

lf the vacuum readingchanges,checkfor these proorems: . l\4isrouted, leaking,broken,or cloggedintakeair bypasscontrol systemvacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e .

. n d m a k es u r e 3 . R a i s ea n d l o w e r t h ee n g i n es p e e d a t h e v a c u u mg a u g er e a d i n gc h a n g e sa s t h e e n g i n e speeocnanges. lf the vacuum readingdoes not change,checkfor these problems: . M i s r o u t e dl,e a k i n gb, r o k e n o, r c l o g g e di n t a k ea i r bypasscontrol system vacuum lines. . A crackedor damagedintakeair bypasscontrol t h e r m a lv a l v e . 4 . H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n neutral)until the radiatorfan comes on, then let it i dl e .

11-161

IntakeAir System Air CleanerReplacement 1. Removethe nuts (A) and the stud (B).

Air CleanerElementReplacement 1 . D i s c o n n e ct h t e P C Vh o s e1 A ) .

{0.3kgf m,2lbf.ft)

2. Removethe air cleaner(C).

2 . O p e nt h e a i r c l e a n e rh o u s i n gc o v e r( B ) .

3 . Installin the reverseorder of removal.

3 . R e m o v et h e a i r c l e a n e r( C )f r o m t h e a i r c l e a n e r h o u s i n g( D ) . 4 . Installin the reverseorder of removal.

11-162

Throttle CableAdjustment 1 . Checkcablefree play at the throttle linkage.Cable f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .

lf the free play is not within spec (10- 12 mm, 3 1 8 - 1 1 2 l n . l , l o o s etnh e l o c k n u (t B ) ,t u r n t h e adjustingnut (C)untilthe free play is as specified, then retightenthe locknut. With the cable properlyadjusted,checkthe throttle valve to be sure it opens fully when you push the acceleratorpedalto the floor. Also checkthe throttlevalve to be sure it returnsto the idle positionwheneveryou releasethe accelerator peoar.

11-163

IntakeAir System Throttle CableRemoval/lnstallation 1. Fully open the throttlevalve,then removethe throttle cable (A)from the throttle link (B).

Installin the reverseorder of removal. 5 . After installing,startthe engine.Holdthe engine at 3,000rpm with no load (in neutral)untilthe radiator fan comes on, then let it idle. H o l dt h e c a b l e ,r e m o v i n ga l l s l a c kf r o m i t . 7 . Set the locknuton the cable bracket{A). Turn the adjustingnut (B)so that its free play is 0 mm. T h e s h o u l db e no crearance.

(P/N08?98-9002)

2 . R e m o v et h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e bracket(D).

('1.0kgf.m, 7.2 tbf.ftl

3 . Removethe throttlecable (A)from the accelerator p e d a l( B ) .

8 . Removethe cablefrom the cable bracket(A).Set the adjustingnut on the other side of the throttle bracket,then tightenthe locknut{C}. 9 . With the cable properlyadjusted,checkthe throttle valve to be sure it opensfully when you push the acceleratorpedalto the floor. Also checkthe throttlevalveto be sure it returnsto the idle positionwheneveryou releasethe accelerator Deoat.

SILICONE GREASE B (P/N08798-9002)

11-164

Throttle Body Removal/lnstallation NOTE: ' Do not adjustthe throttle stop screw. . A f t e r r e a s s e m b l y , a d j u s t t h e t h r o t t l e c a b l e { s e e p a g e l l - 1a6n3d)t h e c r u i s ec o n t r o lc a b l e( s e ep a g e4 - 4 5 ) . . The throttle position(TP)sensoris not removable.

THROTTLE LEVER Thereshould be noclearance

THROTTLECABLE MANIFOLD ABSOLUTEPRESSURE {MAP}SENSOR 22Nm (2.2 kgt.m, 16 lbf.ft)

EVAPORATIVEEMISSION{EVAPI CANISTERPURGEVALVE

IDLEAIR CONTROL {IACI VALVE

11-165

IntakeAir System Throttle Body Disassembly/Reassembly 2 N.m {0.2 kgt m, 1 lbf.ft)

V MAPSENSOR

EMISSION EVAPORATIVE {EVAP) PURGE VALVE CANISTER

L TPSENSOR

THROTTLEBODY

3.5 N.m (0.35kgf m.2.5lbf ft)

11-166

CatalyticConverterSystem DTCTroubleshooting DTCP0420:CatalyticSystemEfficiency BelowThreshold NOTE:lf some of the DTCSlistedbelow are storedat the same time as DTCP0420,troubleshootthose DTCS first, then recheckfor DTCP0420. P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH e a t e dO x y g e nS e n s o r (secondaryHO2S)(Sensor2) r )heater P 0 1 4 1S: e c o n d a r yH O 2 S( S e n s o 2 1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u et o step 2 through 5 to resetthe readinesscode. 2. Startthe engine.Hold the engineat 3,000rpm with n o l o a d( i n n e u t r a lu) n t i l t h er a d i a t o fr a n c o m e so n . D r i v ef o r a b o u t l 0 m i n u t e sw i t h o u ts t o p p i n gY. o u r speeocan vary. 4 . With the transmissionin 4th gear,drive at a steady speed between50 62 mph (80-'100 km/h)for 30 seconds. Repeatstep 4 three times. Betweeneach repetition, closethe throttlecompletelyfor 1 2 seconds.lf the engine is stoppedduring this part of the procedure,repeatsteps3, 4 and 5. Checkfor a TemporaryDTCwith the scantool. Does the scan tool indicate Temporaty DTC P0420? YES Checkthe TWC. lf necessary,replacethe TWC.I N O C h e c kf o r r e a d i n e s cs o d ec o m p l e t i o nl.f t h e readinessis complete,it was a interminentfailure, and the system is OK at this time. lf the readiness code is incomplete,repeatsteps2 through 5.1

11-167

PCVSystem DTCTroubleshooting DTCP1505:PCVAir Leakage 1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 2. Startthe engine.Hold the engineat 3,000rpm with n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n 3. Letthe engineidle tor al least40 secondswith the throttlefully closed. 4. Checkfor a DTCP1505with the scantool ls DTC P1505 indicated? YES-Check these partsfor vacuum leaks l . PCVvalve . PCVhose . EVAPcanisterpurge valve . Throttlebody . Brakeboosterhose NO - Intermittentfailure,system is OK at this time.l

11-168

PCVValve Inspectionand Test 1. Checkthe PCVvalve (A),hoses{B),and connectionsfor leaksor restrictions.

PCVValve Replacement 'L

Disconnectthe PCVhose. Removethe PCVvalve (A).

2 . At idle, make sure there is a clickingsound from the PCVvalve when the hose betweenthe PCVvalve a n d i n t a k em a n i f o l di s l i g h t l yp i n c h e d{ A ) w i t hy o u r f i n g e r so r p l i e r s . lf there is no clickingsound,checkthe PCVvalve grommet for cracksor damage.lf the grommet is OK. reDlacethe PCVvalve and recheck.

(4.5kgf.m,33lbf.ft) l parts in the reverseorder of removal 3 . I n s t a lthe with a n e w g a s k e t( B ) .

11-169

EVAPSystem ComponentLocationIndex

EVAPORATIVEEMISSIONIEVAPI CANISTERPURGEVALVE Troubleshooting, 'l1-175, step 3 on page s t e p1 o n p a g e1 1 - 1 8 0

FUELTANK VAPORCONTROLVALVE Test,page 11'187 R e p l a c e m e npt a, g e1 1 1 8 9 EVAPORATIVEEMISSION{EVAPI CANISTER Troubleshooting, step 28 on page 11'183 page 11-189 Replacement,

SENSOR FUELTANKPRESSURE T r o u b l e s h o o t ipnagg, e11 - 1 7 1 EVAPORATIVEEMISSION{EVAP} BYPASSSOLENOIDVALVE Troubleshooting, p a g e' 1 1 ' 1 7 6 , s t e p1 ' 120o n s t e p o n p a g e1 1 1 8 1

EVAPORATIVEEMISSION{EVAP) CANISTERVENT SHUT VALVE Troubleshooting, step 23 on page 1'l 178, s t e p1 go n p a g el 1 - 1 8 2

11-170

EVAPOBATIVEEMISSON{EVAP) VALVE TWO WAY 'l1-'186 Test,page

DTCTroubleshooting DTCP0451:FTPSensorRange/Performa nce Problem

6. Connecta vacuum pump to the open end of the hose.

SpecialTools Required Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX 1 . R e m o v et h e f u e lf i l l c a p . 2. Turn the ignition switch ON (ll) 3. l\4onitorfuel tank pressure(FTP)sensorvoltage with the HondaPGM Tester,or medsurevoltage betweenECMconnectorterminalsE4 and E14. ECMCONNECTOR E 131P)

7 . Turn the ignition switch ON {ll). 8 . l\4onitorFTPsensorvoltagewith the Honds PGM Tester,or measurevoltage betweenECM c o n n e c t otre r m i n a l sE 4 a n d E 1 4 ,a n d c a r e f u l l y s q u e e z et h e v a c u u mp u m p a l i t t l e . ECMCONNECTOR E 13lPI

W i r es i d eo f f e m a l tee r m i n a l s

ls there about 2.5V? YES-Go to step 4. NO Replacethe FTPsensor.I 4 . Turn the ignitionswitch OFF. Wiresideof lemaleterminals 5 . Disconnectthe hose betweenthe EVAPtwo way valve and the FTPsensorat the EVAPtwo way valve end.

9 . The voltageshould smoothly drop from about 2.5 V t o a b o u t1 . 5V . S t o pa p p l y i n gv a c u u mw h e n t h e voltagedrops to about 1.5V or damageto the FTP sensormay occur. Does the voltage drop to about 1.5 V and hold? YES Checkfor misrouted,leaking,or brokenFTP s e n s o rv a c u u ml i n e s .l f t h e v a c u u ml i n e sa r e O K , updatethe ECM if it does not havethe latest software.or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO

Replacethe FTPsensor.!

11-171

EVAPSystem DTCTroubleshooting(cont'd) DTCP0452:FTPSensorCircuitLow Voltage 1. Checkthe vacuum lines at the FTPsensorfor misrouting,leakage.breakage,or clogging.

6. Turn the ignition switch OFF. 7 . R e i n s t a l l t h feu e lf i l l c a p . 8. Disconnectthe FTPsensor3P connector.

Are the vacuumlines OK? 9. Turn the ignition switch ON (ll) YES Go to step 2. NO Repairor replacevacuum lines as necessary.I

10. Measurevoltage betweenFTPsensor3P connector t e r m i n a l sN o . 1 a n d N o . 2 . 3PCONNECTOR FUELTANKPRESSURE SENSOR

2 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) . 3 . R e m o v et h e f u e l f i l lc a p .

VCgl {YEL/BLU}

4. Turn the ignition switch ON (ll) 5. Monitor FTPsensorvoltagewith the HondaPGM Tester,or measurevoltage betweenbody ground and ECMconnectorterminal E14. E 131PI ECMCONNECTOR

1 2 t 3 t 45

8 9 . / . / 1 1 4 t c 61./18 2C 21 22123241 t 26 271/ 29 31 o

Wiresideof femaleterminals

TP (LTGRN)

ls there about 5 V? '1. YES Go to step 1 NO-Repair open in the wire betweenthe FTP s e n s o ra n dt h e E C M{ E 5 ) . 1

Wire side of femaleterminals

ls thete about2.5 V? YES- Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat the FTPsensorand at the ECrM.l NO Go to step 6.

11-172

11. MeasurevoltagebetweenFTPsensor3P connector t e r m i n a l sN o . 2 a n d N o . 3 . FUELTANKPRESSUBE SENSOR3P CONNECTOR

FTP(LT GBN)

DTCP0453:FTPSensorCircuitHighVoltage 1. Checkthe vacuum lines at the FTPsensorfor misrouting,leakage,breakage,or clogging. Are the vacuumlines OK? Y E S - G o t o s t e p2 . N O R e p a i ro r r e p l a c ev a c u u ml i n e sa s necessary.I

W i r e s i d eo f f e m a l e t e r m i n a l s

2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) . 3. Removethe fuel fill cap.

ls there about 5 V? YES- Replacethe FTPsensor.t N O - G o t o s t e p1 2 .

' t 2 .Turn

4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 5. lvlonitorFTPsensorvoltagewith the Honda PGM Tester,or measurevoltage betweenbody ground a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 .

the ignitionswitch OFF.

1 3 .DisconnectECMconnectorE (31P), 1 4 .Checkfor continuitybetweenFTPsensor3P connectorterminal No. 3 and body ground.

ECMCONNECTOR E 131PI

1 1 2 1 34 5 6 7 I 9 5 6 / t18 2C 21 24 2il./ 29 30 31 TP {LTGRN}

FTPSENSOR3P CONNECTOB

Wire side of femaleterminals FTP (LT GRNI

Is there about 2.5 V?

W i r es i d eo f f e m a l e l e r m i n a t s

ls there continuity?

YES Intermittentfailure,system is OK at this time. Checkfor poor connectionsor looseterminalsat t h e F T Ps e n s o ra n d a t t h e E C M . I NO Go to step 6.

YES Repairshort in the wire betweenthe FTP s e n s o ra n d t h e E C I \ {4E 1 4 ) . I NO-Update the ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodEClvl,replacethe originaE l CM.I

{cont'd)

11-173

EVAPSystem DTCTroubleshooting(cont'dl 6. Turn the ignitionswitch OFF. 7 . R e i n s t al h l e f u e lf i l l c a p .

11, Measurevoltage betweenFTPsensor3P connector t e r m i n a lN s o . 2 a n dN o . 3 . FTPSENSOR3P CONNECTOR

8. Disconnectthe FTPsensor3P connector. 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

FTPILT GRN}

'10.

l\4easure voltage betweenFTPsensor3P connector t e r m i n a l sN o . 1 a n d N o . 2 . FTPSENSOR3P CONNECTOR

VCC3(YEL/BLU)

Wiresideof femaleterminals ls there about 5 V? YES Replacethe FTPsensor.l NO Go to step 12.

Wire side of femaleterminals

l\4easure voltage betweenECMconnector t e r m i n a l sE 4 a n d E1 4 ,

ls there about 5 V? Y E S G o t o s t e p1 1 .

ECMCONNECTOR E (31P)

NO-Repair open in the wire betweenthe FTP sensorand the ECM (E4).!

W i r es i d eo f f e m a l tee r m i n a l s

ls there about 5 V? YES Repairopen in the wire betweenthe FTP s e n s o ra n d t h e E C M( E 1 4 ) . I NO Updatethe ECM if it does not have the latest then software,or substitutea known-goodECN4. recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-174

DTCPl456:EVAPControlSystemLeakage (FuelTankSvstem) The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressuretests as indicatedin these procedures.Excessivepressure/ vacuum would damagethe EVAPcomponentsor cause eventualfuel tank failure.

EVAP Canister Purge Valve Test 3. Disconnectthe vacuum hose from the EVAP canisterpurge valve (A),and connecta vacuum oumo to the hose.

Special Tools Required Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX This is a two-trip code. Oncecleared,it cannot be reproducedin one trip. Also, cenain specificdriving and ambientconditionsmust occur beforethe ECMwill completethe systemchecks.Additionaltest drives may still not meet the specificconditionsneededto reproducethe code.

A973X-041-XXXXX T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

Follow thesetroubleshootingprocedurescarefullyto ensurethe integrityof the system and to confirm the causeof the problemor code.

5 . Apply vacuum to the hose. Does the valve hold vacuum?

NOTE:Freshfuel has a highervolatilitythat creates greaterpressure/vacuum. The optimum condltlonfor testing is fresh fuel, and must be lessthan a full tank. lf possible,to assistin leakdetection,add 1 gallon of fresh fuel to the tank (as long as it will not fill the tank). just beforestartingthese procedures.

YES-The EVAPcanisterpurge valve is OK. Go to s t e p1 1 . NO-Go to step 6. Turn the ignition switch OFF.

Fuel Fill Cap Check 1. Checkthe fuel fill cap (the cap must say "lf not tightened3 clickscheckengine light may come o n ") .

7 . Disconnectthe EVAPcanisterpurge valve 2P connecror.

ls the proper luel till cap installed and properly tightened? YES Go to step 2. NO- Replaceor tightenthe cap.I 2. Checkthe fuel fill cap seal. ls the tuel fill cap seal missing or damaged? YES- Replace t h e f u e lf i l l c a p . I N O T h e f u e l f i l lc a p i s O K .G o t o s t e p3 .

{cont'd)

11-175

EVAPSystem DTCTroubleshooting(cont'd) 8. Checkfor continuitybetweenEVAPcanisterpurge valve2Pconnenctor terminalNo.2 andbody grouno. EVAP CANISTERPURGE VALVE 2P CONNECTOR

EVAP Bypass Solenoid Valve Test 11, Disconnectboth vacuum hosesfrom the EVAPtwo way valve (A),and connecta vacuum pump to the canisterport on the EVAPtwo way valve.

F-

A973X-041-XXXXX Wire side of femaleterminals

ls therecontinuity? YES Goto step9. NO Replace the EVAPcanisterpurgevalve.l B (24P). ECMconnector 9 . Disconnect 1 0 . Checkfor continuitybetweenEVAPcanisterpurge

terminalNo.2 andbodyground. valve2Pconnector EVAPCANISTERPURGE VALVE2PCONNECTOR

Turn the EVAPbypasssolenoidvalve on with the Honda PGM Tester,or connectECMconnecter terminal E20to body ground with a jumper wire. E 131P) ECMCONNECTOR

1 2 3 4 5 6 1 7 l1 8 9 4 5 6 / 118 2C21 2 2 t 2 ? 24 z7l./29 2WBS (BLU/RED} JUMPER WIRE

1 2 PCS {YEL/BLU)

Wiresideof femaleterminals

'.\'

1 3 .Turn the ignitionswitch ON (ll). Wire side of femaleterminals

1 4 .Apply vacuum to the hose. Does the valve hold vacuum?

ls there continuity? Y E S - G o t o s t e p1 5 , YES Repairshort in the wire betweenthe EVAP canistep r u r g ev a l v ea n dt h e E C I \ {48 2 1 ) . 1 NO Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I

11-176

NO Go to step 20.

1 5 . Turn the ignition switch OFF. to.

Disconnectthe EVAPbypasssolenoidvalve 2P connecror.

'19.

Measurevoltage betweenEVAPbypasssolenoid valve 2P connectorterminal No. 1 and body ground. EVAPBYPASSSOLENOID VALVE2PCONNECTOR

1 7 . Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground. EVAP BYPASSSOLENOID VALVE 2P CONNECTOR

2 tG'l

{BLK/ORN)

Wire side ol lemale terminals

Wire side oI Iemaleterminals

ls there continuity? YES Go to step 18. NO-Repair open in the wire bet\iveen the EVAP bypasssolenoidvalve and the ECM (E20).1

'18.T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls there battery voltage? YES Replacethe EVAPtwo way/bypasssolenoid v a l v e( A ) . 1 NO-Repair open in the wire betweenthe EVAP bypasssolenoidvalve and the No. 4 ACG (10A) fuse.l

{cont'd)

11-177

EVAPSystem (cont'dl DTCTroubleshooting 2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y valve,

EVAP Canister Vent Shut Valve Test 22. Disconnectthe vacuum hosefrom the EVAP canistervent filter (A),and connecta vacuum pump to the hose.

While monitoring FTPsensorvoltagewith the HondaPGM Tester,or measuringthe voltage b e t w e e nE C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 , slowly pump the vacuum pump until the voitage droDSto about 1.5volts. ECMCONNECTOR E {31PI

T u r nt h e i g n i t l o ns w i t c hO N ( l l ) . Apply vacuum to the hosewith five strokesof the pump. Does the valve hold vacuum?

YES Go to step 25. NO The EVAPcanistervent shut valve is OK. Go to step 30.

25. T u r nt h e i g n i t i o ns w i t c hO F F . 26. Disconnectthe EVAPcanistervent shut valve 2P Wiresideof femaleterminals

conneclor.

Does the voltagedtop to 1.5 V and hold fot at Ieast 20 seconds?

2 1 . Checkfor continuitybetweenEVAPcanistervent s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y ground.

YES-The EVAPbypasssolenoidvalve/EVAPtwo way valve is OK. Go to step 22.

EVAPCANISTEBVENTSHUT VALVE2PCONNECTOR

N O R e p a i rt h e l e a kf r o m t h e E V A Pb y p a s s solenoidvalve, EVAPtwo way valve.or F T Ps e n s o r . l {LTGRN/REOI

W i r es i d eo f f e m a l et e r m i n a l s

11-178

VacuumHosesand ConnectionsTest 3 0 . Do the fuel tank vapor control valve test (seepage 11 - 1 8 7 ) . ls the fuel tank vapot control valve OK? Y E S - G o t o s t e p3 1 . NO Replace t h e f u e l t a n kv a p o rc o n t r o lv a l v e . l 5 t .

Tightenthe fuel cap 3 "clicks", then monitorthe FTPsensor readingswith the Honda PGM Tester. Startthe engine.and let it idle for 5 minutes.

ls thete continuity? Checkthe FTPsensor readings. YES-Go to step 28. NO-Replace the EVAPcanistervent shut valve (A) a n d o - r i n g( B ) . 1

28. DisconnectECMconnectorE (31P). 29. Checkfor continuitybetweenEVAPcanistervent s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d body ground. EVAPCANISTERVENTSHUT VALVE2PCONNECTOR

ls the reading above 0.5 kpa (4 mm Hg, 0.16 in. Hg) pressure, or about 3 V?

Wire side o{ femaleterminals

YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck{seepage 11-6).lf the symptom/indication goes away with a known-goodECfvl,replacethe originaE l CM.t NO Checkthe following partsfor leaks:l

ls there continuity? YES-Repair short in the wire betweenthe EVAP c a n i s t e vr e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1 NO Updatethe ECM if it does not have the latest soflware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

. F u e l t a n k( A ) . F u e lf i l l c a p ( B ) . F u e lf i l l p i p e( C ) . F u e l t a n kv a p o rc o n t r o lv a l v e ( D ) . F u e l t a n kv a p o rr e c i r c u l a t i ovna l v e( E ) . F u e l t a n kv a p o rr e c i r c u l a t i otnu b e ( F ) . F u e l t a n kv a p o rs i g n a l t u b e( G ) . F u e l t a n kv a p o rc o n t r o lv e n t t u b e ( H ) . FTPsensor(J) - R e p a i ro r r e p l a c ea n y l e a k i n gp a r t s .

11-179

EVAPSystem DTCTroubleshooting(cont'd) DTCPl457:EVAPControlSystemLeakage (EVAPCanisterSystem)

2. Turn the EVAPcanisterpurge valve on with the HondaPGM Tester,or connectECMconnector terminal 821 to body ground with a jumper wire.

The fuel system is designedto allow specified maximum vacuum and pressureconditions.Do not deviatefrom the vacuum and pressuretests as indicatedin these procedures.Excessivepressure/ vacuum would damagethe EVAPcomponentsor causeeventualfuel tank systemfailure.

ECMCONNECTOR A I24P'

SpecialToolsRequired Vacuum pump/gauge,0-30 in.HgA973X-041-XXXXX W i r e s i d eo f l e m a l et e r m i n a l s

This is a two-trip code.Once cleared,it cannot be reproducedin one trip. Also, certainspecificdriving and ambientconditionsmust occur beforethe ECfMwill completethe system checks,Additionaltest drives may still not meet the specificconditionsneededto 16^r^.1'

'^6

rh6

Turn the ignition switch ON (ll). 4 . Apply vacuum to the hose.

^^.16

Does the valve hold vacuum? Followthesetroubleshootingprocedurescarefullyto ensurethe integrityof the system and to confirm the causeof the problem or code. NOTE:Freshfuel has a highervolatilitylhat creates greaterpressure/vacuum. The optimum conditionfor testing is fresh fuel, and there must be lessthan a full tank. lf possible,to assistin leakdetection,add I gallon of fresh fuel to the tank (as long as it will not fill the tank),just beforestartingthese procedures.

YES-Go to step 5. NO-The EVAPcanisterpurge valve is OK. Go to step 10. Turn the ignition switch OFF. b.

Disconnectthe EVAPcanisterpurge valve 2P conneclor,

7 . Checkfor continuitybetweenEVAPcanisterpurge valve 2P connectorterminal No. 2 and body ground.

EVAPCanister Purge Valve Test 1. Disconnectthe vacuum hose from the EVAP canisterpurge valve (A),and connecta vacuum pump to the hose.

EVAPCANISTEN PURG€ VALVE2PCONNECTOR

-4l-fircs ll2l IYEL/8Lu)

(f])

I W i r e s i d eo f f e m a l e l e r m i n a l s

ls therecontinuity? YES-Goto step8. 4973X-041-XXXXX

NO Repairopenin thewire betweenthe EVAP 821).I c a n i s t epru r g ev a l v ea n dt h eE C M / P C(M 8 . T u r nt h ei g n i t i o n s w i t c hO N( l l ) .

11-180

voltagebetweenEVAPcanisterpurge 9. Measure terminalNo. 1 andbodyground. valve2Pconnector EVAPCANISTERPURGE VALVE2PCONNECTOR

EVAP Bypass Solenoid Valve Test 10. Disconnectboth vacuum hosesfrom the EVAPtwo way valve {A),and connecta vacuum pump to the canisterport on the two way valve.

Wire side oI lemaleterminals

ls thetebatteryvoltage? the EVAPcanisterpurgevalve.l YES- Replace NO Repairopenin thewire betweenthe EVAP canisterpurgevalveandthe No.4 ACG(10A) fuse.I

1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 'It

Apply vacuum to the hose. Does the valve hold vacuum? YES The EVAPtwo way/bypasssolenoid valveis O K . G o t o s t e p1 8 . N O - G o t o s t e p1 3 . Turn the ignition switch OFF.

1 4 . Disconnectthe EVAPbypasssolenoidvalve 2P connector. Checkfor continuitybetweenEVAPbypass s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d b o d yg r o u n d . EVAPBYPASSSOLENOID VALVE2P CONNECTOR

Wire sideof female terminals

(cont'd)

11-181

EVAPSystem DTCTroubleshooting(cont'd) EVAP Canisler Vent Shut Valve Test 18. Disconnectthe vacuum hosefrom the EVAP canistervent filter (A),and connecta vacuum pump to the hose.

ls there continuity? YES Go to step 16. NO- Replacethe EVAPtwo waylbypasssolenoid valve (A).1 t o . DisconnectECMconnectorE {31P).

't7.

Checkfor continuitybetweenEVAPbypass solenoidvalve 2P connectorterminal No. 2 and body ground. EVAPBYPASSSOLENOID VALVE2P CONNECTOR

\ ,

lI l tl - 2l l

19. Turn the EVAPcanistervent shut valve on with the HondaPGM Tester,or connectECMconnector terminal E21to body ground with a jumper wire. ECMCONNECTOR E (3TP)

1 1 2 1 34 5 1/

1 5tal/la

z3lz4

zil./

2WBS

JUMPER WIRE

-[BLU/REo) ())

8 9 vsv( {LTGBN/RED) 2A21 m 31

Wiresideol lemaleterminals

Wire side of femaleterminals

20. Turn the ignitionswitch ON (ll) ls there continuity?

2 1 .Apply vacuum to the hose. YES Repairthe short in the wire betweenthe EVAPbypasssolenoidvalve and the ECM{E20).f NO Updatethe ECI\4if it does not havethe latest software.or substitutea known-goodEClvl,then recheck(seepage 11-6).lf the symptom/indlcation goes away with a known-goodECM,replacethe o r i g i n aE l CM.I

Does the valve hold vacuum? YES-The EVAPcanistervent shut valve is OK. Go to step 27. NO Go to step 22.

2 2 . Turn the ignitionswitch OFF. 2 3 . Disconnectthe EVAPcanistervent shut valve 2P connector.

11-182

24. Checkfor continuitybetweenEVAPcanistervent Nlo . 2 a n d b o d y s h u t v a l v e2 P c o n n e c t o r t e r m i n a ground. VATVE2P CONNECTOR

-4l-T_*u r 2l

Canister System Leak Test 27. Turn the ignition switch oFF. 2 8 , C o n n e c t t w ot,h r e e - w a yT - f i t t i n g s( A )i n t o t h e h o s e from the EVAPcanisterto the EVAPtwo way valve. Connectthe FTPsensorto one of the T-fittingsand t h e v a c u u mp u m p t o t h e o t h e l

ILTGFN/REDI

@ wn€ s de ol l€ma1e terminals

ls therc continuity? YES Go to step 25. NO Repairopen in the wire betweenthe EVAP c a n i s t e vr e n ts h u tv a l v ea n dt h e E C I V(IE 2 1 ) . 1

25. T u r nt h e i g n i t i o ns w i t c ho N ( l l ) . 26. Measurevoltage betweenEVAPcanistervent shut v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d . VENTSHUT EVAPCANISTER VALVE2PCONNECTOR

29. Removethe vent hosefrom the EVAPcanistervent shut valve (A),and cap the port (B)to sealthe fresh air vent of the EVAPcanister.

Wlreside oflem. € rerm na s

3 0 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

ls there battery voltage? YES Replacethe EVAPcanistervent shut valve ( A )a n d t h e o - r i n g( B ) . I NO Repairopen in the wire betweenthe EVAP c a n i s t e vr e n ts h u tv a l v ea n dt h e N o . 4 A C G ( 1 0 A ) fuse.I

(cont'd)

11-183

EVAPSystem

DTCTroubleshooting(cont'dl 31. While monitoring FTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump the vacuum oumD.

37. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between E C Mc o n n e c t otre r m i n a l sE 4a n d E1 4 ,s l o w l yp u m p t h e v a c u u mp u m p .

ECMCONNECTOR E 13lPI

ECMCONNECTOR E {31PI

Wire side ot femaleterminals

Wiresideof lemaleterminals

32. Continueto pump vacuum until the voltagedrops to about 1.5V. Make sure the enginecoolant temperatureis still above 95'F 135.C)and your v a c u u mp u m p h a s n o l e a k .

38. Continueto pump vacuum until the voltagedrops

33. Monitor the voltagefor 20 seconds.

39. Monitor the voltagefor 20 seconds

Does the voltage drop 1.5V and hold for at least 20 seconds? YES Inspectthe EVAPcanistervent shut valve l i n ea n d c o n n e c t i o n s . l

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

Does the voltage hold for at least 20 seconds? YES Inspeclthe fuel tank vapor control lineand connections.I NO Go to step 40.

NO-Go to step 34.

40. T u r nt h e i g n i t i o ns w i t c hO F F . 34. Turn the ignition switch OFF. 35. Disconnectthe quick-connectfitting (A) fromthe EVAPcanister,and plug the canisterport {B).

3 6 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

11-184

4 1 .Disconnectthe purge line hose {A) from the c a n i s t e ar t t h e m e t a ll i n e a n d p l u gt h e h o s e( B ) .

4 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

43. While monitoringFTPsensorvoltagewith the Honda PGM Tester,or measuringvoltage between ECMconnectorterminalsE4 and E14,slowly pump t h e v a c u u mp u m p . E {31P) ECMCONNECTOR

Wiresideof femaleterminals

4 4 . Continueto pump vacuum until the voltagedrops to about 1.5V.Make sure the enginecoolant temperatureis still above 95'F (35'C)and your v a c u u mp u m p h a sn o l e a k .

45. Monitor the voltagecontinuouslyfor 20 seconds. Does the voltage drop to 1.5 V and hold f or at least 20 seconds? YES Inspectthe EVAPcanisterpurge valve line and connections.lf they are OK, perform the EVAP two way valvetest (seepage 11-186)and the fuel tank vapor controlvalve test (seepage 1'l-187)l NO-Replace the EVAP canister ( s e ep a g e1 1 - 1 8 9 ) . 1

11-185

EVAPSystem EVAPTwo Way ValveTest Special Tools Required . V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g A973X-041-XXXXX . Vacuum/Pressure cauge.0-4 in. Hg 07JAZ-0010008

4. Move the vacuum pump hosefrom the vacuum fitting to the pressurefitting,and move the vacuum gauge hosefrom the vacuum side to the pressure side (A) as shown.

1 . R e m o v et h e f u e l f i l l c a p . 2. Disconnectthe vapor line from the EVAPtwo way valve (A).Connectit to a T-fitting(B)from the v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n ,

07JAZ-0010008

Slowly pressurizethe vapor line while watchingthe gauge.The pressureshould stabilizemomentarilV a b o v e1 . 0k P a( 8 m m H g ,0 . 3i n . H g ) .

Apply vacuum slowly and continuouslywhile watchingthe gauge.The vacuum should stabilize m o m e n t a r i l ya t 0 . 8 2 . 1 k P a( 6 1 6 m m H g , 0 , 2 0 . 6i n . H g ) . lf the vacuum stabilizes{valveopens)below 0.8 kpa ( 6 m m H g , 0 . 2i n . H g )o r a b o v e2 . 1k P a( 1 6m m H g , 0.6 in.Hg),installa new valve and retest.

11-186

. lfthe pressuremomentarilystabilizes(valve o p e n s )a b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e v a l v ei s O K . . lf the pressurestabilizesbelow 1.0 kPa(8 mmHg, 0.3 in.Hg),installa new valve and retest.

FuelTankVaporControlValveTest SpecialToolsRequired 0-30 in. HgA973X-041-XXXXX VacuumPump/Gauge,

FloatTest 1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l .

ValveTest 1 . N 4 a kseu r et h e f u e lt a n k i s l e s st h a n h a l ff u l l 2 . R e m o v et h e f u e l f i l l c a p . 3. Disconnectthe fuel tank vapor signaltube (A).

2. Removethe fuel fill cap to relievefuel tank pressure,then reinstallthe cap. 3. Disconnectthe fuel tank vapor recirculationtube t v a c u u mP u m Pt o i t . { A ) ,a n d c o n n e c a

4 . Disconnectthe vacuum hoses(A) from the EVAP

canister(B),then plug the ports with plugs (C)

A973X-041-XXXXX P l u gt h e l i n e( B ) . 5 . Apply vacuum to the fuel tank vapor recirculation tuDe. lf the vacuum holds, replacethe fuel tank vapor c o n t r o lv a l v e( s e ep a g e1 1 - 1 8 9 ) . lf the vacuum does not hold, the float is OK. Do the valve test.

A973X-O41-XXXXX 5. Disconnectthe vacuum hose (D)from the EVAP canistervent shut valve (E),and connecta vacuum pump to the vacuum hose. 6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s . . l f t h e v a c u u mh o l d s ,g o t o s t e P7 . . l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .

(cont'd)

11-187

EVAPSystem FuelTankVaporControlValveTest (cont'd) 7. Connecta secondvacuum pump to the fuel tank v a p o rs i g n a l t u b e( A ) .

Fill the fuel tank with fuel, then checkfor fuel in the EVAPtwo way valve (A),and fuel tank vapor recirculationhose (B). NOTE:At either location,tiny dropletsof fuel are normal. . lf fuel runs out of th e hosesat either location, replacethe fuel tank vapor control valve. . l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t, h e f u e l tank vapor systemfunction is normal.

8. Apply vacuum (1 pump) to the fuel tank vapor signaltube (A).then checkthe vacuum on the pump in step 6. . lf the vacuum holds,replacethe fueltank vapor c o n t r o lv a l v e{ s e ep a g e1 1 - 1 8 9 ) . . If the vacuum is released,goto step 9.

Checkfor fuel rirnningout.

Checkfor fuel runningout.

1 0 .Disconnectthe fuel tank vapor quickdisconnect from the EVAPcanister,then plug lhe port on the canister.Reapplyvacuum (80 pumps). . lf the vacuum holds,replacethe fuel tank control v a l v e( s e ep a g e11 - 1 8 9 ) . . lf the vacuum does not hold, insDectthe EVAP canistervent shut valve o-ring.lf the o-ring is OK, replacethe EVAPcanister,and repeatstep 4.

11-188

EVAPCanisterReplacement

FuelTankVapor ControlValve Replacement

l. Removethe vacuum hoses(A). 1 . R e m o v et h e f u e lt a n k ( s e e p a g e l l - 1 5 5 ) . 2 . R e m o v et h e f u e l t a n kv a p o rc o n t r o lv a l v e ( A )f r o m t h e f u e lt a n k( B ) .

2. Removethe boit (B). 3. Removethe EVAPcanister(C).

3 . Installthe fuel tank vapor control valve.

4. Installin the reverseorder of removal.

4 , Installthe fuel tank (seepage 1 -155).

11-189

Clutch .........12-2 Tools Special I n d e x . . . . . . . . . . . . . . . . . . . . . . . , .1. .2.-. 3 ........ L o c a t i o n Comoonent Switch,and ClutchPedal,ClutchPedalPosition 12-4 SwitchAdiustment.................... ClutchInterlock 12-5 ..................... CfutchMasterCylinderRep|acement 12-7 .'........ SlaveCylinderReplacement .....12-9 ................... ClutchReplacement

Clutch

SpecialTools Ref. No.

(1, @

Tool Number OTJAF-PM7O11A 07LAB-PV001 00 or 07924-PD20003 07zAF-PR8A100 07936-3710100

Description C l u t c hA l i g n m e n tD i s c R i n gG e a rH o l d e r C l u t c hA l i g n m e n tS h a f t R e m o v e rH a n d l e

Oty ,l

1 1 1

l .

l _ l

'l-r o

o .{\

.tt./

'\-'/

12-2

ComponentLocationIndex

""*--/ \,L_.Ei

/i (,'.'

_,___-,-s\

SWITCH CLUTCHINTERLOCK page12-4 Adjustment,

PEDAL CLUTCH POSTTTON SWITCH A d j u s t m e npta, g e ' 1 2 - 4

RETAININGCLIP Replace.

UTCHPEDAL A d j u s t m e n tP, a g e1 2 4

O-RING Replace. CLUTCHMASTERCYLINDER pagel2-5 Replacement, CLUTCHDISC Bemoval,page 12-9 I n s t a l l a t i op na , ge'12-12

PRESSURE PLATE page'12-9 Removal, l n s t a l l a t i opna,g e1 2 - 1 2 RELEASE BEARING B e p l a c e m epnat ,g e1 2 - 1 3

FLYWHEEL page'12-1 1 Inspection, page12-11 Replacement, CLUTCHHOSE CLIP

SLAVECYLINDER page 12-7 Replacement,

\".rr"*"o*

12-3

Clutch ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch Adjustment NOTE: . To checkthe clutch pedal positionswitch (seepage 4-45). . To checkthe clutch interlockswitch (seepage 4-6). . Removethe driver's side floor mat beforeadjusting the clutch pedal. . The clutch is self-adjustingto compensatefor wear. . lf there is no clearancebetweenthe mastercylinder pistonand push rod, the releasebearingwill be held againstthe diaphragmspring.which can resultin clutchslippageor other clutch problems. 1. Loosenthe clutch pedal positionswitch locknut(A), and backoff the clutch pedal positionswitch (B) until it no longertouchesthe clutch pedal (C). J 9.8 N.m (1.0kgf.m,7.2lbf.ft)

A 9.8 N.m 11.0kgf.m,7.2 lbf.ft)

18 N.m {1.8kgf.m, 13 tbf.ftl

Loosenthe clutch push-rodlocknut(D).and turn the push rod (E)in or out to get the specifiedheight (F),stroke(G).free play (H)and disengagement h e i g h t( l ) a t t h e c l u t c hp e d a l . Clutch PedalStroke:

130 140 mm ( 5 . 1 2 5 . 5 1i n . l Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.) Clutch PedalHeight: 193 mm (7.60in.) Disengagement Height: 115 mm (4.53in.) Between Floor And Carpet Height (ApproximateValuel: 38 mm {1.50in.l

12-4

3. Tightenthe clutch push-rodlocknut(D). 4. With the clutch pedal released.turn the clutch pedal positionswitch (B) in until it contactsthe clutch pedal (C). 5. Turn the clutch pedal positionswitch {B) in an additional3/4 to 1 turn. 6. Tightenthe clutch pedal positionswitch locknut(A). 7. Loosenlocknut(J)and the clutch interlockswitch (K). 8. Pressthe clutch pedalto the floor. 9 . R e l e a s teh e c l u t c hp e d a l1 0 ' l 6 m m ( 0 , 3 9 0 . 6 3 i n . ) from the fully pressedposition,and hold it there. Adjust the positionof the clutchinterlockswitch (K) so that the enginewill startwith the clutch pedal in thls position. 10. Tightenthe clutch interlockswitch locknut(J).

ClutchMasterCylinderReplacement NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint; if brakefluid does contactthe paint, wash it off immediatelVwith water. 1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B ) out of the yoke. Removethe mastercylinder mounting nuts (C).

6. Disconnectthe reservoirhose (D)fromtheclutch mastercylinder reservoir.Plugthe end of the reservoirhose with a shop towel to preventbrake fluid from coming out. 7. Removethe O-ring(E)and the clutch master cylinderseal (F)from the mastercylinder. 8. Installtheclutch mastercylinder in the reverse order of removal.Installa new O-ring. 9. Make sure the hose clamps (A) are positionedon the mastercylinder (B)and reservoir(C)as shown.

R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r cleanerhousing (seestep 6 on page 5-2).

3 . Removethe brakefluid from the clutch master cylinder reservoirwith a syringe. Removethe clutchline bracketfrom the frame rail, and removethe clutch line clip. Removethe clutch mastercylinder(A),and pull it toward the middle of the enginecompartment. Removethe retainingclip (B).Disconnectthe clutch line (C).Plugthe end of the clutch line with a shop towelto preventbrakefluid from coming out.

g-E

(cont'd)

12-5

Clutch ClutchMasterCylinderReplacement(cont'd) 10. To preventthe retainingclip (A)from coming off, pry open the tip of the retainingclip (B)with a screwdriver,

1 1 .Tightenthe mastercylindermounting nuts to 13 N m ( 1 . 3k g f m , 9 . 4 l b f . f t ) . Bleedthe clutch masterhydraulicsystem (seestep 11 o n p a g e 1 2 - 8 ) . N O T ET : h e r e s e r v o ifri l l i n gi s c o v e r e di n t h e bleedingprocedure. l n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e 5-15).

12-6

SlaveCylinderReplacement NOTE: . U s ef e n d e rc o v e r st o a v o i dd a m a g i n gp a i n t e d surfaces. . D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i; t m a y d a m a g e the paint; if brakefluid does contactthe paint,wash it off immediatelywith water.

6. Removethe mounting bolts (A) andtheslave c y l i n d e r( B ) .

1. Write down the frequenciesfor the radio's preset buttons.Disconnectthe negative( ) cablefirst, then the positive(+)cable from the battery. Removethe battery. 2. Removethe batterytray.

7 . Removethe roll pins (C).Disconnectthe clutch line ( D ) ,a n d r e m o v et h e O - r i n g( E ) .P l u gt h e e n d o f t h e clutch line with a shop towel to preventbrakefluid f rom coming out. Installtheslavecylinder in the reverseorder of removal.Installa new O-ring (A).

R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r c l e a n e rh o u s i n g( s e es t e p6 o n p a g e5 - 2 ) . 4 . Removethe intakeair duct (seestep 8 on page 5-3).

5 . Removethe clutch line bracket(A).

,,6NJ' =-#.q!4sEn (P/N08798-90021

(Brak6Assembly Lube)

9 . P u l l t h eb o o t ( B )b a c k ,a n d a p p l yb r a k ea s s e m b l y l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l the boot.

1 0 .Apply super high temp urea grease(P/N087989 0 0 2 )t o t h e p u s h r o d o f t h e s l a v ec y l i n d e rT. i g h t e n t h e s l a v ec y l i n d e rm o u n t i n gb o l t st o 2 2 N m ( 2 . 2 kgfm, 16lbf.ft).

(cont'd)

12-7

Clutch SlaveCylinderReplacement(cont'd) 11. Bleedthe clutch hydraulicsystem. . Aftach a hoseto the bleederscrew (A),and suspendthe hose in a containerof brakefluid. . M a k es u r et h e r ei s a n a d e q u a t es u p p l yo f f l u i d i n the clutch mastercylinder,then slowly pump the clutch pedal until no more bubblesappearatthe bleederhose. . lt may be necessaryto llmit the movement of the releasefork (B)with a blockof wood to remove all the air from the system. . Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf ft); do not ovenightenit, . Refillthe clutch mastercylinderwith fluid when done. . Always use only Honda DOT3 brakefluid.

L 12. Installthe intakeair duct (seestep 36 on page 5-14). 1 3 .I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e 5-15). 1 4 . Installthe batterytray. t5.

Installthe battery,connectthe positive(+) cable first, then the negative(- ) cable.

1 6 . Resetthe frequenciesfor the radio stationpreset buttons,

12-8

ClutchReplacement Spscial Tools Required . Clutchalignmentdisc 07JAF-PM701 1A . Ringgear holder07LAB-PV00100 or 07924-PD20003 . Clutchalignmentshaft 07ZAF-PR8A100 . Removerhandle07936-3710100

2 . I n s t a l l t h es p e c i atl o o l s . A

PressurePlateand GlutchDiscRemoval 1 . C h e c kt h e d i a p h r a g ms p r i n gf i n g e r sf o r h e i g h t using lhe speciallool and feelergauge.lf the height is more than the servicelimit, replacethe pressure ptate.

A-.-

nl I

\ffim 9fra-I

StandardlNewl: ServiceLimit:

0.6 mm (0.02in.) max. 0.8 mm {0.03in.)

07zAF-PR8A100 07936-3710100 OTJAF-PM7O11A

07LAB-PV00100 or 07924-PD20003

plate To preventwarping,unscrewthe pressure patternin several mountingbolts(A)in a crisscross plate(B). steps,then removethe pressure Inspectthefingersof the diaphragmspring(A)for wearat the releasebearingcontactarea.

5. Inspectthe pressureplate 1A)surfaceforwear, cracks.and burning.

(cont'd)

12-9

Clutch ClutchReplacement(cont'd) 6. Inspeclfor warpage using a straightedge (A) and feeler gauge (B).l\4easureacrossthe pressureplate (C).lf the warpage is more than the servicelimit, replacethe pressureplate. Standard{New): ServiceLimit:

0.03mm (0.001in.) max. 0.15mm (0.006in.)

9. lvleasure th e clutchd isc th ickness.lfthethickness is lessthan the servicelimit, replacethe clutchdisc. StandardlNew): ServiceLimit:

8.3 8.9 mm (0.33 0.35in.) 6.0 mm {0.24in.)

1 0 .Measurethe rivet depthfrom the clutchdisc lining 7 . R e m o v et h e c l u t c hd i s ca n d s D e c i a l t o o l s .

1 d

surface(A) to the rivets(B)on both sides.lf the rivet depth is lessthan the servicelimit, replacethe c l u t c hd i s c . Standard(New): ServiceLimit:

I n s p e c t t h el i n i n go f t h e c l u t c hd i s cf o r s i g n so f s l i p p i n go r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r oil soaked.reolaceit.

12-10

1.65 2.25 mm (0.065 0.089in.) 0.7 mm (0.03in.)

FlywheelInspection 1. Inspectthe ring gear teeth for wear and damage.

FlywheelReplacement 1 . I n s t a l l t h es p e c i atlo o l .

2. Inspectthe clutchdisc mating surfaceon the flywheel for wear, cracks,and burning. 3. Measurethe flywheel (A) runout using a dial indicator(B)through at leasttwo full turns. Push againstthe flywheel eachtime you turn it to take up the crankshaft th rust washerclearance.lf the runout is more than the servicelimit, replacethe flywheel and recheckthe runout.Resurfacingthe flywheel is not recommended. Standard(New): 0.05mm (0.002in.) max. ServiceLimit: 0.15mm (0.006in.)

2 . Removethe flywheel mounting bolts in a crisscross patternin severalsteps,then removethe tlywheel.

3 . Installtheflywheel on the crankshaft,and install the mounting bolts fingertight. 4 . I n s t a l l t h es p e c i a l t o o lt,h e nt o r q u et h e f l y w h e e l

mounting bolts in a crisscrosspatternin several sreps.

1 2 x 1 . 0m m 103 N.m (10,skst.m. 76 lbf ftl

(cont'd)

12-11

Glutch ClutchReplacement(cont'dl ClutchDiscand PressurePlateInstallation 'L

T e m p o r a r i l yi n s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s of the transmissionmainshaft,Make sure the clutch disc slidesfreely on the mainshaft.

2 . l n s t a l l t h er i n g g e a rh o l d e r .

pattern, 5. Torquethe mountingboltsin a crisscross Tightenthe boltsin severalstepsto prevent warping spring. t h ed i a p h r a g m PRESSURE PLATE MOUNTING BOLTTOROUE: 25 N.m{2.6kgt.m,19lbt.ft)

O?ZAF.PRSAIOO

\---,

07936-3710100

{P/N08798-9002) 07LAB-PVo0'100 or 0792,1-PD20003

3 . Apply super high temp urea grease(P/N087989002)to lhe splines(A) of the clutch disc (B),then installthe clutchdisc usingthe specialtools. Removethe specialtools. Installthe pressureplate (A) and the mounting bolts (B)finger-tight.

12-12

1 . Make sure the diaphragmspringfingers are all the s a m eh e i g h t .

ReleaseBearingReplacement 'L

Removethe releasefork boot (A)from the clutch h o u s i n g( B ) .

4 . Apply super high temp urea grease{P/N087989002)to the releasefork (A),the releasefork bolt ( B ) ,t h e r e l e a s eb e a r i n g( C ) ,a n d t h e r e l e a s eb e a r i n g g ui d e ( D )i n t h e s h a d e da r e a s . 1 . 0 1 . 6g 10.04 0.06oz)

l-'..\ \\

!ac \ ) ) / /-/

Xrl-Rl It\'1 f-l\-._

-A

{re\

I L!),l-*E

0 . 4 1 . 0g 10.01 0.04o

0.t 1.09 (0.01 0.04oz)

2 . Removethe releasefork (C)from the clutch h o u s i n g( B )b y s q u e e z i n tgh e r e l e a s ef o r k s e ts p r i n g ( D ) w i t hp l i e r s R . e m o v et h e r e l e a s eb e a r i n g( E ) .

3 . Checkthe releasebearingfor play and noise by p l a yo r s p i n n i n gi t b y h a n d .l f t h e r ei s e x c e s s i v e n o i s e ,r e p l a c et h e r e l e a s eb e a r i n gw i t h a n e w o n e . NOTE:The releasebearingis packedwith grease. Do not wash it in solvent.

With the releasefork slid betweenthe release b e a r i n gp a w l s .i n s t a l l t h er e l e a s eb e a r i n go n t h e m a i n s h a fw t h i l e i n s e r t i n gt h e r e l e a s ef o r kt h r o u g h t h e h o l ei n t h e c l u t c hh o u s i n g . 6 . Align the detentof the releasefork with the release fork bolt,lhen pressthe releasefork over the r e l e a s ef o r k b o l ts q u a r e l yM . a k es u r et h e r e l e a s e f o r k s e t s p r i n g( F )i s p r o p e r l ys e t . 7 . I n s t a l l t h er e l e a s ef o r k b o o t{ E ) .M a k es u r et h e b o o t s e a l sa r o u n dt h e r e l e a s ef o r k a n d c l u t c hh o u s i n g . 8 . Move the releasefork (A) right and left to make s u r et h a t i t f i t s p r o p e r l ya g a i n s t h e r e l e a s eb e a r i n g ( B )a n d t h a tt h e r e l e a s eb e a r i n gs l i d e ss m o o t h l y .

12-13

ManualTransmission SpecialTools 13-2 Transmission FluidInspection a n dR e o 1 a c e m e. n. .t. . . . . . . . . . . .|.5-J ...-. Back-Up LightSwitchTest ..........t J - 5 Transmission Removal 13-4 Transmission Installation........... I J-at Transmission Disassemblv........1 3 - 1 4 Reverse ShiftForkClearance lnsoection 13-19 ChangeLeverClearance lnsoection 13-19 ChangeLeverAssembly Disassembly/Reassembly .......13-20 ShiftForksClearance Inspection 13-21 ShiftForks Disassembly/Reassembly .......13-22 Mainshaft Assemblv Clearance Inspection 13-23 't3-25 Mainshaft Disassembly Mainshaft lnsoection 13-26 Mainshaft Reassembly | 5-2.5 Countershaft Assemblv Clearance Inspection 13-31 Disassembly Countershaft .........13-32 Inspection............. Countershaft 13-33 Reassembly.......... Countershaft 13-34 SynchroSleeveand Hub Inspection andReassembly .... 13-39

SynchroRingandGear Insoection .......13-39 Mainshaft BearingandOilSeal R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.4, .1. . Countershaft Bearing ReDlacement .. 13-42 Mainshaft ThrustClearance Adiustment .....13-43 Transmission Reassemblv.........13-46 Gearshift Mechanism R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.5. .1. .

M/T Differential Comoonent LocationIndex ........13-52 Backlash Inspection..................... 13-53 FinalDrivenGear/Carrier Replacement .. 13-53 ... 13-54 CarrierBearings Replacement Oil SealReplacement 13-55 .................. Differential ThrustClearance Adiustment .....13-56

ManualTransmission SpecialTools ToolNumber

Ref.No.

Description E n g i n eH a n g e rA d a p t e r ,2 . 0t o 2 . 4 L i t e r E n g i n eH a n g e r ral M a i n s h a fH t older 07GAJ-PG20' ]10 M a i n s h a fB t ase 07GAJ-PG20130 @ O i l S e a lD r i v e r 07JAD-P190100 Oil Seal DriverAftachment 07NAD-P20A100 AdjustableBearingPuller,20-40mm 07736-A01000B ri) Attachment,42 x 47 mm 07746-0010300 Driver,40 mm LD. 07746-0030100 @ Driver,30 mm LD. 07746-0030300 @ Driver 07749-0010000 @ of Mainshaft Inspection on T o o lS e t .0 7 G A J - P G 2 0 1 0 2 . Tool Set, '16 S l i d eH a m m e r . M u s t b e u s e dw i t h c o m m e r c i a l lay v a i l a b l e3 / 8 "

(!l ar\

o o

Z-'

-4

I rS'D

A nDr f ; \".,i'i

\'---''

IN @

-4

-a ,/

Q)-'' o

13-2

Oty

vs802c000015 vs802c000018

l l ,l

Transmission FluidInspectionand Replacement

Back-UpLight Switch Test 1. Disconnecttheback-uplight switch (A) connector.

'1.

Parkthe vehicleon level ground,and turn the e n g i n eO F F .

2 . R e m o v et h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k the conditionof the fluid, and make sure the fluid is at the proper level (C).

2 . Checkfor continuitybetweenthe back up light s w i l c h2 P c o n n e c t o N r o.1 andNo.2 terminals. There should be continuitywhen the shift lever is in reverse. l f t h e t r a n s m i s s i ofnl u i d i s d i n y , r e m o v et h e d r a i n p l u g( D )a n d d r a i nt h e f l u i d .

3 . lf necessary,replacethe back-uplight switch. A p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 - 0 0 0 1a)n, d i n s t a l il t o n t h et r a n s m i s s i oh nousing.

A 44 N.m{4.5kgt.m,

33rbr.ftl

R e i n s t a tl lh e d r a i np l u gw i t h a n e w w a s h e r ,a n d refillthe transmissionfluid to the proper level. Oil Capacity 1.50 (1.6US (F) at tluid change 1.70 {1.8US qt) at overhaul Always use Honda ManualTransmissionFluid (MTF).Using motor oil can causestiffer shifting and noise becauseit does not containthe proper additives. 5 . R e i n s t a tl lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r .

13-3

ManualTransmission Transmission Removal SpecialToolsRequired . E n g i n eh a n g e ra d a p t e r . 2 . t0o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5 . E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR'T 12566' ' . SubframeadaDterEOS02C000011 * A v a i l a b l et h r o u g ht h e H o n d aT o o l a n d E q u i p m e n t Program888-424-6857

8. Removethe cable bracket(A).then disconnectthe c a b l e s( B )f r o m t h e t o p o f t h e t r a n s m i s s i o h nousing. Carefullyremove both cablesand the bracket togetherso as not to bend the cables.

A i

@ l

NOTE:Use fender coversto avoid damaging painted surfaces. 1 . Write down the frequenciesfor the radio'spreset buttons.Disconnectthe negative( ) cablefirst, then the positive( )cable from the battery. Removethe battery. Removethe intakemanifoldcover {seepageg-3). R e m o v et h e a i r c l e a n e rh o u s i n g( s e ep a g e11 - 1 6 2 ) . 4 . Removethe intakeair duct {seestep 8 on page 5-3).

Removethe batterytray (A). 9 . R e m o v et h e h a r n e s sc l i p .

D i s c o n n e ct h t e t r a n s m i s s i o gn r o u n dc a b l e( B ) . 7 . Disconnectthe back-uplight switch connector(A) a n dv e h i c l es p e e ds e n s o r( V S S )c o n n e c t o(rB ) .

13-4

10. Carefullyremovethe slavecylinderand clutchline bracketso as not to bend the clutch line. Do not operatethe clutch pedalonce the slavecylinder has been removed,

12. Attach the specialtool to the threaded hole in the c y l i n d e rh e a d .

vsB02c00001s

tJ.

1 1 .Removethe enginewire harnesscover (A) by lifting up on the locktab (B),then slidethe harness f o r w a r do f f t h e a i r c l e a n e rh o u s i n gm o u n t i n g bracket{C).

I n s t a l l t h ee n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t hanger {B) to the vehicle,then attachthe hook to the sDeciaitool.

vs802c000015

1 4 . Removethe two upper transmissionmounting bolts.

(cont'd)

13-5

ManualTransmission Removal(cont'd) Transmission 15. Removethe transmissionmount bracket(A) and t r a n s m i s s i om n o u n t i n gb o l t ( B ) .

20. Removethe three way catalyticconverter(TWC) assembly(seestep 30 on page 5-5)

2 1 . Removethe driveshafts(seepage 16-3). 22. Removethe intermediateshaft {seepage 16-19). 23. Removethe front enginemount bracketmounting bolt.

t o . R e m o v et h e a i r c l e a n e rb r a c k e {t C ) .

1 7 . R a i s et h e v e h i c l e a, n d m a k es u r ei t i s s e c u r e l y supponed. 1 8 . D r a i nt h e t r a n s m i s s i o fnl u i d .R e i n s t a tl lh e d r a i nb o l t w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) .

24. Removethe three bolts securingthe transmission

1 9 . R e m o v et h e s p l a s hs h i e l d .

r e a rm o u n I .

db-qF

€Ds

13- 6

25. Supportthe subframewith the subframeadapter and a jack.

27. Removethe clutchcover.

---

EOS02C000011 2 8 . R e m o v et h e f r o n t e n g i n em o u n t .

26. Make referencemarks (A) on the front suspension subframe(B)and mounting bolts (C).then remove the front suspensionsubframe.

29. P l a c et h e t r a n s m i s s i oina c ku n d e rt h e t r a n s m i s s i o n , and removethe transmissionmounting bolts.

(cont'd)

13-7

ManualTransmission TransmissionRemoval(cont'd)

TransmissionInstallation

30. Pullthe transmissionaway from the engine until

Special Tools Required . Enginehangeradapter,2.0to 2.4 liter VS802C000015 . En g i n eh a n g e rV S 8 0 2 C 0 0 0 0 1 8 . Enginesupport hanger,A & RedsAAR-T-12566" . subframe adaDterEoS02c000011 * Availablethrough the HondaTool and Equipment Program888-424-6857

the transmissionmainshaftclearsthe clutch pressureplate,then lower the transmissionon the transmissionjack. Removethe transmissionrear mount (A) and the transmissionrear mount bracket{B).

1. Checkthe two dowel pins are installedin the clutch h o u s nr g . Apply super high temp urea grease(P/N087989002)to the releasefork (A) and the releasebearing (B).Installthe releasefork and the releasebearing. 1 . 0 ' 1 . 6g {0.04 0.06oz)

3 2 . Removethe boot (A),the releasefork {B).and the r e l e a s eb e a r i n g( C )f r o m t h e t r a n s m i s s i o (nD ) .

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

1 2 x 1 . 2 5m m 64 N.m {6.5 ksf.m, 47 tbf.ft)

P l a c et h e t r a n s m i s s i o o n n t h e t r a n s m i s s i o ina c k . and raiseit to the engine level.

13-8

5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts. 1 2 x 1 . 2 5m m 64 N.m 16.5kgf m.47 lbt ft)

8. Supportthe subframewith the subframeadapter a n da j a c k .

1 2 x 1 . 2 5m m 64 N.m (6.5kgf.m,47 lbf.ft) 6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .

9 . I n s t a l l t h ef r o n t s u s p e n s i o sn u b f r a m e( A )i n i t s originap l o s i t i o nb y a l i g n i n gt h e m a r k s( B )y o u made in the removal procedure,

12 x 1.25ftrn 64 N.m (6.5 kgf m. 47 lbf.ft)

12x 1.25mm 64 N.m (6.5kst.m,47 lbf ft) 7 . l n s t a l l t h e c l u t c hc o v e r . 1 4x 1 . 5m m

6x1.0mm 12 N.m {1.2kgI.m,9 lbf ftl

(cont'd)

13-9

ManualTransmission Transmission Installation(cont'dl '10.

Installthethree rear mounting bolls for the transmissionrear mount.

1 5 .Installthe transmissionmount bracket(A) and the transmissiom n o u n t i n gb o l t{ B ) . 6x1.0mm 12Nm

1 2 x 1 . 2 5m m 54 N.m {5.5ksf.m, 40lbf.ft) 12x 1.25nn 54 N.m (5.5kgf.m, 40 tbt.ft)

/t':::= -)

12 x 1.25 mm 54 N.m (5.5kgf.m, 40 tbf.ftl

1 6 . Installthe air cleanerbracket(C). 10 x 1.25mm

59 N.m(6.0kgf.m,43tbf.ft)

1 7 . Installthe two uppertransmissionmounting bolts.

1 1 .Looselytighten the front engine mount bracket mounting bolt.

12x 1.25mrn 64 N.m(6.5kgt.m,47lbf.ftl

12. Installthe intermediateshaft (seepage 16-24). t5.

Installthedrivershafts(seepage 16-17).

1 4 . lnstallthe three way catalyticconverter(TWC) assembly(seestep 17 on page 5-12).

13-10

1 8 . R e m o v et h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m engrne.

19. Tightenthe front engine mount bracketmounting bolt. '12x 1.25mm 64 N.m 16.5kgf.m, il7 lbf.ft)

21. lnstallthe brakeboosterand EVAPline bracket mounting bolts (A).and air cleanerhousing bracket m o u n t i n gb o l t ( B ) .T i g h t e nt h e a i r c l e a n e rh o u s i n g bracketmounting bolt (C),and installthe water pipe mounting bolt (D). A 9.8N.m ( 1 , 0k q f

2 0 . I n s t a ltl h e s p l a s hs h i e l d .

22N.m l2.2kglm, 16rbt.ft)

9.8Nm (1.0kgf m. 'B 7.2tbl{rl 22Nm {2.2kgf m, 16 lbf ft)

22. I n s t a l l t h ee n g i n eh a r n e s sc o v e r .

(cont'd)

13-11

ManualTransmission Transmission Installation(cont'dl Applysuperhightemp ureagrease(P/N087989002)to the endof the slavecylinderrod.Installthe slavecylinderandthe clutchlinebracket. Takecare

2 5 . I n s t a l l t h ec a b l eb r a c k e (t A )a n d c a b l e s( B ) .

BWZ[i:i'u'T!'*n'-'

not to bend the clutch line. 8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbf ft)

a^_

#._gEEa9En (P/N08798-9002)

6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbt.ftl

lPlN 08798-9002)

2 4 . I n s t a l l t h eh a r n e s sc l i p .

26. Apply a light coat of super high temp urea grease (P/N08798- 9002)to the cable ends. t1

13-12

Connectthe back-uplight switch connector(A) and t h e v e h i c l es p e e ds e n s o r{ V S S ) c o n n e c t o( B r ).

28. Connectthe transmissionground cable (A). 8 x 1.25mm 22 N.m (2.2kgf.m, 16lbf.ft)

[---.-.---e e

6x1,0mm 9.8 N.m {1.0kgl m. 7 lbf ftl

8x125mm 22Nm 12.2kgt m, 16lbf ft)

29. lnstallthe batterytray (B). 30. Installthe intakeair duct (seestep 36 on page 5-14). I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 9 o n p a g e 5-15).

3 2 . Installthe intakemanifoldcover (seestep 41 on p a g e5 - 1 5 ) .

33. Installthe battery.Connectthepositive(+) cable first, then the negative(-)cable to the battery.

34. R e f l l l t h et r a n s m i s s i ofnl u i d ( s e ep a g e1 3 - 3 ) . 35. Test-drivethe vehicle. 36. Checkthe clutchoperation. 3 1 .Checkthe front wheel alignment(seepage 18-4). 38. Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets.

39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .

13-13

ManualTransmission Transmission Disassembly ExplodedView-ClutchHousing

,.Y

/ ,, tl ' r'<__J'.@t j=-X ri ,1.-6

'-==-Yh,_-9 n""

-',ot/u

,tA'

v i6

\? q'/V^

-1 t3l

t€4

.!) DIFFERENTTAL ASSEMBLY r2lSHIFTFORKASSEMBLY a9l6 mm FLANGEBOLT 1 2 N . m ( 1 . 2k g f m , 9 l b f f t l ..4]BEARINGsET PLATE G, COUNTERSHAFTASSEMBLY O NEEDLEBEARING 3 OIL GUIDEPLATEC e 14 x 20 mm DOWELPIN .9-iMAGNET i.!! MAINSHAFTASSEMBLY U 28 mm WASHER

13-14

i[, 28 mm SPRINGWASHER iO BALLBEARING (l 28 x 43 x 7 mm OIL SEAL Replace. .D REVERSE GEARSHAFT IDLERGEAR 1' REVERSE f lr 6 mm SPECIALBOLT 15 N.m (1.5kgt.m, 11 lbf.ft) (!I REVERSESHIFTFORK .4' REVERSELOCKCAM Q-t35 x 58 x 8 mm OIL SEAL Replace.

?]] BACK-UPLIGHTSWITCH 29 N m (3.0kgf.m,22 lbf ftl .?1O.RING Replace.

(Vss) SPEEo sENsoR 1!)VEHICLE .O 8 mm FLANGEBOLT 22 N.m (2.2kgf m, 16lbf.ftl .' CLUTCHHOUSING iI6)TRANSMISSIONHANGER tl 10 mm FLANGEBOLT 44 N.m {4.5kgt.m,33 lbf.ft}

Housing ExplodedView-Transmission tt-P @

"=-@

'\b e o,.

rai \€:/

z-W €: P\B iq

{

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O=-rl

@------

F,z

,-1 _\ (g/----------__"^\

\-/r*---------..-,

HOUSING O TRANSMISSION O 10 mm WASHER Replace. @ 10 mm FLANGEBOLT 44 N.m {4.5kgf.m,33lbf.ft) O 8 mm FLANGEBOLT 27 N.m 12.8kgf m,20lbl.ft) .' TRANSMISSIONHANGERA O INTERLOCKBOLT 39N m (4.0ksf.m,29lbf.ft) O OILGUIOEPLATEM €.172 mm SHIM .' OIL GUTTEBPLATE

{i) 80 mm SHIM PIN 0 8 x 14mm DOWEL [A CHANGELEVERASSEMBLY a06 mm FLANGEBOLT 12N m {1.2kgf.m,9lbfft} BOLT O DETENT 22 N.m{2.2kgf.m,16lbf.ft) O 12mm waSHER

ReDlace. (D SPRING [I STEELBALL (D TRANSMISSION HANGERB (9 CLUTCHLINE CLIPBRACKET

@)20 mm WASHER Replace. q,]FILLERPLUG 44 N m {4.5kgf.m,33 lbf.ft) @ 40 x 56 x 8 mm OILSEAL Replace. qO14 mm WASHER Replace. q' DRAIN PLUG 39 N.m (4.0kgf.m,29 lbf.ftl @ 32 mm SEALINGCAP 34 N m (3.5 kgf.m, 25 lbf.ft)

(cont'd)

13-15

ManualTransmission TransmissionDisassembly(cont'd) NOTE:Placethe clutch housingon two piecesof wood thick enoughto keepthe mainshaftfrom hittingthe workbench.

3, Removethe interlockbolt (A),the changelever a s s e m b l y( B ) ,8 x 1 4 m m d o w e lp i n s( C ) ,a n d t h e c l u t c hl i n ec l i p b r a c k e{t D ) .

1. Removethe detent bolts (A),springs,steel balls, and back-uplight switch (B).

€

R e m o v et h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d 1 0 m m f l a n g eb o l t ( C ) . Removethe vehiclespeedsensor(VSS)(A) and O - r i n g( B ) .

13-16

5. Removethe 8 mm flange bolts in a crisscross Datternin severalsteos.

10. Removethe reverselock cam.

g t.l

6 . Removethe transmissionhangerA, and transmissioh n a n g e rB .

Y g

1 1 .Removethe reverseidler gear {A) and reversegear s h a f t{ B ) .

7 . R e m o v et h e 3 2 m m s e a l i n gc a p ( A ) .

E x p a n dt h e 7 2 m m s n a pr i n g ( B )o n t h e countershaftball bearing,and remove it from the groove using a pair of snap ring pliers. L R e m o v et h e t r a n s m i s s i o h n o u s i n g( C )a n d 1 4 x 2 0 m m d o w e l p i n s( D ) .

(cont'd)

13-17

ManualTransmission TransmissionDisassembly(cont'd) 15. Removethe differentialassembly(A) and magnet ( B) .

12. Removethe reverseshift fork.

t1 I

Apply vinyl tape to the mainshaftsplinesto protect the seal,then removethe mainshaftassembly(A) and countershaftassembly(B)with the shift forks { C ) f r o mt h e c l u t c hh o u s i n g( D ) .

1 4 . R e m o v et h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m w a s h e r( F ) .

13-18

1 6 . Removethe oil gutter plate (A),72mm shim (B), a n d o i l g u i d ep l a t eM .

ReverseShift ForkClearance Inspection 1. Measurethe clearancebetweenthe reverseidler gear {A) and the reverseshift fork (B)with a feeler gauge (C).lf the clearanceis more than the service limit, go to step 2.

ChangeLeverClearanceInspection 1 . Measurethe clearancebetweenchangelever (Al and the selectlever (B)with a feelergauge (Cf.lf i s m o r et h a nt h e s e r v i c el i m i t ,g o r o theclearance step 2. 0.05 0.25 mm (0.002-0.010in.) Standard: ServiceLimit: 0.50mm {0.020in.)

0.20-0.59 mm (o.oo7 0.024 in.l Standard: ServiceLimit: r.3 mm {0.051in.)

2. Measurethe groove of the changelever' Measure the width of the reverseshift fork. . l f d i s t a n c ei s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e t h e reverseshift fork with a new one. . lf distanceis within the standard,replacethe reversegear wrln a new one. Standard: 13.4 13.7mm (0.527 0.539in.l

. lf distanceis not within the standard,replacethe c h a n g el e v e rw i t h a n e w o n e . . l f d i s t a n c ei s w i t h i n t h es t a n d a r dr,e p l a c e t h e selectlever with a new one. Standard: 1 5 . 0 0 1 5 . 1 0m m ( 0 . 5 9 1 - 0 . 5 9 4i n . )

,tl I

13-19

ManualTransmission ChangeLeverAssemblyDisassembly/Reassembly Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactsurface.

@).1 l L

r rrl

BREATHER CAP Turnthe arrowtowardthe{ront andinstallit. o{ thevehicle,

LEVER SELECT Becarefulnotto damagethedustseal w h e ni n s t a l l i ni tg.

I l

DUSTCOVEB

a^^

7 Fr"irr6-rooa SHIFTARM COVER

ROLLER (P/N 08798-9002) 6x1.0mm 12 N.m (1.2kgl.m,8.7 lbf.ft)

\op (g)'

WASHER

\r'

E-='1sr/2No !-d

Fl q

)-=^l

€2

sPntruc

H\ srx lV

tr7

-, OILSEAL ReDlace.

sELEcr

(A) ,.* tace.ix#,,l -z:-=:l-':

/-r,s \__/

INTERLOCK

SHIFTARM

SELECT SPRING

,/u / SELECTSTOP PLATE 9.8Nm {1.0kgf.m,7.2 lbf.ft) LOCKCAM REVERSE STRIKER

13-20

Shift ForksGlearanceInspection NOTE:The synchrosleeveand synchrohub should be replacedas a set. 1. Measure the clearancebetweeneach shift fork (A) and its matchingsynchrosleeve(B).lf the clearanceexceedsthe servicelimit, go to step 2.

3. Measurethe clearancebetweenthe shift fork (A) and the shift arm (B).lf the clearanceexceedsthe servicelimit, go to slep 4. 0.2-0.5 mm (0.007 0.020in.) Standard: ServiceLimit: 0.62mm (0.024in.)

Standard: 0.35 0.65 mm {0.014 0.026in.1 ServiceLimit: 1.0 mm 10.039in.l

4 . Measurethe width of the shift arm.

2 . l\4easurethe thicknessof the shift fork fingers. . l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s n o t within the standard,replacethe shift fork with a new one. . l f t h e t h i c k n e s s otfh e s h i f tf o r k f i n g e ri s w i t h i n the standard,replacethe synchrosleevewith a new one.

. l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e standard,replacethe shift arm with a new one. . l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d , replacethe shift fork and shift piecewith a new one. Standard: 16.9-17.0 mm (0.665-0.669in.)

Standard:7.4 7.6 mm (0.29-0.30 in.)

13-21

ManualTransmission Shift ForksDisassembly/Reassembly Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactparts.

sTH SHIFTFORK

PINDRIVER, 5 mm

13-22

MainshaftAssemblyClearanceInspection NOTE:lf replacementis required,always replacethe synchrosleeveand hub as a set. 1. Supportthe bearinginner racewith an appropriate sizedsocket(A).and push down on the mainshaft (B).

4. Measurethe clearancebetween4th gear (A) and t h e d i s t a n c ec o l l a r( B )w i t h a d i a l i n d i c a t o (r C ) . . lf the clearanceis more than the servicelimit, go to step 5. . lf the clearanceis within the servicelimit, go to step 7. Standard: ServiceLimit:

0.06 0.16 mnl (0.002 0.006in.) 0.25mm {0.010in.)

Measurethe clearancebet\iveen2nd (C)and 3rd (D) gearswith a feelergauge {E). . l f t h e c l e a r a n c ies m o r et h a nt h e s e r v i c el i m i t .g o to step 3. . lf the clearanceis within the servicelimit, go to step 4. MeasuredistanceO on the distanceco[ar. Standard: ServiceLimit:

0.06 0.16mm {0.002 0.006in.l 0.25 mm (0.010in.l

. lf distance't is notwithin the standard,replace the distancecollarwith a new one. . lf distancee is within the standard,go to step 6.

Measurethe thicknessof 3rd gear. Standard: . lf thethickneso s f 3 r d g e a r i s l e s s t h a n t h es e r v i c e l i m i t ,r e p l a c e3 r d g e a r w i t ha n e w o n e . . lf thethickneso s f 3 r dg e a r i s w i t h i n t h e s e r v i c e limit, replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit:

24.03 24.08mm {0.946-0.9/uin.}

23.92-23.97 mm (0.941 0.944in.) 23.80mm (0.937in.)

(cont'd)

13-23

ManualTransmission MainshaftAssemblyClearanceInspection(cont'd) 6. Measurethe thlcknessof 4th gear. . lf thethickneso s f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e limit, replace4th gear with a new one. . l f t h e t h i c k n e s s o4f t h g e a r i s w i t h i nt h e s e r v i c e limit. replacethe 3rd/4thsynchrohub with a new one. Standard: ServiceLimit:

8. MeasuredistanceO on the distancecollar. . l f d i s t a n c eO i s n o t w i t h i n t h e s t a n d a r dr ,e p l a c e the distancecollar with a new one. ' l f d i s t a n c e Oi s w i t h i n t h es t a n d a r dg, o t o s t e p 9 . Standard:

24.03 24.08mm (0.946 0.947in.)

23.92 23.97mm (0.941 0.944in.) 23.80mm (0.937in.)

9. Measurethe thicknessof 5th gear.

7. l\4easure the clearancebetweenthe distancecollar ( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o (r C ) .l f t h e clearanceis more than the servicelimit. go to step i s w i t hi n t h e s e r v i c el i m i t ,g o t o 8.lf theclearance steD10. Standard: ServiceLimit:

13-24

0.06 0.16mm (0.002-0.006in.) 0.25 mm (0.010in.)

. l f t h e t h i c k n e s s o5f t h g e a r i s l e s s t h a n t h e s e r v i c e limit, replace5th gear with a new one. . lf the thicknessof sth gear iswithin the service limit. replacethe 5th synchrohub with a new one. Standard: Service Limit:

23-92 23.97mm 10.9410.944in.l 23.80mm (0.937in.l

MainshaftDisassembly '10. M e a s u r et h e t h i c k n e s so f t h e M B S d i s t a n c ec o l l a r . . l f t h et h i c k n e so s f M B S d i s t a n c ec o l l a ri s l e s s than the standard,replacethe MBS distance c o l l a rw i t h a n e w o n e . Standard:

1 . R e m o v et h e a n g u l a rb a l l b e a r i n g( A )a n d t h e taperedcone ring using a commerciallyavailable b e a r i n gs e p a r a t o{rB )a n d a c o m m e r c i a l l a yvailable b e a r i n gp u l l e r{ C ) .B e s u r et h e b e a r i n gs e p a r a t oirs u n d e rt h e t a p e r e dc o n er i n g .

23.95 24.05mm {0.9(3 0.947in.)

E-f Support5th gear (A) on steel blocks,and pressthe mainshaftout of the sth synchrohub (B).Use of a jaw-typepuller can damagethe gear teeth.

(cont'd)

13-25

ManualTransmission MainshaftDisassembly(cont'dl 3. Supportthe 3rd gear (A) on steel blocks,and press the mainshaftout of the 3rd/4thsynchrohub (B). Use of a jaw-type puller can damagethe gear teeth.

MainshaftInspection 1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g et,h e n m e a s u r et h e m a i n s h a fat t pointsA, B, C, D, and E. lf any part of the mainshaft is lessthan the servicelimit, reDlaceit with a new on e . Standard: A Ball bearingsurface(transmissionhousingside): 2 7 . 9 8 7 2 8 . 0 0 0m m ( 1 . 1 0 1 9 1 . 1 0 2 4 i n . ) B Distance collar surtace: 31.984 32.000mm {1.2594 1.2598in.) C Needle bearing surlace: 38.984-39.000mm (1.53/t8 1.5354in.) D Ball bearingsurface(clutchhousingside): 2 7. 9 7 7- 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . ) E Bushing surface: 20.80 20.85mm (0.819 0.821in.) ServiceLimit; A : 2 7 . 9 3m m 1 1 . 1 0 i0n . l B: 31.93 mm |.1.257in.l C: 38.93mm 11.533in.l Di 27.92mm {1.099in.l E: 20.75mm 10.817in.l

{

13-26

2. Inspectthe runout by supponing both ends of the mainshaft.Rotatethe mainshafttwo complete revolutionswhen measuringthe runout. lf the runout is more than the servicelimit. reolacethe mainshaftwith a new one. Standard: 0.02mm (0.001in.) max. ServiceLimit: 0.05mm (0.002in.)

13-27

ManualTransmission MainshaftReassembly ExplodedView

QJ'

frfl Y7

3RD/4TH SYNCHRO SLEEVE 3RD/4TH SYNCHROHUB

ANGULAB BALL BEARING Checkfor wear and operation. Note the directionof installation. TAPEBEDCONERING MBS DISTANCECOLLAR

SYNCHRO SPRING SYNCHROSLEEVE SYNCHRORING

NEEDLE BEARING Checkfor wearandoperation.

MAINSHAFT

NEEDLEBEARING

Checkfor wear and operation.

(

GEAR 4TH/5TH GEAB DISTANCECOLLAR SYNCHRORING SYNCHROSPRING

a 13-28

SpecialTools Required . D r i v e r , 4 0m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0 . Attachment,30mm l.D.07746-0030300

6. Installthe3rd/4thsynchrosleeve(A) by aligning the stops (B)with the 3rd/4thsynchrosleeveand hub. After installing,checkthe operationof the 3rd/ 4th synchrohub set.

NOTE:Referto the ExplodedView as neededduring this procedure. '1. Cleanall the parts in solvent,dry them, and apply lubricantto all contactsurfacesexceptthe 3rd/4th and 5th synchrohubs.

@--

2. I n s t a l l t h en e e d l eb e a r i n ga n d 3 r d g e a ro n t h e mainshaft. I n s t a l l t h es y n c h r or i n g a n dt h e s y n c h r os p r i n g . 4 . I n s t a l l t h e3 r d / 4 t hs y n c h r oh u b ( A ) b y a l i g n i n gt h e

synchroring fingers (B)with 3rd/4thsynchrohub grooves(C). -A

lnstallthe 3rd/4thsynchrohub {A) usingthe special tool.

7 . I n s t a l l t h es y n c h r os p r i n g( A ) .

I n s t a l l t h es y n c h r or i n g ( B )b y a l i g i n gt h e s y n c h r o cone fingers (C)with 3rd/4thsynchrohub grooves (D). 9 . I n s t a l l t h e4 t h g e a r ,n e e d l eb e a r i n gd, i s t a n c ec o l l a r , n e e d l eb e a r i n ga, n d s t h g e a r .

07746-0030100

(cont'd)

13-29

ManualTransmission MainshaftReassembly(cont'dl 1 0 . I n s t a l l t h es y n c h r or i n g a n d t h e s y n c h r os p r i n g . 1

\ 1 4 . I n s t a l l t h es y n c h r os p r i n g( A ) .

'1.

I n s t a l l t h es t h s y n c h r oh u b ( A )b y a l i g n i n gt h e synchrocone fingers (B)with sth synchrohub grooves(C).

t5.

12. I n s t a l l t h e5 t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l tools.

I n s t a l l t h es y n c h r or i n g ( B )b y a l i g n i n gt h e s y n c h r o cone fingers (C)with sth synchrohub grooves(D).

1 6 . I n s t a l l t h eM B S d i s t a n c ec o l l a ra n dt h e t a p e r e d c o n er i n g . 1 1 . I n s t a l l t h en e w b a l l b e a r i n g{ A ) u s i n gt h e s p e c i a l t o o l sa n d a p r e s s( B ) .

U 07746-0030100 07746-0030300

07746-0030100

1 3 . I n s t a l l t h e5 t h s y n c h r os l e e v e .

13-30

CountershaftAssemblyClearancelnspection 1 . Measurethe clearancebetweenthe 1st gear (A) a n dt h e d i s t a n c ec o l l a r( B ) w i t ha f e e l e rg a u g e( C ) .

3. Measure the thicknessof the 1st oear.

. lftheclearance i s m o r et h a nt h e s e r v i c el i m i t ,g o to step 2. . lftheclearance i s w i t h i nt h e s e r v i c el i m i t .g o t o step 4.

. l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h es e r v i c e l i m i t ,r e p l a c el s t g e a r w i t h a n e w o n e . . lf the thicknessof '1stgear is within the service limit, replacethe lst/2nd synchro hub with a new one.

Standard: 0.06 0.16mm 10.002 0.006in.l ServiceLimit: 0.25 mm (0.010in.l

22-92 22.97 mm 10.902 0.904 in.l Standard: ServiceLimit; 22.87mm {0.900in.)

2. fvleasurethe thicknessof the distancecollar. . l f t h e t h i c k n e s iss n o t w i t h i nt h e s t a n d a r dr,e p l a c e t h e d i s t a n c ec o l l a rw i t h a n e w o n e . ' lf the thicknessis within the standard,go to

Standard:

23.03 23.08mm (0.907 0.909in.l

4. Measurethe clearancebetweenthe 2nd gear (A)

a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e clearanceis more than the servicelimit, go to steD5. Standard: 0.06 0.16 mm (0.002 0.006in.) ServiceLimit: 0.25mm {0.010in.l

(cont'd)

13-31

ManualTransmission CountershaftAssemblyClearance Inspection(cont'd)

CountershaftDisassembly 1 . Securelyclamp the countershaftassemblyin a benchvlse with wood blocks.

5. Measurethe th icknessof the distancecollar. . l f t h e t h i c k n e s si s n o t w i t h i nt h e s t a n d a r dr,e p l a c e the distancecollar with a new one. . l f t h e t h i c k n e s si s w i t h i n t h es t a n d a r dg, o t o step 6. Standard:

28.03 28.08mm {1.104-1.106in.)

Removethe specialbolt (left-handthreads). Supportthe ball bearing(A) on steel blocks,then use a press (B)and an attachment(C)to pressthe countershaftout of the ball bearing. 6. Measurethe thicknessof the 2nd qear. . lf thethickneso s f 2 n d g e a r i s l e s s t h a nt h e servicelimit, replace2nd gear with a new one. . l f t h e t h i c k n e s s o2f n d g e a r i s w i t h i n t h e s e r v i c e limit, replacelhe 1sV2ndsynchro hub with a new one. 27-92-21.97 mm|.1.099 1.r01 in.l Standard: ServiceLimit: 27.87mm 11.097in.)

4 . R e m o v et h e 3 5 m m s h i m a n d d i s t a n c ec o l l a r .

I 13-32

Countershaftlnspection 5. Support4thgear(A)on steelblocks,thenusea (B)to pressthe pressandan attachment (C) countershaft out ofthe 5thgear.

1. Inspectthe gear surfaceand bearingsurfacefor w e a r a n d d a m a g e t, h e n m e a s u r et h e c o u n t e r s h a f t at pointsA, B, and C. lf any part of the countershaft is lessthan the servicelimit, replaceit with a new one. Standard: A Ballbearingsurfaceltransmissionhousingsidel: 3 0 . 0 2 0- 3 0 . 0 3 3m m { 1 . 1 8 1 9 1 . 1 8 2 4 i n . ) B Distancecollar surface; 39.937- 39.950mm 11.5723 1.572Ain.l C Needlebearingsurface(clutchhousingside): 3 5 . 0 0 0 3 5 . 0 1 5m m { r . 3 7 8 0 - 1 . 3 7 8 5i n . ) Service Limit: A : 2 9 . 9 7m m { 1 . 1 8 0i n . ) B: 39.88mm {1.570in.l C: 34.95mm {1.376in.)

6 . Support2nd gear (A) on steel blocks,then use a Dressand an attachment{B}to pressthe countershaft(C)out of the 3rd gear.

2 . lnspectthe runout by supportingboth ends of lhe countershaft.Rotatethe countershafttwo complete revolutionswhen measuringthe runout. lf the runout exceedsthe serviceIimit, replacethe countershaftwith a new one. Standard: ServiceLimit:

0.02mm (0.001in.) max. 0.05mm (0.002in.)

13-33

ManualTransmission CountershaftReassembly ExplodedView

SPECIAL BOLT Eeplace. ( 1 1 8N . m 1 2k g fm ,8 7l b ff t )

REVERSE GEAR

BALL BEARING Checkfor wear and operation. Note the directionof installation.

1ST/2ND SYNCHRO HUB

35 mm SHIM

SPRING TRIPLECONESYNCHRO

ANCE COLLAR

GEAR 4THGEAR

1STGEAR

NEEDLE BEARING Checkfor wear anoopera!on. DISTANCECOLLAR

Checkfor wear and operation. DISTANCECOLLAR FRICTIONDAMPER Checkfor wear and damage.

( COUNTERSHAFT

TRIPLECONESYNCHRO

SYNCHROSPRING

(

13-34

SpecialToolsRequired . Driver,40 mm l.D.07746-0030100 . Aftachment.30 mm 07746-0030300

6 . I n s t a l l t h es y n c h r os p r i n g( A ) .

NOTE:Referto the Exploded Viewas neededduring lhis procedure. 1. Cleanall partsin solvent,dry them,andapply lubricanttoall contactsurfaces. I n s t a l l t h ed i s l a n c ec o l l a r ,n e e d l eb e a r i n ga, n d 1 s t gear onto the countershaft.

3 . Installthe triple cone synchroassembly(A) by

'lst gear aligningthe synchrocone fingers (B)with grooves(C),then installthe synchrospring {D). 1 . lnstallthe triple cone synchroassembly(B) by aligningthe synchrocone fingers (C)with the 1sv2ndsynchro hub grooves(D). 8 . Installthedistancecollar (A) and friction damper (B) by aligningthe friction damper fingers (C)with the 1sv2ndsynchro hub grooves(D).

'1st/2nd Installthe s y n c h r oh u b ( A ) b y a l i g n i n gt h e synchrocone fingers (B)with 1sV2ndsynchrohub grooves(C).

5 . I n s t a l l t h er e v e r s eg e a r .

(cont'd)

13-35

ManualTransmission

CountershaftReassembly(cont'dl 1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oal n d a press(B).Do not exceedthe maximum pressure.

9 . I n s t a ltl h e n e e d l eb e a r i n g .

1 0 .I n s t a l l t h e2 n d g e a r( A )b y a l i g n i n gt h e s y n c h r o cone fingers (B)with znd gear grooves(C).

B 14,700 N {1,500 kgt, 3,307lbf) max. 07746-0030100

1 . Supoortthe countershaft(A) on the steel blocks, t h e n i n s t a ltl h e 3 r d g e a r( B )u s i n gt h e s p e c i atlo o l and a press(C).Do not exceedthe maximum Dressure. 14,700N (1,500kgf, 3,307lbflmax.

07746-0030100

13-36

I n s t a l l t h e5 t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a press(B).Do not exceedthe maximum pressure. 14,700N (1.500kgl, 3.307lbf) max. 07746-0030100

1 4 . I n s t a ltlh e d i s t a n c ec o l l a r( A ) ,3 5 m m s h i m ,a n d o l d ball bearing(B)using the specialtools and a press

(c).

16. lf the clearanceis more than the standard,selecta new shim from the following table. lf the clearance measuredin step 15 is within the standard,replace o n l yt h e b a l lb e a r i n g . 35 mm Shim

D E F 11

K L M N

R t5.

Measurethe clearancebetweenthe old bearing(A) a n dt h e 3 5 m m s h i m ( B )w i t h a f e e l e rg a u g e( C ) .

T U

Standard: 0.04 0.10mm 10.002 0.004in.)

PartNumber Thickness 23981-PPP-0000.87mm (0.0343n . 23981-PPP-9000 . 9 1m m { 0 . 0 3 5 8 n, 23982-PPP-0000 . 9 5m m ( 0 . 0 3 7 4 n. 23982-PPP-9000.99mm (0.0390n , 23983-PPP-0001 . 0 3m m 1 0 . 0 4 0n6, 23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n . 23984-PPP-0001 . 11 m m ( 0 . 0 4 3 7 n. 23984-PPP-9001 . 1 5m m ( 0 . 0 4 5 3 n. 23985-PPP-0001 . ' 1 9m m ( 0 . 0 4 6 9n . n 23985-PPP-9001 . 2 3m m ( 0 . 0 4 8 4 n. 23986-PPP-0001 . 2 7m m ( 0 . 0 5 0 0 23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6i n . 23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1i n . 23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7n . 23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3i n . 23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9i n in 23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4 in 23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0

23990-PPP-0001 . 5 9m m { 0 . 0 6 2i6n . 23990-PPP-9001 . 6 3m m { 0 , 0 6 4i2n . 23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7i n

23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3i n 23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9i n 23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5i n

23993-PPP-0001 . 8 3m m ( 0 . 0 7 2i0n 23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6i n 23994-PPP-000' 1 . 9 1m m ( 0 . 0 7 5 2i n

AD AE AF

in. 23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8 in. 23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3

{cont'd)

13-37

ManualTransmission CountershaftReassembly(cont'd) 1 1 . Supportballbearing(A)on steelblocks(B),then

(D)to pressthe usea press(C)andan attachment (E)out of the ballbearing. countershaft

20. Tightenthe new specialbolt (A) (left-handthreads).

'l18 N.m (12kgf.m, 87 tbf.ftl

1 8 . l f n e c e s s a r yi n, s t a l l t h e3 5 m m s h i m s e l e c t e di n step 16,then recheckthe clearance, 1 9 . Installthe distancecollar (A).35 mm shim, and new b a l l b e a r i n g( B )u s i n gt h e s p e c i a l t o o l a s n da p r e s s

(c).

46-0030r00

13-38

SynchroSleeveand Hub Inspection and Reassembly 1. lnspectthegearteeth on ali synchro hubs and synchrosleevesfor roundedoff corners,which indicatewear.

SynchroRingand GearInspection 1 . Inspectthe insideof each synchroring (A) for wear. Inspectthe teeth (Bi on each synchro ring for wear (roundedoff).

2. Installeach synchrohub (A) in its mating synchro sleeve(B),and checkfor freedom of movement.Be sure to match the three sets of longerteeth (C)(120 degreesapart)on the synchrosleevewith the three sets of deepergrooves(D) in the synchrohub. Do not installthe synchrosleevewith its longerteeth in the 1sv2ndsynchrohub slots (E)becauseit will d a m a g et h e s p r i n gr i n g . NOTE;lf replacementis required,always replace the svnchrosleeveand svnchrohub as a set.

Exampleof synchroring teeth

WORN

GOOD

Inspectthe teeth (C)on each synchrosleeveand matchingteeth on each gear for wear (roundedoff).

Exampleof synchro sleeve teeth and gearteeth

t GOOD

WORN

\ (cont'd)

13-39

ManualTransmission SynchroRing and GearInspection(cont'dl 3. Inspectthe thrust surface{D)on each gear hub for wear.

{

7. Measurethe clearancebetweeneach gear (A) and i t s s y n c h r or i n g ( B )a l l t h ew a y a r o u n d .H o l dt h e synchroring againstthe gear evenlywhile measuringthe clearance.lf the clearanceis less than the servicelimit, replacethe synchro ring and gear. Synchro Ring.to.Gear Clearance Standard: 0.70 1.49mm 10.028 0.059in.) ServiceLimit: 0.4 mm {0.016in.)

Inspectthe cone surface(E)on each gear hub for wear ano rougnness. Inspectthe teeth on all gears(F)for unevenwear, , n dc r a c k s . s c o r i n gg, a l l i n g a Coatthe cone surfaceof each gear (E)with oil, and placeits synchro ring on it. Rotatethe synchroring, m a k i n gs u r et h a t i t d o e sn o t s l i p .

13-40

Triple Cone Synchro-to-Gear Clearance Slandard: O: Outer Synchro Ring {B}to SynchroCone (Cl 0-70 1.19mm (0.028-0.047in.) @: Synchro Cone lC) to cear (A) 0.50- 1.04mm (0.020-0.041in.) O: Outer Synchro Ring (B) to Gear (Al 0.95 1.68mm 10.037 0.066in.) ServiceLimit: O: 0.3 mm (0.012in.) : 0.3 mm (0.012in.) O; 0.6 mm 10.024in.l

MainshaftBearingand Oil SealReplacement Special Tools Required . O i l s e a ld r i v e r0 7 J A D - P 1 9 0 1 0 0 . A d j u s t a b l eb e a r i n gp u l l e r , 2 0 4 0 m m 07736-4010008 . Driver07749-0010000 . Attachment,42x 47 mm 07746-0010300 . S l i d eh a m m e r ,c o m m e r c i a l l a yvailable

4 . Drive the new oil seal in from the transmissionside

using the specialtools.

07749-0010000 07746-0010300

1. Removethe differentialassembly, 2 . R e m o v et h e b a l l b e a r i n g( A ) f r o mt h e c l u t c h h o u s i n g( B )u s i n gt h e s p e c i a l t o oal n d a c o m m e r c i a l lay v a i l a b l e3 / 8 " - l 6 s l i d eh a m m e r( C ) .

Drivethe new ball bearing(A) in from the t r a n s m i s s i o sni d eu s i n gt h e s p e c i a l t o o l .

Removethe oil seal (A) from the clutch side. Be carefulwhen removingthe seal so the clutch h o u s i n gi s n o t d a m a g e d .

13-41

ManualTransmission CountershaftBearingReplacement Special Tools Required . Adiustablebearingpuller,20-40 mm 07736-A0tOOOB . Oil seal driver 07JAD-AP190100 . S l i d eh a m m e r ,c o m m e r c i a l l a yvailable

3. Positionthe oil guide plate C and new needle bearing(A) in the bore of the clutchhousing(B).

1. Removethe bearingset plate (A)from the clutch h o u s i n g( B ) .

I n s t a l l t h en e e d l eb e a r i n gu s i n gt h e s p e c i a l t o o l . Installthe bearingset plate (A)wirh bolts (B). Removethe needlebearing(A) usingthe special tool and a commerciallyavailable3/8" - 16 slide hammer (B),then removethe oil guide plate C.

B 6 x 1 . 0n n 12N.m{1.2kgt m,

8.7 tbf.ft)

(

07736-A010008

13-42

MainshaftThrust ClearanceAdiustment Special Tools Required . Mainshaftbase07GAJ-PG20130 . M a i n s h a fht o l d e r0 7 G A J - P G 2 0 1 1 0

5 . Measuredistance@ betweenthe end of the clutch h o u s i n g( A )a n d t h e b e a r i n gi n n e rr a c e( B ) w i t ha straightedge and depth gauge.Measureat three locationsand averagethe readings.

1 . R e m o v et h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM from the transmissionhousing(B).

,5---o v/

Shim Selection Formula: Installthe3rd/4thsynchrohub (A),the distance c o l l a r( B ) ,t h e 5 t h s y n c h r oh u b { C ) .d i s t a n c ec o l l a r ( D ) ,a n d b a l l b e a r i n g( E )o n t h e m a i n s h a f(t F ) ,t h e n i n s t a l l t h ea s s e m b l e dm a i n s h a fitn t h e t r a n s m i s s i o n h o u s i n g( G ) .

6, Selectthe proper 72 mm shim from the chan. Follow the examplebelow, and use the measurementsyou made in steps4 and 5: ( B a s i cF o r m u l a ) ( 0 . 8* 0 . 1 1 )= s h i m t h i c k n e s s( m a x i m u m ) O+@ ( 0 . 8+ 0 . 1 7 )= s h i m t h i c k n e s s( m i n i m u m ) + O O . Add distanceO (step5) to distanceO (step4) . 0 . 8m m ( 0 . 0 3 1i n ) :S p r i n gw a s h e r ,a d i m e n s i o ni n the installation. . 0 . 1 1m m ( 0 . 0 0 4i n ) :l v l i n i m u mt h r u s tc l e a r a n c e . 0 . 1 7m m ( 0 . 0 0 7i n ) :M a x i m u mt h r u s tc l e a r a n c e . ( F o re x a m p l e ) 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 1 ) =1 . 5 6m m ( 0 . 0 6 1i n . ) 2 . 3 2+ 0 . 1 5- ( 0 . 8+ 0 . 1 7 ) =1 . 5 0m m ( 0 . 0 5 9i n . )

lnstallthe washer (H) on the mainshaft.

T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m ( 0 . 0 6 0i n . )s h i m .

MeasuredistanceO betweenthe end of the transmissionhousingand washerwith a straight edge and verniercaliper.Measureat three locationsand averagethe reading.

{cont'd)

13-/li|

ManualTransmission MainshaftThrust ClearanceAdjustment (cont'dl 72 mm Shim

PartNumber Thickness 2 3 9 3 1 - P 2 1 - 0 0 00 . 6 0m m { 0 . 0 2 3i6n . ) 23932-P21-000 0.63mm (0.0248 in. 2 3 9 3 3 - P 2 1 - 0 0 00 . 6 6m m ( 0 . 0 2 6i0n . 2 3 9 3 4 - P 2 1 - 0 0 00 . 6 9m m ( 0 . 0 2 7 1i n . 23935-P21-000 0 . 7 2m m ( 0 . 0 2 8i3n . 23936-P21-000 0 . 7 5m m ( 0 . 0 2 9i5n . 23931-P21-000 0 . 7 8m m ( 0 . 0 3 0i7n . 23938-P2'l-000 0 . 8 1m m ( 0 . 0 3 1i9n 23939-P21-000 0 . 8 4m m ( 0 . 0 3 3i1n 23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3i n , 23941-P21-000 0.90 mm (0.0354in. 23942.P21-000 0.93mm (0.0366in. 23943-P21-000 0 . 9 6m m ( 0 . 0 3 7i8n . 23944-P21.000 0 . 9 9m m ( 0 . 0 3 9i0n . 23945-P21-000 1 . 0 2m m ( 0 . 0 4 0i2n . 23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3i n . 23941-P2't-000 'l.08mm (0.0425 in 23948-P2'l-000 ' 1. 11 m m { 0 . 0 4 3i7n 23949-P21-000 ' 1 . 1 4m m ( 0 . 0 4 4 9i n 23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n . 23951-P21-000 1.20mm 10.0472 n. 23952-P21-000 1.23mm (0.0484n . 23953-P21-000 1 . 2 6m m { 0 . 0 4 9 6 n. 23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n . 23955-P21-000 1 . 3 2m m ( 0 . 0 5 2 0 n. 23956-P21,000 1 . 3 5m m ( 0 . 0 5 3i1n 23957-P21-000 1 . 3 8m m ( 0 . 0 5 4i3n 23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n 23959-P21-000 1 . 4 4m m ( 0 . 0 5 6 7 n. 23960-P21-000 1.47mm (0.0579n . 2 3 9 6 1 - P 2 1 - 0 0 01 . 5 0m m ( 0 . 0 5 9 1n . 23962-P21-OOO 1 . 5 3m m ( 0 . 0 6 0 2 n. 23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n . 23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n . 23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8i n 23966-P21-000 1 . 6 5m m ( 0 . 0 6 5i0n 23967-P21-000 1 . 6 8m m ( 0 . 0 6 6i1n -000 1 . 7 1m m ( 0 . 0 6 7i3n . 23968-P2r 23969-P21-000 1 . 7 4m m ( 0 . 0 6 8i5n . 23970-P21-000 1 . 7 7m m ( 0 . 0 6 9i7n .

2 3 9 7 1 - P 2 ' t - O O O1 . 8 0m m ( 0 . 0 7 0 9 in.

D E F

L M N

o P

o R

T U X

z AB AC

AD AE AF AG AH AI AJ

AK AL

7 . I n s t a l l t h e7 2 m m s h i m ( A )s e l e c t e da n d o i l g u i d e p l a t eM i n t h e t r a n s m i s s i o h n o u s i n g( B ) .

,6,,-o V

8 . Thoroughlycleanthe spring washer (A) and washer (B) before installingthem on the clutch h o u s i n gs i d eb a l l b e a r i n g{ C ) .N o t et h e i n s t a l l a t i o n directionof the spring washer.

{

9 . l n s t a l l t h em a i n s h a fitn t h e c l u t c hh o u s i n g .

1 0 .Placethe transmissionhousingover the mainshaft and onto the clutchhousing. 1 1 .Tightenthe clutchand transmissionhousingswith several8 mm bolts. NOTE:lt is not necessaryto use sealingagent betweenthe housings.

12. Tap the mainshaftwith a plastichammer.

13-44

13. Attachthe specialtool to the mainshaftas follows:

1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .

. B a c k - o ut th e m a i n s h a fht o l d e rb o l t{ A )a n d l o o s e n the two hex bolts (B). . Fit the holderover the mainshaftso its lip is towards the transmission. . Align the mainshaftholder'slip aroundthe groove at the insideof the mainshaftsplines, then tightenthe hex bolts.

07GAJ-PG20130

1 4 . Seatthe mainshaftfully by tapping its end with a p l a s t i ch a m m e r .

1 7 . Turn the mainshaftholder bolt (B)clockwise;stop turning when the dial gauge (A) has reachedits maximum movement.The readingon the dial gauge is the amount of mainshaftend play NOTE:Do not turn the mainshaftholder bolt more than 60 degreesafter the needleof the dial gauge stops moving,this may damagethe transmission.

1 8 .lf the readingis within the standard,the clearance Threadthe mainshaftholder bolt in until it just contactsthe wide surfaceof the mainshaftbase.

is correct.lf the readingis not within the standard, recheckthe shim thickness. Standard:0.11-0.17 mm (0.004 0.007in.)

13-45

ManualTransmission Transmission Reassembly N O T E :P r i o r t or e a s s e m b l i n gc ,l e a na l l t h e p a r t si n solvent,dry them, and apply lubricantto any contact surfaces.

\ 4. Installthe reverseshift fork. 6x1.0mm 15 N.m (1.5kgf.m,11 lbf.ft)

1. Installthe magnet (A) and differentialassembly(B).

n-",-o l;-D

f.) Installthe reverseidler gear (A) and reversegear s h a f t( B )b y a l i g n i n gt h e m a r k{ C ) w i t ht h e r e v e r s e g e a rs h a f th o l e ( D ) .

Installthe 28 mm spring washer (A) and 28 mm washer (B) over the ball bearing(C).Note the installationdirectionof the spring washer {A).

Apply vinyl tape to the mainshaftsplines(D)to p r o t e c t t h es e a l .I n s t a l l t h em a i n s h a fat n d countershaft(E)into the shift forks {F}.and install themas an assembly.

13-46

(

6 , l n s t a l l t h er e v e r s el o c kc a m . z/ --' €t

- 2 6 x 1 , 0m m / 15 N.m / {1 5 kgf m, 11 tbf.ft) I

Fl g

8. Removethe dirt and oil f rom the tramsmission h o u s i n gs e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N to the sealingsurface.Be sure to seai 08718-0001) the entirecircumferenceof the bolt holesto preventoil leakage. NOTE:lf 5 minuteshave passedafter applying liquid gasket,reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly beforefilling the transmissionwith oil.

7 . Selectthe proper size72 mm shim (A) accordingto the measurementsmade during the Mainshaft '13-43), Thrust ClearanceAdjustment(seepage , nd I n s t a l l t h eo i l g u t t e rp l a t e( B ) ,o i l g u i d e p l a t el \ 4 a n o u s i n g( C ) . 7 2 m m s h i m i n t ot h e t r a n s m i s s i o h

- -

-Liquid gasket

{cont'd)

13-47

ManualTransmission TransmissionReassembly(cont'dl 9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) . 34 N.m (3.5 kgf.m, 25 rbf.ft)

( 11. Lowerthe transmissionhousingthe rest of the way as you expandthe 72 mm snap ring {C).Release the snap ring so it seatsin the groove of the countershaftbearing. 12. Checkthat the 52 mm snap ring is securelyseated in the groove of the countershaftbearing. DimensionO as instalted: 3.3 6.0 mm { 0 . 1 3 0 . 2 4i n . l

1 3 .Apply liquid gasket(P/N08718-0001) to the threads o f t h e 3 2 m m s e a l i n gc a p { D ) ,a n d i n s t a l il t o n t h e transmissioh nousing,

't4.

I n s t a ltl h e t r a n s m i s s i o h n a n g e r sA . a n d B , a n d t h e 8 mm flange bolts finger-tight.

e./ ./

1 5 . Tightenthe 8 mm flange bolts in a crisscross PatternIn severalsteDs. 8 x 1.25mm 27 N.m (2.8kgf.m. 20 rbf.ft)

1 0 .Set the taperedcone ring (B)as shown. Placethe transmissionhousingover the clutch housing, being carefulto line up the shafts.

13-48

16. Removethe dirt and oil from the shift iever cover s e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 0001)to the sealingsurface.

1 9 . I n s t a l l t h ed r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m f l a n g eb o l t ( C )w i t h n e w w a s h e r s . /..l-.=,'-B g ^

44N.m

@ Ut !?iJl'.'l,''

NOTE:lf 5 minuteshave passedafter applylng liquid gasket.reapplyit and assemblethe housings. Allow it to cure at least20 minutesafter assembly b e f o r ef i l l i n gt h e t r a n s m i s s i ow n ithoil.

R\-: \

-.-t

A 39Nm (4.0 kgf m, 33 tbl.ft)

?0,,.ru^

44 N m {4.5kgt m,33lbf.ft}

20. Installthedetent bolts (A),spring,and steel balls with new washers. - -

-Liquidgasket

1 7 . I n s t a l l t h e8 x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p b r a c k e (t B ) ,a n d c h a n g el e v e ra s s e m b l y( C ) .

{3.0kgf.m.22lbf.ft)

2 1 . A p p l y l i q u i dg a s k e t{ P / N0 8 7 1 8 - 0 0 0 1 } t oh e t h r e a d s o i t h e b a c k - u pl i g h ts w i t c h( B ) ,a n d i n s t a l il t i n t h e transmissioh nousing. 6x1.0mm

12N.m(1.2kgf.m,9lbtft)

1 8 . A p p l y l i q u i dg a s k e t( P iN 0 8 7 1 8 - 0 0 0 t1o) t h e t h r e a d s of the interlockbolt (D),and installit on the transmissioh nousing.

(cont'd)

13-49

ManualTransmission TransmissionReassembly(cont'dl

(

22. Installthevehiclespeedsensor(VSS){A)and O - r i n g( B ) .

22 N.m (2.2kgf.m,r6 lbf.ft)

{

13-50

GearshiftMechanismReplacement

8 x 1.25mm 22 N.m (2.2 kgf.m, 16 lbt ftl

,.-,'-'

KNOB --SHIFT LEVER 8 N m {0.8ksr.m.5.8lbf.ft}

l'/

SHIFTLEVERHOUSING

{P/N 08798-9002}

SHIFTCABLECLIP Replace.

r-LlRotatethe shift cable t o w a r dt h e o p e n i n g .

6x1.0mm 9.8Nm (1.0kgf.m, 7.2 tbf.fr) COTTERPINS {P/N 08798-9002)

qrBemovethe shift cable from the shift leverbracket.

13-51

M/T Differential ComponentLocationIndex

(

DRIVENGEAR Beplacement,page 13-53

\ BacklashInsoection.oaoe 13-53 Feplacemeni,paoe I 3-5-3

,<-=/

I \c1 \

13-52

,/BALL BEARING Beplacemenl,page 13-54

Backlashlnspection

FinalDrivenGear/Carrier Replacement

1 . Placethe differentialassemblyon V-blocks(A),and installboth axles. 1. Removethe bolts (left-handthreads)in a crisscross patternin severalsteps,then removethe final driven gear (A)from the differentialcarrier{B).

\tt

x t . om m { t o )

1 2 1N m (12.3kgf m, 89 rbt.ft)

M e a s u r et h e b a c k l a s h o f b o t h p i n i o ng e a r s( B )w i t h a dial indicator(C).lf the backlashis not within the standard,replacethe differentialcarrier. Standard(New):0.05 0.15mm (0.002 0.006in.)

Installthe final driven gear with the chamferon the i n s i d ed i a m e t e fra c i n gt h e c a r r i e rA . l i g nt h e m a r k s o n t h e f i n a ld r i v e ng e a ra n d t h e c a r r i e rT. i g h t e nt h e bolts in a crisscrosspatternin severalsteps.

13-53

M/T Differential CarrierBearingsReplacement Special Tool Bequired Driver,40 mm l.D.07746-0030100 1. Checkthe carrierbearingsfor wear and rough rotation.lf they rotatesmoothly and their rollers show no signs of wear, the bearingsare OK,

\ 3. Installthe new bearings(A)with the specialtool and a press.Presseach bearingon until it bottoms. There should be no clearancebetweenthe bearinos and the carrier. NOTE:Turn the sealed(B)side of the bearingaway from the differentialtoinstallit.

2. Removethe carrierbearing(A) with a c o m m e r c i a l l y - a v a i l a bbleea r i n gp u l l e r( B ) .

077i16-0030100

13-54

07746-0030100

{

Oil SealReplacement Special Tools Required . Driver07749-0010000 . Oil seal driver attachment07NAD-P20A100

4 . I n s t a l l t h en e w o i l s e a li n t h e t r a n s m i s s i o hn o u s i n q with the specialtools.

1. Removethe differentialassembly. 2. Removethe oil seal (A) from the transmission h o u s i n g( B ) .

5 . I n s t a l l t h en e w o i l s e a li n t h e c l u t c hh o u s i n gw i t h the specialtools.

3 . R e m o v e t h e o i sl e a l( A )f r o m t h e c l u t c hh o u s i n g( B ) .

13-55

M/T Differential DifferentialThrust ClearanceAdjustment SpecialToolRequired Driver.40 mm LD.07746-0030100 1 . I n s t a lal n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e one you removeo.

Installthe transmissionhousingonto the clutch housing,then tightenthe 8 mm flange bolts in a crisscrosspatternin severalsteps(seestep 15 on page 13-48). 8 x 1 . 2 5m m 27 N m (2.8 kgf'm, 20 lbf.ft) Use the specialtoolto bottom the differential a s s e m b l yi n t h e c l u t c hh o u s i n g .

00746-0030100

2 . Installthe differentialassemblyinto the clutch housing.

5 . Measurethe clearancebetweenthe 80 mm shim a n d b e a r i n go u t e rr a c ei n t h e t r a n s m i s s i o h nousing. Standard:0

0.10mm l0 0.004in.)

-i.

w .t

-- --

13-56

..1

:,- -=.

6. lf the clearanceis more than the standard,selecta n e w s h i m f r o m t h e f o l l o w i n gt a b l e .l f t h e c l e a r a n c e m e a s u r e di n s t e p5 i s w i t h i nt h e s t a n d a r dg, o t o step 9. 80 mm Shim Part Number

D E F rt

tvl N P

o R

Thickness 4 1 4 4 1P L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4 n. 41442-PL3-B001 1 mm (0.0433 n. 4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2 n.

4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2n . 4 1 4 4 5 - P L 3 - 8 10 0 1 . 4m m 1 0 . 0 5 5 1n . 4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n . 41447-PL3-8 1 0 0 1 . 6m m ( 0 . 0 6 3 0n . 4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n . 4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n . 41450-PL3-80001. 0 5m m ( 0 . 0 4 1 3n . ) 4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l 41452-PL3-80001 . 2 5m m ( 0 . 0 4 9 2n . l 41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . ) 41454-PL3-80001. 4 5m m ( 0 . 0 5 7 1n . l 41455-PL3-80001 . 5 5m m ( 0 . 0 6 1 0n . )

5 m ( 0 . 0 6 5i0n . ) 41456-PL3-8000' 1 . 6m 41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9i n . )

7 . R e m o v et h e b o l t sa n dt r a n s m i s s i o h nousing. 8 . Replacethe thrust shim selectedin step 6, then recheckthe clearance. 9 . R e i n s t a tl h l et r a n s m i s s i o n .

13-57

Driveline/Axle ............. 16-2 SpecialTools ......................... 16-3 Driveshaft Inspection Driveshafts Removal .......................... 16-3 ................... 16-5 Driveshafts Disassembly DynamicDamperReplacement ........16-8 .................... 16-9 Driveshafts Reassembly ...................... 16-17 Driveshafts lnstallation .............. 16-19 lntermediate ShaftRemoval Intermediate ................................. 16-20 ShaftDisassembly lntermediate .................................. 16-22 ShaftReassembly 16-24 lntermediate Shaftlnstallation....................................

Driveline/Axle

SpecialTools Ref. No.

n] @

@ t9

ToolNumber 07GAD-PH70201 07MAC-S100200 0 7N A F - S R 3 0 1 0 1 07xAc-001010A 07746-0010400 07746-0030400 07749-0010000 07947-S800100

t g[]

Orv

DescriDtion O i l S e a lD r i v e r B a l l J o i n tR e m o v e r2, 8 m m Half Shaft Base ThreadedAdapter,22 x 1.5mm Attachment,52 x 55 mm u f l v e r ,J 5 m m L U . Driver O i l S e a lD r i v e r

1 1 1 1 1 1 1 1

r\J ? )

,0)

16-2

DriveshaftInspection 1. Checkthe inboardboot (A) andthe outboardboot (B)on the driveshaft(C)for cracks,damage,leaking grease,and loose boot bands (D).lf any damageis found, reDlacethe boot and boot bands.

DriveshaftsRemoval Special Tool Required B a l l j o i n tr e m o v e r 2, 8 m m 0 7 M A C - S 1 0 0 2 0 0 1. Loosenthe wheel nuts slightly 2. Raisethe front of the vehicle,and support it with safetystandsin the proper locations(seepage 1-8). 3. Removethe wheel nuts and front wheels.

Turn the driveshaftby hand,and make sure the splines(E)and joint are not excessivelyloose. Make sure the driveshaftis not twisted or cracked; if it is, replaceit. 4 . Lift up the lockingtab (A) on the spindle nut (B),

then removethe nut. lf the !eft driveshaftor the intermediateshaft is to be removed,drain the transmissionfluid. Reinstall t h e d r a i np l u g u s i n ga n e w w a s h e r( s e ep a g e1 3 - 3 ) . H o l dt h e s t a b i l i z ebr a l l j o i n tp i n ( A )w i t h a h e x wrench {B),and removethe flange nut (C). Separatethe front stabilizerlink (D)from the lower ar m .

(cont'd)

16-3

Driveline/Axle DriveshaftsRemoval(cont'd) 7 . R e m o v et h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l joint castlenut (B),and removethe nut. NOTE: . T o a v o i dd a m a g i n gt h e b a l l j o i n t ,i n s t a l a l hexnut on to the threadsof the ball joint, . Be carefulnot to damagethe balljoint boot when installingthe remover.

\ 10. Left driveshaft:Pry the inboardjoint (A)from the differentialcasewith a prybar.Rightdriveshaft: Drivethe inboardjoint (A) off of the intermediate shaft with a drift and hammer. Removethe driveshaftas an assembly.Do not pull on the driveshaft(B),becausethe inboardjoint may come apart.Draw the driveshaftstraightout to avoid d a m a g i n gt h e o i l s e a l . Left driveshaft:

t 07MAC-S100200

.."8

w^ 'e

Separatethe ball joint from the lower arm (C)with the specialtool (seestep 3 on page 18-19). Be carefulnot to dislodgethe lower ball joint from the knuckle. 9 . Pullthe knuckleoutward,and removethe driveshaftoutboardjoint from the front wheel hub u s i n ga p l a s t i ch a m m e r .

16-4

Right driveshaft:

Driveshafts Disassembly Special Tools Required . T h r e a d e da d a D t e r . 2 x2 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A . S l i d eh a m m e r ,c o m m e r c i a l l a yvailable . Boot band pincers,commerciallyavailable

Inboard Joint Side: 1. Removethe set rlng from the inboardjoint.

Low Profile Type

Removethe boot bands.Be carefulnot to damage the boot and dynamic damper. . lf the boot band is a welded type (A),cut the boot b a n d( B ) . . lf the boot band is a double loop type (C),lift up t h e b a n db e n d( D ) ,a n d p u s hi t i n t ot h e c l i p ( E ) . . lf the boot band is a low profiletype (F),pinch the b o o t b a n du s i n ga c o m m e r c i a l l a y v a i l a b l eb o o t b a n dp i n c e r s( G ) . Welded Type

(cont'd)

16-5

Driveline/Axle DriveshaftsDisassembly{cont'd) M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r dj o i n t (C)to identifythe locationsof rollersand grooves i n t h e i n b o a r dj o i n t .T h e n r e m o v et h e l n b o a r dj o i n t on the shop towel (D).Be carefulnot to drop the rollerswhen separatingthem from the inboard Jornt.

8. Wrap the splineson the driveshaftwith vinyl tape (A)to preventdamageto the boot.

9 . R e m o v et h e i n b o a r db o o t .B e c a r e f u n l ottodamaoe the boot. 10. Removethe vinyl tape. N4akea mark (A) on the rollers(B) and spider (C)to identifythe locationsof rollerson the spider,then removethe rollers.

R e m o v et h e c i r c l i p{ D ) .

6 . Mark the spider (C)and driveshaft(E)to identifythe positionof the spider on the shaft, 7 . R e m o v et h e s p i d e r( C ) .

16-6

OutboardJoint Side: 1 . R e m o v et h e b o o t b a n d s .B e c a r e f u n l ottodamage t h e b o o ta n d d y n a m i cd a m p e r . . l f t h e b o o t b a n di s a n e a r c l a m p t y p e( A ) ,l i f t u p the three tabs (B)with a screwdriver.

Wipe off the greaseto exposethe driveshaftand t h e o u t b o a r dj o i n t i n n e rr a c e . 4 . Make a mark (A) on the driveshaft(B) at the same

positionof the outboardjoint end {C).

Ear Clamp Type

5. Carefullvclamp the driveshaftin a vise.

2 . Slidethe outboardboot (A)to the inboard ioint side. Be carefulnot to damaoethe boot.

Removethe outboardjoint (A) usingthe special t o o l a n da c o m m e r c i a l la y v a i l a b l e5 / 8 " x 1 8s l i d e h a m m e r( B ) . 7 . Removethe driveshaftfrom the vise.

(cont'd)

16-7

Driveline/Axle DriveshaftsDisassembly(cont'dl

DynamicDamperReplacement

8. Removethe stopringtromthe driveshaft.

1 . R e m o v et h e i n b o a r dj o i n t ( s e ep a g e1 6 - 5 ) . 2, Removethe dynamic damper bands.Be carefulnot to damagethe dynamic damper (seepage 16-5). . l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h eb o o t band. . l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e band bend, and push it into the clip. . lfthe boot band is a low profiletype, pinch the b o o t b a n du s i n ga c o m m e r c i a l l a y v a i l a b l eb o o t band pincers. 3. Wrap the splineson the driveshaftwith vinyl tape (A)to preventdamageto the dynamic damper.

9 . Wrap the splineson the driveshaftwith vinyl tape (A) to preventdamageto the boot.

Removethe dynamic damper. Be carefulnot to d a m a g et h e d y n a m i cd a m p e r . 5 . Adjust the positionof the new dynamic damper to the figure below. 1 0 . Removethe outboardboot. Be careful not to damagethe boot. 1 1 .Removethe vinyl tape.

Left driveshaft{Directionall:

296 300mm ( 1 1 . 6 -1 1 . 8i n . ) Right driveshaft(Directionall: 301 305 mm ( 1 1 . 9- 1 2 . 0i n . l

6 . I n s t a l l t h ed y n a m i cd a m p e rb a n d( s e es t e pI o n p a g e1 6 ' 1 2 ) . 7 . I n s t a ltlh e i n b o a r dj o i n t ( s e ep a g e1 6 - 11 ) .

16-8

DriveshaftsReassembly ExplodedView '02 model SETRING Replace.

//ROLLER

/''"oH?"'

#'g!!a$il

.?-// "\

in the rr Use the greaseIncluded inboardboot inboard set. boot set

// /,/7\

II t,//>\ Usethe greaseincludedin the inboardboot set.

l>/

I I

.''

.'(9

OOUBLELOOPBAND Replace.

/'..-:'\ .-\ |

\\1lg n --.r.

.^-.1 //^\l

, \ V L/ A

DYNAMTC DAMPER ,/

// DOUBLE LOOPBAND Replace.

STOPRING Replace.

EAR CLAMP BANDS

JOINT OUTBOARD

Usethe greaseincludedin the outboardboot set,

(cont'd)

16-9

Driveline/Axle

DriveshaftsReassembly(cont'dl ExplodedView '03 model

SET RING / Replace.

DOUBLE LOOPBAND Replace. (Bootbandreplacement only.)

INBOAROJOINT ROLLEB CIRCLIP

s l

E. -"-,,,

@( Usethe greaseincluded in the nboard boot set.

(^Y \ \_,/

LOWPROFILE BAND Beplace.

Usethe greaseincluded in the inboardboot set.

DOUBLELOOPBAND Replace.

(Boot band replacementonly.)

DYNAMICDAMPER

OUTBOARDJOINT

at-

BOOTITPI OUTBOARD

Usethe greaseincludedin the outboardboot set.

16-10

Special Tools Required . Boot band tool, KD-3191or equivalent,commercially available . Boot band pincers,Kent-MooreJ-359'10or equivalent, commerclallyavailable . Boot band pincers,commercially available

3. Installthe spider (A) onto the driveshaftby aligning the marks (B)on the spider and the end of the driveshaft.

NOTE:Referto the ExplodedView as neededduring this procedure.

lnboardJoint Side: 1. Wrap the splineswith vinyl tape (A)to prevent damageto the inboardboot.

4 . Fit the circlip (C)into the driveshaftgroove.Always rotatethe circlip in its groove to make sure it is fully seated. 5

Installthe inboardboot onto the driveshaft,then removethe vinyl tape, Be carefulnot to damageI n e inboardboot.

Fit the rollers (A) onto the spider {B)with their high shouldersfacing outward,and note these items: ' Reinstalltherollers in their original positionson the spider by aligningthe marks (C). . Holdthe driveshaftpointed up to preventthe rollersfrom falling off.

(u @\

(cont'd)

16-11

Driveline/Axle

DriveshaftsReassembly(cont'd) 6 . Packthe inboardjointwith thejointgrease

includedin the newdriveshaft set. Greasequantity Inboardioint: 130 140g (4.6-4.9oz) Usethe greaseincludedin the inboardboot set.

8 . Make sure the ends of the boot are sealedin the groovesin the driveshaftand joint, then installthe boot bands. . For the double loop type, go to step 12. (Replacementboot bands only) . For the low profiletype, go to step 9. 9 . Installthe new low profile band {A) onto the boot {B).then hook the tab (C)of the band,

7 . Fit the inboardjoint onto the driveshaft,and note these items: . Reinstallthe inboardjoint onto the driveshaftby a l i g n i n gt h e m a r k s( A )o n t h e i n b o a r dj o i n ta n d the rollers. . Hold the driveshaftso the inboardjoint is pointing up to preventit trom falling off.

1 0 .Closethe hook portionof the band (A) with a commerciallyavailableboot band pincers(B),then hook the tabs of the band.

1 1 .Installthe boot band on the other end of the boot, and reoeatsteos9 and 10.

16-12

Fit the boot ends onto the driveshaftand the inboardjoint, then installthe new double loop band {A) onto the boot.

15. Threadthe free end ofthe band through the nose sectionof the commerciallyavailableboot band tool KD-3191or equivalent(A),and into the slot on t h e w i n d i n gm a n d r e l( B ) .

P u l lu p t h e s l a c ki n t h e b a n db y h a n d M a r ka p o s i t i o n( A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 0 . 6i n . )f r o m t h e c l i p { B ) .

1 6 . Placea wrench on the winding mandrelof the boot band tool, and tightenthe band until the marked spot (C)on the band meetsthe edge of the clip 1 7 . L i f tu Dt h e b o o t b a n dt o o l t o b e n d t h e f r e e e n d o f the band 90 degreesto the clip. Center-punchthe c l i o ,t h e nf o l d o v e rt h e r e m a i n i n gt a i l o n t ot h e c l i p .

(cont'd)

16-13

Driveline/Axle DriveshaftsReassembly(cont'dl 18. Unwind the boot band tool, and cut off the excess free end of the bandto leavea 5- 10 mm (0.2-0.4 in.) tail protrudingfrom the clip

19. Bendthe band end (A) by tapping it down with a nammer. NOTE; . Make sure the band and clip do not interferewith anythingand the band does not move. . Removeany greaseremainingon the surroundingsurfaces

20. Repeatsteps 12through 19 for the band on the other end of the boot.

16-14

{ 2 ' 1 .I n s t a l l t h en e w s e t r i n g .

OutboardJoint Side:

4. Insertthe driveshaft(A) into the outboardjoint (B) until the stop ring (C)is closeto the joint.

1. Wrap the splineswith vinyl tape (A) to prevent damageto the outboardboot.

I n s t a l l t h en e w e a r c l a m pb a n d s( B )a n d o u t b o a r d boot,then removethe vinyl tape. Be carefulnot to damagethe outboardboot.

3 . Installthe new stop ring into the driveshaftgroove (A).

5 . To completelyseatthe outboardjoint, pick up the driveshaftand joint, and drop them from about 10 cm (4 in.) onto a hard surface.Do not use a hammer as excessiveforce may damagethe driveshaft.Be carefulnot to damagethe threaded section(A) of the outboardjoint.

1 0c m ( 4i n . )

- ..,..,1;,t,:-,;

{cont'd)

16-15

Driveline/Axle DriveshaftsReassembly(cont'd) Checkthe alignmentof the paint mark (A)with the o u t b o a r dj o i n t e n d ( B ) .

{ 8. Adjust the length of the driveshaftsto the figure below,then adjustthe boots to halfwaybetween full compressionand full extension.Make sure the ends of the boots seat in the groovesof the driveshaftand joint. Leftdriveshaft:497502mm (19.6 19.8in.)

-tTfi'.D.ilTD Rightdriveshaft:475 480 mm {18.7 1 8 . 9i n . l

7. Packthe outboardjoint (A)with the joint grease includedin the new ioint boot set. Grease quantity Outboardioint: 105 115g (3.7 4.1 ozl

/llt,)r -*> \{(

'.,o"o :;,"0'A?g.fff :l:f

16-16

9 . Fit the boot (A) ends onto the driveshaft(B)and o u t b o a r dj o i n l ( C ) .

DriveshaftsInstallataon 10. Closethe ear portion (A) of the band with a commerciallyavailableboot band pincersKentMoore J-35910or equivalent(B).

1 1 .Checkthe clearancebetweenthe closedear portlon of the bands.lf the clearanceis not within the standard,closethe ear podion of the bandsfarther.

1. Installa new set ring onto the set ring groove of the driveshaft{left driveshaft).

Apply 0.5 1.0g {0.02 0.04oz) of specifiedgrease t o t h e w h o l e s p l i n e ds u r f a c e( A )o f t h e r i g h t driveshaft.After applyinggrease,removethe greasefrom the splinedgroovesat intervalsof 23 s p l i n e sa n d f r o m t h e s e t r i n gg r o o v e( B )s o t h a t air can bleedfrom the intermediateshaft.

in.)MAX 6.0mm 10.24

3.0 mm {0.12in.} MAX

12. R e p e ast t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r end of the boot.

(cont'd)

16-17

Driveline/Axle DriveshaftsInstallation(cont'd) Cleanthe areaswhere the driveshaftcontactsthe differentialthoroughlywith solvent,and dry with compressea d i r .I n s e n t h ei n b o a r de n d { A )o f t h e driveshaftinto the differential(B)or intermediate shaft {C) until the set ring (D)locks in the groove (E).

{ 5 . W i p e o f f t h e g r e a s ef r o m t h e b a l l i o i n ta n d l o w e r arm taperedsurfaces.Installtheknuckle(A) onto the lower arm {B).Be careful not to damagethe ball joint boot.Wipe off the greasebeforetightening the nut at the ball joint. Torquethe new castlenut (C)to the lower torque specification,then tighten it o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gi t . NOTE:Make sure the ball joint boot is not damage or cracks.

"-'t-

4. Installthe outboardjoint (A) into the front hub (B). 1 2 x 1 . 2 5m m 59 69 N.m (6.0-7.0 kgf m, 43 51 tbt.ftl

I n s t a l l t h en e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n hole from the insideto the outsideof the vehicle. 7 . Connectthe front stabilizerlink {A)to the lower arm. H o l dt h e s t a b i l i z elri n kb a l l j o i n tp i n ( B )w i t h a h e x w r e n c h{ C ) ,a n d t i g h t e nt h e n e w f l a n g en u t { D ) .

'10x 1.25mm 39 N.m {4.0kgf.m,29 lbf.ft)

16-18

lntermediateShaft Removal 8. Installa newspindlenut{A),thentightenthe nut. usea driftto stakethe spindlenut Aftertightening, shoulder{B)againstthe driveshaft.

1 . Removethe right driveshaft(seepage 16-3). 2 . R e m o v et h e h e a ts h i e l d .

108N.m (11.0kgf.m, 80 tbt.ft)

/ o oo e

3 . R e m o v et h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) . 22x 1.5 mm 1 8 1N . m

{18.5kgf.m,134lbt.ft)

9. Cleanthe mating surfacesofthe brakedisc and the front wheel, then installthe front wheel with the wheel nuts.

€.---2" E

€

10. Turn the front wheel by hand,and make sure the clearancebetweenthe driveshaftand circumferenceparts. 1l. Refillthe transmissionwith recommended transmissionfluid (seepage 13-3). 12. Checkthe front wheel alignment,and adjust it if necessary(seepage 18-4).

(cont'd)

16-19

Driveline/Axle IntermediateShaft Removal (cont'dl

IntermediateShaft Disassembly

4. Removethe intermediateshaft (A) from the differential.Hold the intermediateshaft horizontal until it is clear of the differentialto preventdamage to the differentialoil seal (B).

Special Tools Required . Oil seal driver 07947-5800100 . Half shaft base07NAF-SR30101

{

1 . R e m o v e t h e s e rt i n g ( A ) ,o u t e r s e a (l B ) ,a n d e x t e r n a l s n a pr i n g ( C ) .

Pressthe intermediateshaft (A) out of the intermediateshaft bearing(B) using a press.Be carefulnot to damagethe metal rings (C)on the intermediateshaft during disassembly. PRESS

16-20

3. Removethe internalsnap ring.

4. Pressthe intermediateshaft bearing(A) out of the b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a oress. 07947-s800100

07NAF-SR30101

16-21

Driveline/Axle IntermediateShaft Reassembly ExplodedView

INTERMEDIATE SHAFTRING

FLANGEBOLT 10 x '1.25mm 39IVm {4.0kgf.m,29lbt.ftl

,tto", *,"o p

\--'+7\ E

BEARING SUPPOBT

Packthe interiorof the outer seal.

16-22

Special Tools Required . Driver07749-0010000 . Attachment,52x 55 mm 07746-0010400 . Attachment,35 mm 1.D.07746-0030400 . Oil seal driver 07GAD-PH70201

4. Pressthe intermediateshaft (A) intotheshaft b e a r i n g( B )u s i n gt h e s p e c i atl o o l a n d a p r e s s . PRESS

NOTE:Referto the ExplodedView as neededduring this procedure. 1 . C l e a nt h e d i s a s s e m b l epda r t sw i t h s o l v e n t a, n d d r y them with compressedair. Do not wash the rubber partswith solvent. 2. Pressthe intermediateshaft bearing(A) intothe b e a r i n gs u p p o r t( B )u s i n gt h e s p e c i atl o o l sa n d a press. PRES

07746-0030400 I n s t a l lt,h e n s e a tt h e e x t e r n asl n a pr i n g { A ) i n t ot h e groove of the intermediateshaft (B). 07746-0010400

3 . I n s t a l lt,h e n s e a tt h e i n t e r n asl n a pr i n g i n t ot h e groove ofthe bearingsupPort.

(cont'd)

16-23

Driveline/Axle IntermediateShaft Reassembly (cont'd) 6 . l n s t a l l t h eo u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B ) usingthe specialtool and a press. PRESS

IntermediateShaft Installation 1 . U s es o l v e n to r b r a k ec l e a n e tr o t h o r o u g h l yc l e a n the areaswhere the intermediateshaft {A) contacts the transmission(differential),and dry with compressedair. Insertthe intermediateshaft assemblyinto the differential.Hold the intermediateshaft horizontalto preventdamageto the differentialoil seal (B).

Packthe interior ofthe outer seal.

7 . I n s t a l l t h es e t r i n g .

2 . I n s t a l l t h el l a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l . A 10 x 1.25mm 39Nm (4.0kgf.m,29lbf.ft)

16-24

B l 0 x 1 . 2 5m m 39 N.m (4.0kgf.m, 29 tbf.ftl

(

3. Installthe heat shield,and tightenthe three bolts. 8 x 1.25mm 22Nm

12.2

4 . I n s t a l l t h er i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,

16-25

Steering Steering . . . . . . . . . .1. .7.- 2 S p e c i aTl o o l s . .7. .-.3. . . . . . . . . C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 17-4 PlayCheck.....................". WheelRotational Steering 17-4 .......... PowerAssistCheck.................. 17-5 ................. andGearboxInspection SteeringLinkage ........... l e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1. .7. -. 6 S t e e r i nW g h e eR 17-7 ................ WheelDisassembly/Reassembly Steering 17-8 ............... WheelInstallation Steering 17-9 Steering ColumnRemovalandInstallation...........'... 17-11 .............. ColumnInspection Steering 17-'12 .......................................'. Replacement SteeringLock . . . . . " . . . . . . . . '1. .7' .- .1 3 R a c kG u i d eA d i u s t m e n t

ElectricalPowerSteering(EPS)

17-15

Steering (

SpecialTools Ref.No.

Tool Number 07MAA-S100200

Description LocknulWrench.43 mm

-.tt)-

---<,/ L\2 r

.Vo

1 7-2

Oty

ComponentLocationIndex

DRIVER'S AIRBAG ASSEMBLY Removal/lnstallation, p a g e2 3 - 1 1 3

STEERINGWHEEL Removal,page 17-6 Disassembly/Reassembly, page 17-7 Installation,page 17-8

STEERING COLUMN SteeringColumnRemovaland Installation, p a g e1 7 ' 9 SteeringColumn Inspection, p a g e1 7 - 1 ' l SteeringLockReplacement, page 11-12

STEERING GEARBOX page'17-13 RackGuideAdjustment,

17-3

Steering SteeringWheelRotationalPlay Check

PowerAssistCheck 1 . Startthe engine,and let it idle.

1. Turn the front wheelsto the straightaheadposition. 2. Measurehow far you can turn the steeringwheel left and right without moving the front wheels.

Attach a commerciallyavailablespring scaleto the s t e e r i n gw h e e l .W i t h t h e e n g i n ei d l i n ga n d t h e v e h i c l eo n a c l e a n ,d r y f l o o r ,p u l lt h e s c a l ea s shown, and read it as soon as the tires begin to turn.

. lf the play is within the limit, the gearboxand l i n k a g ea r e O K . . lfthe playexceedsthe l i m i t ,a d j u s t t h er a c kg u i d e '17-13). lf the play is still excessiveafter {seepage rackguide adjustment,inspectthe steering l i n k a g ea n d g e a r b o x{ s e ep a g e1 7 - 5 ) . BOTATIONAL PLAY:0 10mm (0-0.39in.l

+ :

3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) , the power assistis OK. lf it readsmore, checkthese items: . Fronttire pressure . Steeringlinkage(seepage 17-5) . Rackgulde adjustment(seepage 17-13) . EPSsystem (seepage 17-18)

17-4

SteeringLinkageand GearboxInspection

BOOT Inspect Ior damageanddeterioration.

Checkfor looseness, a n db i n d i n g .

12 mm BOLTS Inspectfor looseness.

STEERING COLUMN Inspect for loosecolumn mountinghardware STEERING JOINTS Checkfor looseioint bolts, andlooseor bindingioints.

TIE.RODLOCKNUTS Checkfor looseness.

STEERING GEARBOX Inspectfor loosemounting hardware. GEARBOXMOUNTING CUSHIONS Inspectfor deterioration.

TIE.RODENOBALLJOINT lnsoect tor looseness, b i n d i n ga,n dd a m a g e .

BALLJOINT BOOT Inspect for damageanddeterioration.

17-5

Steering SteeringWheelRemoval SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13),and precautionsand procedures(seepage 23-14)in the SRS sectionbeforeperformingrepairsor service. 1. Align the front wheels straightahead,then remove the driver'sairbagfrom the steeringwheel (see p a g e2 3 - 1 1 3 ) . 2. Disconnectthe cruisecontrol sevresumeswitch connector(A),and loosenthe steeringwheel nut {B).

{ 3. Installa commerciallyavailablesteeringwheel puller {A) on the steeringwheel (B).Freethe steeringwheel from the steeringcolumn shaft by t u r n i n gt h e p r e s s u r eb o l t( C )o f t h e p u l l e r . Note these items when removing the steering wheel: . Do not tap on the steeringwheel orthesteering column shaft when removingthe steeringwheel. . l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l hub more than 5 threads,the bolts will hit the cable reel and damageit. To preventthis, install a p a i ro f j a m n u t s5 t h r e a d su p o n e a c hp u l l e rb o l t . D

i Bemovethe steeringwheel puller,then removethe steeringwheel nut and steeringwheel from the sleerinocolumn.

17-6

SteeringWheelDisassembly/Reassembly

WHEEL STEERING ACCESSPANELA

CONTACTPLATE

75*-=offi

CONNECTORHOLDERS

ffi)Y

MOOULESETBRACKET

-f

STEERING WHEELREABCOVER

,/*

accEss PANEL B

CRUISECONTROLSWITCH

17-7

Steering SteeringWheelInstallation 1 . B e f o r ei n s t a l l i n g t h e s t e e r i n gw h e e l ,m a k es u r et h e front wheels are alignedstraightahead,then center the cable reel (A).Do this by first rotatingthe cable reel clockwiseuntil it stops.Then rotate it counterclockwiseabout two and a half turns.The a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t straightup.

3. Installthe steeringwheel nut (A),and tighten it to the specifiedtorgue. A 39 N.m(4.0kgf m.29lbt ftl

_ B

lr,',,t ;. _,:! '' '1i::..'.'l

Connectthe cruisecontrol set/resumeswitch connector(B).fvlakesure the wire harnessis routed and fastenedproperly. Positionthe two tabs (A) of the turn signal canceling s l e e v e( B )a s s h o w n .I n s t a l l t h es t e e r i n g wheel onto the steeringcolumn shaft, makingsure the steerlngwheel hub (C)engagesthe pins (D) of the cable reel and tabs of the cancelingsleeve.Do not tap on the steeringwheel or steeringcolumn shaft when installingthe steeringwheel.

I n s t a ltlh e d r i v e r ' sa i r b a g a , n d c o n f i r mt h a tt h e system is operatingproperly{seepage 23-113). C h e c kt h e h o r n ,t u r n s i g n a lc a n c e l i n g a n dc r u i s e control switchesfor proper operation. 7 . Reconnectthe batteryand do the following: . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 l - 1 3 9 ) , . Powerwindow control unit resettingprocedure \see page 22-1281. . Enterthe anti-theftcord for the radio,then enter the custmer'sradio stationpresets. . Set the clock.

17-8

{

SteeringColumnRemovaland Installation SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.

Removal 1, Recordthe radio stationpresets,and disconnectthe battery. 2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a1n1d3t)h e s t e e r i n gw h e e l( s e ep a g e1 7 - 6 ) . p a g e2 0 - 6 0 ) . 3 . R e m o v e t h ed r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e ep a g e2 0 - 5 9 a) n d u n d e r c o v e r ( s e e 4. Removethe column covers(A:

I x 1.25mm 16 N.m (1.6kgf.m, 12 lbl.fr)

5 . Disconnectthe wire harnessconnectorsfrom the combinationswitch assembly{B). 6 . Removethe combinationswitch assemblyfrom the steeringcolumn shaft by removingthe screw (C)on the top of the combinationswitch. 7. Disconnectthe connectorsfrom the ignition switch,and releasethe wire harnessclips from the steeringcolumn. 8. Disconnectthe steeringjoint (D),and remove it from the column shaft. 9. Removethe steeringcolumn {E)by removingthe attachingnuts and bolts.

\ (cont'd)

17-9

Steering SteeringColumnRemovaland Installation(cont'd) lnstallation 1 . I n s t a ltl h e s t e e r i n gc o l u m n ,a n d m a k es u r et h e wires are not caught or pinchedby any parts. Insertthe upper end ofthe steeringjoint onto the steeringshaft {A) (line up the bolt hole (B)with the flat portion (C)on the shaft).

8 x 1 , 2 5m m 28 N.m {2.9 kgf m,

21rbr.ft) A

Slip the lower end of the steeringjoint onto the pinion shaft {D) (line up the bolt hole with the g r o o v e( E )a r o u n dt h e s h a f t )a, n d l o o s e l yl n s t a l l t h e lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. 4 . Pull on the steeringjoint to make sure that the s t e e r i n gj o i n t i s f u l l y s e a t e dT. h e n i n s t a l l t h eu p p e r joint bolt, and tighten it to the specifiedtorque. Tightenthe lower joint bolt to the specifiedtorque. Finishthe installation,and note these items: . Make surethe wire harnessis routed and fastenedproperly. . Make sure the connectorsare properlyconnected. . R e i n s t a l l t h se t e e r i n gw h e e l( s e ep a g e1 7 - 8 ) . . Reconnectthe battery. - Do the power window control unitreset procedure{seepage 22-128). - Enterthe anti-theftcode for the radio,then enterthe custmer'sradio stationpresets. - Set the clock. . Verify horn, turn signalswitch,and cruisecontrol switch operation. . Checkwheel alignment,if necessary(seepage 18-4). . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n p r o c e d ur e { s e ep a g e' 1 1 - 1 3 9 ) .

17-10

{

SteeringColumnInspection . C h e c kt h e s t e e r i n gc o l u m nb a l l b e a r i n g ( A a ) n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m el fnatn. y bearingis noisy or has excessiveplay, replacethe steeringcolumn as an assembly, ' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l af o t er sd(i F s t)o r t i o na n d breakage.lf there is distortionor breakage,replacethe steeringcolumn as an assembly.

17-11

Steering SteeringLockReplacement NOTE:Do not try to re-keya replacementsteeringlock. lf necessary,re-keythe other locks. 1 . R e m o v et h e s t e e r i n gc o l u m n( s e ep a g e1 7 - 9 ) . 2. Centerpunch each ofthe two shear bolts (A),and drill their headsoff with a 5 mm (3i16 in.) drill bit. Be carefulnot to damagethe switch body when removingthe shear bolts,

7. Tightenthe shearbolts (A) untilthe hex heads(B) twist off. A

:..'-":'

3. Removethe shear bolts from the switch body. 4. Installtheswitch body without the key inserted. 5. Looselytighten the new shear bolts. 6. Insertthe ignition key,and checkfor proper operationof the steeringwheel lock and that the ignition key turns freely.

17-12

RackGuideAdjustment Special Tool Required Locknutwrench, 43 mm 07MAA-S100200

6. Tightenthe rackguidescrew(A)ro25 N.m (2.5 kgf.m,18lbf.ft).thenloosenit. 5" Max.

1. Set the wheels in the straightaheadposition. j

i-rrrr-,

2. Removethe heat shield(A).

'-.i. ''

9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t ) I

32 on page 13-8).

4il N.m

{a.5kgf.m,33lbt.ft)

3 . Removethe transmissionmount bracket(seestep

7 . Retightenthe rack guide screw to 6 N.m (0.6kgf m, 4 lbf.ft),then back it off to the specifiedangle.

Loosenthe rackguide screw locknut(A)with the specialtool, then removethe rack guide screw (B). 07MAA-S100200

Specified Return Angle: 5' Max. Hold the rack guide screw stationarywith a wrench, and tighten the locknutby hand until it's fully seated. 9 . I n s t a l l t h es p e c i atl o o l o n t h e l o c k n u (t B ) ,a n d h o l d the rackguide screw (A) stationarywith a wrench, Tightenthe locknutan additional30" with the specialtool.

1 0 .Reinstallthe transmissionmount bracketand heat s hi el d , Removethe old sealantfrom rackguide screw,and apply new sealantto the middle of the threads(A). Looselyinstallthe rackguide screw on the steering gearDox.

1 1 .Checkfor unusualsteeringeffort through the c o m p l e t et u r n i n gt r a v e l .

12. Checkthe steeringwheel rotationplay (seepage 17-4)and the power assist(seepage 17-4).

17-13

ElectricalPowerSteering(EPSI

SpecialTools . . . . . . . . . .1. .7-. 1 6 C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7. .-.1. .7. . . . . . . Troubleshooting General Information....................... 17-18 DTCTroubleshooting Index .............. 17-22 SymptomTroubleshooting Index ............................... 17-23 SystemDescription................. ........... 17-24 CircuitDiagram .........17-26 DTCTroubleshooting ............... .......... 17-28 EPSlndicator CircuitTroubleshooting ....................... 17-47 MotorRemoval/lnstallation ............... 17-49 Steering GearboxRemoval ............... 17-51 Steering GearboxOverhaul ............... 17-55 Steering GearboxInstallation ........... 17-63 EPSControlUnitRemova l/lnsta llation....................... 17-67 Tie-rodBallJointBootReplacement .......................... 17-67

EPSComponents SpecialTools Rel.No. Tool Number (!) 07MAC-S100200 at' 070AD-P0A0100

07zAA-S5A0100

otv

Description

B a l lJ o i n t R e m o v e r2, 8 m m Attachment,42 mm LocknutWrench

1 'l

,.^G) C\

_---1t

h5--d-'

)

u_r-.c_t t ) \L-,

a 17-16

ComponentLocationIndex

GAUGE ASSEMBLY UNDER.DASH FUSE/RELAY BOX

UNDER.HOOD FUSE/RELAY BOX

-,'/.,....

'.,i, X \ ]

DATA LINK CONNECTORI16P)

TOROUE SENSOR STEERINGGEARBOX SteeringGearboxRemoval,page 17-51 SteeringGearboxOverhaul,page 17-55 SteeringGearboxInstallation,page 17-63

EPSCONTROL UNIT EPSControlUnitRemoval/lnstallation, page17-67 MOTOR

Removal/lnstallation, page l7-49

17-17

EPSComponents

GeneralTroubleshooting Information EPSIndicator Undernormalconditions, the EPSindicator comeson when the ignitlonswitchis turnedto theON(ll)position, thengoes Thisindicates off afterthe engineis started. thatthebulband itscircuitareoperating correctly. lf thereis anytroublein thesystemaftertheengineis started, will stayon,andthe powerassistis turned theEPSindicator off. WhenEPSindicator lightcomeson,thecontrolunit memorizes the DTC.In thiscase,thecontrolunitwill not activate the EPSsystemaftertheenginestartsagain,but it keepsthe EPSindicator on. WhenDTC12,16,17,18or 67 is storedin thecontrolunit,the EPSindicator will stayon untiltheDTCis erased. Whena problemis detected andthe EPSindicator comeson,thereare stayson untiltheignitionswitchis caseswhenthe indicator goesoff turned0FF,andcaseswhenthe indicator whenthesystemreturnsto normal.Eventhough automatically thesystemis operating normally, the EPSindicator will come on underthefollowingconditions: '1: Condition . Thevehiclewastraveling at least12.4mph(20km/h),then . A rapid changein vehiclespeedwas detected,then . Thevehicle(orthevehiclespeedsensorsignal)stoppedfor at least5 seconds 'l,640rpmorhigherforatleastS . T h ee n g i n se p e e d w a ss t i l l seconds C o n d i t i o n2 : Afterthevehicle(orthevehiclespeedsensorsignal)has yettheenginespeedwasstill for at least10seconds, stopped 1,640rpmor higherforat least20seconds. C o n d i t i o n3 : When is280rpmor less, andthevehicle istraveling theengine speed at a speed of6,2mph(10km/h) or morefor3 seconds. To determine theactualcauseofthe problem,question the duringwhichthe problem customer abouttheconditions takingtheaboveconditions intoconsideration. occured,

DiagnosticTroubleCode(DTCI . lf theCPUcannotbeactivated, or itfails,theEPSindicator comeson,butthe DTCis notmemorized. . Thememorycanholdanynumberof DTCS. However, when thesameDTCis detected morethanonce,the mostrecent onlyone DTCis writtenoverthe priorDTC,therefore occurrence is memorized. . TheDTCS areindicated repeatedly untiltheignitionswitchis turnedOFF. . lf theDTCis not memorized,the EPSindicator blinks.

17-18

. TheDTCS arememorized in theEEPRO|(non-volatile memory)therefore the memorized DTCS cannotbe erased by disconnecting the battery. Perform thespecified procedures to clearDTCS.

Self-diagnosis Self-diagnosiscan be classifiedinto two categories: . I n i t i a l d i a g n o s i sp: e r f o r m e dr i g h ta f t e rt h e e n g i n e startsand until the EPSindicatorgoes off. . Regulardiagnosis:performedright after the initial d i a g n o s i su n t i lt h e i g n i t i o ns w i t c hi s t u r n e dO F F . The EPScontrol unit performsthe following functions when a problem is detectedby self-diagnosis; '1. T u r n so n t h e E P Si n d i c a t o r . 2. Memorizesthe DTC. 3. Stops power assistand manual steeringoperation begrns. NOTE: . When DTC23 (a problemwith the circuitfor enginespeedsignal)is detected,the power a s s i sw t i l l r e t u r nt o n o r m a lw h e n t h e v e h i c l e s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e . . Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes off automaticallywhen the system relurnsto n o r m a l .F o ra l l o t h e rc o d e s t, h e E P Si n d i c a t o r goes off when the system is OK afterthe ignition switch is turned from OFFto ON (ll).

Restrictionon PowerAssistOperation Repeatedextremesteeringforce.such as turning the steeringwheel continuouslyback-and-forth with the vehiclestopped,causesan increaseof power consumptionin the EPSmotor. The increaseof electric t h i sh e a t c u r r e n tc a u s e st h e m o t o rt o h e a tu p . B e c a u s e adverselyaffectsthe system,the control unit monitors the electriccurrent of the motor. When the control unit detectsheat build-upin the motor, it reducesthe electriccurrentto the motor graduallyto protectthe system,and it restrictsthe power assist o p e r a t i o nT. h e E P Si n d i c a t o dr o e sn o t c o m e o n d u r i n g t h i sf u n c t i o n . When steeringtorque is not appliedto the steering wheel, or when the ignition is turned off, and the motor cools,the control unit will restorethe power assist graduallyuntil it's fully restored(afterapproximately15 m i n u t e sm a x i m u m ) .

How to TroubleshootEPSDTCs The troubleshootingflowchart proceduresassumethat the causeof the problem is still presentand the EPS indicatoris still on, Followingthe flowchartwhen the EPSindicatordoes not come on can result in incorrect diagnosis. The connectoriliustrationsshow the female terminal c o n n e c t o rw s i t h a s i n g l eo u t l i n ea n d t h e m a l et e r m i n a l connectorswith a double outline. 1. Ouestionthe customeraboutthe conditionswhen the problem occured,and try to reproducethe same conditionsfor troubleshooting.Find out when the EPSindicatorcame on, such as while t u r n i n g .a f t e r t u r n i n gw, h e n t h e v e h i c l ew a s a t a certain speed,etc.

2 . T u r nt h e i g n i t i o nO N ( l l ) ,a n d f o l l o wt h e p r o m p t so n the PGM Testerto displaythe DTC(s)on the screen. After determiningthe DTC,referto the DTC TroubleshootingIndex. NOTE:See the HondaPGM Testeruser's manual for specificinstructions. ServiceCheckSignalCircuit Method: 1 . W i t h t h e i g n i t i o ns w i t c hO F F ,c o n n e c t h e H o n d a P G MT e s t e r( A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o(rD L C ) (B) locatedunderthe dash on the driver'sside of the vehicle.

2. When the EPSindicatordoes not come on during the test drive, but troubleshootingis done basedon the DTC,checkfor looseconnectors,poor terminal contact.etc in the affectedcircuit,beforeyou start troubleshooting. 3. After troubleshooting,clearthe DTCand test-drive the vehicle.Be sure the EPSindicatordoes not c o m eo n .

How to RetrieveEPSDTCs Honda PGM Tester Method: 1, With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (B) locatedunderthe dash on the driver'sside of thevehicle.

Short the SCScircuitto body ground using the HondaPGN4Tester. T u r nt h e i g n i t i o ns w i t c hO N { l l ) . Recordthe DTC.

(cont'd)

17-19

EPSComponents GeneralTroubleshootingInformation(cont'dl 5. The blinkingfrequencyindicatesthe DTC.DTCSare indicatedby a seriesof long and short blinks.One l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A . d d t h e l o n ga n d short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC TroubleshootingIndex. The system will not indicatethe DTCunlessthese conditionsare met: . Set the front wheels in the straightaheaddriving position. . The ignition switch is turned ON (ll). . The engine is stopped. . The SCScircuit is shortedto body ground before the ignition switch is turned ON (ll).

How to ClearEPSDTCs Honda PGM Tesler Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) ( B )l o c a t e du n d e rt h e d a s ho n t h e d r i v e r ' ss i d eo f the vehicle.

Exampleof DTC23

Long blinks Short blinks (two times) (three timesl

Turn the ignition switch ON (ll),and clearthe DTC{s)by following the screenpromptson the PGM Tester. NOTE:Seethe Honda PGMTesteruser'smanual for specificinstructions.

6 . Turn the ignitionswitch OFF. 7 . Disconnectthe Honda PGM Testerfrom the DLC.

17-20

Service Check Signal Circuit Method: NOTE:Use this procedurewhen the PGM Tester softwaredoes not matchthe yearlmodelvehicleyou are working on. 1. With the ignitionswitch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector{DLC) (B) locatedunderthe dash on the driver'sside of the vehicle.

1 . Within 4 secondsafter the EPSindicatorgoes off, returnthe steeringwheel to the straightahead driving positionagain and releasethe steering wheel.The EPSindicatorblinkstwice 4 seconds after releasingthe steeringwheel, indicatingthat the DTCwas erased. NOTE:If the EPSindicatordoes not blinktwice, an error was made in the procedureand the DTCwas not erased.Turn the ignition switch OFF,and repeatthe operationfrom step 3. Turn the ignition switch OFFafterthe EPSindicator blinkstwice. 9. Disconnectthe Honda PGM Testerfrom the DLC. 10. Performthe DTCcode output operation,and be sure that the code has been erased.

With the vehicleon the ground,set the front wheels in the straightaheaddriving position. Short the SCScircuitto body ground using the HondaPGM Tester. 4. Turn the ignition switch ON (ll).The EPSindicator

comes on for about 6 seconds.Within 4 secondsof turning the switch ON, while the EPSindicatoris on, turn the steeringwheel 45 degreesto the left from the straightaheaddriving position,and hold the steeringwheel in that positionuntil the EPS indicatorgoes off. Within 4 secondsafterthe EPSindicatorgoes off, returnthe steeringwheel to the straightahead driving positionand releasethe steeringwheel. The EPSindicatorcomes on again 4 secondsafter releasingthe steeringwheel, Within 4 secondsafter the EPSindicatorcomes on, turn the steeringwheel 45 degreesto the left again and hold it in that position. The EPSindicatorgoes off after 4 seconds.

17-21

EPSComponents DTCTroubleshootingIndex DTC

Detection ltem

Note

DTC;12

A problem with voltagefor torque sensorT/SlG

(seepage 17-28)

D T C1: 6

A problemwith averageof voltagefor torque sensorVT3 and VT6

(seepage 17-29)

DTC:17

A problemwith thevoltagefor torquesensor12V powersourceVcc1

( s e ep a g e1 7 - 3 1 )

DTC:18

A problemwith the voltagefor torque sensor5 V power sourceVcc 2

( s e ep a g e1 7 - 3 1 )

DfC:22

A problemwith the averagefor vehiclespeedand enginespeed

( s e ep a g e1 7 - 3 3 )

Excessivechangeof the vehiclespeed sensorsignal

{seepage 17-33)

DTC:23

A problemwith the engine speedsignal circuit

( s e ep a g e1 7 - 3 3 )

DTC:37

A problemwith the circuitfor input motor voltage in the EPScontrol unit

(seepage 17-35)

DTC:41

A problemwith the motor voltage

( s e ep a g e1 7 3 6 )

DfC: 42

A problemwith the motor driven current (opencircuitor short to grounol

(seepage '17-38)

DTC:43

A problem with the motor driven current (shortto power)

( s e ep a g e1 7 - 4 1 )

DTC:45

A problemwith the motor driven current (opencircuitor short to grounol

(seepage 17-38)

DfC: 47

A problemwith the motor relav in the EPScontrol unit

{ s e ep a g e1 7 - 4 2 )

DTC:50

A problem with the CPU in the EPScontrol unit

( s e ep a g e1 7 - 4 3 )

D T C :5 1

A problemwith EEPROM in the EPScontrolunlt

(seepage 17-43)

DTC:62

Fail-saferelay stuckON

( s e ep a g e1 7 - 4 4 )

DTC:64

A problem with low batteryvoltage

(seepage 17-44)

Fail-saferelay contactfailure

(seepage 17-44)

DTC:66

A problem with the motor driven voltage

{seepage 17 45)

DTC:67

A problemwith the torque sensorl/F circuit

( s e ep a g e1 7 ' 4 5 )

DTC:68

A problemwith the interlockcircuit (torque)

{seepage 17-45)

DTC:69

A p r o b l e mw i t h t h e i n t e r l o c kc i r c u i t( c u r r e n t )

( s e ep a g e1 7 - 4 6 )

17-22

Symptom TroubleshootingIndex Symptom

Diagnostic procedure

EPSindicatordoes not come on

EPSlndicatorCircuitTroubleshooting(seepage 17-47)

EPSindicatordoes not go off and no DTC is stored

EPSIndicatorCircuitTroubleshooting(seepage 17-47)

EPSindicatordoes not stay on, no DTCis stored,and there is no power assist

1. Checkthe motor wires betweenthe EPScontrol unit and the motor for a short to ground. Repairas needed. 2. lf the motor wires are OK, replacethe steeringgearbox {short in the motor).

Also check fo]

17-23

EPSGomponents SystemDescription EPSGontrolUnit Inputsand Outputsat ConnectorA (2pl EPSCONTROLUNIT CONNECTORA {2P)

Wire side of femaleterminals Termanal Wire color numbol

Terminalsign (Terminalnamel

Description

WHT/BLU -' BAT (Plus bafterv) 2

8LK

Measurement Conditions lqnitiqr switch ON (lll l Ground Constant Terminals

Powersourcefor the actuatormotor Groundforthe actuator

Voltage Battery voltage

2-Ground

EPSControlUnit Inputsand Outputsat ConnectorB (2P) EPSCONTROLUNITCONNECTOB B {2P}

Wire side of femaleterminals Terminal Wire colol numDer

Terminalsign {Te.mioalname)

Description Terminals

RED

M1 (Motor 1

Driveslhe actuatormotor

1-Ground

GRN

Drives the actuator motor

2'Ground

17-24

Measuremenl Conditions lqnition switch ON llll

Voltage

EPSGontrolUnit Inputsand Outputsat ConnestorC (20P1 EPSCONTROLUNITCONNECTOR C (2OP)

Wire side of femaleterminals

Terminal

Wire color

numbel 2

Terminalsign {Terminelname}

Descriplion Terminals

Measuremeni Conditions {lqnitionswitch ON {lll)

T/SGND Groundfor the torque (Torquesensorqround) 3-Ground tarttheenqrne Powersourcefortorque ORN vccl (Voltaqe common1 Detectstorque sensor 5 Ground Starttheengineand YEUBED VT6 (Voltaqe turnthe steerinowheel stonal torque6) ON Drivesthe EPSindicator 6 Ground E P S YEUBLU (Warninqlamp) uTllidhr tnotcatol Raisethe vehicleoff the Detectsthe vehiclespeed BLUAVHT VSP groundandspinthe ( V e h i c l es p e e d p u l s e i inputsignalfor the speed sensoror the ECM(4 pulse/

Voltage

PNK

BRN

YEL

GRN//EL

SCS checksiqnal) {Servjco IG1 llqnition1

vcc2

Detectsservicecheck

Drivesthetorquesensor

Batteryvoltage

on switchON (ll) on switchOFF 1'l-Ground tan the enoine

Battervvoltaqe About5V

on switch OFF

8LU/ORN VT3

Detectstorque sensor

YEUBLK T/SIG (TorquesensorF/S

Detectstorque sensor srgnal

(Voltaoe toroue3)

OV Banervvoltaqe Alternating voltageabout OV 5V OV-5V

8-Ground SCSnot grounded

Powersourcefor activating 10-Ground

(Voltaqe common2)

Ba$ervvoltaqe OV About

1'l

LT GRN/ B IK

BLU

Providespower steering PSW iPowersteerinoswitch) switchsional Detectsthe enginepulse NEP

GRY

DIAG-H

with Communications HondaPGNITester

About 13-GroundStarttheengineand trrrnthe steerinowheel 5 - 0 v Momentarily 5V 15-GroundStarttheengine 0-12V l7-Ground Starttheengineand nrrnthe steerinowheel 19-GroundStarttheengine,and let ;t idte 5V 20-Ground PGMTesternot

17-25

EPSComponents CircuitDiagram

SPE€DSENSOR 3P CONNECTOR

@ GAUGEASSEMATY22PCONNECTOR

TOFOUESENSOR 6P CONNECTOR

lli2l3F r;T;T-I (=J_:_LvJ Wn. !ide ot f.m.l€ r.fmin.ls

17-26

GAUGEASSEMBLY22PCONNECTON

OATA !IN( CONN€CTOA(T6P)

EPSCOI{IFOIUNIT cou{EcToR A (2P) F-l

vTTrvaEvnrv

A EPSCONTNOLUNIT co|lNEcTofi 8 {2P} | l l

wwzna

MOTOF CONNECTOR

riTt

t2)

T.rmin.l.id.

oll.m.l.r.rmin.l.

Wir. !.le ol l.m.l. t.tman.r.

17-27

EPSComponents DTCTroubleshooting DTC12: TorqueSensorT/SIG 1 . C l e a rt h e D T C .

1 . Turn the ignition switch ON (ll). 8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .

2 . S t a nt h e e n g i n e . 3. Wait at least 10 seconds. Does the EPS indicatot come on?

EPSCONTROL UNITCONNECTOR C (2OP)

2 3

YES Go to step 4.

5 6 1 8

T/SIG {YEL/BLK)

NO Checkfor loosewires or poor connections.lf the connectionsare good, the system is OK at this time.l 4 . Stop the engine,and verify the DTC.

Wire side ot lemaleterminals

ls DTC12 indicated? I s there battery v oltage? YES Go to slep 5. NO-Perform the appropriatetroubleshootingfor the code indicated.t

YES-Repair short to power in the + circuitwire betweenthe torque sensorand EPScontrol unit.l NO Go to step 9.

5 . Make sure the ignitionswitch is OFF,then

disconnectEPScontrol unit connectorC (20P)and the torque sensor6P connector.

9 . Turn the ignition switch OFF.

Checkfor continuitybetweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .

1 0 . Checkfor continuitybetweenEPScontrol unit connectorC (20P)terminal No. 15 and the torque sensor6P connectorterminal No. 4.

EPSCONTROL UNITCONNECTOR C {2OP)

EPSCONTROL UNITCONNECTOR C (2OPI

T/SIG (YEL/BLK)

W i r es i d eo f f e m a l et e r m i n a l s

TOROUE SENSOR 6PCONNECTOR T/SIG (YEL/BLK) Wire side of femaleterminals Wire side ot femaleterminals

ls therecontinuity?

ls there continuity?

YES- Repairshortto bodygroundin thewire betweenthetorquesensorandEPScontrolunit.l

YES Go to step 1'1,

NO Go to step7.

NO Repairopen in the wire betweenthe torque sensorand the EPScontrol unit.I

17-28

'I 1 . Substitutea known-goodEPScontrol unit, and connectthe all disconnectedconnectors.

DTC16:TorqueSensorVT3andW6

1 2 .Start the engine.

1 . C l e a rt h e D T C . 2. Startthe engine. 3 . W a i t a t l e a s t1 0 s e c o n d s .

Does the EPS indicator come on? Does the EPS indicator come on? YES Go to step 13. YES Go to step 4. NO Checkfor loose EPScontrol unitconnectors.lf necessary,replacethe EPScontrol unit and retest.l

NO Checkfor loosewires or poor connnections.lf the connectionsare good,the system is OK at this time.l

1 3 .Stop the engine,and verify the DTC. 4. Stop the engine,and verify the DTC. ls DTCl2 indicated? ls DTC16 indicated? YES Checkfor loosetorque sensorconnectors. lf necessary,substitutea known-goodsteering gearboxand recheck.l NO-Perform the appropriatetroubleshootingfor the code indicated.!

YES-Go to step 5. NO Performthe appropriatetroubleshootingfor the code indicated.t 5. Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorC (20P)and the torque sensor6P connector. 6, Checkfor continuitybetweenthe appropriateEPS control unit connectorC (20P)terminal and body ground (seetable). Terminalname

C EPScontrolunitconnector terminalNo.

Vccl

Vcc2 VT3 VT6

T/S GND

5 2

EPSCONINOTUNITCONNECIOR C (2OP)

W re s d€ oltemalelermi.als

ls there continuity? YES- Repairshort to body ground in the appropriatesensorcircuit betweenthe torque sensorand EPScontrol unit,! NO Go to step7. {cont'd)

17-29

EPSComponents

DTCTroubleshooting(cont'd) 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

9 . Turn the ignition switch OFF.

8 . Measurethe voltage betweenthe appropriateEPS control unit connectorC (20P)terminal and body ground (seetable).

1 0 . Checkfor continuitybetweenthe appropriateEPS control unit connectorC {20P)terminal and the torque sensorterminal (seetable).

EPScontrol unitconnector C t e r m i nN a lo . 3

T e r m i n a l TorqueSensor EPScontrol name t e r m i n aNl o , unitconnector C t e r m i n aNl o . Vccl 2 3 Vcc2 3 11 'l 't3 VT3 VT6 6 5 6 T/S GND 2

Terminalname Vccl

Vcc2 VT3 VT6

T/S GND

13 5

EPSCONTROLUNITCONNECTOR C {2OP}

TOROUESENSOR6PCONNECTOR Vccz (GRN/YELI Wire side of f e m a l et e r m i n a l s

VT6 {YEL/RED)

T/S GND {PNK) Wire side of femaleterminals

EPSCONTROLUNIT CONNECTOR C I2OP) VT6{YEL/RED}

ls thete battery voltage? YES Repairshon to power in the + circuitwire betweenthe EPScontrol unit and torque sensor.l NO Go to step 9. Wire side of femaleterminals

ls therecontinuty? Y E S G ot o s t e p1 1 . NO Repairopenin the appropriate torquesensor wirecircuitbetweenthe EPScontrolunitandthe t o r q u es e n s o r . l

17-30

1 1 .Substitutea known-goodEPScontrol unit, and reconnectthe disconnectedconnectors.

't2.

DTC17: TorqueSensorVccl DTC18:TorqueSensorVcc2

Start the engine. 1 . C l e a rt h e D T C . Does the EPS indicator come on? 2 . S t a r tt h e e n g i n e .

YES Go to step 13. 3. Wait at least 10 seconds. NO Checkfor looseor poor connectionsat the EPScontrol unit and the torque sensorconneclors. lf the connectionsare good, replacethe EPScontrol u n i ta n d r e c h e c k . I

1 3 .Stop the engine,and verify the DTC. ls DTC16 indicated?

Does the EPS indicator come on? YES Go to step 4. NO Checkfor loosewires or poor connections.lf the connectionsare good, the system is OK at this time.I

YES Replacethe steeringgearboxand recheck.l

4 . Stop the engine,and verify the DTC.

NO Performthe appropriatetroubleshootingfor the code indicated.l

Is DTCl7 or DTCl8 indicated? YES Go to step 5. NO Do the troubleshootingfor the DTc indicated.I Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorC (20P)and the torque sensor6P connector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 3 a n d b o d y g r o u n d . UNITCONNECTOR C (2OP) EPSCONTROL

Wiresideo{femaleterminals

ls there continuity? Y E S R e p a i rs h o n t o b o d y g r o u n di n t h e w i r e betweenthe torque sensorand EPScontrol unit.I NO Go to step 7. (cont'd)

17-31

EPSComponents DTCTroubleshooting(cont'dl 7. Checkfor continultybetweenEPScontrol unit c o n n e c t oC r ( 2 0 P t)e r m i n a lN o . 3 a n d t h e t o r q u e sensor6P connectorterminal No. 2. EPSCONTROL UNITCONNECTOR C I2OP)

\ 9. Checkfor continuitybetweenEPScontrol unit connectorC {20P)terminal No. 11 and the torque sensor6P connectorterminal No. 3. EPSCONTROL UNITCONNECTOR C (2OP}

Vcc2(GRN/YEL)

Wire side ol lemale terminals

Wire side of femaleterminals

ls thete continuity?

ls therc continuity?

YES Go to step 8.

YES-Go to step 10.

NO Repairopen in the wire betweenthe torque s e n s o ra n d E P Sc o n t r o lu n i t . I

NO Repairopen in the wire betweenthe torque sensorand EPScontrol unit.l

8 . Checkfor continuitybetweenEPScontrol unit c o n n e c t oC r ( 2 0 P t)e r m i n a lN o . 1 1 a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR C (2OP)

1 0 .Substitutea known-goodEPScontrol unit, and connectall the disconnectedconnectors. 1 1 .Start the engine. Does the EPS indicator come on?

2 3 lvcc2

5 6 1 8

{GRN/YEL)

Wire side of femaleterminals

YES Go to step 12. NO Checkfor looseor poor connectionsat the EPScontrol unit and the torque sensorconnectors. lf the connectionsare good, replacethe EPScontrol u n i ta n d r e c h e c k . l

12. Stop the engine,and verity the DTC. ls DTC17 or DTC18 indicated?

ls therecontinuity? YES-Replace the steeringgearboxand recheck.l

YES Repairshortto bodygroundin thewire betweenthetorquesensorandEPScontrolunit.t NO Goto step9.

17-32

NO Performthe appropriatetroubleshootingfor the code indicated.l

DTC22: VehicleSpeedSensorSignal

3 . Blockthe rearwheels and raisethe vehicle,and make sure it is securelysupported.

DTC23: EngineSpeedSignal 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

NOTE: . lf the MIL indicatoris ON, troubleshootthe PGIVI-Fl systemfirst. . Eventhough the system is operatingnormally,the EPSindicatorwill come on underthe following conditions. - C o n d i t i o n1 : . The vehiclewas travelingat least '12.4mph (20 km/h),then . A rapld changein vehiclespeedwas detected, then . T h e v e h i c l e( o rt h e v e h i c l es p e e ds e n s o rs i g n a l ) stoppedfor at least5 seconds,and . The engine speedwas still 1,640rpm or higherfor at least5 seconds - Condition2: After the vehicle(or the vehiclespeedsensor signal)has stoppedfor at least10 seconds,yetthe e n g i n es p e e dw a s s t i l l 1 , 6 4 0r p m o r h i g h e rf o r a t least20 seconds. - Condition3: W h e nt h e v e h i c l es p e e di s 1 0 k m / h ( 6 . 2m p h )o r a b o v ea n d t h e e n g i n ei s r u n n i n ga t 2 8 0 r p m o r below for 3 seconds. 1. Startthe engineand checkthe tachometer. ls the tachometer working correctly?

5 . Blockthe right front wheel, and slowly rotatethe left front wheel, and measurethe voltage between E P Sc o n t r o lu n i tc o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 7 a n d b o d yg r o u n d . EPSCONTROL UNITCONNECTOR C {2OP)

Wire side of femaleterminals

Does the voltagepulse 0 V and 5 V? YES Go to step 6. NO Repairopen in the wire betweenthe EPS control unit and the VSS. lf the wire is OK,checkfor a loose or poor connectionsat the EPScontrol unit. lf necessary,substitutea known-goodEPScontrol u n i t ,a n d r e c h e c k . l

YES- Go to step 2. N O - G o t o s t e p9 . 2. Test-drivethe vehicleabove 15 km/h {9.3mph). ls the speedometerworking correctly? YES Go to step 3. NO-Perform the speedometersystem troubleshooting{see page22-651.a

(conr'd)

17-33

EPSGomponents DTCTroubleshooting(cont'dl Turn the ignition switch OFF,and disconnectEPS control unit connectorC (20P). 7 . Startthe engine,and let it idle.

11. Measurethe voltage betweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d . EPSCONTROLUNITCONNECTOR C {2OPI

8 . Measurethe voltage betweenEPScontrol unit c o n n e c t oC r { 2 0 P t) e r m i n a lN o . 1 9a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR C {2OP)

Wiresideof femaleterminals

ls there about 6 V at idle? (With the metet set tor trequency, is therc 33 Hz per 1,000 engine rpn?) Wire side of {emaleterminals

ls there about 6 V at idle? (With the meter set lol t requency,is there 33 Hz per 1,000engine rpm?)

YES Checkfor loose EPScontrol unitconnectors. lf necessary,substitutea known-goodEPScontrol u n i ta n d r e c h e c k . I NO Go to step

YES Checkfor loose EPScontrol unit connectors. lf necessary,substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l

'12.

1 2 .Turn the ignition switch OFF. 1 3 .Disconnectthe ECMconnectorE (31P)connector.

NO Repairopen in the wire betweenthe EPS c o n t r o lu n i ta n d t h e E C M . I 9 . Turn the ignition switch OFF,and disconnectEPS control unit connectorC (20P).

1 0 .Startthe engine,and let it idle.

! 17-34

'14. Checkfor continultvbetweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d E C M connectorE (31P)terminal No. 26. ECMCONNECTOR E {31PI

DTC37: EPSControlUnitInternal Circuit (lnputCircuitForMotorVoltage) 1 . C l e a rt h e D T C . 2. Startthe engine. 3. Turn the steeringwheel from lock-to-lockseveral times, and wait 10 secondsor more. Does the EPS indicator come on? YES Go to step 4. NO Checkfor loosewires or poor connections.lf the connectionsare good,the system is OK at this trme.l

ls thete continuity?

4. Stop the engine,and verify the DTC.

YES-Go to step 15.

ls DTC 37 indicated?

N O - R e p a i r o p e n i n t h e w i r e b e t w e e nt h e E P S c o n t r o lu n i ta n d E C M . I

Y€S Checkfor loose EPScontrol unit conneclors. lf necessary,substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l

1 5 . Disconnectthe gauge assembly22Pconnector. Checkfor continuitybetweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d b o d y g r o u n d ,

NO Performthe appropriatetroubleshootingfor the code indicated.l

EPSCONTROL UNITCONNECTOR C (2OP}

Wiresideof femaleterminals

ls there continuity? Y E S R e p a i rs h o r t t ob o d y g r o u n di n t h e w i r e betweenthe EPScontrol unit, the test tachometer connector,the gaugeassembly,and the ECM.I NO Checkfor loose ECMcontrol unit connectors. lf necessary,substitutea known-goodECMcontrol u n i ta n d r e c h e c k . I

17-35

EPSComponents

DTCTroubleshooting(cont'dl DTC41: VoltageForMotor

7. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .

1 . C l e a rt h e D T C . EPSCONTROLUNITCONNECTOR B I2P)

2 . S t a r tt h e e n g i n e . 3. Turn the steeringwheel from lock-to-lockseveral times, and wait 10 secondsor more,

Tit M2 {GRN)FJ

-r

Does the EPS indicator come on?

YES-Go to step 4.

NO Checkfor loosewires or poor connections.lf the connectionsare good,the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTC 41 indicated?

Wiresideof femaleterminals

ls there continuity? Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e betweenthe EPScontrol unit and the motor,l

YES Go to step 5. NO Go to step 8. NO Performthe appropriatetroubleshootingfor t h e c o d ei n d i c a t e d . l 5. Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorB (2P)and the motor 2P conneclor.

Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 1 a n d N o . 2 . B {2P) EPSCONTROL UNITCONNECTOR

6. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d . B {2P} EPSCONTROLUNIT CONNECTOR M2 (GRNI

M1 (RED}H

F---t||

Itr (f)) T

Wiresideof femaleterminals

ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor.! N O - G o t o s t e p7 .

17-36

Wiresideof femaleterminals

ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i t a n dt h e m o t o r . l NO Go to step 9.

9. Turn the ignition switch ON (ll),and measurethe voltagebetweenEPScontrol unit connectorB (2P) terminal No. 1 and body ground EPSCONTROLUNITCONNECTOR B (2P)

1 1 .T urn the ignition switch is OFF. Substitutea known-goodEPScontrol unit, and connectall the disconnectedconnectors.

1 3 .Start the engine,and turn the steeringwheel from lockto lock severaltimes.

M1 IREDI H r-_-1 ||

,<.)\ uL,/ Y

WiresideoI femaleterminals

Does the EPS indicator come on? Y E S - G o t o s t e p1 4 . NO-Check for loose or poor connectionsatthe EPScontrol unit and the motor connections.lfthe connectionsare good, replacethe EPScontrol unit andrecheck.l 1 4 . S t o pt h e e n g i n e a , n d v e r i t yt h e D T C .

Is there battety voltage? ls DTC 41 indicated? YES Repairshort to power in the + circuitwire betweenthe EPScontrol unit and the motor.I

YES Replacethe steeringgearboxmotor and recheck.l

N O - G o t o s t e p1 0 .

1 0 .Measurethe voltagebetweenEPScontrol unit

NO Performthe appropriatetroubleshootingfor t h e c o d ei n d i c a t e d . l

c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d . EPSCONTROL B (2P) UNITCONNECTOR

razrcnrrrr l{. I l-t

I (v)

Y I

Wire side of femaleterminals

ls there battery voltage? YES-Repair shortto power in the - circuitwire betweenthe EPScontrol unit and the motor.! N O G o t o s t e p1 1 .

17-37

EPSComponents DTCTroubleshooting(cont'd) DTC42,45: MotorDrivenCurrent

{ 7. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P l t e r m i n aNl o . 2 a n d b o d y g r o u n d .

1. Clearthe DTC. EPSCONTROLUNITCONNECTOR B I2PI

2. Start the engine. 3. Turn the steeringwheel from lock-to-lockseveral t i m e s ,a n d w a i t 1 0 s e c o n d so r m o r e .

r',rz tcnnrt ll -](o)

Does the EPS indicator come on?

YES- Go to step 4.

NO-Check for loosewires or poor connections.lf the connectionsare good, the system is OK at this time.I

Wiresideof femaleterminals

Stop the engine,and verify the DTC.

lsthere continuity?

ls DTC 42 or 45 indicated?

YES Repairshort to body ground in the GRNwire betweenthe EPScontrol unit and the motor.l

YES-Go to step 5. NO Go to step 8. NO- Performthe appropriatetroubleshootingfor t h e c o d ei n d i c a t e d . I M a k es u r et h e i g n i t i o ns w i t c hi s O F F ,t h e n disconnectEPScontrol unit B connector(2P)and the motor 2P connector.

Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P )t e r m i n a lN o . 1 a n d N o . 2 . EPSCONTROL UNITCONNECTOR B {2P)

6 . Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 1 a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR B I2P) M2 {GRN)

M1 IRED}H

f2-l

W i r es i d eo f f e m a l et e r m i n a l s

(C))

Wire side of femaleterminals

ls there continuity? YES Repairshort to body ground in the REDwire betweenthe EPScontrol unit and the motor,I N O - G o t o s t e p7 .

17-38

ls there continuity? YES Repairshort betweenthe REDand GRN wires in the motor circuit betweenthe EPScontrol u n i ta n d t h e m o t o r . l NO Go to step 9.

9. Turn the ignition switch ON (ll),and measurethe voltage betweenEPScontrol unit connectorB (2P) t e r m i n a lN o . I a n d b o d y g r o u n d .

11. Checkfor continuitybetweenEPScontrol unit connectorB (2P)terminal No. 1 and the motor 2P connectorterminal No. 2.

EPSCONTROLUNITCONNECTOR B (2PI

EPSCONTROLUNIT B 12P) CONNECTOR

M1{RED}H T-----l | |

M1 IRED)

(v)

MOTORCONNECTOR {2PI

lil

M1 (RED}

Wiresideo{ Iemaleterminals

ls there battety voltage? YES-Repair short to power in the + circuitwire betweenthe EPScontrol unit and motor.l

Wire side of femaleterminals

ls therecontinuity? YES-Go to step'12. NO-Repairopenin the REDwire betweenthe EPS controlunitandthe motor.l

NO Go to step 10.

1 0 .Measurethe voltage betweenEPScontrol unit c o n n e c t oB r { 2 P } t e r m i n aNl o . 2 a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR B (2P}

mzrcnrur ll-l A (v)

Y I

W i r es i d eo f f e m a l et e r m i n a l s

ls there battery voltage? Y E S R e p a i rs h o r tt o p o w e ri n t h e + c i r c u i t w i r e betweenthe EPScontrol unit and the motor.a N O - G o t o s t e p1 1 .

(cont'd)

17-39

EPSGomponents

DTGTroubleshooting(cont'd) 12. Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 2 a n dt h e m o t o r2 P c o n n e c t otre r m i n a lN o . 1 . EPSCONTROLUNIT CONNECTORB I2PI

MOTORCONNECTOR {2P)

15. Stop the engine,and verify the DTC. ls DTC 42 or 45 indicated? YES Replacethe steeringgearboxmotor and recheck.l NO Performthe appropriatetroubleshootingfor the code indicated.l

M2 IGRN)

Wire side of femaleterminals

ls there continuity? Y E S - G o t o s t e p1 3 . NO-Repair open in the GRNwire betweenthe EPS control unit and the motor.l Checkfor loosewires or poor connections,if the connectionsare good. substitutea known-good EPScontrol unit, and connectallthe disconnected connectors. 1 4 . Startthe engine,and turn the steeringwheel from lockto lock severaltimes. Does the EPS indicatot come on? YES Go to step 15. NO Checkfor loose EPScontrol unitconnectors.lf necessary,replacethe EPScontrol unit and recheck.a

17-40

(

DTCtli|: MotorDrivenCurrentis Excessively Hish 1 . C l e a rt h e D T C .

8. Measurethe voltagebetweenEPScontrol unit c o n n e c t oB r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR B I2PI

2. Startthe engine. 3. Turn the steeringwheel from lock-to-lockseveral '10 times, and wait secondsor more.

Til

M2tcRNl F-l f---1 z I

(v)

Does the EPS indicator come on?

YES Go to step 4. NO-Check for loosewires or poor connections.lf the connectionsare good,the system is OK at this ttme.I

W i r es i d eo f f e m a l et e r m i n a l s

ls there battety voltage? 4. Stop the engine,and verify the DTC. ls DTC 43 indicated?

YES- Repairshort to power in the - circuitwire betweenthe EPScontorl unit and the motor.!

YES Go to step 5.

NO-Go to step 9.

NO-Perform the appropriatetroubleshootingfor the code indicated.I 5. Make sure the ignition switch is OFF,then disconnectEPScontrol unit connectorB (2P)and the motor 2P connector.

9 . Turn the ignition switch OFF. 1 0 . Checkfor continuitybetweenEPScontrol unit c o n n e c t oB r ( 2 P )t e r m i n a l sN o . 1 a n d N o . 2 . EPSCONTROL UNITCONNECTOR B {2P)

6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenEPScontrol unit '1 c o n n e c t oB r ( 2 P ) t e r m i n aNl o . a n d b o d y g r o u n d . EPSCONTROLUNITCONNECTOR B {2P} M2 {GBN)

M 1 { R E o )H T------t

I I

Itr (v) T -L

Wiresideot Iemaleterminals

Wire side of femaleterminals

ls there continuity? YES Repairshort betweenthe GRN and RED wires in the motor circuitbetweenthe EPScontrol u n i ta n d t h e m o t o r . l N O G o t o s t e p1 1 .

ls therc battery voltage? YES Repairshort to power in the + circuitwire betweenEPScontrol unit and motor.l N O - G o t o s t e p8 .

( c o n td )

17-41

EPSComponents DTCTroubleshooting(cont'dl 1 1 .Substitutea known-goodEPScontrol unit, and connectall the disconnectedconnectors.

1 2 .Start the engine,and turn the steeringwheel from

(

DTC47: EPSControlUnitlnternalCircuit (PowerRelay) 1. Clearthe DTC.

lockto lock severaltimes. 2. Startthe engine. Does the EPS indicator come on? Does the EPS indicator come on? YES Go to step 13. NO -Check for loose or poor connectionsat the EPScontrol unit and the motor connections.lf the connectionsare good, replacethe EPScontrol unit and recheck.l

1 3 .Stop the engine,and verity the DTC.

YES-Go to step 3, NO-Check for loosewires or poor connections,lf the connectionsare good, the system is OK at this time.I 3. Stop the engine,and verify the DTC.

ls DTC 43 indicated?

ls DTC 47 indicated?

YES-Replacethe steeringgearboxmotor and recheck.tl

YES Checkfor loose EPScontrol unit connectors. lf necessary,substitutea known-goodEPScontrol u n i ta n d r e c h e c k . l

NO-Perform the appropriatetroubleshootingfor the code indicated.l

17-42

NO Performthe appropriatetroubleshootingfor the code indicated.I

DTC50: EPSControlUnit InternalCircuit (CPUor Microcomputer)

DTC51: EPSControlUnitInternalCircuit (EEPROM)

1. Clearthe DTC.

1 . C l e a rt h e D T C .

2. Start the engine.

Does the EPS indicator come on?

Does the EPS indicatot come on?

YES Go to step 3.

YES-Go to step 3.

NO Checkfor loosewires or poor connections.lf the connectionsare good. the system is OK at this t i m e .t

NO-Check for loosewires or poor connections.lf the connectionsare good, the system is OK at this time.I

3. Stop the engine,and verify the DTC.

ls DTC 50 indicated?

ls DTC 51 indicated?

YES-Check for looseor poor connectionsat the EPScontrol unit connections.lf the connectionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe original EPScontrol unit.l

YES-Check for looseor poor connectionsat the EPScontrol unit connections.lf the connectionsare good. substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe original EPScontrol unit.!

NO Performthe appropriatetroubleshootingfor the code indicated.t

17-43

EPSComponents (cont'dl DTCTroubleshootang DTC62: EPSControlUnit InternalCircuit (Fail-safe RelayStuckON) '1.

(

Low DTC64: BatteryVoltageis Excessively (Fail-safe RelayContactFailureandMotor VoltageFallOff)

Clearthe DTC.

2. Startthe engine.

1 . C l e a rt h e D T C . 2. Startthe engine.

Does the EPS indicator come on?

Does the EPS indicatot come on?

YES-Go to step 3.

YES Go to step 3.

NO-Check for loosewires or poor connections.lf the connectionsare good, the system is OK at this time.I

NO Checkfor loosewires or poor connections.lf the connectionsare good,the system is OK at this trme.l

3. Stop the engine,and verify the DTC.

ls DTC 62 indicated?

ls DTC 64 indicated?

YES-Check for loose or poor connectionsat the EPScontrol unit. lf the connectionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe originalEPScontrol unit and recheck.l

YES Go to step 4.

NO-Perform the appropriatetroubleshootingfor the code indicated.t

NO Performthe appropriatetroubleshootingfor the code indicated. '18(604) 4. Checkthe No. fuse in the under-hoodfuse/ relay box, and reinstallthefuse if it is OK. Is the f use OK? YES Go to step 5. NO Replacethe fuse and recheck.l 5. DisconnectEPScontrol unit connectorA (2P). 6. Measurethe voltage betweenEPScontrol unit c o n n e c t oA r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .

-Blwt{r/Bl.urH l \9

ls there battety voltage? YES- Checkfor loose or poor connectionsat the EPScontrol unit connectors,and checkfor a poor ground at G 151. lf necessary,substitutea knowngood EPScontrol unit and recheck.l NO Repairopen in the WHT/BLUwire between t h e N o . 1 8 ( 6 0 , 4 ) f u saen d E P Sc o n t r o lu n i t . l

17-44

DTC66,68: EPSControlUnitlnternalCircuit

DTC67: TorqueSensorl/FCircuit

1 . C l e a rt h e D T C .

1. Clearthe DTC.

2. Start the engine.

2 . S t a r tt h e e n g i n e .

3. Turn the steeringwheel from lock-to-lockseveral times, and wait 10 secondsor more.

3. Turn the steeringwheelfrom lock-to-lockseveral times, and wait 10 secondsor more.

Does the EPS indicator come on?

YES-Go to step 4.

NO-Check for loosewires or poor connections.lf the connectionsare good.the system is OK at this time.l

NO Checkfor loose wires or poor connections.lf the connectionsare good, the system is OK at this time. ! 4. Stop the engine,and verify the DTC.

4. Stop the engine.and verify the DTC. ls DTC 67 indicated? ls DTC 66 or 68 indicated? YES-Check for looseor poor connectionsat the EPScontrol unit. lf the conneclionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe original EPScontrol unit and recheck.I NO Performthe appropriatetroubleshootingfor the code indicated.t

YES Checkfor looseor poor connectionsat the EPScontrol unit. lf the connectionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe original EPScontrol unit and recheck.! NO-Perform the appropriatetroubleshootingfor the code indicated.I

17-45

EPSComponents DTCTroubleshooting(cont'd) DTC69: EPSControlUnit InternalCircuit 1 . C l e a rt h e D T C . 2. Startthe engine. 3. Turn the steeringwheel from lock-to-lockseveral times, and wait 10 secondsor more, Does the EPS indicator come on? YES Go to step 4. NO-Check for loosewires or poor connections.lf the connectionsare good, the system is OK at this time.l 4. Stop the engine,and verify the DTC. ls DTC 69 indicated? YES-Check for loose or poor connectionsat the EPScontrol unit. lf the connectionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe original EPScontrol unit and recheck.l NO- Performthe appropriatetroubleshootingfor the code indicated.l

17-46

EPSIndicatorCircuitTroubleshooting 1 . Turn the ignitionswitch ON (ll),startthe engine, and watch the EPSindicator.

5. Turn the ignition switch OFF. 6. DisconnectEPScontrol u n it connectorC (20P).

Does the EPS indicator come on? 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . YES lf the EPSindicatorcomes on and goes off, it's OK. lf the EPSindicatorstayson or blinks.go to s t e p1 2 .

8. ConnectEPScontrol unit connectorC (20P) terminal No. 6 to body ground with a jumper wire.

NO Go to step 2.

EPSCONTBOLUNIT CONNECTOBC {2OP)

Turn the ignition switch OFF,then ON (ll) again, and watch the brakesystem indicator, Does the brake system indicator come on? YES-Go to step 3. W i r e s d € o f l e m a l e 1 6 r m i n as

NO Repairopen in the indicatorpower source circuit.l . B l o w nN o . 1 0 ( 7 . 5 A ) f u s e . . Open in the wire betweenthe No. 10 (7.5A)fuse and gaugeassembly. . Open circuitinsidethe under-dashfuse/relaybox, . Faultygauge assembly.

Does the EPS indicatot come on? YES Go to step 9. NO Repairopen in the wire betweenthe gauge assemblyand the EPScontrol unit.l

3 . Turn the ignitionswitch OFF, 9 . Turn the ignitionswitch OFF. 4 . Connecta jumper wire betweenthe gauge

assembly22Pconnectorterminal No. 13 and body g r o u n d ,t h e nt u r n t h e i g n i t i o ns w i t c hO N ( l l ) . (Blueconnector) 22PCONNECTOR GAUGEASSEMBLY

1 0 .DisconnectEPScontrol unit connectorA (2P), ' l1 .

Checkfor continuitybetweenEPScontrol unit connectorA terminal No. 2 and body ground. A I2PI EPSCONTROL UNITCONNECTOA

w i r e s d e o f t e m a l et e r m i n a l s

Wiresideof femaleterminals ls there continuity? Does the EPS indicator come on? YES-Go to step 5. N O I n s p e ctth e E P Si n d i c a t o b r u l b ,i f t h e b u l b i s O K , r e p l a c et h e b u l bc i r c u i tb o a r di n t h e g a u g e assembly.l

YES Checkfor loose or poor connectionsat the E P Sc o n t r o lu n i t .l f t h e c o n n e c t i o nasr e g o o d , substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe originaE l P Sc o n t r o lu n i ta n d r e c h e c k . I N O R e p a i ro p e ni n t h e w i r e o r a b a d g r o u n da t G151,t (cont'd)

17-47

EPSComponents

EPSIndicatorCircuitTroubleshooting(cont'dl 1 2 .Turn the ignitionswitch OFF.

16. Measurethe voltagebetweenEPScontrol unit '1 connectorA (2P)terminalNo. and body ground.

1 3 .DisconnectEPScontrol unit connectorC (20P). 1 4 .Turn the ignitionswitch ON (ll). Does the EPS indicator come on? YES-Repair short to ground in the YEUBLUwire betweenthe gaugeassemblyand the EPScontrol unit,or replacethe bulb circuit board in the gauge assembly.l NO-Go to step 15. Measurethe voltagebetweenEPScontrol unit c o n n e c t oC r ( 2 0 P ) t e r m i n aNl o . 1 0 a n d b o d y g r o u n d . EPSCONTROL UNITCONNECTOR C I2OP)

EPSCONTROL UNITCONNECTON A (2P}

+B (WHT/BLUIH

Itr

v -L

Wire side of female terminals

ls there battery voltage? YES-Go to step 17. NO-Check for a blown No. 18 (604)fuse in the under-hoodfuse/relaybox or open/shortin the WHT/BLUwire betweenthe under-hoodfuse/relay box and the EPScontrol unit.l 1 7 . Turn the ignition switch OFF. 1 8 , ReconnectEPScontrol unit connectorA (2P). 1 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 20. Measurethe voltage betweenEPScontrol unit connectorC (20P)terminalNo. 8 and body ground.

Wire side of femaleterminals

ls therebatteryvoltage?

EPSCONTROL UNITCONNECTOR C (2OP)

Y E S - G ot o s t e p1 6 . NO-Repairopenin thewire betweenEPScontrol unitconnector C (20P)andthe No, 10(7.5A)fuse.t

Wiresideof femaleterminals

ls therc about 10 V? YES Checkfor looseor poor connectionsat the EPScontrol unit. lf the connectionsare good, substitutea known-goodEPScontrol unit. lf the symptom/indicationgoes away, replacethe originalEPScontrol unit and recheck.l NO Repairshort to ground in the BRNwire betweenthe data link connectorand the EPS c o n t r o lu n i t . I

17-48

Motor Removal/lnstallation Bemoval 1. Make sure you havethe anti-theftcode for the radio, then write down the frequenciesfor the preset buttons.

4. Removethe connectorbracket(A) onthegearbox housing,and disconnectthe motor 2P connector (B). 9.8 N.m {1.0kgf.m,

2. Disconnectthe negativecablefrom the battery,and wait 3 minutesbefore beginningwork. 3. Removethe air cleanerassembly(A).

5. Removethe motor {A) from the gearboxhousing.

6. Removethe O-ring (B)and discardit.

(cont'd)

17-49

EPSComponents (cont'dl Motor RemovaUlnstallation

(

r 0 .Installthe motor on the gearboxby engagingthe

lnsiallation 7. Cleanthe mating surfaceof the motor (A) and gearbox.

8 x '1.25 mm 20 N.m 12.0kgt.m,7.2lbl ftl

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

1 2 .Installthe removedDartsin the reverseorder of removal.and note these items:

L==-

c].E@

Apply a thin coat of siliconegrease(P/N087338070E)tothe new O-ring(B),and carefullyfit it on the motor. 9 . Apply grease{Nippon GreaseWR-S or equivalent steeringgear grease)into the motor shaft (C).

17-5 0

lvlakesure the motor 2P connectoris properly connected. lvlakesurethe motor and EPSwires are not caughtor pinchedby any parts. Reconnectthe negativecableto the battery. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . Enterthe anti-theftcode for the radio station Dresets.Resetthe clock, Do the oower window control unit reset procedure(seepage 22-1241.

1 3 .After installation,startthe engine,and let it idle. Turn the steeringwheel from lock-to-lockseveral times. Checkthat the EPSindicatordoes not come on.

SteeringGearboxRemoval Special Tool Required Ball ioint remover,2Smm 0TlvlAC-S100200

8. Removethe cotter pin (A)from the tie-rod balljoint nut {B),and loosenthe nut.

_t\

1. Raisethe front of vehicle,and make sure it is securelysupponed. 2. Removethe front wheels. R e m o v et h e d r i v e r ' sa i r b a g ( s e e p a g e 2 3 - 1 1 3 ) . 4 . Removethe steeringwheel (seepage 17-6). 5 . Removethe motor on the steeringgearbox (see p a g el T - 4 9 ) .

6 . Removethe driver'sdashboardlower cover (see page20-59)and under cover {seepage20-60). 7 . Removethe steeringjoint bolts (A),and disconnect the steeringjoint by moving the steeringjoint (B) toward the column.

l,a.:

'/ --L-

r0 mm HEXNUT

07MAC-S100200

9 . Separatethe tie-rod balljoint and damper steering arm usingthe specialtool (seepage 18-10).Repeat on the other side of the vehicle.

1 0 .G r a s pt h e r i g h ts i d et i e - r o d a, n d p u l lt h e r a c ka l l t h e way to the passenger'sside, 1 1 . Removethe heat shield (A) mounting bolts from the body stiffener,and let the heat shield lay againstthe exhaust.

(cont'd)

17-51

EPSComponents SteeringGearboxRemoval(cont'd) 12. Disconnect the EPSwire harness6Pconnector (A), andremovethe EPSwire harness(B)andmountino bracket(C).

1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc l a m p s{ A ) f r o m the three mounting brackets.

-a--zi i

F--_1

t5.

1 3 . Removethe groundcableterminal(A)fromthe steeringgearboxhousing. ..(

.,/

a bH \

ry T,-.lt'^ \ '"

_ - 1 . . 1 . - '

17-52

\--

Removethe heaterhose {B)from the bracket.

1 6 . Open the heatervalve cableclamp (A),and disconnectthe heatervalve cable(B).Removethe heatervalve (C)from the bulkhead,and move jt aside.

17. Removethe bodv stiffener(A).

19. Removethe steeringstiffenerB from the right side of the steeringgearbox.

i t1-:: .,

1 8 .Removelhe steeringstiffenerA from the left side of the steeringgearbox.

20. Lower the steeringgearbox,and rotateit so the pinion shaft points upward. 21. Removethe pinion shaft grommet (A)from the top of the torque sensor.

(cont'd)

17-53

EPSComponents SteeringGearboxRemoval{cont'd) 22. Move the steeringgearboxand tie-rod ends as an assemblyto the wheelwellopening on the passenger'sside. 23. Carefullyraisethe driver'sside (pinionside)ofthe steeringgearbox(A) and tie-rod (B) until clearsthe mastercylinderand under-hoodfuse relay box, then removethe steeringgearbox.Be careful not to damagethe hoses,linesand wtre narnesses.

17-51

SteeringGearboxOverhaul ExplodedView mm I x '1.25 ftl 20 N.m(2.0kgf.m,7.2lbt O.RING Replace.

CONNECTOR

PINION SHAFT GROMMET

RACKGUIDE

-@ . . DISCWASHEB @'--g

-sPRrNG SCREW

L)-RACKGUIDE 6

' v---\

\.oc**u.

v \ >-*\{i#r^i --. i

6^:,; BOOT BAND Beplace.

-'t

'"''/

s(./t' J -l

GUIDE \ SLTDER

SRACKET

{^il \J" \

@ II

\ \

\ BOOTBAND - Replace.

LOCKWASHER Replace.

stot *,tttc Renrace

\ LocK '162 scREw

N.m l t o . sr g f m , 1 1 9 l bfft ) Beqtace.

TIE.RODEND

rtE-ROD

54 N m {5.5kgf.m,40lbf ft)

44 N m {4.5 kgf.m, 33 tbt.ft)

(cont'd)

17-55

EPSComponents SteeringGearboxOverhaul(cont'dl Special Tools Required . Locknutwrench 07ZAA-S5A0100 . Pincers,Oetiker1098or equivalent,commercially available.

4. Removethe stop plate (A).the 12 mm flange bolts (B),the O-rings(C),and the bracket(D)from the sleeringgearbox.

NOTE: . Referto the ExplodedView as neededduring this procedure. . Do not allow dust, dirt, or other foreign materialsto enter into the steeringgearbox. Eemoval 1, Removethe steeringgearbox(seepage 17-b1). Disassembly 2. Unbendthe lock washer (A).

. -

-,'i. Loosenthe locknut(A),then removethe rack guide screw (B),sprlng (C),disc washer (D),and rack g u i d e( E )f r o m t h e s t e e r i n gg e a r b o x .

- -.i::..:4,.-,

Holdthe bracket(A) with one wrencn, anq unscrew both tie-rod ends (B)with anotherwrench. Remove the lockwashers.

17- 56

:.--. '

6. Removethe two boot bands (A)from boot (B). Compressthe boot by hand,and apply vinyl tape (C)so the boot ends stay collapsedand pulled back

8. Installthespecialtool (A) on the lock screw (B) securely.then loosenand removethe lock screw from the steeringgearboxhousing.

07zAA-S5A0r00

1 . Attachthe yoke (A) of a universalpullerto the steeringgearboxmounts with bolts.Securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin the vise.

Removethe specialtool.

1 0 .Pull on the rackhousing(A)to remove it from the steeringgearboxhousing,Removethe boot {B) and s l i d e rg u i d e( C )f r o m t h e c y l i n d e r .

(cont'd)

17-57

EPSComponents SteeringGearboxOverhaul(cont'd) 'll.

Checkthe slider guide for damageand cracks. Using verniercalipersto measurethe thicknessof the slider guide. lf the thicknessis lessthan service l i m i t ,r e p l a c et h e s l i d e rg u i d e ,

-.---(fr--', I ( f

Z,-----:-r-.--------.t.t'E-r

i @ r 25.3mm {0.925in.}

/i\

,)))

15. Applymultipurpose greaseto the indicated part part) of the {shaded outersurfaceof the rack housing.Do not applyto the dentsandgrooves.

I |

25.3 mm {0.925in.l

Removeanddiscardthestopring{A)onthe cylinderby expanding it with snapringpliers. Removeanddiscardthe lockscrew{B}.

13. Installthe new lock screw on the rack housing. 1 4 . I n s t a l l t h en e w s t o p r i n g i n t h e g r o o v e( C ) o nt h e cylinderby expandingit with a snap ring pliers.Be carefulnot to scratchor damagethe housing surfacewith the stop ring edges.

I 17-58

16. Set the new boot bands (A) on the band installation groovesof the boot (B) by aligningthe tabs (C)with the holes (D)of the band.Do not closethe ear of the boot band in this step.

1 1 . Compressthe boot by hand,and apply vinyl tape (E)to the bellowsso the boot ends stay collapsed and pulled back. Passthe boot over the rack housingso the smaller diameterend of the boot facesthe steering gearboxhousing.

'19. Pushthe rack housing(A) into the steeringgearbox housing(B) so the notch (C)is alignedwith the pin (D)on the bottom of the gearboxhousinginside

20. Tightenthe lock screw {A) by hand first, then install the specialtool (B)on the lock screw. Lightly tighten the lock screw.Do not tighten the lock screwto the specifiedtorque Yet.

1 8 .Attachthe yoke (A) of a universalpuller to the gearboxhousingmounts with bolts.then securely clamp the yoke in a vise as shown. Do not clamp the steeringgearboxhousingin a vise.

21. Removethe specialtool.

(cont'd)

17-59

EPSComponents SteeringGearboxOverhaul(cont'dl 22. Apply multipurposegreaseto the sliding surface and circumferenceofthe rackguide (A),and install it onto the gearboxhousing.Wipe the greaseoff the threadedsectionofthe housrno.

{ 25. Centerthesteeringrackwithin its stroke,and align t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) . Fit the slider guide to the boot by pressingaround the edgesof the holessecurely

- .- =-1,...'. ,. ,l .j

2 3 . I n s t a l l t h ed i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e f a c i n gt h e r a c kg u i d e .I n s t a l l t h es p r i n g( C ) .A p p t y sealantto the middle of the threadson the rack guide screw (D),then installand tighten it to 25 N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut (E). 24. Apply multipurposegreaseto the sliding surfaceof the slider guide (A).Keepgreaseoff of the rack-toslider guide mating surfacesand the boot-to-slider guide mating surfaces. Slidethe steeringrack all the way to left, and place t h e s l i d e rg u i d eo n t h e s t e e r i n gr a c kb y a l i g n i n gt h e bolt holes (B).

E 25 N.m 12.5kgt.m,18tbt.ft) 26. Beforeinstallingthe bracket(D),cleanthe mating surfaceofthe 12 mm flange bolts (E)and the bracket.Coatthe new O-rings{F)with multipurpose g r e a s ea, n d i n s t a l l t h e mo n t h e ' 1 2m m f l a n g eb o l t s . 27. Looselyinstallthe bracketon the steeringrack by tighteningthe 12 mm flange boltsto 25 N.m (2.5 kgf.m, 18lbf.ft). 28. Hold the gearboxhousingusing a yoke,then install the specialtoolon the lock screw (A).Retightenthe lock screwto the specifiedtorque values.

A { 1 6 . 5k g t . m , 1 1 9 l b f . f t }

29. Removethe specialtool.

17-60

30, Retightenthe 12 mm flange bolts (A) to the soecifiedtoroue value.

3 4 . C l o s et h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h , e t i k e r1 0 9 8o r c o m m e r c i a l la v v a i l a b l ep i n c e r sO e q u i v a l e n(tC ) .

74 N.m (7.5kgf.m,5irlbf.ft)

5 t .

After tighteningthe 12 mm flange bolts, installa new stop plate (B)over one of the bolt heads.Be surethe tabs (C)of the stop plate are alignedwith the flat surfacesof the bolt head.

32,

Cleanoff any greaseor contaminationfrom the b o o t i n s t a l l a t i ognr o o v e so n t h e h o u s i n g . Expandthe boot (A) by removingthe vinyltape, and fit the boot ends (B) in the installationgrooves o n t h e c y l i n d e rh o u s i n g .

3 5 . I n s t a l l t h en e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d side facing (B)the tie-rod (C),and screwthe tie-rod on the bracket(D).Repeatthis step for the other side of the tie-rod.Hold the bracketwith one wrench,and tightenthe tie-rodsto the specified torque with anotherwrench.

. .,,";=-. , . , *=,,',

(cont'd)

17-61

EPSComponents SteeringGearboxOverhaul(cont'dl 36. Bendthe lock washer againstthe flat spots on the bracketwitha Iarge pair of pliers.

37. Adjust the rackguide screw {seepage 17-13).

17-62

SteeringGearboxInstallation '1.

Beforeinstallingthe steeringgearbox,slidethe rack all the way to the passenger'sside (right direction).

4. Insertthe pinion shaft up through the bulkhead, then slip the right side of the steeringgearbox housing(A) over the mounting stud (C)on the gearboxmounting bracket.

2 . Passthe right side of the steeringgearboxtogether with the tie-rodsthrough the wheelwell openingon the passenger'sside.Continuemoving the steering gearboxtoward the passenger'sside untilthe driver'sside tie-rodend and gearboxclearsthe mastercylinderand under-hoodfuse Ielay box. Lower the steeringgearbox.and move it toward t h e d r i v e r ' ss i d eu n t i l t h es t e e r i n gg e a r b o xi s l n Dosition.

--'

'.'',

:-1

. . . .

Be carefulnot to damagethe hoses,lines and wire harnesses. 10 x '1.25mm 61 N.m

{62 kgl m, 45 lb{ ftl

Installthe steeringstiffenerB, and lightlytighten the steeringgearboxmounting nuts. Installthe steeringstiffenerA with the gearbox m o u n t i n gb o l t s .T h e nt i g h t e na l l t h e s t e e r i n g gearboxmounting hardwareto the specifiedtorque. 1 0x 1 . 2 5m m 6l N.m (6.2 kgt.m, 45 lbt.ft)

3 . I n s t a l l t h ep i n i o ns h a f tg r o m m e t( A ) .

.: --.-{ .

( c o n t ' d)

17-63

EPSComponents SteeringGearboxInstallation(cont'd) 7. Installthebodystiffener(A),andtorquethe mountingboltsto the specified torque.

9. Reinstallthe heaterhose (A) on the hose bracket.

8 x 1.25mm 29 N.m {3.0kgf.m,22lbf.ftl

1 0 .Installthe enginewire harnessclamps (B)to the three harnessbrackets.

L Installthe heatervalve (A) on the bulkhead,and connectthe heatervalve cableend (B)to the heater valve arm (C).Readjustthe heatervalve cable{see page21-46).

L-t

:.i.t'

9.8N.m (1.0kgf m, 7.2tbf.ftl

17-64

' It . Under

the steeringgearbox,installthe ground cableterminal (A) on the steeringgearboxhousing. 9 . 8N . m {1.0kgf.m,7.2lbf.ft)

12. lnstalltheEPSwire harnessbracket(A)on the (B) gearboxhousing,andconnectthe 6Pconnector propefly. 9.8 N.m {1.0kgt m,7.2 lbt.ftl

1 4 . Centerthe steeringrackwithin its stroke. 1 5 . Wipe off any greasecontaminationfrom lhe ball joint taperedsectionand threads.Then reconnect the tie-rod ends 1A)tothe damper steeringarms. lnstallthe ball joint nut (B) and tighten them.

,-', ''l :

)

B 10x 1.25mm

i€ N.m {4.4 kgf.m. 32 tbt.ftl

1 3 . I n s t a l l t h eh e a ts h i e l d( A ) .

t o . Installthe new cotter pins (C),and bend them as

shown.

,.!,.. ''6f

(cont'd)

17-65

EPSComponents

SteeringGearboxInstallation(cont'dl 1 7 . Installthe motor on the steeringgearbox(seepage 17-49).

1 8 . lnstallthe steeringjoint (A).and reconnectthe steeringshaft (B) and pinion shaft (C).Make sure the steeringjoint is connectedas follows: . I n s e r t t h eu p p e r e n do f t h e s t e e r i n gj o i n t o n t o t h e steeringshaft (line up the bolt hole (D)with the flat portion (E)on the shaft). . Slip the lower end of the steeringjoint onto the pinion shaft (line up the bolt hole with the groove (F)around the shaft),and looselyinstallthe lower joint bolt. Be sure that the lower joint bolt is securelyin the groove in the pinion shaft. . Pull on the steeringjoint to make surethat the steeringjoint is fully seated.Then installthe upper joint bolt, and tighten it to the specified torque.Tightenthe lower joint bolt to the specifiedtorque.

22. After installation,performthe following checks. . Performthe front toe inspection. . C h e c kt h e s t e e r i n gw h e e ls p o k e a n g l el.f s t e e r i n g spokeanglesto the right and left are not equal (steeringwheel and rackare not centered), correctthe engagementof the joinvpinion shaft serrations,then adjustthe front toe by turning the tie-rods,if necessarv.

\ 8 x '1.25mm 28 N.m {2.9kgf.m, 21 tbt.ft)

1 9 .Installthedriver's dashboardlower cover (see page 20-59)and under cover (seepage 20-60).

20. lf the steeringwheel was turned,centerthe cable reel by first rotatingit clockwiseuntil it stops.Then rotateit counterclockwise(abouttwo and half turns) untilthe arrow mark on the label points straightup. Reinstallthe steeringwheel (seepage 17-8). )1

Installthe front wheels.

17-66

EPSControlUnit Removal/ Installation

Tie-rodBallJoint Boot Replacement Special Tool Required Attachment,42 mm 07OAD-P0A0100

1. Removethe passenger'sunder panel. 2. Turn up the floor carpel,removelhe EPScontrol untr.

l. Removethe boot from the tie-rod end, and wipe the old greaseoff the ball pin. 2 . P a c kt h e l o w e ra r e ao f t h e b a l l p i n ( A ) w i l h f r e s h mulr purposegrease.

*-4

r/\-,

d______i.l+_D

-6rA

3 . Disconnectthe EPScontrol unit connectors.

lnstallthe EPScontrol unit in the reverseorder of removal.

3. Packthe interiorof the new boot (B) and lip (C)with fresh multipurposegrease.

After installation,startthe engine,and let it idle. Turn the steeringwheelfrom lock-to-lockseveral times. Checkthat the EPSindicatordoes not come on.

Note these items when installingnew grease; . Keepgreaseoffthe boot installationsection(D) and the taperedsection(E)of the ball pin. . Do not allow dust, dirt, or other foreign materials to enterthe boot. 4. Installthe new boot (A) usingthe specialtool.The boot must not have a gap at the boot installation sections(B).After installingthe boot.checkthe ball pin taperedsectionfor greasecontamination,and wipe it if necessary. 07(lAD-P0A0100

17-67

Suspension Frontand RearSuspension SpecialTools ............. 18-2 Component LocationIndex ......................................... 18-3 W h e eA l l i g n m e n .t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 8. - 4 18-8 WheelBearingEndPlayInspection............................ 18-9 WheelRunoutInspection .................. ... 18-10 B a l Jl o i n tR e m o v a l

FrontSuspension Knuckle/Hu bAVheelBearingReplacement BallJoint Boot Reolacement.................. StabilizerBar Rep|acement.................... StabilizerLink Removal/lnstallation LowerArm Removal/lnstallation ............... Damper/Spring Replacement

18-1 18-16 18-17 18-18 18-19 18-20

RearSuspension H u bB e a r i n U g n i tR e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . 18-26 18-28 KnuckleReolacement 18-30 Stabilizer BarReplacement .................... 18-31 Link Removal/lnstallation Stabilizer .......................... 18-32 UpperArm Removal/lnstallation ............... 18-33 TrailingArm Removal/lnstallation 18-34 Damper/Spring Replacement

Frontand RearSuspension SpecialTools Ref.No.

o G)

Tool Number

07GAF-SE00100 07MAC-S100200 07746-0010500 07749-0010000 07965-SA50500 07965-SD90100

otv

Description Hub Dis/AssemblyTool B a l lJ o i n t R e m o v e r2, 8 m m Attachment,62 x 68 mm Driver Front Hub Dis/AssemblyTool Support Base

[]

18-2

a6,l

ComponentLocationIndex FrontSuspension: DAMPER/SPRING page18-20 Replacement, STABILIZER BAR page18-17 Replacement, STABILIZER LINK page18 18 Removal/lnstallation, KNUCKLE/HU8/WHEELBEARING page 18-11 Replacement, Ball Joint Boot page'18-16 Replacement,

LOWEBARM page 18 19 Removal/lnstallation,

RearSuspension: STABILIZER BAR page18-30 Replacement. UPPERARM Removal/lnstallation, page'18-32

DAMPER/SPRING page'18-34 Replacement,

UNIT HUBBEARING page18'26 Replacement, KNUCKLE page18-28 Replacement, TRAILINGARM page 18 33 Removal/lnstallation,

18-3

Frontand RearSuspension WheelAlignment The suspensioncan be adjustedfor front camber,front toe, and reartoe. However,each of these adjustments are interrelatedto each other. For example,when you adjustthe toe, the camberchanges.Therefore,you must adjustthe front wheel alignmentwheneveryou adjustthe camberor toe.

Front Casterlnspection

Pre-Alignment Checks

Checkthe casterangle.lf the casterangle is not within the specification,checkfor bent or damaged susoensroncomoonents.

For proper inspectionand adjustmentof the wheel alignment,do these checks:

o u rw h e e l U s ec o m m e r c i a l l a vvailable c o m D u t e r i z ef d a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t (caster,camber,toe, and turning angle).Follow the eouiomentmanufacturer'sinstructions.

Front casterangle: 1'40't

1. Releasethe parkingbraketo avoid an incorrect measurement.

2 . Make sure the suspensionis not modified. 3 . C h e c kt h e t i r e s i z ea n d t i r e p r e s s u r e Tire size: Front/rear: 195/60R15 Tire pressure: 230 kPa {2.3kgf/cm',33 psil Front: Rear: 210 kPa |'2.1kgf/cm', 30 psi) Checkthe runout of the wheels and tires. Checkthe suspensionball joints. (Holda wheel with your hands,and move it up and down and right and left to checkfor wobbling),

Bouncethe vehicleup and down severaltimes to stabilizethe suspension.

18-4

Front CamberInspection

Front CamberAdjustment

Use commerciallyavailablecomputerizedfour wheel alignmentequipmentto measurewheel alignment (caster,camber,toe, and turning angle).Follow the equipmentmanufacturer'sinstructions.

The front cambercan be adjustedby exchangingone or both of the damDerDinchbolts with the smaller diameteradjustingbolt(s).The differencebetweenthe adjustingbolt diameterand the pinch bolt hole d i a m e t e ra l l o w sa s m a l lr a n g eo f a d j u s t m e n t .

Checkthe camberangle.lf the camberangle is not within the specification,adjustthe camber. Front camber angle:

0"30' t 45'

DamDerPinchBolt:

AdiustingBoh: P/N 90188-55A-000

1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. L o o s e nt h e d a m p e rp i n c h n u t sa n d b o l t s( A ) ,a n d adjustthe camber by moving the bottom of the d a m p e rw i t h i nt h e r a n g eo f t h e d a m p e rp i n c hb o l t free play.

A 1 6 x 1 . 5m m 157 N.m (16.0kgf.m, 116 tbf.ftl

3 . Tightenthe boltsto the specifiedtorque. 4 . Reinstallthe front wheels.Lower the front of the

v e hi c l et o t h e g r o u n d ,a n d b o u n c et h e v e h i c l e s e v e r atl i m e st o s t a b i l i z teh e s u s p e n s i o n . 5 . C h e c kt h e c a m b e ra n g l e .l f i t i s w i t h i nt h e specification,checkthe front toe. lf it is not within the specification,go to step 6. (cont'dl

18-5

Frontand RearSuspension WheelAlignment (cont'd) Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. 7 . Replacethe damper pinch boltswith the adjusting bolts (A),and adjustthe camber angle. NOTE:The camberangle can be adjustedup to t 15' (centerof tolerance)by replacingone damper pinch bolt with the adjustingbolt. The camber angle can be adjustedup to a 30' by replacingboth upper and lower damper pinch bolts with the adjustingbolts.

RearCamberInspection Use commercially-available computerizedfour wheel alignmentequipmentto measurewheel alignment (caster,camber,toe, and turning angle).Followthe eouiDmentmanufacturer'sinstructions. C h e c kt h e c a m b e ra n g l e .l f l h e c a m b e ra n g l ei s n o t within the specification,checkfor bent or damaged susDenstoncomoonenrs. Rearcamberangle:

0 0"55' t 45'

NOn-dEl Do not loosenthe specialb o l t so n t h e t r a i l i n ga r m .

'rntr

1 5 x 1 . 5m m 157N.m {16.0kgt.m, 116tbf.ft)

i,iY.a

.:r,//

8 . Tightenthe boltsto the specifiedtorque. Reinstallthe front wheels.Lower the front of the vehicleto the ground, and bouncethe vehicle severaltimes to stabilizethe suspension.

1 0 .Checkthe camber angle.lf it is within the specification,checkthe front toe. and adjust it if necessary.lf it is not within the specification, readjust,and recheck.lJthe camber anglecannot be adjustedto the specification,checkfor bent or damagedsuspensioncomponents.

18-6

Front Toe Inspection/Adjustment

RearToe Inspection/Adiustment

Use commercially-available computerizedfour wheel a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t (caster,camber,toe, and turning angle).Followthe equipmentmanufacturer'sinstructions,

1. Centerthe steeringwheel spokes.

1, Release t h e p a r k i n gb r a k e .

2. Checkthetoe.lf it is not with in the specification,go to step 3.

2. Checkthetoe. lf it is not within the specification.go to step 3.

Front toe-in: 0 t 3 mm {0 t 0.12in.) 3. Loosenthe locknut(A) while holdingthe tie-rod end ( B) .

1,;

A 1 4 x 1 . 5m m ,14N.m (a.5 kgt m,33 lbt.ftl

Reartoe-in {inspection): 1 1 3 mm (0.04a 0.12 in.) 3. Loosenthe self-lockingnut (A)while holdingthe adjustingbolt (B).

Do not loosenlhe specialbolts (C)on the lower arm to adjustthe alignment.

Turn the tie-rod(C)untilthe toe is correct. 5 . After adjusting,tighten the locknutwhile holding the tie-rodend. Make sure the toe settingdoes not change.

4. Replacethe self-lockingnut with a new one, and l i g h t l yt i g h t e n . NOTE:Always use a new self-lockingnut whenever it has been loosened. Turn the adjustingbolt until the toe is correct. Rear toe.in (adiustment): 2 ' , mm {0.08 "' ,. in.} Tightenthe self-lockingnut to the specifiedtorque w h i l e h o l d i n gt h e a d j u s t i n gb o l t .

( c o n t ' d)

18-7

Frontand RearSuspension WheelAlignment (cont'dl TurningAngleInspection Use commercially-available computerizedfour wheel a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t (caster.camber,toe, and turning angle).Followthe equiDmentmanufacturer'sinstructions. 1 . T u r nt h e s t e e r i n gw h e e lf u l l y t o t h e r i g h t a n d l e f t while applyingthe brake,and checkthe turning anglesof both front wheels, lf the turning angle is not within the specificationor the inward turning anglesdiffer betweenthe right and left side,go to steD2.

WheelBearingEnd PlayInspec'tion 1. Raiselhe vehicle,and support it with safetystands in the proper location(seepage 1-8).Removethe wheels. 2. Installsuitable f lat washers (A) and wheel nuts,and tighten the nuts to the specifiedtorque to hold the b r a k ed i s cs e c u r e l ya g a i n s t h e h u b . Front:

Turning angle: lnward: 34'00'+ 2' Outward: 28'00' {reference)

108N.m (11.0kgf.m, 80 rbf.ft)

Rear: \

Checkthe toe. lf it is correct,but the turning angle is not within the specification,checkior bent or damagedsuspensioncomponents,

108N.m (11.0kgf.m,80 lbf.ft)

3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s shown, and measurethe bearingend play moving the brakedisc inward and outward. Bearing end play: Standard: Front/rear: 0 0.05 mm {0 0.002in.} 4. lf the bearingend play is more than the standard, replacethe wheel bearing.

18-8

WheelRunoutInspection 1 . Raisethe vehicle,and supportit with safetystands in the proper location(seepage 1-5,. Checkfor a bent or deformedwheel. Set up the dial gauge as shown, and measurethe axial runout by turning the wheel.

4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o ns h o w n ,a n d measurethe radial runout. Front and rear wheel radial runout: Standard: Aluminum wheel: 0 0.7 mm (0 0.03io.) 1.5 mm {0.06in.} Servicelimit:

Front and rear wheel axial runout: Standard: Aluminum wheel: 0-0.7 mm (0-0.03 in.) Servicelimit: 2.0 mm {0.08in.l

lf the wheel runout is not within the specification, checkthe wheel bearingend play (seepage 18-8), and make sure the mating surfaceson the brake disc and the insideof the wheel are clean. lf the bearingend play is within the specification but the wheel runout is more than the servicelimit. replacethe wheel.

18-9

Frontand RearSuspension BallJointRemoval Special Tools Required Ball ioint remover.2Smm 07MAC-SL00200

Always use a ball joint removerto disconnecta ball joint. Do not strikethe housingor any other part of the ball joint connectionto disconnectit.

3. Loosenthe pressurebolt (A),and installthe special tool as shown. Insen the jaws carefully,making sure not to damagethe ball joint boot. Adjustthe jaw spacingby turning the adjustingbolt (B). 10 mm HEXNUT

'1,

I n s t a lal h e x n u t ( A )o n t o t h e t h r e a d s o f t h e b a l l j o i n t { B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n end to preventdamageto the threadedend of the b a l l i o i n to i n .

07MAC-S100200 After adjustingthe adjustingbolt, make sure the head (C)of the adjustingbolt is in the position shown to allow the jaw to pivot. 5 . With a wrench,tighten the pressurebolt until the b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n ga r m o r knuckle.lf necessary.apply penetratingtype lubricantto loosenthe ball joint pin

2 . Apply greaseto the specialtool on the areasshown (A).This will easeinstallationof the tool and preventdamageto the pressurebolt {B)threads.

NOTE:Do not use pneumaticor electrictools on the pressurebolt.

6 . Removethe tool, then removethe nut from the end o f t h e b a l l j o i n tp i n ,a n d p u l l t h eb a l l j o i n to u t o f t h e s t e e r i n ga r m o r k n u c k l eI.n s p e c t t h eb a l l j o i n tb o o t , and replaceit if damaged.

18-10

FrontSuspension Knuckle/Hub/WheelBearingReplacement ExplodedView

WHEELBEARING Replace. SNAPRING

5 mm SCREWS Replace.

FLATSCREWS 6x1.0mm 9.8Nm (1.0kgf.m,7.2lbf.ft)

KNUCKLE Checkfor delormation a n oo a m a g e .

SPLASHGUARD Checkfor corrosion.delormation. and damage. Replaceif rusted.

BRAKEDISC SPINDLENUT 22 x 1.5mm 1 8 1N m (18.5kgf.m, 134 lbt.ft) Replace.

'--7.l

'tq

I A p p ya s m a lal m o u not f e n g i n o eil to theseatingsurface.

lcont'd)

18-11

FrontSuspension Knuckle/Hub/WheelBearingReplacement{cont'dl Special Tools Required . Hub dis/assemblytool 07GAF-SE00100 . Balljoint remover,2Smm 0TlvlAC-S100200 . Attachment62 x 68 mm 07746-0010500 . Driver07749-0010000 . SuDDortbase07965-5D90'100

5. Raisethe stake(A),and removethe spindle nut (B).

' ,

1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8).

B 22x1.5mm 1 8 1N . m ('18.s kgf.m, 134tbt.ft)

2. Removethe wheel cap,wheel nuts, and front wheel. 1 0 8N . m (11.0kgf m, 80 rbf.ftl

6. Removethe brakedisc retainingflat screws(A).

3. Removethe brakehose bracketmounting bolt (A). A 8 x 1.25mm 22N.m 12.2ksl.m, 26 tbf.ftl

B 12 x 1.25mm 108N.m {11.0kgf.m, 80 rbf.ftl

A 6x1.0mm 9.8 N.m {1.0kgt.m, 7.2 tbl.ttl

7. Screwtwo 8 x 1.25mm bolts (B)into the discto oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively,

4 . Removethe caliperbracketmounting bolts (B),and removethe caliperassembly(C)from the knuckle. To preventdamageto the caliperassemblyor brakehose,use a short pieceof wire to hang the caliperassemblyfrom the undercarriage.Do not twist the brakehose with force.

18-12

8. Removethe flange bolt {A) andwheel sensor(B) from the knuckle.Do not disconnectthe wheel sensorconneclor. A 5x1.0mm 9.8 N.m (1.0kgl.m, 7.2 tbt.ftl

10. Removethe lock pin (A)from the lower arm ball joint, and removethe castlenut (B). NOTE:During installation,insertthe lock pin into t h e b a l l j o i n tp i n f r o m t h e l n s i d et o t h e o u t s i d eo f the vehicle.The closedend of the lock Din must be i n t h e r a n g es h o w n .

07MAC-SL00200

€--....-"

'R.

9 . Removethe flange nut (A) while holdingthe joint pin (B)with a hex wrench (C),and disconnectthe s t a b i l i z el ri n k{ D )f r o m t h e l o w e ra r m ( E ) .

12x 1.25mm 59 69N m

(6.0 7.0 kgl m, 43 -51 lbf tt)

1 1 .Disconnectthe lower arm from the knuckleusing the specialtool (seepage l8-10).

12. Loosenthe damper pinch bolts (A) while holding the nuts (B),and removethe bolts and nuts.

10 x 1.25mm 39 N.m (,1.0kgf.m,29lbf.ft)

'13.Removethe driveshaftoutboardjoint

{C)fromthe knuckle(D) by tappingthe driveshaftend (E)with a plastichammer while drawing the knuckleoutward, then removethe knuckle. NOTE:Do not Dullthe driveshaftend outward.The driveshaftjoint may come off.

(cont'd)

18-13

FrontSuspension (cont'd) Knuckle/Hub/Wheel BearingReplacement 14. Separatethe hub (A)from the knuckle(B) usingthe specialtool and a hydraulicpress.Be carefulnotto deform the splashguard. Hold onto the hub to keep it from falling when pressedclear.

1 6 . R e m o v et h e s n a pr i n g ( A )a n dt h e s p l a s hg u a r d( B ) f r o m t h e k n u c k l e( C ) .

07GAF-SE00100

.-''-

a'\s

1 1 . Pressthe wheel bearing(A) out of the knuckle(B usingthe specialtool and a press. 1 5 . Pressthe wheel bearinginner race(A) off of the h u b ( B )u s i n gt h e s p e i i a l t o o l ,a c o m m e r c i a l l y a v a i l a b l eb e a r i n gs e p a r a t o(rC ) ,a n d a p r e s s . 07GAF-SE00100 \

18-14

Press

Pross

1 8 . W a s ht h e k n u c k l ea n d h u b t h o r o u g h l yi n h l g hf l a s h point solventbefore reassembly.

2 2 . P r e s sa n e w h u b b e a r i n gu n i t{ A )o n t o t h e h u b ( B ) usingthe specialtools and a press.

1 9 . Pressa new wheel bearing(A) into the knuckle(B) usingthe old bearing(C),a steel plate {D).the specialtool, and a press.Placethe wheel bearing on the knucklewith the packseal side facing (metal color)toward the inside.Be careful not to damage the sleeveof the packseal.

"-t-_"*,,''

_,.' . . a-.) ../ ..-.

23. I n s t a l l t h ek n u c k l e / h u b / h ubbe a r i n gu n i t i n t h e reverseorder of removal,and notethese items:

2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yi n t h e k n u c k l e( B ) .

D 6 N.m10.6kgf.m,4lbfft) lnstallthe splashguard (C),and tighten the screws (D)to the specifiedtorque.

. B ec a r e f u n l o t t o d a m a g e t h eb a l l j o i n tb o o t w h e n installing the knuckle. . Tightenall mounting hardwareto the specified l O r q u ev a l u e s . . Torquethe castlenut to the lower torque specification,then tighten it only far enoughto a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t align the castlenut by looseningit. . Installa new look pin on the castlenut after torquing. . U s ea n e w s p i n d l en u t o n r e a s s e m b l y . . B e f o r ei n s t a l l i n g t h e s p i n d l en u t ,a p p l ya s m a l l amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t . . B e f o r ei n s t a l l l n gt h e b r a k ed i s c ,c l e a nt h e m a t i n g surfaceof the front hub and the insideof the b r a k ed i s c . . B e f o r ei n s t a l l i n g t h e w h e e l ,c l e a nt h e m a t i n g surfaceof the brakedisc and the insideof the wneet. . Checkthe front wheel alignment,and adjustit if necessary(seepage 18-4).

18-15

FrontSuspension BallJoint Boot Replacement Special Tools Required Front hub dis/assemblytool 07965-5450500

Inst€llthe boot onto the ball joint pin, then squeeze it gentlyto force out any air. Do not let dlrt or other foreign materialsget into the boot.

1. Removethe boot. 2. Packthe interiorand lip (A) of a new boot with fresh grease.Keepthe greaseoff of the boot-to-knuckle mating surfaces(B).

Pressthe boot with the specialtool until the bottom seatson the knuckle(A) evenly around. pross 07965-SA50500

-6r

rffi

€l

6 . After installinga boot,wipe any greaseoff the exposedportion of the ball joint pin.

Wipe the greaseoff the taperedsectionof the pin (C),and packfresh greaseonto the base (D).

18-16

StabilizerBar Replacement 1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe self-lockingnuts (A)while holdingthe joint pin (B)with a hex wrench (C),and disconnect t h e s t a b i l i z el ri n k s( D ) f r o mt h e s t a b i l i z ebr a r ( E )o n the right and left. D

''i]

4. lnstallthe stabilizerbar in the reverseorder of removal.and note these itemsl . Use new self-lockingnuts on reassembly. . Note the right and left directionof the stabilizer oar. . A l i g nt h e e n d so f t h e p a i n tm a r k s( A )o n t h e stabilizerbar with each end of the bushings(8). . Note the forelaft directionofthe bushing holders. . Referto stabilizerLink Replacementto connect t h e s t a b i l i z ebr a r t o t h e l i n k s( s e ep a g e1 8 - 1 8 ) .

,.'i i .

i.',.:-l

,' \'r'j--,r'r-'1

i-ii::;i

I _: i'i :..

;4-llt,-'j--;

1 0x 1 . 2 5m m 39Nm (4.0 kgf m, 29 tbl,ft)

Removethe flange bolts {A) and bushingholders {B),then removethe bushings(C)and the stabilizer b a r( D ) .

FORWARD A 1 0x 1 . 2 5m m 39Nm (4.0ksf.m, 29lbl.ftl

18-17

Front Suspension StabilizerLink Removal/lnstallation 1 . Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe self-lockingnut (A) and flange nut {B) while holdingthe respectivejoint pin (C)with a hex wrench (D),and removethe stabilizerlink (E).

4. Installthe self-lockingnut and flange nut, and lightlytighten them. NOTE:Use a new self-lockingnut on reassembly. 5. Placethe floor jack under the lower arm balljoint, and raisethe suspensionto load it with the vehicle's weaght.

mri-dEl Do not placethe jack againstthe lower arm balljoint. 6. Tightenthe self-lockingnut (A) and flange nut (B)to the specifiedtorque valueswhile holdingthe respectivejoint pins (C)with a hex wrench (D). A 10 x 1.25mm 38 N.m (3.9kgf m,28 lbf.ft)

\ 3 . l n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B ) and lower arm (C)with the joint pins (D)set at the centerof their rangeof movement.

.., B 10 x 1.25mm 39 N.m {4.0kgf.m,29lbf.ft}

1 . After 5 minutesof driving, re-tightenthe self, lockingnut again to the specifiedtorque.

18-18

Lower Arm Removal/lnstallation SpecialToolsRequired Balljoint remover,2Smm 07|MAC-S100200

5. Removethe flange bolts (A),and removethe lower arm {B}.

1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe flange nut (A) while holdingthe joint pin {B)with a hex wrench (C),and disconnectthe s t a b i l i z el ri n k( D ) f r o mt h e l o w e ra r m ( E ) .

1 4x 1 . 5m m 83 N.m(8.5kgf.m,61lbf.ft) 6. Installthe lower arm in the reverseorder of removal,and note these items:

10x 1.25mm 39 N.m {4.0kgf m, 29 lbt.ft)

3 . Removethe lock pin (A) from the lower arm ball joint, and removethe castlenut (B). NOTE:During installation,insertthe lock pin into the ball joint pin from the insideto the outsideof the vehicle.The closed end of the lock pin must be i n t h e r a n g es h o w n .

6--__ @a

. Be carefulnot to damagethe ball joint boot when connectingthe lower arm to the knuckle. ' Tightenall mounting hardwareto the specified torque values, . F i r s t i n s t a lal l l t h e c o m p o n e n t sa n d l i g h t l y t i g h t e n the bolts and nuts.then raisethe suspensionto load it with the vehicle'sweight beforefully tighteningit to the specifiedtorques. . Torque the castlenut to the lower torque then tighten it only far enoughto specification, align the slot with the ball joint pin hole. Do not allgn the castlenut by looseningit. . Installa new lock pin on the castlenut after torquing. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneet. . C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f '18-4). necessary(seepage

oTMAc-sloo2oo 1 2x 1 . 2 5m m 59 69Nm 16.0-7.0kgt-m, 43 51 lbf.ft)

4 . Disconnectthe lower arm from the knuckleusing t h e s p e c i atl o o l ( s e ep a g e1 8 - 1 0 ) .

18-19

Front Suspension Damper/SpringReplacement ExplodedView /.' ^a ta

,,/

./ SELF-LOCK|NGNUT 12 x 1.25inm 44 N.m {4.5kgt.m,33lbf.ftl neDtace.

e9 -€.-

1, @-:'\--""' lF \-:-./ - ,

MOUNTINGBASE - DAMPER checkfor delormation

E9-

DAMPERMOUNTING BEARING

UPPER SPRINGMOUNTING CUSHION Checkfor deterioration anooamage,

DAMPER SPRING Checkfor lreelength.

DAMPERUNIT Checkfor oil leaks, gas leaks,and smooth operatron.

18-20

SpecialToolsRequired Balljoint remover,28mm 07MAC-S100200

5. Removethe damper pinch bolts (A)while holding t h e n u t s( B ) .

Removal 1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels. Removethe cotterpin (A) from the tie-rod end ball ioint, and removethe nut (B).

6. Removethe flange nuts (A)from the top ofthe damper, A 'l.25 mm 10x 10 mm HEXNUT 07MAC-S1002000 Disconnectthetie-rodend from the steeringarm o n t h e d a m p e ru s i n gt h e s p e c i a l t o o(l s e ep a g e1 8 1 0) . 4. Removethe bolts,and removethe wheel sensor harnessbracket{A) and brakehose bracket(B) from the damper.Do not disconnectthe wheel sensorconnector. A

6x1.0mm

7. Lower the lower arm, and removethe damper a s s e m b l y( B ) .

x 1.25nm

/.8

(cont'd)

18-21

FrontSuspension (cont'd) Damper/Spring Replacement Disassembly/lnspection 1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y availablestrut spring compressor(A) accordingto the manufacturer'sinstructions.then removethe s e l f - l o c k i nngu t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t (C)with a hex wrench (D).Do not compressthe spring more than necessaryto removethe nut,

Reassembleall the pans, exceptfor the upper s p r i n gs e a ta n d s p r i n g . 4. Compressthe damper assemblyby hand,and

checkfor smooth operationthrough a full stroke. both compressionand extension.The damper should extend smoothly and constantlywhen compressionis released.lf it does not, the gas is leakingand the damper should be replaced.

Releasethe pressurefrom the strut spring compressor,then disassemblethe damper as shown in the ExplodedView.

C h e c kf o r o i l l e a k s a , bnorman l o i s e sa, n d b i n d i n g during thesetests.

18-22

FrontSuspension (cont'dl Damper/Spring Replacement Installation

Right side:

1. Lower the lower arm, and positionthe damper assemblyin the body, Turn the damper mounting baseso the "AL" or "AR" mark (A)facestoward the outsideof the vehicle. B 10x 1.25mm ,14N.m {4.5kgt.m,33lbf.ft)

Hold the bottom of the damper with your hand,and compressthe spring. Do not compressthe spring excessively.

9 . I n s t a l l t h e1 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) . Hold the damper shaft with a hex wrench (C),and tighten the 12 mm nut to the specifiedtorque.

,1,6 Looselyinstallthe flange nuts (A) onto the top of the damper.

(4.5 kgt.m, 33 lbf ft)

1 0 .Removethe damperassembly fromthe strutspring compressor.

18-24

3 . P o s i t i o nt h e d a m p e ro n t h e k n u c k l ea, n d i n s t a l l t h e new damper pinch bolts (A) and nuts (B),and lightlytighten the nuts.

8. Connectthe tie-rod end to the steeringarm, and tightenthe nut (A)to the specifiedtorque. Install the cotterpin (B)after tightening,and bend lts end asshown.

B 1 6 x 1 , 5m m 157N.m (16.0kgt m, 116tbt.ftl

4 . P l a c et h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t , and raisethe suspensionto load it with the vehicle's weight.

Do not placethe jack againstthe lower arm balljoint. 5 . Tightenthe flange nuts on the top of the damperto the specifiedtorque.

9. Cleanthe mating surfaceofthe brakedisc and the insideof the wheel,then installthe front wheels. 1 0 . C h e c kt h e w h e e la l i g n m e n ta, n d a d j u s t i t i f necessary{seepage 18-4).

Tightenthe damper pinch nuts to the specified torque. 1 . Installthe brakehose bracket(A) and the wheel sensorharnessbracket(B)onto the damper,and tighten the bolt to the specifiedtorque. 9.8N.m 11.0kgf.m,7.2lbf.ftl

22N|rl. 12.2kgI m, 16rbr,ftl

18-25

RearSuspension Hub BearingUnit Replacement ExplodedView

SPLASHGUARD Checkfor deformation.

x 1.0 mm 9.8 N.m (1.0kgf.m,?1 lbf ftl

Checkfor wear and damage.

',[ ',, / -o\ ' 0

KNUCKLE

Checkfor delormation.

HUBBEARING UNIT Checkfor faultymovement andwear.

6x1.0mm 9,8 N.m {1.0kgf.m,7 lbf.ft}

HUB CAP Replace. SPINDLENUT 22 x 1.5mm 181 N.m {18.5kgt.m, 134lbf.ft} Beplace.

-A

T Appy a small amount oI engineoil to the seatingsurface.

18-26

1 . Raisethe rear of the vehicle,and support it with 'l-8). safetystandsin the proper location(seepage

Releasethe parkingbrakelever. 5 . Removethe brakehose mounting bolt (A).

Removethe wheel cap. wheel nuts, and rearwheel. C

B 1 0x 1 . 2 5m m 55Nm {5.6kgf m.41lbf.ft}

108N.m(11.0kgf.m,80lbfftl Removethe hub cap (A), raisethe stake(B),and r e m o v et h e s p i n d l en u t ( C ) .

(2.2kgtm, 16lbt.ftl Removethe caliperbracketmounting bolts (B),and hang the caliper(C)to one side.To preventdamage to the caliperor brakehose,use a short pieceof w i r e t o h a n gt h e c a l i p e rf r o m t h e u n d e r c a r r i a g e . 7 . Removethe brakedisc retainingscrews(A).

O \

ap 2 2 x 1 , 5m m 1 8 1N . m (18.5kgf.m, 134lbf.ftl

t \

I A 6x1.0mm 9 . 8N . m (1.0kgf.m,?.2lbf.ftl

Screwtwo 8 x 1.25mm bolts (B) into the disc {C)to oush it awav from the hub. Turn each bolt two turns at a time to preventcockingthe disc excessively. Removethe brakedisc.

(cont'd)

18-27

RearSuspension Hub BearingUnit Replacement (cont'd) 9. Removethe hub bearingunit (A) from the spindle.

KnuckleReplacement 1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels. R e m o v et h e b r a k ed i s ca n d h u b b e a r i n gu n i t( s e e s t e p 1 o n p a g e1 8 - 2 7 ) . Removethe flange bolts (A) and splashguard (B) from the knuckle.

,=,,,

1 0 .Installthe hub bearingunit in the reverseorder of removal,and note these items: . Tightenall mounting hardwareto the specified torque values, . Beforeinstallingthe brakedisc,cleanthe mating surfaceot the hub and the insideof the brake disc. . Use a new spindle nut on reassembly. . After tightening,use a drift to stakethe spindle n u t s h o u l d e ra g a i n s t h e s p i n d l e . . Use a new hub cap on reassembly. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneel.

kgf.m,7.2lbf ft) 11.0 4. Removethe wheel sensor(A),braKenose m o u n t i n gb r a c k e (t B ) ,a n d p a r k i n gc a b l em o u n t i n g bracket(C)from the knuckle.Do not disconnectthe wheel sensorconnector.

8 x 1.25mm 22 N.m {2.2kgfm, 16lbf ftl

6x1.0mm 9.8 N,m {I.0 kgt.m,7.2lbf ft)

18-28

5. Placethe floor jack underthe trailing arm {A),to support it.

Do not placethe jack againstthe plate sectionof the lower arm, Be carefulnot to damageany suspensioncomponents.

12x 1.25mm 59 N.m {6.0ksf.m.43lbf.ft)

Removethe flange bolt (B),and disconnectthe upper arm {C)from the knuckle. 1 . Mark the cam positionsof the adjustingbolt (A) and adjustingcam (B),the removethe self-lockingnut {C},adjustingcam, and adjustingbolt. Discardthe self-lockingnut.

12x 1.25mm 59 N.m {6.0kgf m,43lbl.ft)

9 . I n s t a l l t h ek n u c k l ei n t h e r e v e r s eo r d e ro f r e m o v a l , and note these items: . F i r s ti n s t a l a l l l t h e s u s p e n s i o cno m p o n e n t sa, n d lightlytighten the bolts and nuls,then placea floor jack under the lower a rm, and raisethe suspensionto load it with the vehicle'sweight beforefully tighteningthe bolts and nutsto the specifiedtorque values. . Align the cam positionsof the adjustingbolt (A) and adjustingcam (B)with the markedpositions w h e nt i g h t e n i n g . . Use a new self-lockingnut on reassembly. . T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e specifiedtorque values. . U s ea n e w s p i n d l en u t o n r e a s s e m b l y . . B e f o r ei n s t a l l i n g t h e s p i n d l en u t ,a p p l ya s m a l l amount of engine oil to the seatingsurfaceof the nut. After tightening,use a drift to stakethe s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t . . Beforeinstallingthe brakedisc,cleanthe mating surfaceof the hub and the insideof the brake drsc. . U s ea n e w h u b c a po n r e a s s e m b l y . . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjust it if necessary{seepage 18-4).

12x 1.25mm 59Nm(6.0kgf.m, 43 tbI.ftl

8. Remove the flange bolt (D), and remove the k n u c k l e{ E ) .

18-29

RearSuspension StabilizerBar Replacement 1 . Raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. Removethe self-lockingnuts (A)while holdingthe joint pins (B)with a hex wrench (C),and disconnect t h e s t a b i l i z el ri n k s( D )f r o m t h e s t a b i l i z ebr a r { E )o n the right and left. A 1 0 x 1 . 2 5m m 38 N.m (3.9 kgf.m,28 lbf.ft)

4. Inslallthestabilizerbar in the reverseorder of removal,and notethese items: . Use new self-lockingnuts on reassembly. . lMakesure the right and left ends of the stabilizer bar are installedon their respectivesidesof the vehicle. . Align the ends of the paint marks (A) on the s t a b i l i z ebr a r w i t h t h e b u s h i n g s( B ) . . Referto StabilizerLink ReDlacement to connect t h e s t a b i l i z ebr a rt o t h e l i n k s{ s e ep a g e1 8 - 3 1 ) .

\....'..: .

Al .----'';-r'--\---r-

-tt'.,'t),

(

Removethe flange bolts (A) and bushing holders (B),then removethe bushings{C)and the stabilizer bar(D).

18-30

StabilizerLink Removal/lnstallation 1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels.

4. lnstallthe self-lockingnut and flange nut, and lightlytighten them. NOTE:Use a new self-lockingnut on reassembly.

2. Removethe self-lockingnut (A) and flange nut (B) while holdingthe respectivejoint pin {C)wilh a hex wrench (D),and removethe stabilizerlink (E).

Placea jack under the trailing arm at the knuckle side end. and raisethe suspensionlo load it with the vehicle'sweight. Tightenthe selflocking nut (A) and flange nut {B)to the specifiedtorque valueswhile holdingthe respectivejoint pins (C)with a hex wrench (D). A 1 0 x 1 . 2 5m m 38 N.m 13.9kgf.m,28lbf.ftl

\,1 i

i'-r d *l'',:

3 . I n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B ) a n dt r a i l i n ga r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e centerof each moving range,

7. After 5 minutesof driving, re-tightenthe selflockingnut again to the specifiedtorque.

18-31

RearSuspension UpperArm Removal/lnstallation 1 . Raisethe rear of the vehicle,and supportlt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels. P l a c ea f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d supportthe suspensron. Removethe flange bolt (A) and wheel sensor h a r n e s sb r a c k e (t B ) .

8 x 1 . 2 5m m 22 N.m(2.2kgf.m, 16rbf.ft) Removethe flange bolts (A),and removethe upper arm{B).

1 2 x 1 . 2 5m m 59 N.m {6.0kgf.m, ir3 lbf.ft)

18-32

1 2 x 1 . 2 5m m 59 N.m 16.0kgf m, 43 tbf.ft)

5. Installthe upper arm in the reverseorder of renloval,and note these items: . F i r s ti n s t a l a l l l t h e s u s p e n s i o cno m p o n e n t sa n d lightlytighten the bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e suspensionto load it with the vehicle'sweight beforefully tighteningthe bolts and nuts to the specifiedtorque values. . T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e specifiedtorque values. ' B e f o r ei n s t a l l i n g t h e w h e e l ,c l e a nt h e m a t i n g surfaceof the brakedisc and the insideof the wheel. . Checkthe wheel alignment,and adjustit if necessary(seepage 18-4).

TrailingArm Removal/lnstallation 1 . Raisethe rear of the vehicle,and suppon it with safetystandsin the proper location(seepage 1,8). Removethe rearwheels. Removethe knuckle(seepage 18-28).

7. Removethe trailing arm rear mounting bolt (A).

Do not loosenthe specialbolts (B)on the t r a i l i n ga r m . A 12 x 1.25mm

3 . P l a c et h e f l o o rj a c ku n d e rt h e t r a i l i n ga r m ( A )t o support it.

59 N.m

-----\':,'.ttg '.,--1..-r.':1 B 1 0x 1 . 2 5m m 38Nm (3.9kgl.m, 28 tbf.ftl

1 2x 1 . 2 5m m 61N m (6.2kgt m. 4s tbf,ft)

8 . Lower the jack,and removethe trailing arm. 9 . Installthe trailing arm in the reverseorder of

Removethe flange nut (B),and disconnectthe s t a b i l i z el ri n k( C )f r o m t h e t r a i l i n ga r m . Removethe flange bolt {D),and disconnectthe d a m p e r( E )f r o m t h e t r a i l i n ga r m . Removethe trailing arm front mounting bolts (A).

removal,and note these items: . F i r s ti n s t a l a l l l t h e s u s p e n s i o cn o m p o n e n t sa n d lightly tlghtenthe bolts and nuts,then placea j a c ku n d e rt h e t r a i l i n ga r m , a n d r a i s et h e suspensionto load it with the vehicle'sweight beforefully tighteningthe bolts and nuts to the specifiedtorque values. . Tightenallthe mounting hardwareto the specified torque values. . Beforeinstallingthe wheel, cleanthe mating surfaceof the brakedisc and the insideof the wneei. . Checkthe wheel alignment,and adjust it if necessary(seepage'18-4).

, ' a ' : -r A 12 x 1.25Jnm 108N.m {11.0kgt.m, 80 tbf.ft)

18-33

RearSuspension

Replacement Damper/Spring ExplodedView

9-----.---.-. -=\ SELF-LoCK|NGNUT

I€tI t=J

10 x 1.25mm 29 N m {3.0kgf.m,22 lbf.ft} Replace.

DAMPER MOUNlING COLLAR

DUSTCOVER

-tr€) qnJ/ \ \ 9... E

n \ lt

BUMP sroP PLArE

\ BUMPSTOP

tor weakness Check and damage.

DAMPERSPRING Checkfor weakened compressionand damage.

OAMPERUNIT Checkfor oil leaks, gas leaks,and smooth operation,

18-34

Removal

5. Removethe damper assemblyfrom the body.

1. Raisethe rear of the vehicle.and support it with safetystandsin the proper location(seepage 1-8). Removethe rearwheels.

i 2. Removethe flange bolt {A) from the bottom of the damper.

3 . Removethe rear bulkheadcover (seepage 20-51). Removethe flange nuts (A) from the top of the damper in the trunk.

( c o n td )

18-35

RearSuspension (cont'dl Damper/Spring Replacement Disassembly/lnspection 1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y availablestrut compressor(A) accordingto the manufacturer'sinstructions.then removethe selfl o c k i n gn u t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t( C ) with a hex wrench (D).Do not compressthe spring more than necessarvto removethe nut.

Reassembly 1 . I n s t a lal l l t h e p a r t s e x c e p t t h e s e l f - l o c k i nngu t o n t o the damper unit by referringto the ExplodedView. Align the bottom of the spring {A} and the stepped part of the lower spring seat (B),and align the d a m p e rm o u n t i n gb a s ea s s h o w n ,

,, '161\

7fi)1,, \3P qY/

Releasethe pressurefrom the strut spring compressor,then disassemblethe damper as shown ln the ExplodedView. ?

Reassembleall the pans, exceptfor the spring.

4 . Compressthe damper assemblyby hand,and

checkfor smooth operationthrough a full stroke, both compressionand extension.The damper should extend smoothly and constantlywhen compressionis released.lf it does not, the gas is leakingand the damper should be replaced.

I n s t a l l t h ed a m p e ra s s e m b l yo n a c o m m e r c i a l l y availablestrut spring compressor(C). C o m p r e s tsh e d a m p e rs p r i n gw i t h t h e s p r i n g compressor. Installthenew self'lockingnut (A) on the damper shaft.

10 x 1.25mm 29Nm (3.0kgt m,22 lbt.ft)

5. Hold the damper shaft {B)with a hex wrench (C), and tighten the self-lockingnut to the specified torque. Checkfor oil leaks,abnormal noises,or binding during thesetests.

18-36

Installation

3. Looselyinstallthe flange bolt (A) on the bottom of thedamper.

1. Positionthe damper assemblyin the body. Note the directionof the damper mounting base so that the small hole dot on it is toward the front and insideof the vehicle.

1 2 x1 . 2 5m m 61N m {6.2kgf.m.45lbf.ft)

Looselyinstallthe flange nuts (A) onto the top of the damper,

A 1 0 x 1 . 2 5m m 59 N.m 16.0kgt.m, ia lbt ft)

Raisethe suspensionwith a floor jack to load the vehicleweight, and tighten the nuts and bolt to the specifiedtorque values. C l e a nt h e m a t i n gs u r f a c eo f t h e b r a k ed i s ca n d t h e i n s i d eo f t h e w h e e l ,t h e n i n s t a ltl h e r e a rw h e e l . Checkthe wheel alignment,and adjust it if necessary(seepage 18-4).

18-37

Brakes ConventionalBrakeComponents Tools Special ........... l9-2 C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . .9. .-.3. . . . . . . . . BrakeSystemInspectionand Tests............... .......... 19-4 BrakePedaland BrakePedalPositionSwitch Adjustment .............. 19-6 ParkingBrakeCheckand Adjustment .............. 19-7 BrakeSystemBleeding ...................... 19-8 BrakeSystemIndicatorCircuit Diagram . . . . . . . . . . . . . .1. 9. .-.9. ParkingBrakeSwitchTest ................. 19-10 BrakeFluidLevelSwitchTest ...................................... 19-10 FrontBrakePadslnsoection and Replacement ........... 19-11 FrontBrakeDiscInspection ............... 19-13 FrontBrakeCalioerOverhaul...................................... 19-14 MasterCylinderReplacement ........... 19-15 MasterCylinderInspection ................ 19-16 BrakeBooster PushrodClearance Adjustment................................ 19-16 BrakeBoosterTest................... .......... 19-18 BrakeBoosterReolacement .............. 19-19 RearBrakePadsInspection and Reolacement ........... 19-20 RearBrakeDiscInspection ................ 19-22 RearBrakeCaliperOverhaul....................................... 19-23 BrakeHosesand LinesInsoection .... 19-24 BrakeHoseReolacement ................... 19-25 ParkingBrakeCableReplacement .............................. 19-26

ABS (Anti-lockBrakeSystem) Gomponents

... 19-29

ConventionalBrakeComponents SpecialTools Ref.No.

19-2

Tool Number 07JAG-SD40100

DescriDtion PushrodAdiustmentGauoe

Qty 1

ComponentLocationIndex

INDICATOR BrakeSystemIndicatorCircuit D i a g r a mp, a g e1 9 - 9 ParkingBrakeSwitch Test,page 19 10 BrakeFluidLevelSwitch Test,page 19-10

BRAKECABLE P a r k i n gB r a k eC a b l e Replacement,page 19 26

REARDISCBRAKE RearBrakePads Inspectionand Replacement,page l9-20 RearBrakeDisc Inspection,page 19'22 R e a rB r a k eC a l i p e O r verhaul, page 19'23

FRONTBRAKES FrontBrakePads,Inspectionand page 19-11 Replacement, FrontBrakeDisc Inspection,page 19'13 FrontBrakeCaliper O v e r h a u lp, a g e1 9 - 1 4 BRAKEBOOSTER BrakeBooster Test,page 19-18 BrakeEooster page 19 19 Replacement,

PARKING BRAKE LEVER Parkino Brake page19-7 CheckandAdjustment, BRAKEPEDAL BrakePedalandErakePedalPosition Switch pagel9-6 Adjustment,

BRAKEHOSESand LINES BrakeHosesand Lines Inspection,page 19 24 BrakeHoses page 19 25 Replacement, MASTERCYLINDER MasterCylinder Fl6^1.^6m6nr

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1O-18

M a s t e rC y l i n d eIrn s p e c t i o np ,a g e1 9 - 1 6 BrakeBoosterPushrodClearance A d j u s t m e n tp, a g e ' 1 9 - 1 6 BrakeSystemBleeding,page 19-8

19-3

BrakeComponents Gonventional BrakeSystemInspectionand Tests Component l\4asterCylinder

BrakeHoses

Caliper

ABS l\ilodulator

Procedure Look for damageor signs of fluid leakageat; . Reservoiror reservoirgrommets . L i n ej o i n t s . Betweenmastercvlinderand booster Look for damageor signs of fluid leakageat: . Line joints and banjo bolt connections . Hosesand lines.also inspectfor twisting or damaqe Lookfor damageor signs of fluid leakageat: . Pistonseal . Banjo bolt connections . Bleederscrew Lookfor damageor signs of fluid leakageat: . Linejoints . Modulator

Also check for:

Bulging,twisted or bent lines.

S e i z e do r s t i c k i n gc a l i p e rp i n s .

BrakeSystemTest Brake pedal sinks/fades when braking 1. Startthe engine,and let it warm up to operatingtemperature. 2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference mark acrossit.

3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then releasethe parkingbrake. While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the steeringwheel, noting where the tape measurelines up with the referencemark you made on the maskingtape. 5 . Apply steadypressureto the brakepedalfor 3 minutes. 6 . Watch the tape measure. . if it moves lessthan 10 mm, the mastercylinderis OK. . if it moves more than 10 mm replacethe mastercylinder.

19-4

Rapid brake pad wear. Vehicle vibration {after a long drivel, or High, hard brake pedal 1 . D r i v et h e v e h i c l eu n t i lt h e b r a k e sd r a go r u n t i l t h e pedal is high and hard.This can take 20 or more brakepedal applicationsduring an extendedtest drive.

5. Loosenthe hydrauliclines at the mastercylinder, then spin the wheelsto checkfor brakedrag. ls there brake drag at any of the wheels? YES Go to step 6. NO- Replacethe mastercylinder.l

2 . W i t h t h e e n g i n er u n n i n g r, a i s et h e v e h i c l eo n a l i f t , a n d s p i n a l l f o u r w h e e l sb y h a n d .

6. Loosenthe bleederscrewsat each caliper,then spin the wheels to checkfor brakedrag.

ls there btake drag at any of the wheels? Is there brake drag at any of the wheels? YES Go to step 3. NO Lookfor other causesof the pad wear, high p e d a l ,o r v e h i c l ev i b r a t i o n . I

YES Disassembleand repairthe caliperon the w h e e l ( sw ) i t h b r a k ed r a g . l NO Inspectbrakehose (s)/line(s).

3. Turn the engineoff, pump the brakepedalto depletethe vacuum in the brakebooster,and then spin the wheels againto checkfor brakedrag. ls therc brake dtag at any ot the wheels? YES-Go to step 4. NO Replacethe brakebooster.I 4. Without removingthe brakelines,unbolt and separatethe mastercylinderfrom the booster,then spin the wheelslo checkfor brakedrag. ls there btake drag at any of the wheels? YES Go to step 5, NO-Check the brakepedal positionswitch adjustmentand pedalfree play.I

19-5

ConventionalBrakeComponents BrakePedalandBrakePedalPosition SwitchAdjustment PedalHeight 1 . Disconnectthe brakepedal positionswitch connector,turn the brakepedal positionswitch (A) c o u n t e r c l o c k w i saen, d p u l l i t b a c ku n t i li t i s n o l o n g e rt o u c h i n gt h e b r a k ep e d a l .

PedalFreePlay 4. With the engineoff, inspectthe play (A) on the p e d a lp a d ( B )b y p u s h i n gt h e p e d a lb y h a n d . F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )

Lift up the carpetand the insulatorcutout (B). l\4easure the pedal height (C)from the middle of the left side of the pedal pad (D). StandardPedalHeight (with carpet removed): 184 mm (7 4/16in.)

lf the pedalfree play is out of specification,adjust the brakepedal positionswitch (C).lf the pedalfree p l a yi s i n s u f f i c i e n itt, m a y r e s u l ti n b r a k ed r a g .

Loosenthe pushrodlocknut(A),and screwthe pushrodin or out with pliers until the standard pedal heightfrom the floor is reached.After adjustment,tighten the locknutfirmly. Do not adjustthe pedal heightwith the pushrodpressed.

1 5N . m (1.5kgl m. 11lbl ft)

19-6

6 . Pushin the brakeoedal oositionswitch until its dnd(A)touching p l u n g e ri s f u l l y p r e s s e d( t h r e a d e e the pad (B)on the pedal arm).Then,turn the switch 45" clockwiseto lock it. The gap betweenthe brake pedal positionswitch and the pad is automatically a d j u s t e dt o 0 . 4t o 3 . 0m m ( 0 . 0 1 6 0 . 1 1 8i n . )b y l o c k i n gt h e s w i t c h .M a k es u r et h e b r a k el i g h t sg o otf when the pedal is released.

7 . C h e c kt h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e db e l o w .

ParkingBrakeCheckand Adiustment Check

Removethe rear console{seepage 20-57).

1. Pullthe parkingbrakelever {A) with 196 N (20 kgf, 44 lbf) of forceto fully apply the parkingbrake.The parkingbrakelever should be lockedwithin the specifiednumber of clicks(B).

Pull the parkingbrakelever up one click,

Leverlockedclicks: 7-8

l2okqf,a4lbl)

2. Adjustthe parkingbrakeif the leverclicksarenot withinthe specification.

7, Tightenthe adjustingnut {A} until the parking brakesdrag slightlywhen the rear wheels are t ur n e d . A

Adjustment 1. Releasethe parkingbrakeleverfully. Loosenthe parkingbrakeadjustingnut, startthe engine,and pressthe brakepedal severaltimes to set the self-adjustingbrakebeforeadjustingthe parkingbrake. Blockthe front wheels,then raisethe rear of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Make sure the parkingbrakearm (A) on the rear brakecalipercontactsthe brakecaliperpin (B), NOTE:The parkingbrakearm will only contactthe brakecaliperpin when the parkingbrakeadjusting nut is loosened.

8 . Releasethe parkingbrakelever fully, and check that the parkingbrakesdo not drag when the rear wheels are turned. Readjustif necessary. 9 . Make surethe parkingbrakesare fully applied when the parkingbrakelever is pulled up fully. 1 0 . Reinstallthe rear console.

19-7

ConventionalBrakeComponents BrakeSystemBleeding NOTE: . Do not spill brakefluid on the vehicle;it may damage the painUif brakefluid does contactthe paint.wash it off immediatelywith water. . The reservoiron the mastercylindermust be at the MAX (upper)level mark at the start of the bleeding procedureand checkedafter bleedingeach brake c a l i p e rA . d d f l u i da s r e q u i r e d . . Do not reusethe drainedfluid. . Always use Honda DOT3 brakefluid. Non-Honda brakefluid can causecorrosionand shortenthe life of the system. . Make sure no din or other foreign matter is allowed to contaminatethe brakefluid.

5. ReDeattheprocedurefor eachwheel in the sequenceshown below until air bubblesno longer a p p e a ri n t h e f l u i d . BLEEDING SEOUENCE: OFront Right

ORe.r Right

O Front Left

ORoar Loft

1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t t h e M A X ( u p p e r )l e v e ll i n e( A ) . Refillthe mastercylinder reservoirto the MAX {upper)level line. FRONTBRAKE:

9 N.m 10.9kgf.m,7 lbl.ft)

2 . Slide a pieceof clear plastichoseover the flrst bleed screw,and submergethe other end in a containerof new brakefluid. Havesomeoneslowly pump the brakepedal severaltimes,then apply steadypressure. Startingat the left-front,loosenthe brakebleed screwto allow air to escapefrom the system.Then tighten the bleedscrew securely.

19-8

REARBRAKE: 9 N m 10.9kgf.m, 7 lbf ft)

BrakeSystemIndicatorCircuitDiagram

UNDER.OASH FUSE/FELAYBOX

A Y

EBAK€FLUID IEVELSwlICH

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19-9

Conventional BrakeComponents ParkingBrakeSwitch Test

BrakeFluidLevelSwitch Test

1. Removethe rear console,and disconnectthe connector(A)from the switch (B).

Checkfor continuitybetweenthe terminals(A) with the float in the down positionand the up position.

'dFu !UF-

. Removethe brakefluid completelyfrom the reservoir. With the float down, there should be continuity. . F j l l t h er e s e r v o iw r i t h b r a k e f l u i d t oM A X ( u p p e r )l e v e l (B).With the float up, there should be no continuity.

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Checkfor continuitybetweenthe switchterminal a n d b o d yg r o u n d : . With the brakelever up, there should be continuity. . With the brakelever down, there should be no continuity.

19-10

Front BrakePadsInspectionand Replacement Replacement F r e q u e nitn h a l a t i o no f b r a k ep a d d u s t ,r e g a r d l e sos f m a t e r i acl o m p o s i t i o nc,o u l db e h a z a r d o utso y o u r

1 . R e m o v et h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r( B )u p o u t of the way. Checkthe hose and pin boots for d a m a g ea n d d e t e r i o r a t i o n .

. Avoid breathingdust particles. . N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k e a s s e m b l i e sU. s ea n O S H A - a p p r o v evda c u u m cleaner.

lnspection 1. Raisethe front of the vehicle,and support it with safetystandsin the proper location{seepage 1'8). Removethe front wheels. 2. Checkthe thicknessof the inner pad iA) and outer p a d { B ) .D o n o t i n c l u d et h e t h i c k n e s so f t h e b r a k e pad backingplate.

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Brakepad thickness: 9.5 10.5mm (0.37 0.41 in.l Standard: Servicelimit: 1.6 mm (0.06in.)

A 2 . R e m o v et h e p a d s h i m i A ) a n d p a d s { B ) .

Innerpad:

' . . ' ,

Outer pad:

.^hv/ lf the brakeDadthicknessis lessthan the service l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .

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(cont'd)

19-11

ConventionalBrakeGomponents Front BrakePadsInspectionand Replacement(cont'dl 3. Removethe pad retainers(A),and checkthe caliper pins for free movement.

10. Push in the piston (A) so the caliperwill fitoverthe pads.Checkthe brakefluid level.The brakefluid may overflow if the reservoiris too full. lvlakesure the piston boot is in positionto preventdamagingit when pivotingthe caliperdown

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8x1.0mm 34 N.m 3.5 kgt m. 25 tbf.ft)

4. Cleanthe caliperthoroughly;remove any rust,and checkfor groovesand cracks. 5. Checkthebrakedisc for damageand cracks. 6. Apply Dow CorningMolykoteM77 greaseto the retainerson their mating surfacesagainstthe caliperbracket. 7. Installthe pad retainers.Wipe excessgreaseoffthe retainers.Contaminatedbrakediscsand pads reducestoppingability.Keepgreaseoff the discs andpads. 8. Apply Molykote l\477greaseto both sidesof the p a d s h i m { A ) ,t h e b a c ko f t h e p a d s( B ) ,a n d t h e o t h e r areasindicatedby the arrows. Wipe excessgreaseoff the shim. Contaminated brakediscsand pads reducestoppingability.Keep greaseoff the discs and pads.

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Installthe brakepads and pad shim correctly. Installthe padswith the wear indicators(C)on the inside. lf you are reusingthe pads,always reinstallthe brakepads in their original positionsto preventa momentary loss of brakingefficiency.

19-12

11. Pivotthe caliperdown into position.Beingcareful not to damagethe pin boots,installthe bolt (B),and tighten it to the specifiedtorque. 1 2 . P r e s st h e b r a k ep e d a ls e v e r atli m e s t o m a k e s u r e the brakeworks,then test drive. NOTEE : n g a g e m e not f t h e b r a k em a y r e q u i r ea greaterpedal strokeimmediatelyafter the brake pads have been replacedas a set.Several applicationsof lhe brakepedalwill restorethe normal pedalstroke. 13. After installation,checkfor leaksat hose and line joantsor connections,and retightenif necessary.

Front BrakeDisclnspection Runout

Thicknessand Parallelism

1. Raisethe front of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe front wheels.

1. Raisethe front of the vehicle,and supportit with safetystandsin the proper location(seepage 1-8). Removethe front wheels.

2 . R e m o v et h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) .

2. Removethe brakepads (seepage 19-11).

3. Inspectthe disc surfacefor damageand cracks. Cleanthe discthoroughly,and removeall rust

3. Using a micrometer,measurediscthicknessat eight points,approximately45" apart and 10 mm {0.4 in.) in from the outer edge of the disc.

4. lnstallsuitable flat washers(A) andwheel nuts,and tightenthe nuts to the specifiedtorque to hold the brakedisc securelyagainstthe hub.

Brake Oisc Thickness: Standard:20.9 21.8mm {0.82-0.86 in.} Max. RefinishingLimit: 19.0mm 10.75in.) in.) Brake Disc Parallelism: 0.015 mm 10.0(X)6 max. NOTE:This is the maximum allowabledifference betweenthe thicknessmeasurements

10 mm lo.itin.l

': . --'t-'"'t , . Set up the dial gaugeagainstthe brakedisc as shown, and measurethe runout at 10 mm (0 4 in.) from the outer edge of the disc. BrakeDiscRunout: ServiceLimit: 0.10mm (0.00ttin.l lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RetinishLimit: 19.0mm (0.75in.) NOTE: . l f t h e b r a k e d i s ci s b e y o n d t h e s e r v i c lei m i t f o r r e f i n i s h i n gr ,e p l a c ei t ( s e ep a g e1 8 - 11 ) . . A new disc should be refinishedif its runout is g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .

4 . l f t h e s m a l l e sm t e a s u r e m e ni ts l e s st h a nt h e m a x . refinishinglimit, replacethe brakedisc (seepage 18-11). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe. The Kwik-Latheproducedby Kwik-way "Front BrakeDisc ManufacturingCo. and the Lathe" offered by Snap-onTools Co. are approved for this operation.

19-13

ConventionalBrakeComponents Front BrakeCaliperOverhaul

{

Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health. . Avoid breathingdust particles. ' N e v e ru s ea n a i r h o s eo r b r u s ht o c l e a nb r a k ea s s e m b l i e su.s e a n o s H A - a p p r o v e d v a c u u mc l e a n e r . Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items: ' D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f immediatelywith water. . To preventdripping,cover disconnectedhose joints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e d air. . Beforereassembling,checkthat all parts are free of dust and other foreign particles. . Replacepartswith new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter is allowedto contaminatethe brakefluid, ' When reusingpads,always reinstallthemin their original positions to preventloss of brakingefficiency. . Do not reusedrainedbrakefluid. 'AlwaysuseHondaDOT3brakefluid.Non'Hondabrakefluidcancausecorrosionandshortenthelifeofthesvstem. . Do not mix differentbrandsof brakefluid as they may not be compatible. . C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r e w i t h c l e a nb r a k e f l u i d . . Make sure no greaseor oil gets on the brakediscs or pads. . Replaceall rubber partswith new ones wheneverdisassembled. . After installingthe caliper,checkthe brakehose and line for leaks,interference,and twistinq. >:@:Honda

caliper sreaso tplN 08C30-80234M)

Boors

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3.4N.m {3.5kef m,

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25 lbf ft)

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BRAKE HOSE/ / / / / / /

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tz x t.zsmm

1 0 8N . m 1 1 1 . 0k g f . m , 80 tbt.ft)

19-14

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//' SEAL|NG WAStrtXS WASHEaS

RepracF #.'@ PADRETATNERS \

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MasterCylinderReplacement NOTE:Do not spill brakefluid on the vehicle;it may damagethe paint;if brakefluid does contactthe paint, wash it off immediatelywith water, r s s e m b l y( A ) . 1 , R e m o v et h e a i r c l e a n e a

3 . R e m o v et h e c l u t c hr e s e r v o i (r B )a n d e n g i n e w i r e harnessclip (C)from the mastercylindermounting b a s e( D ) . 4. Removethe reservoircap and brakefuid from the reservoir. 5. Removethe reservoir(E)on the mastercylinder m o u n t r n gD a s e . 6, Disconnectthe brakelines (F)from the master cylinder (G).To preventspills,cover the hosejoints with rags or shop towels. 7. Removethe mastercylinder mounting nuts {H)and washers. 8. Removethe mastercylinderfrom the brakebooster. Be carefulnot to bend or damagethe brakelines when removingthe mastercylinder.

2, Disconnectthe brakefluid level sensorconnector (A).

9. Removethe rod seal (l) from the mastercylinder. 10. Installthe mastercylinder in the reverseorder of removal,and note these items:

1 5N . m {1.5kgt.m,11 lbt.ft)

. Replaceall the rubber partswith new ones wheneverthe mastercylinder is removed. . Checkthe pushrodclearancebeforeinstallingthe mastercylinder.and adjust it if necessary(see p a g e1 9 - 1 6 ) . . Use a new rod seal on reassemblY . Coatthe inner bore lip and outer circumference of the new rod seal {A) with the recommended seal greasein the mastercylinderset. . I n s t a l l t h er o d s e a lo n t o t h e m a s t e rc y l i n d e rw i t h its groovedside (B)towardthe mastercylinder. . Checkthe brakepedal height and free play after t h e m a s t e rc y l i n d e ra, n d a d j u s ti t i f installing necessary(seepage 19-6).

19-15

ConventionalBrakeComponents MasterCylinderInspection NOTE: . Beforereassembling,checkthat alI partsare f ree of dust and other foreign particles. . D o n o t t r y t o d i s a s s e m b l e t hm e astercylinder assembly.Replacethe mastercylinder assemblywith a new part if necessary. . Do not allow dirt or foreign matterto contaminatethe b r a k ef l u i d . RESERVOIB CAP unecKIor otocKage

of vent holes.

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RESERVOIR r ' , , . J \ +

RESERvOIRSEAL Checklor damaoe and deterioration.

BrakeBoosterPushrodClearance Adjustment SpecialToolsRequired Pushrodadjustmentgauge07JAG-SD40100 NOTE:Brakeboosterpushrod-to-piston clearancemust be checkedand adjustmentsmade, if necessarV,before installingthe mastercylinder. 1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d ebr o d v (B),push in the centershaft (C)until the top of it contactsthe end of the secondarypiston {D) by t u r n i n gt h e a d j u s t i n gn u t ( E ) .

STRAINER Removeaccumulated seotment.

RESERVOIR HOSES Inspecthosesfor damage,leaks,and deterioration.

MASTER CYLINDER Checkfor leaks,rust,anddamage

Without disturbingthe centershaft'sposition, installthe specialtool(A) backwardson the booster. 1 5N m { r . 5 11tbf.ftl

Installthe mastercylinder nuts (B),and tighten them to the specifiedtorque. Conneclthe boosterin line with a vacuum gauge { C )0 - 1 0 1 k P a{ 0 ' - 7 6 0m m H g ,3 0 i n . H g )t o t h e booster'senginevacuum supply,and maintainan e n g i n es p e e dt h a tw i l l d e l i v e r6 6 k P a( 5 0 0m m H g , 2 0 i n . H g )v a c u u m .

19-16

5. With a feelergauge (A),measurethe clearance betweenthe gauge body and the adjustingnut (B) as snown, lf the clearancebetweenthe gauge body and the adjustingnut is 0.4 mm (0.02in.),the pushrod-topistonclearanceis 0 mm. However.if the clearance betweenthe gauge body and the adjustingnut is clearanceis 0 4 mm 0 mm, the pushrod-to-piston {0.02in.) or more. Thereforeit must be adjusted and rechecked.

9 . C h e c kt h e p u s h r o dl e n g t h( A )a s s h o w n i f t h e boosteris removed,lf the length is incorrect, loosenthe pushrodlocknut(B),and turn the clevis (C)in or out to adjust. A 1 1 6m m { 4 . 6i n . )

Clearance: 0-0./t mm (0-0.02 in.)

1 0 x 1 . 0m m 1.5 N'm 11.5kgf.m,11 lbf.ftl

1 0 . I n s t a l l t h em a s t e rc y l i n d e r( s e ep a g el 9 - 1 5 )

lf the clearanceis incorrect,loosenthe star locknut (A).and turn the adjuster(B)in or out to adjust. . Adjustthe clearancewhile the specifiedvacuum is appiiedto the booster. . Holdthe clevis(C)while adjusting. A 22N.n 0 0.4mm l0 -0.02in.)

07JAG-SO40100 7. Tightenthe star locknutsecurely. 8. Removethe specialtool (D).

19-17

Gonventional BrakeComponents

BrakeBoosterTest FunctionalTest 1. With the enginestopped,pressthe brakepedal severaltimes to depletethe vacuum reservoir,then pressthe pedal hard, and hold itfor 15 seconds.lf the pedalsinks,eitherthe mastercylinderis bypassinginternally,or the brakesystem (master c y l i n d e rl,i n e s .m o d u l a t o ro, r c a l i p e r si)s l e a k i n g .

3. Disconnectthe brakeboostervacuum hose (check valve built-in)(A) at the boosterside.

2. Startthe enginewith the brakepedal pressed.lf the pedal sinksslightly,the vacuum boosteris working properly.lf the pedal heightdoes not vary, the boosteror checkvalve is faulty. 3. With the engine running,pressthe brakepedal l i g h t l y .l f t h e b r a k ep e d a ls i n k sm o r e t h a n 1 Om m {3/8 in,) in 3 minutes,the mastercylinder is faulty. A slight changein pedal heightwhen the Ay'C compressorcycleson and off is normal.(TheA,/C compressorload changesthe vacuum availableto the booster.)

LeakTest 1. Pressthe brakepedalwith the engine running,then stop the engine.lf the pedal height does not vary while pressedfor 30 seconds,the vacuum booster is OK. lf the pedal rises,the boosteris faulty. 2. With the engine stopped,pressthe brakepedal severaltimes using normal pressure.When the pedal is first pressed,it should oe row. On consecutiveapplications,the pedal height s h o u l dg r a d u a l l yr i s e .l f t h e p e d a lp o s i t i o nd o e s n o t varv, checkthe boostercheckvalve.

4 . Startthe engine,and let it idle.Thereshould be v a c u u ma v a i l a b l el .f n o v a c u u mi s a v a i l a b l et ,h e checkvalve is not working properly.Repiacethe brakeboostervacuum hose and checkvalve,and relesI. 5 . Reconnectthe brakeboostervacuum nose. Startthe engine,and then pinch the brakebooster vacuum hose betweenthe checkvalve and the booster, Turn the ignition switch OFF,and wait 30 seconds, Pressthe brakepedal severaltimes using normal pressure, When the pedal is first pressed,it should be low. On consecutiveapplications,the pedal height s h o u l dg r a d u a l l yr i s e . . lf the pedal positiondoes notvary, replacethe brakebooster. . lf the pedal positionvaries,replacethe brake boostervacuum hose/checkvalve assembly.

19-18

BrakeBoosterReplacement 1 . R e m o v et h e m a s t e rc y l i n d e r( s e ep a g e1 9 - 1 5 ) .

5 . R e m o v et h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d disconnecttheyoke from the brakepedal.

Removethe mastercylinder brakelines {A) from t h e b r a k el i n ec l i p .

.,.,....

alu i

' - /

'..

c 6x1.0mm 9.8 N.m (1.0kgf.m, 7.2 tbf.ft)

Removethe vacuum hose mounting bracket(B). Disconnectthe vacuum hose {C)from the brake booster.

{'l.3kgf.m,9lbf.ftl Removethe brakeboostermounting nuts (C). 7 . Removethe brakebooster(A)from the engine comparlmenr.

INdAdEI

. Be carefulnot to damagethe booster surfacesand threadsof the boosterstud bolts. . Be carefulnot to bend or damagethe b r a k el i n e s .

lnstallthe brakeboosterin the reverseorder of removal,and note these items: . Adjustthe pushrodclearancebeforeinstalling the brakebooster(seepage 19-16). . U s ea n e w c l i pw h e n e v e ri n s t a l l i n g . . After installingthe brakeboosterand master cylinder,fill the reservoirwith new brakefluid, bleedthe brakesystem (seepage 19-8),and adjustthe brakepedal height and free play (see p a g e1 9 - 6 ) ,

19-19

Conventional BrakeComponents RearBrakePadsInspectionand Replacement Replacement Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your h e ah h . . Avoid breathingdust particles. . Never use an air hose or brushto clean brake assemblies,Use an OSHA-approvedvacuum cleaner.

1. Removethe bolt (A) and brakehose {B}from the mounting bracket.

Inspection '1.

Raisethe rear of the vehicle,and supportjt with safetystandsin the proper location(seepage 1-8). Removethe rearwheels,

2. Checkthe thicknessof the inner pad (A) andouter pad (B).Do not includethe thicknessof the brake pad backingplate. Brakepad thickness: Standard: 8.5 9.5 mm {0.33-0.37 in.} Servicelimit: 1.6 mm (0.06in.)

Removethe caliperbolts (C),and removethe caliper(D)from the caliperbracket.

3 . R e m o v et h e p a d s h i m s( A )a n d p a d s( B ) .

t {

-::--

3 . lf the brakepad thicknessis lessthan the service l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .

r\ )

19-20

)

tI A

4. Removethe pad retainers(A).and checkthe caliper pins for free movement. :.i _ _l

11. Rotatethe caliperpiston clockwiseinto the cylinder, then align the cutout (A) in the pistonwith the tab {B) on the inner pad by turning the piston backso t h e c a l i p e rc a n b e i n s t a l l e do n t h e p a d .L u b r i c a t e the boot with rubbergreaseto avoid twisting the Distonboot. lf the piston boot is twisted,back it out so it is positionedproperly.

8 x 1 . 2 5m m 22 N.m l2.2kgt m, 16rbl.ttl

5. Cleanthe caliperthoroughly;remove any rust.and checkfor groovesand cracks. 6, Checkthe brakedisc for damageand cracks. 7 . Apply Dow CorningMolykoteM77 greaseto the retainerson their mating surfacesagainstthe caliperbracket, .ar

8 . Installthe pad retainers.Wipe excessgreaseoffthe retainers.Contaminatedbrakediscs and pads reducestoppingability.Keepgreaseoff the discs a n dp a d s . 9 . Apply Dow CorningMolykotelvl77greaseto both sidesof the pad shims {A),the backof the pads (B), and the other areasindicatedby the arrows.Wipe excessgreaseoff the shim. Contaminatedbrake discs and pads reducestoppingability.Keep greaseoff the discsand pads.

. .-.

D 8 x 1.25mm 23Nm {2.3kgf.m, 17rbf.ft)

I n s t a l l t h eb r a k ec a l i p e r( C )a n d c a l i p e rb o l t s( D ) . and tighten the boltsto the specifiedtorque.

1 3 .I n s t a l l t h eb r a k eh o s e( E ) . 1 4 . Pressthe brakepedal severaltimes to make sure the brakeworks, then test-drive. NOTE:Engagementof the brakemay requirea greeterpedal strokeimmediatelyafterthe brake pads have been replacedas a set. Several applicationsof the brakepedalwill restorethe n o r m a lp e d a ls t r o k e , 1 5 . C h e c kt h e p a r k i n gb r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) . 1 0 . I n s t a l l t h eb r a k ep a d sa n d p a d s h i m sc o r r e c t l y . I n s t a l l t h ep a d sw i r h t h e w e a r i n d i c a t o r {sC )o n t h e inside. lf you are reusingthe pads,always reinstallthe brakepads in their originalpositionsto preventa momentaryloss of brakingefficiency.

1 6 . A f t e ri n s t a l l a t i o nc ,h e c kf o r l e a k sa t h o s ea n d l i n e joints or connections,and retightenif necessarY.

19-21

Conventional BrakeComponents RearBrakeDiscInspection Runout

Thicknessand Parallelism

1. Raisethe rear of the vehicle,and support it with safetystandsin the proper location(seepage 1-8). Removethe rear wheels,

1. Raisethe rear of the vehicle,and supportwith safetystandsin the proper location(seepage l-g). Removethe rearwheels.

2. Removethe brakepads (seepage 19-20).

2. Removethe brakepads {seepage 19 20).

3. Inspectthe disc surfacefor damageand cracks. Cleanthe discthoroughly,and remove all rust,

3, Using a micrometer,measurediscthicknessat , p p r o x i m a t e l4y5 ' a p a r ta n d 1 0 m m e i g h tp o i n t s a {0.4 in.)from the outer edge of the disc.

4. lnstallsuitable f lat washers(A) and wheel nuts, and tighten the nuts to the specifiedtorque to hold the brakedisc securelyagainstthe hub.

BrakeDiscThickness: Standard:9.9-10.1 mm (0.389 0.397in.l Max. RetinishingLimit: 9.0 mm (0.35in.) BrakeDiscParallelism: 0.016mm 10.0006in.) max.

108N.m (11.0kgf.m,80lbf.ft) Set up the dial gauge againstthe brakedisc as shown. and measurethe runout at 10 mm (0.4in.) from the outer edge of the disc. Brake Disc Runout; ServiceLimit: 0.10mm {0.004in.) lf the disc is beyondthe servicelimit, refinishthe brakedisc. Max. RefinishLimit: 9.0 mm (0.35in.) NOTE: . l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c lei m i t f o r refinishing,replaceit (seepage 18-26). . A new disc should be refinishedif its runout is g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .

19-22

4 . lf the smallestmeasurementis lessthan the max. refinishinglimit, replacethe brakedisc (seepage 18-26). lf the disc is beyondthe servicelimit for parallelism, refinishthe brakedisc with an on-carbrakelathe.

RearBrakeCaliperOverhaul

Frequentinhalationof brakepad dust, regardlessof materialcomposition,could be hazardousto your health. ' Avoid breathingdust particles. . Never use an air hose or brushto clean brakeassemblies.Use an OSHA-approvedvacuum cleaner' Remove,disassemble,inspect,reassemble,and installthe caliper,and note these items: . D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n t ;i f b r a k ef l u i d g e t so n t h e p a i n t ,w a s h i t o f f immediatelywith water. . To preventdripping.cover disconnectedhosejoints with rags or shop towels. . C l e a n a l lp a r t s i n b r a k e f l u i d a n d a i r d r y ; b l o w o u t a lpl a s s a g e s w i t ch o m p r e s s e a dir' . Beforereassembling,checkthat all parts are free of dust and other foreign particles . Replacepans with new ones as specifiedin the illustration. . Make sure no dirt or other foreign matter contaminatesthe brakefluid. . When reusingpads,always reinstallthemin their originalpositionsto preventloss of b raking efficiency. . Do not reusedrainedbrakefluid. . U s eo n l y c l e a nH o n d aD O T3 b r a k ef l u i d .N o n - H o n d a b r a k ef l u i d c a nc a u s ec o r r o s i o na n d s h o r t e nt h e l i f eo f t h e system. . Do not mix differentbrandsot brakefluid as they may not be compatible. . C o a t t h ep i s t o n ,p i s t o ns e a lg r o o v e ,a n d c a l i p e rb o r ew i t h c l e a nb r a k ef l u i d . . Make sure no greaseor oil gets on the brakediscsor pads. . R e p l a c e a lrlu b b e rp a r t sw i t h n e w o n e sw h e n e v e rd i s a s s e m b l e d . . After installingthe caliper,checkthe brakehose and line for leaks,interference.and twisting. oG

BOLT 3 4 N . m( 3 . 5k g f m , 2 5 l b t f t ) WASHERS

, nonau."rip6r qreas€lP/N 08c30-aoa4Ml

BRAKEHOSE

",1 ;[.,.JF /;;;;---

ADJUSTINGBOLT

\-"o, V((rA

t H\a \l / t,i*t'*" ?,,.t/*"^.,,.:,"", l, /"V4# ,/

i,,'IltE" / !!;,ff

olT-J,.o"c.

CUP Beplace.

ffi

lii.'i rz.rrgr..

.ARKING NUr

2 7 N m { 2 . 8 k g ft .mm, , 20 tbf.ftr

PADSPRING

A,n

--t\)(*ff '(

INNEBPA'SHIM /

O.RING Beplace.

7lfl,lif,loffi',,0,n, \ ,,:,o"\

":;*" *dF

.r.:._U

i*E

fr.x{_>@ ,,.-"iV : .:r=,9!q!q}l

''"'t!1'ry#'

l^7k

,.2>a>-

fftt **-->**^'"

,/q &'"o.,"."""o"^.,

10 MM FLANGE BOLTS 55 N m (5.6 lgf-m, 4r lbt ft)

19-23

ConventionalBrakeComponents BrakeHosesand LinesInspection

{

1. Inspectthe brakehosesfordamage,deterioration,leaks,interference,andtwisting. 2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines. 3. Checkfor leaksat hose and line joints or connections,and retightenif necessary. 4. Checkthe mastercylinderand ABS modulator unit for damageand leakage. NOTE:Replacethe brakehose clip wheneverthe brakehose is serviced.

BRAKELINE-to-BRAKE HOSE 15 N.m (1.5kgf.m, 11 lbf.ftl

BRAKEHOSE-to-CALIPER lBANJOBOLTI 3il N.m {3.5kgf.m.25lbt'ft) BLEEO SCREW 9 N.m{0.9kgf.m,7lbf.ftl ABS MODULATORUNIT-Io-BRAKELINE 15N.m{1.5kgf m.11lbf.ftl

t''

/,i'i' ,/ ,l t

t,..

MASTERCYLINDEB-to-BRAKE LINE 15 N m {1.5kgt.m,ll lbf.ft)

BRAKEHOSE.tO-CALIPER {BANJO BOLTI 34 N.m {3.5kgf.m,25 lbl.ft) BLEEDSCBEW 9 N.m 10.9kgf.m, 7 lbf ft)

19-24

CONTROLVALVE-to-

BRAKELINE 15N.m11.5kgf m, 11lbf.ft) BRAKELINE-Io-BRAKEHOSE 15 N.m (1.5kgf.m,11lbf.ftl

BrakeHoseReplacement NOTE: . Do not spill brakefluid on the vehicle;it may damage the paint;if brakefluid gets on the paint,wash it off immediatelywith water. . To preventdripping,cover disconnectedline joints with rags or shop towels. . Beforereassembling,checkthat all parts are free of dust and other foreign particles. . Replacepartswith new ones wheneverspecifiedto do so.

6. Installthe brakehose bracket(A)on the damper with the flange bolt (B)first, then connectthe brake hose (C)to the caliperwith the banjo bolt {D) and n e w s e a l i n gw a s h e r s( E ) .

1. Replacethe brakehose (A) if the hose is twisted, cracked,or if it leaks.

7. lnstallthe hose onto the hose bracketon the bodv with a new hose clip (A).

i !

1 0 x 1 . 0m m 15 N.m (1.5kgf.m, 1t tbt.ftl

Disconnectthe brakehosefrom the brakeline (B) using a 10 mm flare nut wrench {C) Removethe flange bolt (A),and removethe brake hose bracketsfrom the damper.

Connectthe brakeline to the brakehose. 9 . After installingthe brakehose,bleedthe brake system (seepage l9-8).

1 0 .Do the following checks: I x 1 . 2 5m m

. Checkthe brakehose and line joint for leaks,and tighten if necessary. . Checkthe brakehosesfor interferenceand twisting.

4. R e m o v ea n d d i s c a r dt h e h o s ec l i p ( B ) .

Removethe banjo bolt (C),and removethe brake h o s e( D ){ r o m t h e c a l i p e r .

19-25

ConventionalBrakeComponents

ParkingBrakeCableReplacement ExplodedView

ADJUSTING NUT

PARKINGBRAKE swtTcH

L e PARKING BRAKECABLE for stiffness, Check binding,anddamage.

19-26

8 x 1.25 22 N.m 12.2kgl

NOTE: . The parkingbrakecablesmust not be bent or distorted.This will leadto stiff operationand prematurefailure. . Referto the ExplodedView as neededduring this proceoure. 1 . R e l e a s teh e p a r k i n gb r a k el e v e rf u l l y .

7 . l n s t a l l t h en e w c a b l ei n t h e r e v e r s eo r d e ro f removal.and note these items: . Be careful not to bend or distortthe cable. . M a k es u r et h e p a r k i n gb r a k ec a b l ec l i p i s f u l l y seatedon the cable housing. . Do the parkingbrakecable adjuslment(seepage 1 9 - 7) .

2. Removethe rearconsole(seepage 20-57).

4 . Removethe parkingbrakecableclip (A) from the

b r a k ec a b l e( B ) .

Disconnecttheparkingbrakecablefrom the lever

{c). 6 . Removethe parkingbrakecable mounting hardware,then removethe cable.

19-27

Brakes BrakeComponents................ 19-1 Conventional ABS (Anti-lockBrakeSystem)Components C o m o o n e nLto c a t i olnn d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1 . .9. .-.3. .0. . . . . . . Troubleshooting Information....................... 19-31 General .............. 19-34 DTCTroubleshooting Index 19-35 SymptomTroubleshooting Index ...,........................... ................. ........... 19-36 SystemDescription .........19-42 CircuitDiagram .......... 19-45 DTCTroubleshooting ............... 19-52 ABSIndicator ...................... CircuitTroubleshooting BrakeSystemIndicator Circuit T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . . . . . . . . . . . . . .1. 9 - 5 5 ABSModulator-Control UnitRemovaland ............. 19-57 lnstallation 19-59 WheelSensorInsoection ................... .............. 19-59 WheelSensorReolacement

ABSGomponents ComponentLocationIndex

(

RIGHT-REAR WHEELSENSOR page19-59 Inspection, page19-59 Replacement, UNDER.OASH FUSE/RELAY BOX

UNDER.HOOD FUSE/RELAY BOX

\L LEFT.REAR WHEELSENSOR Inspection,page 19-59 page 19-59 Replacement, DATA LINKCONNECTOR I16PI RIGHT.FRONT WHEELSENSOR Inspection,page 19-59 page 19-59 Replacement,

ABSMODULATOR.CONTROL UNIT page19'57 Removal andInstallation,

19-30

LEFT-FRONT WHEELSENSOR page19-59 Inspection, page1959 Replacement,

GeneralTroubleshootingInformation ABS Indicator

DiagnosticTroubleCode{DTCI

. lf the system is OK,theABS indicatorgoes off 2 secondsafter turning the ignition switch ON (ll) without startingthe engine,and then comes on again and goes off 2 secondslater after startingthe engine. This occursbecausethe ABS control unitisturned on by the lG2 power source. . The ABS indicatorcomes on when the ABS control unit detectsa problem in the system.However,even though the system is operatingproperly,the indicator will come on underthese conditions: - Only the drive wheels rotate - One drive wheel is stuck - The vehiclegoes into a spin - The ABS continuesto operatefor a long time. - The vehicleis subjectedto an electricalsignal disturbance

. The memory can hold three DTCS.However,when the same DTCis detectedmore than once,the more recentDTCis written over the earlierone. Therefore,when the same problem is detected repeatedly,it is memorizedas a single DTC. . The DTCsare in the order they occurred,beginning with the most recent. . The DTCSare memorizedin the EEPROM(nonvolatile memory).Therefore.the memorizedDTCs are not clearedwhen the batteryis disconnected,the ignition switch is turned off, or the system returnsto normal. Do the specifiedproceduresto clearthe DTCs.

To determinethe actualcauseof the problem,question the customeraboutthe problem.taking the above condilionsinto consideration. . When a Droblemis detectedand lhe ABS indicator comes on, there are caseswhen the indicatorstays on until the ignition switch is turned OFF,and cases when the indicatorgoes off automaticallywhen the sYstemreturnsto normal. - DTC61: The ABS indicatorgoes off automatically when the system returnsto normal. - D T C1 1 ,1 3 , 1 5 , 1 7, 3 1 , 3 2 , 3 3 ,3 4 ,3 5 ,3 6 ,3 7 ,3 8 ,5 4 , or 81: The ABS indicatorstayson until the ignition switch is turned OFFwhether or not the system returnsto normal. - D f C 1 2 ,1 4 ,1 6 ,1 a , 2 1 , 5 1 , 5 2o, r 5 3 ;T h e A B S indicatorgoes off when the vehicleis driven again and the system is OK afterthe ignition switch is t u r n e df r o m O F Ft o O N { l l } .

Self-diagnosis . Self-diagnosiscan be classifiedinto two categories: - I n i t i ad l iagnosis: Done right after the enginestarts and until the ABS indicatorgoes off - R e g u l ad r iagnosis: D o n er i g h t a f t e r t h ei n i t i a d l i a g n o s i su n t i lt h e ignition switch is turned OFF . When a problem is detectedby self-diagnosis, the system does the following: - Turnsthe ABS indicatoron - Memorizesthe DTC - StopsABS control

Kickback The pump motor operateswhen the ABS is functioning, and the fluid in the reservoiris forced out to the master k t t h e b r a k ep e d a l . c y l i n d e rc, a u s i n gk i c k b a c a

PumpMotor . The pump motor operateswhen the ABS is functioning. . The ABS control unit checksthe pump motor operationwhen the vehicleis startedthe first time after the ignition switch is turned ON (ll).You may hearthe motor operateat this time, but it is normal.

(cont'd)

19-31

ABSComponents GeneralTroubleshootingInformation(cont'd) How to TroubleshootABS DTCs The troubleshootingflowchartproceduresassumethat the causeof the oroblem is still Dresentand the ABS indicatoris still on. Followingthe flowchartwhen the ABS indicatordoes not come on can resultin incorrect diagnosis. The connectorillustrationsshow the female terminal connectorswith a singleoutline and the male terminal connectorswith a double outline. 1. Ouestionthe customeraboutthe conditionswhen the problem occured,and try to reproducethe same conditionsfor troubleshooting.Find out when the ABS indicatorcame on, such as during ABS control,after ABS control,when the vehicle was at a certainspeed,etc.

2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n df o l l o wt h e prompts on the PGM Testerto displaythe DTC{S) on the screen.After determiningthe DTC,referto the DTCTroubleshootingIndex. NOTE:Seethe HondaPGM Testeruser'smanual for specificinstructions. Service Check Signal (SCS)Circuit Method: 1. With the ignition switch OFF,connectthe Honda PGM Tester(A)to the 16Pdata link connector(DLC) (BI underthe driver'sside of the dashboard.

2. When the ABS indicatordoes not come on during the test-drive,but troubleshootingis done basedon the DTC,checkfor looseconnectors.poor terminal contact,etc.,beforeyou starttroubleshooting. 3. After troubleshooting,clearthe DTC,disconnect the HondaPGM Tester.and test-drivethe vehicle. Make sure the ABS indicatordoes not come on.

How to RetrieveABS DTCs Honda PGM Tester Method: 1, Wjth the ignition switch OFF,connectthe Honda PGMTester(A)to the 16Pdata link connector(DLC) (B) under the driver'sside of the dashboard.

19-32

2. Short the SCScircuitto body ground usingthe HondaPGM Tester. 3. Turn the ignition switch ON (ll).

4. The blinkingfrequencyindicatesthe DTC.DTCSare indicatedby a seriesof long and short blinks.One l o n gb l i n ke q u a l s1 0 s h o n b l i n k s A . d d t h e l o n ga n d short blinkstogetherto determinethe DTC.After determiningthe DTC,referto the DTC T r o u b l e s h o o t i nI gn d e x .

How to ClearABS DTCs Honda PGM Tester Method: 1. With the ignition switch OFF,connectthe Honda P G MT e s t e r( A ) t o t h e l 6 P d a t a l i n kc o n n e c t o (r D L C ) { B }u n d e rt h e d r i v e r ' ss i d eo f t h e d a s h b o a r d .

NOTE: . lf the DTCis not memorized,the ABS indicator will go off for 3.6 seconds,and then come back on. . lf the ABS indicatorstayson, troubleshootfor "ABS indicator does not go off" (seestep 1 on page 19-53). Th€ system will not indicate the DTC unless these conditions are met: . The brakepedal is not pressed. . The ignitionswitch is turned ON {ll). . The SCScircuitis shortedto body ground before t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) . Example ot DTC15 Long blink

Short blinks {five timesl

T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c l e a r t h e DTC(s)by following the screenprompts on the PGM Tester. NOTE:Seethe HondaPGl\4Testeruser's manual for sDeclfic instructions.

Examole of DTC 22 Long blinks (two times)

Cycling the lgnition Switch Method: C l e a rt h e D T Cb y t u r n i n gt h e i g n i t i o ns w i t c hO N ( l l )t h e n O F Fa t l e a s t2 0 t i m e s .

5 . Turn the ignition swltch OFF, Disconnectthe HondaPGM Testerfrom the DLC.

19-33

ABSGomponents DTCTroubleshootingIndex DTC DTC:11

DTC:12 DTC:13 DTC:14 DTC;15

DTC:16 DTC:17

DTC:18

Drc:2l DTC:3'l DTC:32 DTC:33 DTC:34 DTC:35 DTC;36 DTC:37 DTC:38 DTC:51

DTC:52 DTC:53 DTC:54 DTC:61

DTC:81

19-34

Detection ltem Rioht-frontwheel sensor{ooen/shortto bodv qround/shortto power) Faultv riqht-frontwheel sensoroulse siqnal Left-frontwheel sensor{oDen/shortto bodv qround/shortto power) Faultvleft-frontwheel sensorDulsesrqnal Riqht-rearwheel sensor(oDen/shortto bodv qround/shortto power) F a u l t vr i q h t - r e awr h e e ls e n s o ro u l s es i q n a l Left-rearwheel sensor (open/shortto bodv qround/shortto power) Faultvleft-rearwheel sensorDulsesiqnal d ulser) C o n t i n u o uo s D e r a t i o (nc h i o D e D Solenoid Solenoid Solenoid Solenoid Solenoid S ol en oi d S ol en o i d S o l en oi d lvlotor Iocked lvlotor stuck off lMotorstuckon Main relav stuckoff lG2 voltaqe cPU (CentralProcessinqUnit)

Note (seeoaoe 19-45) {seeoaoe 19-46) (seeoaqe 19-45) (seepaqe 19-46) (seeDaqe19-45) (seepaqe 19-46) (seeDaoe'19-45) (seeDaqe'19-46) (seepaqe 19-47) (seeDaoe19-48) { s e eD a q e1 9 - 4 8 ) {seeDaoe19'48) lsee oaqe 19-48) (seepaqe 19-48) (seeDaqe19-48) (seeDaqe19-48) (seeDaoe19-48) ( s e eD a q e1 9 - 4 8 ) (seeDaoe19-49) (seeDaoe19-50) ( s e ep a q e1 9 - 5 1 { s e eo a q e1 9 - 5 ' l {seepaqe 19-52)

Symptom Troubleshooting Index Symptom ABS indicatordoes nol come on ABS indicatordoes not go off and no ABS DTCis stored Brakesystem indicatordoes nol come on Brakesystem indicatordoes not go off and no ABS DTCis stored

Diagnostic procedure ABS IndicatorCircuitTroubleshooting(seepage 19-52) ABS IndicatorCircuitTroubleshooting{seestep 1 on Daqe19-53) BrakeSystem lndicatorCircuitTroubleshooting (seepaqe 19-55)

Also check for

BrakeSystemIndicator CircuitTroubleshooting (seesteo1 on Daqe19-55)

19-35

ABS Gomponents SystemDescription ABSControlUnit Inputsand Outputsfor 31PConnector

1 2

4 5 6 7 B I

1 6 1 1 1B 1 9

1112

1 41 5

20 ?1/t/t/l/t/

Wire side of temaleterminals

Terminal number

Wire color

Terminal sign

Description

Measurement Terminals Conditionsllgnition

Voltage

switch ON (ll))

BLU/ YEL GRN/ YEL BLU

RRS

GRN/ BLK

F R S( + )

BRN/ WHT BLU/ ORN

F L S( _ )

GRY/ RED

R L SH

R L S( + )

YEU RED LT BLU

DIAG K

BRN

DIAG L

19-36

(+) RRS F R S( - )

F L S{ + )

Detects righfrear wneetsensor srgnal Detectsright-front wneetsensor srgnal

;a-_-l

S p i nw h e e l a t AC:0.053V or I turn/second above Wheel

Detectsleft-front wneet sensor srgnal

6-7

Detectsleft-rear wneetsensor srgnal

8 9

Communications with HondaPGM rester DTCindication

Oscilloscope 0 . 1 5V p - po r above

Terminal number

Wire color

Terminalsign

Description

Measurement Terminals Conditions {lgnition

WHT/ BLK BLV ORN

STOP

Detectsbrake switchsiqnal

I 4 - GN D

rG2

15-GND

BLK

M-GND

Powersource for activating the svstem Ground forthe motor 0umD

+ B-MR

Powersourcefor the oumDmotor Powersourcefor thevalverelav Groundfor the modulator assemDtv

17-GND

WHT/ RED WHT/ GRN BLK

14 t5

'19

BLU/ RED BRN/ YEL

+ B-FSR GND

ABS

DrivesABS indicator

EBD Drivesbrake (Electronic brake systemindicator distribution)

switch oN lll)) Brakepedal Pressed Released

16-GND

,18-GND

Eattery voltaoe Baftery voltage Below 0.3V

Atalltimes

Battery voltaoe

Atalltimes

Battery voltaoe

19.GND 20-GND

Voltage

ABS indicator 2 1 - G N D Brakesystem indicator

Below 0.3V ON OFF OFF

ONfor bulb cnecK

A b o u t1 1V Below 1 V

Below 0.3V 8attery voltage

( c o n t ' d)

19-37

ABS Gomponents SystemDescription(cont'd) Features When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an event.the maneuverabilityof the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverabilityand stabilityof thevehicle. The ABS calculatesthe slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe brakefluid pressureto reachthe target slip rate. Grip Force of Tire and Road Surface TARGETSLIPRATE

OF COEFFICIENT FRICTION

SLIPRATE

19-38

ABSControlUnit Main Control The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received,then it calculatesthe vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration basedon the rate of deceleration. The ABS control unit calculatesthe slip rate of eachwheel and transmitsthe control signalto the modulatorunit solenoidvalve when the slip rate is high. The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying. T---

Self-diagnosisFunction 1 . T h e A B S c o n t r ou ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s . 2. The CPUScheckthe circuitof the system. 3 . T h e A B S c o n t r oul n i t t u r n so n t h e A B S i n di c a t o rw h e n t h e u n i t d e t e c t s ap r o b l e ma n d t h e u n i ts t o p st h e s y s t e m . 4. The self-diagnosiscan be classifiedinto thesetwo categories: . l n i t i a ld i a g n o s i s . R e g u l ad r iagnosis On-boardDiagnosisFunction The ABS can be diagnosedwith the Honda PGM Tester. The ALB Checkercannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.

(cont'd)

19-39

ABSComponents SystemDescription(cont'd) ABSModulator The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir,pump, pump motor, and the damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-typemodulator b e c a u s e t h eb r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i ch caos n t r o l three modes:pressureintensifying,pressureretaining,and pressurereducing.The hydrauliccircuitis an independent four-channeltype o ,n e c h a n n efl o r e a c hw h e e l .

Pressureintensifyingmode: Inletvalveopen,outlel valve closed M a s t e rc y l i n d e fr l u i d i s p u m p e do u t t o t h e c a l i p e r . Pressureretainingmode:

lnlet valve closed,outlet valve closed Caliperfluid is retainedby the inlet valve and outlet valve.

Pressurereducingmode:

Inletvalve closed,outlet valve open Caliperfluid flows through the outlet valveto the reservoir.

lvlotoroperationmode:

When startingthe pressurereducingmode,the pump motor is ON. When stoppingABS operation,the pump motor is OFF. T h e c a l i p e rf l u i d i s p u m p e do u t b y t h e p u m p ,t h r o u g ht h e d a m p i n gc h a m b e rt,o t h e m a s t e rc v l i n d e r .

19-40

t WheelSensors The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic coil, AC current is generated.The AC frequencychangesin accordancewith the wheel speed.The ABS control unit detectsthe wheel sensorsignalfrequencyand therebydetectsthe wheel speed. GEARPULSER

.r HIGXSPEED

WHEELS€NSOR

!t LOW SPEED

Wheel Speed and Modulator Control VEJ!q!ESPEEq 8E!EEETqE

PRESSURE

OUTLET VALVE 9p OFF INLET VALVE oN OFF

MoroR -,.

I l t

OFF

When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary,the outlet valve opens momentarilyto reducethe caliperfluid pressure.The pump motor startsat this time. As the wheel speed is restored,and the outlet valve closes,the inlet valve opens momentarilyto increasethe caliperfluid pressure.

19-41

ABSGomponents CircuitDiagram

"'----G50l

L "*'*" lJ5 Il

rI * *r +' tl ? l I

lo+-sN

csl

LqF**,

19-42

*- :ffrre, *riq.r.srbm

r.l

q_ L

md/Y4

7--:::

19-43

ABSComponents CircuitDiagram(cont'd) UNDER-HOOD FUSE/RELAY BOXCONNECTORS CONNECTOR CONNECTOR A {12P) {12P) CONNECTOR B {2P}

BRAKEPEDALPOSITION SWITCH4PCONNECTOR

UNDER.DASH FUSE/RELAY BOXCONNECTORS CONNECTOR I {5P) CONNECTOR K I17P)

MULTIPLEX CONTROL UNIT13PCONNECTOR

5 67 1011121 31 415 1 1

1l2l3l,/15 1 2 3 4 8

GAUGEASSEMBLY CONNECTORS CONNECTOR A I22P)

1 2 3

CONNECTOR B I22PI

ABSCONTROL UNIT3IP CONNECTOR

1 2

4 5 6 7 8 I

16 1 1 1 8 1 9

1112 1 415 20 21/1,/1,/vl,/l

/t,/t/t,/t/

Wire side of femaleterminals

OATA LINK CONNECTOR{16P)

WHEELSENSOR2PCONNECTORS FRONT J --T:-l L q t t / ) l 'lt L_.:-:J r \-r-----Tr' e:l

Terminalside of femaleterminals

RIGHT.REAR

LEFT-REAR

tslTt?t I tL |

/J 1T-1\ \t rlziJ

T e r m i n asl i d eo f m a l el e r m i n a l s

19-44

,/ ,/

6 7 8 9 10 11n213

DTCTroubleshooting DTC11,13,15,17:WheelSensor (Open/Short to Power) to BodyGround/Short

5. Checkfor continuitybetweenthe appropriate wheelsensor(+ ) circuitterminalandbodyground { s e et a b l e ) .

1. Disconnectthe ABS control unit 31Pconnector.

DTC 2. Start the engine. 3. Measurethe voltagebetweenthe appropriate w h e e ls e n s o r( * ) c i r c u i t t e r m i n a lo f t h e A B S control unit 31Pconnectorand body ground (see table).

DTC 11(Rioht-front) 13(Left-front)

Appropriate Terminal

11 (Riqht-front)

N o .5 : F R S( + )

13(Left-front) 1 5( R i o h t - r e a r ) 17(Left-rear)

N o . 7 : F L S( * )

No.2R : R S( * ) N o . 9R L S( + l

ABS CONTROLUNIT31PCONNECTOR

ADpropriate Terminal N o . 5 :F R S( t ) N o , 7 : F L S( * )

15 {Riqht-rear} 17 (Left-rear)

N o .2 : R R S( * ) N o . 9R t S( f )

ABS CONTROLUNIT 31P CONNECTOR

F R S{ + I I G N R / B L K } F L SI + I ( B L U R R S{ + ) (GNR/YEL)

Wire W i r esside i d eof femaleterminals

ls therecontinuity?

YES Goto step6. NO-Go to step7. Wiresideof femaleterminals ls thete battery voltage? YES Repairshort to power in the (+) circuitwire betweenthe ABS modulator-controlunit and the appropriatewheel sensor.I NO Go to step 4. 4. Turn the ignition switch OFF.

Disconnectthe harness2P connectorfrom the appropriatewheel sensor,then checkfor continuity b e t w e e nt h e 1 + ) a n d ( ) t e r m i n a l so f t h e h a r n e s s and body ground. ls there continuity? Y E S - R e p a i rs h o r t t o b o d y g r o u n di n t h e ( + ) o r { ) circuitwire betweenthe ABS modulator-control unit and the wheel sensor.l NO Repiacethe wheel sensor.l

(cont'd)

19-45

ABS Components DTCTroubleshooting(cont'dl 7. Checkthe resistancebetweenthe appropriate w h e e ls e n s o r( + ) a n d ( ) c i r c u i t e r m i n a l s{ s e e ta ble).

DTC 11 {Riqht-front)

'13 {Left-front)

1 5( R i o h t - r e a r ) 17 (Left-rear)

Appropriate Terminal *lSide l+) Side N o . 5 :F R S( * ) N o . 4 : F R1S- ) N o .7 : F L S{ + i N o . 6F: L S( (-) No.2:RBS {+) N o .1 : R B S N o . 9 :R L S1 - N o . 8B : L S( -

ABS CONTROLUNIT31PCONNECTOR

DTC12,14, 16,18:WheelSensorPutse Signal NOTE:lf the ABS indicatorcomes on for the reasons describedbelow,the indicatorgoes off when you testd r i v et h e v e h i c l ea t 3 1 m p h ( 5 0k m / n l . . Only the drive wheel rotated . T h e v e h i c l es p u n . Electricalnoise 1 . V i s u a l l yc h e c kf o r a p p r o p r i a t w e h e e ls e n s o r a n d pulserinstallationand condition(seetable).

DTC 12 14 18

Appropriate Wheel Sensor Riqht-front Left-front Riqht-rear Left-rear

Ate they installed correctly and not damaged? YES-Go to step 2, Wire side of femaleterminals

NO Reinstallor replacethe appropriatewheel s e n s o ro r p u l s e r , I Is the rcsistance between 450

2,000 A ?

YES Checkfor a looseABS control unit3lP connector.lf necessary.substitutea known-good ABS modulator-controlunit, and recheck.l

2. Disconnectthe ABS control unit 31Pconnector. 3 . Measurethe resistancebetweenthe appropriate w h e e ls e n s o r( f ) a n d ( ) c i r c u i t e r m i n a l s( s e e table).

NO Go to step 8.

DTC Disconnectthe harness2P connectorfrom the appropriatewheel sensor,and checkthe resistance b e t w e e nt h e ( + ) a n d { ) t e r m i n a l s o ft h e w h e e l sensor.

12 {Rioht-front) 14 (Left-front) 1 6( R i q h t . r e a r ) 18 (Left-read

ls the resistance between 450- 2,000 Q ?

Appropriate Terminal l*) Side ) Side N o . 5 : F (B*S No.4:FBS N o . 7 ; F Ll *S No,6:FLS N o . 2R: R(S* N o1 . :BRS N o . 9B: L S 1No.8:RLS

Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i tw i r e ,o r short betweenthe (+) circuitwire and the { ) circuitwire betweenthe ABS modulator-control u n i ta n d t h e w h e e ls e n s o r . l NO Replace t h e w h e e ls e n s o r . l ls therc less than 450 Q ? YES Go to step 1. N O - G o t o s t e p4 .

19-46

\\|D

4. Checkfor continuitybetweenthe appropriate w h e e ls e n s o r( + ) c i r c u i t t e r m l n aal n d o t h e r w h e e l s e n s o r( + ) c i r c u i t e r m i n a l s( s e et a b l e ) .

DTC Appropiate Terminal 12 No.5: F R W( * i '14 No.7: FLWIT.) to No.2; RRW(T-) No.9: 18 R L W( * )

Other Terminal

(Chipped Operation DTC21:Continuous pulser) 1. Clearthe DTC,then disconnectthe HondaPGM tesler.

No.7

No.2

No.9

2. Test-drivethe vehicleat 19 mph (30 km/h)or more.

No.5

No.2

No.9

Doesthe ABS indicator come on and is DTC 21 indicated?

No.5

No.7

No.9

No.5

N o .7

No.2

YES Go to step 3.

ls there continuity? YES Repairshort in the wires betweenthe appropriatewheel sensorand the other wheel s e n s o rh a r n e s s e s . l NO Clearthe DTC,disconnectthe Honda PGM Tester,and test-drivethe vehicle.lf the ABS indicatorcomes on and the same DTCis indicated, replacethe ABS modulator-controlunit.l

NO The system is OK at this time.l 3. Checkthe pulsergear for a chippedtooth. ls the pulser OK? YES Checkfor a looseABS control unit 31P connector.lf necessary,substitutea known-good ABS modulator-controlunit, and recheck.l NO Replacethe driveshaftor hub unit (chipped p u l s e rg e a r ) . 1

Disconnectthe harness2P connectorfrom the appropriatewheel sensorand checkthe resistance b e t w e e nt h e ( + ) s i d ea n dt h e ( - ) s i d eo f t h e w h e e l sensor. ls there lessthan 450 Q ? YES Replacethe wheel sensor. NO- Repairshort to wire betweenthe appropriate w h e e ls e n s o r( + ) a n d ( - ) c i r c u i t s . l

1g-47

ABSComponents DTCTroubleshooting(cont'd) DTC31,32.33,34,35,36,37,38:Solenoid 1. Clearthe DTC,thendisconnect the HondaPGN4 Tester. 2. Test-drive thevehicle. Doesthe ABSindicator comeon and are DTCs 31, 32, 33, 34, 35, 36, 37, 38 indicated? YES Replace theABSmodulator-control unit.t NO Thesystemis OKat thistime.t

DTC51:Motor Locked '1.

C h e c kt h e N o . 1 0 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d f u s e / retayDox. ls the tuse OK?

YES-Reinstall the fuse, and go to step 2. NO- Replacethe fuse, and recheck.l 2. Disconnectthe ABS control unit 31Pconnector. 3. Measurethe voltagebetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 7a n d b o d y g r o u n d . ABS CONTROLUNIT31PCONNECTOR

I Wiresideof femaleterminals

ls thete battery voltage? YES Go to step 4. NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l

19-48

4. Checkfor continuitybetweenthe ABS control unit 31P connectorterminal No. 16 and body ground. ABS CONTROLUNIT31PCONNECTOR

DTG52:MotorStuckOFF 1 . C h e c tkh eN o .1 0 ( 4 0 Af )u s ei n t h eu n d e r - h o o d box. fuse/relay ls thef useOK? YES-Reinstall the fuse, and go to step 2. NO-Replace the fuse, and recheck.l|

2. Disconnectthe ABS control unit 31Pconnector. 3 . Measurethe voltage betweenthe ABS control unit Wire side of femaleterminals

ls there continuity?

3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d UNIT31PCONNECTOR ABSCONTROL

YES-Go to step 5. NO Repairopen in the wire betweenthe ABS control unit and body ground (G202).1 Reconnectthe ABS control unit 31Pconnector. 6. Clearthe DTC,then disconnectthe HondaPGM tester.

Wire side of femaleterminals

7 . Test-drivethe vehicleat 6 mph (10 km/h) or more. ls there battery voltage? Doesthe ABSindicator come on, and is DTC 51 indicated?

YES-Go to step 4.

YES Replacethe ABS modulator-controlunit.l

NO Repairopen in the wire betweenthe N o . 1 0 (40A)fuse and the ABS control unit.l

NO The system is OK at this time.l

(cont'di

19-49

ABS Components DTCTroubleshooting(cont'dl 4. Checkfor continuitvbetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d . ABSCONTROL UNIT31PCONNECTOR

DTC53:MotorStuckON 1 . C l e a rt h e D T C t, h e n d i s c o n n e ct th e H o n d ap GM Tester. 2. Test-drivethe vehicle. Does the ABS indicatot come on and is DTC 53 indicated? YES -Go to step 3. NO- lntermittentfailure,the system is OK at this trme.l

Wiresideol femaleterminals

3 . Disconnectthe ABS control unit 31Pconnector. ls there continuity? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary,substitutea known-goodABS modulator-controlunit, and recheck.l

Checkfor continuitybetweenthe ABS control unit 3 1 Pc o n n e c t otre r m i n a lN o , 1 6 a n d b o d y g r o u n d . ABSCONTROL UNIT3,IPCONNECTOR

NO Repairopen in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . 1

Wiresideof femaleterminals

ls therc continuity? YES-Replacethe ABS modulator-controlunit.t NO-Repair open in the wire betweenthe ABS c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I

19-50

DTC54:MainRelayStuckOFF 1 . C h e c k t h eN o . 8 ( 2 0 A )f u s e i n t h e u n d e r - h o o fdu s e / f u s ei f i t i s O K . r e l a yb o x ,a n d r e i n s t a l l t h e ls the f use OK?

DTC61:lG2Voltage N O T EC : h e c kt h e N o . 1 1 ( 7 . 5 A f)u s ei n t h e u n d e r - d a s h fuse/relaybox beforetroubleshooting. 1 . C l e a rt h e D T C ,t h e n d i s c o n n e ct th e H o n d aP G M tesler.

YES-Go to step 2. 2. Test drive the vehicle. NO Replacethe fuse, and recheck.l 2. Disconnectthe ABS control unit 31Pconnector. the voltagebetweenthe ABS control unit 3. l\4easure c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d .

Doesthe ABS indicator come on and is DTC 61 indicated? YES Go to step 3. NO The system is OK at this time.l

ABSCONTROL UNIT31PCONNECIOR

t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 3 . D i s c o n n e ct h 4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 5. Measurethe voltage betweenthe ABS control unit 3 1 Pc o n n e c t o r t e r m i n aNl o . 1 5 a n d b o d y g r o u n d . ABSCONTROL UNIT31PCONNECTOR

Wiresideof femaleterminals

Is there battety voltage? YES Replacethe ABS modulator-controlunit.l NO-Repair open in the wire betweenthe ABS control unit and the under-hoodfuse/relaybox.I

Wire side of femaleterminals

ls there battery voltage? YES Replacethe ABS modulator-controlunit.l NO - Repairopen in the wire betweenthe ABS control unit and the under-hood{use/relaybox.l

19-51

ABSComponents DTCTroubleshooting(cont'd) DTC81:CPU(Central Processing Unit) 1. Clearthe DTC,then disconnectthe HondaPGM Tester. 2. Test-drivethe vehicle. Does the ABS indicator come on and is DTC 81 indicated?

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

YES Replacethe ABS modulator-controlunit.l NO Go to step 2, NO-The system is OK at this time. t Pull up the parkingbrakelever. Does the btake system indicator come on? YES Go to step 3. NO Repairopen in the indicatorpower source circuit.lf necassary,substitutea known-goodABS modulator-controlunit, and recheck.I . Blown No, 10 (7.5A)fuse. . O p e ni n t h e w i r e b e t w e e nt h e N o . 1 0 ( 7 . 5 A ) f u s e a n dl h e g a u g ea s s e m b l y , . Open circuitinsidethe fuse box.

3 . Turn the ignitionswitch OFF. Disconnectthe ABS control unit 31Pconnector.

5. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the ABS indicator come on? YES-Check for looseterminalsin the ABS control unit 31Pconnector.lf necessary,substitutea known-goodABS modulator-controlunit, and recheck.l NO Go to step 6. 6 . Turn the ignition switch OFF. 7 . Removethe gauge assembly(seepage 22-64).

19-52

8 . Disconnectthe gaugeassemblyconnectorA (22P).

ABS indicator does not go off

9 . Checkfor continuitybetweengauge assembly

fuse/ 1. ChecktheNo.8 (20Alfusein the under-hood relaybox,andreinstallthefuseif it is OK.

connectorA {22P)terminal No, 12 and body ground. A (22P) CONNECTOR GAUGEASSEMBLY

ls the fuse OK? YES Goto step2. lf thefuseis NO-Replacethefuse,andrecheck. blown,checkfor a shonto bodygroundin thisfuse circuit.ll thecircuitis OK,replacetheABS modulator-control unit.I Checkthe No. 11 (7.5A)fuse in the under-dash fuse/relaybox, and reinstallthe fuse if it is OK.

Wire side of femaleterminals

ls the f use OK? ls there continuity?

YES Go to step 3.

YES- Repairshon to body ground in the wire betweenthe gaugeassemblyand the ABS control unit.l

NO Replacethe fuse, and recheck.If the fuse is blown, checkfor a shortto body ground in this fuse circuit.lf the circuit is OK, replacethe ABS modulator-controlunit.I

NO Go to step 10.

'10.Disconnectthe gaugeassemblyconnectorB (22P). 1 1 .Checkfor continuitybetweengauge assembly

3 . Disconnectthe ABS control unit 31Pconnector. Measurethe voltage betweenterminal No. l8 and body ground.

connectorB (22P)terminal No. 12 and body ground. UNIT3lP CONNECTOR A8S CONTROL B (22PI GAUGEASSEMBLY CONNECTOR

Wire side of femaleterminals

Wiresideol Iemaleterminals ls there battery voltage? ls there continuity? YES-Go to step 5. YES Checkfor looseterminalsin the gauge assemblyconnectors.lf the connectorsare OK, replacethe gaugeassembly.l

NO Repairopen in the wire betweenthe No. 8 (20A)fuse and the ABS control unit.l

NO Repairopen in the wire betweenthe gauge a s s e m b l ya n d b o d y g r o u n d( G 5 0 1 ) . 1 (cont'd)

19-53

ABSComponents ABS IndicatorCircuitTroubleshooting(cont'dl 5. Turn the ignitionswitch ON (ll). 6 . Measurethe voltage betweenthe ABS control unit

10. Connectthe ABS control unit3lPconnector t e r m i n a lN o . 2 0 a n d b o d y g r o u n dw i t h a j u m p e r wire.

31PconnectorterminaI No. 15 and body ground. ABSCONTROLUNIT31PCONNECTOR

ABSCONTROL UNIT3IP CONNECTOR

Wire side of femaleterminats

Wiresideof femaleterminals

Does the ABS indicator go off?

Is there battety voltage?

YES-Check for looseterminalsin the ABS control unil 31Pconnector.lf necessary,substitutea known-goodABS modulator-controlunit, and recheck.I

YES-Go to step 7. NO-Repair open in the wire betweenthe No. 11 (7.5A)fuse and the ABS control unit.I 1 . Turn the ignition switch OFF. 8 . Checkfor continuitybetweenthe ABS control unit 31Pconnectorterminal No. 19 and body ground. ABSCONTROL UNIT31PCONNECTOB

Wire side ot Iemaleterminals

NO Go to step 11. 'l '1.

Removethe gaugeassembly,and leavethe connectorsconnected.Connectthe gauge a s s e m b l yc o n n e c t oA r ( 2 2 P t)e r m i n a lN o . ' 1 2a n d body ground with a jumper wire. GAUGEASSEMBLY CONNECTOR A (22P)

Wiresideof femaleterminals

ls there continuity?

Does the ABS indicator go off?

YES Go to step 9.

YES-Repair open in the wire betweenthe gauge a s s e m b l ya n d t h e A B S c o n t r o lu n i t . I

NO-Repair open in the wire betweenthe ABS control unit and body ground (G202).t 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

19-54

NO-Check for loosegauge assemblyconnectors. lf the connectorsare OK, replacethe printedcircuit b o a r di n t h e g a u g ea s s e m b l y . l

BrakeSystemIndicatorGircuitTroubleshooting Brakesystem indicator does not come on '1.

Disconnectthe m ultiplexcontroI unit l3Pconnector and the ABS control unit 31Pconnector.

Brakesystem indicatordoes not go off 1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . t h e p a r k i n gb r a k e . 2. Release

2. Checkfor continuitybetweenthe ABS control unit 3 l P c o n n e c t otre r m i n a lN o , 2 1 a n d b o d y g r o u n d . ABS CONTROLUNIT31PCONNECTOR

Does the brake system indicatot go ofl after several seconds? YES The system is OK at this time.l NO Go to step 3. 3. Checkthe brakefluid level. ls the level OK? YES Go to step 4.

Wire side of femaleterminals

NO Refillthe brakefluid, and recheck.l 4. Checkthe ABS indicator.

ls there continuity? Does the ABS indicator stay on? YES Repairshort to body ground in the wire betweenthe multiplexcontrol unit and the ABS c o n t r o lu n i t . l NO Go to multiplexcontrol system trou bleshootinglsee page 22''172).a

YES Readthe ABS DTC(seestep 1 on page 19-32). and do the applicabletroubleshootingfor the DTC NO Go to step 5. 5. Turn the ignition switch OFF. t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r . 6 . D i s c o n n e ct h 7 . C o n n e ctth e A B S c o n t r o lu n i t3 1 Pc o n n e c t o r t e r m i n a lN o . 2 1 a n d b o d y g r o u n dw i t h a j u m p e r

ABS CONTROLUNIT31PCONNECTOR

W i r es r d eo f l e m a l el e r m i n a l s

(cont'd)

19-55

ABSComponents BrakeSystemIndicatorGircuitTroubleshooting(cont'd) 8 . Turn the ignititonswitch ON (ll). 9 . Checkthe brakesystem indicator. Does the brake system indicatot go off? YES-Replace the ABS modulator-controlunit.l NO-Go to step 10.

1 0 .Turn the ignitionswitch OFF. 1 1 .Connectthe multiplexcontrol unit 13Pconnector

'l t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e . MULTIPLEX CONTROL UNIT13PCONNECTOR

JUMPER WIRE

\ Wiresideof femaleterminals

12. Turn the ignitionswitch ON (ll). 1 3 .Checkthe brakesystem indicator. Does the btake system indicatot go off? YES Repairopen in the wire betweenthe multiplexcontrol unit and the ABS control unit.l NO Go to multiplexcontrol system troubleshooting (seepage22-172).a

19-56

ABS Modulator-ControlUnit Removaland lnstallation NOTE: . D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i;t m a y d a m a g et h e p a i n Ui f b r a k e f l u i d g e t s o n t h e p a i n t , w a s h i t o f f immediatelywith water. . Becarefulnot to damageor deform the brakelines during removal and installation. . To preventthe brakefluid from flowing, plug and cover the hose ends and joints with a shop towel orequivalent malenal.

Removal '1.

Turn the ignitionswitch OFF.

2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u l nit3lPconnector(B),thendisconnecttheconnector. FLARENUT l5 N.m (1.5kgt.m,11lbt.ftl

6)o

--/Q

I mm NUT 8.8N.m {0.9kgl m.6.5lbfft)

\---' 6 mm BOLT 9.8N.m 11.0ksf.m,7.2lbf.ft)

(cont'd)

19-57

ABS Gomponents ABS Modulator-ControlUnit Removaland Installation{cont'dl 3. Disconnectthesix brakelines. 4. Removethe two I mm nuts. 5. Removethe ABS modulator-controlunit (C).

Installation '1.

I n s t a l l t h e A B Sm o d u l a t o r c o n t r oul n i t ,t h e nt i g h t e nt h e t w o 8 m m n u t s .

2. Align the connectingsurfaceofthe ABS control unit 3'lP connector. 3 . P u s h i n t h e l o c k o f t h e A B S c o n t r oul n i t3 1 Pc o n n e c t o ur n t i ly o u h e a ri t c l i c ki n t o p l a c e t. h e nc o n n e c t h e c o n n e c t o r . 4. Connectthe six brakeIines. 5. Bleedthe brakesystem,startingwith the front wheels. 6. Connectthe PGMTester,and do the solenoidfunctiontest for each wheel. 7. Bleedthe brakesystem again,staning with the front wheels. 8. Startthe engine,and checkthat the ABS indicatorand brakesystem indicatorgo off. 9. Disconnectthe Honda PGMTester.Test-drivethe vehicle,and checkthat the ABS indicatorand brakeqvqtem i n d i c a t odr o n o t c o m e o n .

19-58

WheelSensorInspection

WheelSensorReplacement

1 . Inspectthe front and rear pulsersfor chippedor damagedteeth.

NOTE:Inslallthe sensorscarefullyto avoid twisting the wtres.

2. Measurethe air gap betweenthe wheel sensorand

Front:

the pulserall the way around while rotatingthe pulser.Removethe rear brakedisc to measurethe gap on the rearwheel sensor.lf the gap exceeds 1 . 0m m ( 0 . 0 4i n . ) ,c h e c kf o r a b e n ts u s p e n s i o a nrm.

6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl

Standard: Front; 0.4- 1.0mm (0.02-0.04 in.) Rear: 0.2 1.0mm (0.01 0.04 in.l Front:

0.4 '1.0mm 10.02 0.0'l in.l

6 mm BOLT 9.8 N.m {1.0kgf.m,7.2lbf.ftl

WHEELSENSOR

Rear: 6 mmBOLT 9.8 N.m 11.0kgf.m,7.2lbf.ft)

6 mm BOLT 9.8 N.m (1.0kgf'm,

7.2rbr.ft) Bear:

0.2 1.0mm {0.01 0.04in.}

19-59

Body Doors C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . 20-2 D o o rP a n eR l e m o v a l / l n s t a l l a t i o. .n. . . , . . . . . .20,4 .... DoorOuterHandleReplacement 20-6 DoorLatchReplacement 20-7 DoorGlassand Regulator Replacement 20-9 D o o rS a s hT r i mR e p l a c e m e n. .t. . . . . . . . . . . . . . 2. .0. .t.0. . DoorGlassOuterWeatherstrip Replacement 20- 10 Beplacement DoorWeatherstrip 20-11 D o o rG l a s sA d j u s t m e n t. . . . . . . . . . . . . . . . . . . . . . .20-11 .......... D o o rP o s i t i oA n d j u s t m e n .t . . . . . . . . . . . . . . . . . . .20-12 ......... D o o rS t r i k eA r d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2. .0. .1. 3. . . . .

Mirrors

........ C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20-14 P o w e rM i r r o rR e p l a c e m e n. .t . . . . . . . . . . . . . . . . .2. 0 . .-. 1. .5. . M i r r o rH o l d e R r e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-15 ........ Rearview M i r r o rR e p 1 a c e m e.n. t. . . . . . . . . . . . . .2. 0. .-.1. .6

Glass

C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .2. 0 . .1 . .1. . . W i n d s h i e lR deplacement 20-19 ........ B e a rW i n d o wR e p 1 a c e m e.n. .t . . . . . . . . . . . . . . . .20-25 ........ O u a r t eG r l a s sR e p l a c e m e n. .t . . . . . . . . . . . . . . . . 20-29

Moonroof

C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20,35 ........ Index SymptomTroubleshooting 20-36 t d j u s t m e n.t. . . . . . . . . . . . . . . . . . . . 20-37 .......... G l a s sH e i g hA 20-31 G l a s sR e p l a c e m e n t W i n dD e fl e c t o r8 e p 1 a c e m e n. .t. . . . . . . . . . . . . . .20-38 ....... D r a i nC h a n n eRl e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20 . . . .39 .... .......... S u n s h a dR e e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . . . .20-40 Motor Replacement 20-41 Frameand DrainTubeReplacement............ 20,42 D r a i nC h a n n eSl l i d e a r n dC a b l eA s s e m b l y Replacement 20 44 L i m i tS w i t c hA d j u s t m e n .t . . . . . . . . . . . . . . . . . . . . 20-46 .......... ClosinoForceand ODeninaDraqCheck ......20,44

lnterioiTrim

........ C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .20-49 Trim Removal/lnstallation DoorArea .......... 20 50 Trim Removal/lnstallation -RearSideArea 20-51 Trim Removal/lnstallation -CargoFloorArea 20-52 Trim Removal/lnstallation-Hatch Area .........20-53 HeadlinerRemoval/lnstallation 20-54 * C a r p eR ............ t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .20-55

Consoles

Frontand Rear Consoles, Removal/lnstallation 20-57 FrontConsoleDisassembly/Reassembly .....20-58

Dashboard InstrumentPanelRemoval/lnstallation ........20-59 Driver'sDashboardLowerCover RemovatInstallation 20-59 Driver'sDashboardUnderCover Removat Installation 20-60 Oriver'sPocketRemoval/lnstallation ............ 20,60 ShiftLeverTrim Removal/lnstallation ..........2 0 6 1 C e n t eP r a n eR l e m o v a l / l n s t a l l a t i. o. .n. . . . . . . .20-62 .... Passenger's DashboardLowerCover Removal/lnstallation 20-63 x GloveBox Removal/lnstallation 20-63 Dashboard SideVent R e m o v a l / l n s t a l l a t i. o. .n. . . . . . . . . . . . . . . . . . . . 2 . .0. .-.6. .4. . . . BeverageHolderRemoval/lnstallation ........20-64 Driver'sTrayRemoval/lnstallation ............... 20-65 Passenger's Tray Removal/lnstallation ........20 65 * DashboardRemoval/lnstallation .................. 20-66 S t e e r i"n H q a n q eB r e a mR e o l a c e m e n. .t. . . . . . .2. 0. - 6 8

Seats

ComponentLocationIndex ........................... 20-10 * FrontSeatRemoval/lnstallation ................... 20-11 * FrontSeatDisassembly/ R e a s s e m b l y - D r i v e. .r .' s. . . . . . . . . . . . . . . . . . . . 2. .0. .-.7. .3. . . . * FrontSeatDisassembly/ R e a s s e m b l y - P a s s e n g. .e.r. '.s. . . . . . . . . . . . . .2. 0 . .-. 7. .4. . * F r o n tS e a tC o v e rR e p l a c e m e n. .t . . . . . . . . . . . . .2. .O. .-.7. 5 R e a rS e a tR e m o v a l / 1 n s t a 1 1.a. t. i. o. .n. . . . . . . . .2. .0. -. .8.0 RearSeat-back LatchReplacement.............. 20-81 RearSeat-backStriker Replacement............ 20-81 RearSeat-back CoverReplacement............. 20-82 R e a rS e a tC u s h i o n C o v e rR e p l a c e m e n. .t . . . .2. 0 . 8 4

Bumpers

F r o n tB u m p e R r e m o v a l / l n s t a l l a t .i o . .n. . . . . . .20,85 ... R e a rB u m o e R r e m o v a l / l n s t a l l a t.i.o. .n. . . . . . .20-86 .... Hood Adjustment 20-47 H o o dS e a lR e p l a c e m e n t 20,88 H o o dI n s u l a t oRr e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20,89 .......

Hatch

Adjustment . . . . . . . . . . . . . .2. 0 . .-. 9. 0 H a t c hS u p p o nS t r u tR e p l a c e m e n. .t. . . . . . . . . .2. .0.-. 9 1 HatchWeatherstriD Reo1acement ................. 20-92

FuelFill Door Adiustment

ExteriorTrim

. . . . . . . . . . . . . .2. 0 . .-. 9. 3

F r o n tG r i l l eR e p l a c e m e n. .t. . . . . . . . . . . . 20-94 CowlCoversReplac"rn""t .. . ..................... 20-95 A p i l l a rC o r n eTr r i mR e p l a c e m e n. .t. . . . . . . . . .20-96 .... R o o fl M o l d i nR g e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-97 ........ RearLicenseTrim Replacement 20,98 H a t c hS p o i l e8r e p 1 a c e m e .n.t. . . . . . . . . . . . . . . . .20-99 ........ E m b l e mR e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . .2 0 - 1 0 0

Fenderwell FrontInnerFenderReplacement 20-102 F r o n tF e n d eFr a i r i n gR e p l a c e m e n. .t . . . . . . . . .2. .0. .- 1 0 3 FuelPipeProtectorReplacement 20-104 R e a rA i r O u t l e R t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20-'to4 .......

Openers

C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .2. .0. -. 1 . .0. .5 H o o dO p e n eC r a b l eR e p l a c e m e n. .t . . . . . . . . . .2. .0.-. 1 0 6 * FueF l i l lD o o rO p e n eC r able Replacement 20 107 H o o dL a t c hR e p 1 a c e m e .n. t. . . . . . . . . . . . . . . . . . .2. 0 . .-.1. .0. .8. FueF l i l lD o o rO p e n eR r e p l a c e m e n. .t. . . . . . . . .2.0. .- 1 0 9 H a t c hH a n d l eR e p l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .0. -. 1 .1. .0. H a t c hL a t c hR e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .2. .0.-. 1. .1. .0. H a t c hL o c kC y l i n d eRr e p l a c e m e n. .t. . . . . . . . . .20-111 ....

Frame

SubframeReplacement................................. 20-112 FrameStiffener,Brace,and Gusset Replacement ............. 20-113 r Fremp RFnrir Chrrr

. . . . . . . . . . . . . .2. 0 . -114

Doors

ComponentLocationIndex

DOOROUTERTRIM DOORSASHTRIM page20-10 Replacement,

DOORGLASSOUTER WEATHERSTRIP

page20-10 Replacement,

DOOR Adiustment, Position page20-12

K-p IJ A'A dq

W2"' Ya \J

aita.

t DOORWEATHERSTRIP page20-'l'l Replacement,

POWERWINDOW swtTcH

\ POWERDOORLOCKSWITCH (Driver's)

20-2

GLASS page20-9 Replacement, Adjustment,page20-11

IMMOBILIZER LABEL

@ REGULATOR page20-9 Replacement, RETAINERCLIP

LOCK CYLINDER \

\ LOCKKNOB O OUTERHANDLE PROTECTOR

CYLINDERROO PROTECTOR

,-\

v4,,(, E ) i l - /6X@ W ( STRIKER Adjustment,page20-13

LATCH page20-7 Replacement, POWERDOOR LOCKACTUATOR

20-3

Doors Door PanelRemoval/lnstallation SpecialToolsRequired Trim pad remover,Snap-onA 177Aor equivalent, c o m m e r c i a l la yvailable. NOTE:When prying with a flat-tipscrewdriver,wrap it with protectivetape, and apply protectivetape around the relatedparts.to preventdamage.

3. Removethe armrestcover (A).Takecare not to scratchthe door panel. -1 Pry out the front edge of the cover to release the hooks(B). -2 Pry out the bottom and rear edge of the cover to releasethe hooks(C). -3 Pry out along the top to releasethe tabs (D).

1. Removethe mirror mount cover (seepage 20-15). 2. Inserta hex wrench through the hole (A) in the door grip base(B),Pushthe door grip cover (C)out to r e l e a s et h e h o o k( D )a n d t a b ( E ) ,a n d p u l l o u t t h e cover to releasethe tabs (F)and hook (G) by hand, then removethe cover.

4 . Removethe screws(A, B), and releasethe tabs (C),

then removethe door grip base(D).Removethe screw (A) securingthe door panelfrom the armrest portion. FastgngrLocations A> : Screw,3 B > : Screw,5

20-4

5. Pull out the switch panel (A)to releasethe hook (B), then removethe panelfrom the door panel. Disconnectthe power window switch connector(C).

7. Disconnectthe inner handlecable {A) from the i n n e rh a n d l e( B ) ,a n d d i s c o n n e c t t h p e o w e rd o o r lock switch connector(C){driver's).Takecare not to bend the cable.

8. Detachthe harnessclip (A)from the door panel (B). B Releasethe clipsthat hold the door panel (A) with a commerciallyavailabletrim pad remover (B),then removethe door panel by pulling it upward. Removethe door panelwith as little bendingas possibleto avoid creasingor breakingit, FastenerLocations

> : Clip,9

ffi EtA

95 mm (3.74in.l

12 mm r q---------i.0.17in.l r <_--'rlmm {0.04in.l 45 mm {1.77in.l

9 . Installthe door panel in the reverseorder of removal,and note these items: . Replaceany damagedclips. . Make sure the cable is connectedsecurely,and the connectoris plugged in properly. . Checkthe window and power door lock operatrons,

20-5

Doors Door Outer HandleReplacement NOTE:Puton glovesto protectyour hands.

4. Disconnectthe cylinder rod (A),and releasethe retainerclip (B).then removethe lock cylinder(C).

1, Removetheseitems: . Door panel (seepage 20-4) . Plasticcover,as necessary(seepage 20-2)

2 . R a i s et h e g l a s sf u l l y . 5.

Removethe lock rod protector(A). -l Removethe screw. -2 Releasethe protectorfrom the latch protector (B). -3 Pullthe protectordown to releasethe hook (C) from the door. FastenerLocation ) : Screw,1

Disconnectthe outer handle rod (A). FastenorLocations > : Bolt,2

6x1.0mm 9.8 N.m {1.0kgf.m, 7.2 tbt.ft')

6 . Removethe maintenancecap (B),and removethe b o l t ss e c u r i n gt h e o u t e rh a n d l e( C )w h i l e h o l d i n g the handlefrom outside.Releasethe hook (D).then removethe outer handleprotector(E).

20-6

Door LatchReplacement 7. Pull out the outer handle(A),then remove it.

NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover,as necessary(seepage 20-2) Raisethe glassfully.

3 . Removethe lock rod protector(seestep 3 on page 20-6). 4 . Pullthe glass run channel(A) away as necessary,

and removethe bolt,then removethe centerlower channel(B) by pulling il downward Installthe handlein the reverseorder of removal, and note these items: . Make sure each rod is connectedsecurelv. . Make sure the door locksand opens properly. . W h e n i n s t a l l i n tgh e l o c kc y l i n d e rl.e a v e t h e o u t e r door handlebolts looseso the inner protector does not interferewith the lock cylinder installation,then tighten the handle bolts. . Installthe lockcylinder retainingclip on the handle,then installthe lockcylinder.Be sure the c l i p i s f u l l y s e a t e di n t h e s l o to n t h e l o c kc y l i n d e r . . W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e plasticcover is installedproperly,and is sealed aroundthe coversDerimeter.

FastenorLocation

> : Bolt,1 IIilE

6x1.0mm 8 N.m {0.8 kgf.m, 6 lbf.ftl

(cont'd)

20-7

Doors Door LatchReplacement(cont'dl 5 . Disconnectthe cylinder rod (seestep 4 on page 206). 6 . Disconnectthe outer handle rod (seestep 5 on page 20-6). 7 . Disconnectthe actuatorconnectors(A),and release t h e i n n e rh a n d l ec a b l e( B ) f r o mt h e d o o r b y d e t a c h i n gt h e c a b l ec l i p ( C i .

8 . Removethe screws,then removethe latch{A) through the hole in the door. Takecare not to bend the outer handle rod (B),cylinderrod (C),lock rod ( D ) ,a n d i n n e rh a n d l ec a b l e( E ) . FastenerLocations ) : Screw U.#

6x1.0mm 5Nm {0.5kgf.m, 4 tbf.ft)

20-8

9. Installthe latch in the reverseorder of removal,and notethese rtems: . [Vlakesure the actuatorconneclorsare pluggedin properly,and that each rod and cable are connectedsecurely. . W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e plasticcover is installedproperly,and is sealed aroundthe coversperimeter. . M a k es u r et h e d o o r l o c k sa n d o p e n sp r o p e r l y .

Door Glassand RegulatorReplacement NOTE:Put on glovesto protectyour hands. 1. Removethese items: . Door panel (seepage 20-4) . Plasticcover.as necessary(seepage 20-2) 2 . C a r e f u l l yr a i s et h e g l a s s( A )u n t i ly o u c a n s e e t h e bolts,then removethem. Carefullypull the glass out through the window slot.Takecare not to drop the glass insidethe door. FastenerLocations ):Boh,2

3. Disconnectand detachthe connector(A) and h a r n e s sc l i p ( B )f r o m t h e d o o r . FastonorLocations C>: Bolt.1 D>: Bolt,5

6x1.0mm 8 N.m (0.8kgf.m, 6 rbf.ftl

@ Removethe bolts(C),andloosenthe bolts(D),then removethe regulator(E)throughthe holein the door, greaseto allthe sliding Applymultipurpose surfaces of the regulator(A)whereshown.

6x1.0mm 9.8 N m {1.0kgl.m, 7.2 lbf.ftl

Installtheglassand regulatorin the reverseorder of removal,and note these items: . R o l l t h eg l a s su p a n d d o w n t o s e ei f i t m o v e s freely without binding. . Make sure that there is no clearancebetweenthe g l a s sa n d g l a s sr u n c h a n n e w l h e n t h e g l a s si s ctoseo. . Adjust the positionof the glassas necessary(see p a g e2 0 - 11 ) . . Checkfor water leaks(seestep 7 on page20-121. . Test-driveand checkfor wind noiseand rattles. . W h e n r e i n s t a l l i ntgh e d o o r p a n e l ,m a k es u r et h e plasticcover is installedproperlyand sealed around its perimeter.

20-9

Doors Door SashTrim Replacement

Door GlassOuterWeatherstrip Replacement

NOTE:Takecare not to scratchthe door. 1. Removethe door glassouter weatherstrip. 2. Pull backthe door weatherstrip(A) at the rear upper corner,and removethe screw. Fasten6r Location ) : Screw, I

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

B>:Clip,s

3 . Lift up the door sashtrim {B)to releasethe hooks (C),then removethe trim. lnstallthe trim in the reverseorder of removal.

3 . Installthe weatherstripin the reverseorder ot removal,and replaceany damagedclips.

20-10

Door WeatherstripReplacement

Door GlassAdjustment

NOTE: . Takecare not to scratchthe door. . Use a clip removerto removethe clips.

NOTE: . Checkthe weatherstripsand glassrun channelfor damageor deterioration,and replacethem if necessary. . Wipe the run channelcleanwith a shop towel. . Lubricatethe run channelwith Shin-Etsugrease P/N 08798-9013.

1. At the A-pillar,removethe door stop mounting bolt (A). FastenerLocations A > : B o t t ,1

B>:Clip,1

C > : C l i p ,1 8

1. Placethe vehicleon a firm, level surface. 2. Removethese items: . Door panel (seepage 20-4) . Plasticcover {see page20'2) 3. Carefullymove the glass (A) until you can seethe glass mounting bolts (B),then loosenthem.

' 14.----' 'r, .,'o-,,tL' .

.rrt B 6x1.0mm 9.8N.m(1.0kgf.m,7.2lbf.ft) Pushthe glassagainstthe channel(C),then tighten the glass mounting bolts. Detachthe clips (8, C),then removethe door weatherstrip(D).

Checkthat the glassmoves smoothly.

Installthe weatherstripin the reverseorder of removaland note these items: . Replaceany damagedclips. . Make sure the weatherstripis installedln the h o l d e r( E )s e c u r e l y . . A p p l y l i q u i dt h r e a dl o c kt o d o o r s t o p m o u n t i n g bolt beforeinstallation. . Checkfor water leaks(seestep 7 on page20-'121. . Test-driveand checkfor wind noase.

(cont'd)

20-11

Doors DoorGlassAdiustment{cont'd)

Door PositionAdiustment

6. Raisethe glassfully, and checkfor gaps.Checkthat the glass(A) contactsthe glass run channel(B) evenrv.

NOTE;Checkfor equal gaps betweenthe front, rear, and bottom door edgesand the body. Checkthat the door and body edges are parallel.

1. Placethe vehicleon a firm, levelsurfacewhen adjustingthe door. 2. Adjust at the hinges{A): . Removethe front innerfender (seepage 20-102) and front fenderfairing (seepage 20-103). Loosenthe hinge mounting bolts (B) slightly,and move the door backwardor forward, uD or down as necessaryto equalizethe gaps. . Placea shop towel (C)on the jack (D)to prevent damageto the door when adjustingthe door.

7 . Checkfor water leaks.Run water over the roof and on the sealingarea as shown, and note these items: . U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e rh o s e( A ) . . Adjust the rate of water flow as shown {B). . Do not use a nozzle. . H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m the door (C).

\ t,

12mm1112in,l

\e 300mm {12in.l

Attachthe plasticcover,and installthe door panel (seepage 20-4). 9. Test-driveand checkfor wind noise.

20-12

8x1.25mm

29 N.m (3.0kgf.m, 22 tbt.trl

Door StrikerAdjustment 3. Checkthat the door and body edges are parallel.lf necessary,adjustthe door cushions(A)to make the rear of the door flush with the bodv.

M a k es u r et h e d o o r l a t c h e s e c u r e l yw i t h o u ts l a m m i n g it. lf necessary,adjustthe striker(A):The strikernuts a r ef i x e d ,b u t t h e s t r i k e rc a n b e a d j u s t e ds l i g h t l yu p o r d o w n ,a n d i n o r o u t . 1. Loosenthe screws(B),rhen inserta shop towel (C) betweenthe body and striker.

Apply body paintto the hinge mounting bolts and a r o u n dt h e h i n g e s . 5 . Checkfor water leaks(seestep 7 on page 20-12). Test-driveand checkfor wind noise.

8 x 1 . 2 5m m 18 N.m 11.8kgf m, 13 lbf.ft)

Lightlytlghten the screws. Wrap the strikerwith a shop towel, then adjustthe s t r i k e rb y t a p p i n gi t w i t h a p l a s t i ch a m m e r( D ) .D o not tap the strikertoo hard. Loosenthe screws,and removethe shop towel.

5 . Lightlytighten the screws. 6 . Hold the outer handleout, and push the door againstthe body to be sure the strikerallows a flush fit, lf the door latchesproperly,tighten the screwsand recheck.

20-13

Mirrors ComponentLocationIndex

POWERMIRRORACTUATOR page22-1'18 Replacement,

.a\ b\.\ | \ \-r<,,/ \.J \.4

TWEETER

\ TWEETER

MIRRORMOUNTCOVER

POWERMIRROR page20-15 Replacement,

MIRRORHOLDER Replacement,page20 '15

__.Q -'-' MOUNT /

REARVIEW MIRROR page20 16 Replacement,

20-14

PowerMirror Replacement

Mirror HolderReplacement

1 . Lower the door glassfully.

1 . C a r e f u l l yp u l l o u t t h eb o t t o me d g eo f t h e m i r r o r holder (A) by hand.Takecare not to scratchthe mrrror.

2. Carefullypry out the mirror mount cover (A) by hand in the sequenceshown. Disconnectthe tweeterconnector(B),and releasethe wire harness (C)from the hook (D). FastenerLocation ) : Clip,1

3 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) . 4. Disconnecttheconnector(A),and detachthe h a r n e s sc l i p ( B ) .W h i l eh o l d i n gt h e m i r r o r{ C ) , removethe nuts,then removethe mirror. Takecare not to scratchthe door. FastenerLocrtions O: Nut.3

Separatethe mirror holderfrom the actuator(B) by slowly pullingthem apart while detachingthe clips (C).lf equipped,disconnectthe mirror defogger from the heaterpad terminals. connectors{D) lf equipped,reconnectthe mirror defogger connectors. Reattachthe clips of the mirror holderto the actuator,then positionthe mirror holderon the actuator.Carefullypush on the clip portionsof the m i r r o rh o l d e ru n t i l t h em i r r o r h o l d e rl o c k si n t o prace. 5 . Checkthe operationof the actuator

5 . lnstallthe mirror in the reverseorder of removal, and note these items: . Make sure the connectoris plugged in properly. . Attachthe harnessclip.

20-15

Mirrors RearviewMirror Replacement 1. Turnthe mirrorbase(A)90.in eitherdirection.

2. Slide the rearviewmirror (A) down toward the bottom of the windshield,then detachit from the spring (B) in the mount (C),and removethe rearviewmirror. Takecare notto scratchthe mirror Dase.

3. lf necessary,removethe spring from the mount.

20-16

4, Fit the mirror base over the mount, and securethe mirror by turning the base90".

Glass ComponentLocationIndex

PASSENGER'SAIRSAG CAUTION LABEL

FASTENER,2 glassside) {Self-adhesive-type,

SIDERUBBERDAM WINDSHIELDSIDETRIM

', m-_-==}lny' S{|---..------'RErA'NER,6

f..N\ ;\tJ e N8*?' CLIP,4 Blue

WINDSHIELD page20-19 Beplacement,

CLIP DAM LOWERRUBBER DAM,4 UPPER RUBBER

SPOILER FASTENER,2 (Selt-adhesive-type)

'9> LOWERRUBBERDAM

(cont'd)

20-17

Glass ComponentLocationIndex(cont'd)

OUARTER GLASS FRONTSEAL

- UPPER CLIP tsetl adhesive-typel ..,////

\n iT-

l/ / Pll

/nJ l"

/ LowERcLrp

.--"..---.-_

(Self-adhesive-type)

-.,-'' LEVEMBLEM

('03model) page20-100 Replacement.

20-18

OUARTER GLASS page20-29 Beplacement,

R €AR CLIP (Self-adhesive-type)

WindshieldReplacement NOTE: . Puton glovesto protectyour hands, . Weareyeprotection whilecuttingthe glassadhesive with pianowire. . Useseatcoversto avoiddamaging the seats.

Removethe cowl covers(seepage 20-95). 4. Removethe molding (A) from the upper edge of the

windshield(B).lf necessary,cut the molding with a utility knife.

1. Removetheseitems: . Rearview mirror(seepage20-16) . Windshield wiperarms(seepage22-145) 2. Pullup the sidetrim (A)to release the clips(B)from (C),andpullthetrim rearwardto the retainers releaseit fromthecliD(D)thenremovethetrim from eachsideof thewindshield.

lf the old windshieldis to be reinstalled,make alignmentmarks acrossthe glassand body with a greasepencil. Pull down the front portionof the headliner(see page 20-54).Takecare not to bend the headliner excessively,or you may creaseor breakit. 7 . Apply protectivetape along the edge of the dashboardand body. Using an awl, make a hole through the rubberdam, adhesive.and dashboard sealfrom insidethe vehicleat the corner ponion ot the windshield.Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood.

(cont'd)

20-19

Glass WindshieldReplacement(cont'd) W i t h a h e l p e ro n t h e o u t s i d e p, u l l t h e p i a n ow i r e { A ) backand forth in a sawing motion. Hold the piano wire as closeto the windshield(B)as possibleto preventdamageto the body and dashboard. Carefullycut through the rubber dam and adhesive ( C )a r o u n dt h e e n t i r ew i n d s h i e l d .

,.-

-A

10. With a knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirewindshieldopening flange: . Do not scrapedown to the paintedsurfaceofthe body; damagedpaint will interferewith proper bonding. . Removethe rubberdam and fastenersfrom the oooy. 11. Cleanthe body bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the cleansurface.

,,t""""""""',-\ i-.. -1:-,

-= -.--

12. lf the old windshieldis to be reinstalled,use a puttv knifeto scrapeoff all of the old adhesive,the fastenersand the rubber dam from the windshield. Cleanthe insideface and the edge of the windshieldwith alcoholwhere new adhesiveis to be applied.Make sure the bondingsurfaceis kept free of water, oil, and grease.

20-20

t5.

Glue the side rubber dams (A) and lower rubber dam (B)with adhesivetape (NITTO501M,or equivalent).Glue the fasteners(C)with adhesive tape (3M 4215,or equivalent)to the insideface of t h e w i n d s h i e l d{ D )a s s h o w n :

1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v et a p e{ B ) ( 3 M 4 2 1 2 ,o r e q u i v a l e n t ) t toh e u p p e re d g eo f t h e w i n d s h i e l d( C ) ; . B e s u r et h e a l i g n m e n m t a r k( D )o f t h e m o l d i n g l i n e su p w i t h t h e a l i g n m e n m t a r k( E )o f t h e windshield. . Be carefulnot to touch the windshieldwhere a d h e s i v ew i l l b e a p p l i e d .

. Be sure the rubber dams and fastenersline uD withthealignmenm t a r k s( E ) . . Be carefulnot to touch the windshieldwhere a d h e s i v ew i l l b e a o o l i e d .

t3.

Installthe fasteners(A),retalners(B, C),and clips (D)to lhe body. FastenerLocations A>:Fastener.2 B>:Retainer,2

C > : R e t a i n e r , 6O> : C l i p , 2

(cont'd)

20-21

Glass WindshieldReplacement(cont'dl t o . Set the windshieldin the opening,and centerit.

Make alignmentmarks (A) acrossthe windshield and body with a greasepencilat the four points shown. Be careful not to touch the windshield w h e r ea d h e s i v ew i l l b e a p p l i e d .

18. With a sponge,apply a light coat of glassprimer aroundthe edge of the windshield(A) betweenthe d a m s ( B )a n d m o l d i n g{ C )a s s h o w n ,t h e n l i g h t l y wipe it off with gauzeor cheesecloth: . A p p l yg l a s sp r i m e rt o t h e m o l d i n g . . Do not apply body primer to the windshield,and do not get body and glassprimer spongesmixed

up. . Nevertouch the primed surfaceswith your hands. lf you do, the adhesivemay not bond to the w i n d s h i e l dp r o p e r l yc. a u s i n ga l e a ka f t e r t h e w i n d s h i e l di s i n s t a l l e d . . Keepwater. dust, and abrasivematerialsaway from the primed surface. 'l',,1rr Applyglassprimerhere.

) - ' G1)'r'

1 7 . R e m o v et h e w i n d s h i e l d .

l l

,,/ ll\ -A tl

lnside

20-22

19. With a sponge,apply a light coat of body primer to the originaladhesiveremainingaroundthe windshieldopeningflange, Letthe body primer dry for at least 10 minutes: . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaceswith your hands. . l\4askoff the dashboardbefore paintingthe flange.

21. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the windshield(B) betweenthe d a m s ( C )a n d m o l d i n g( D )a s s h o w n .A p p l yt h e adhesivewithin 30 minutesafter applyingthe glass primer. Make a slightlythickerbead at each corner.

l'1fifr.,1: ?mm

n ,..-

in.l 10.28 A..

20 mm (0.79in.l

$?I.",x1"u.80."., trl .,r []\"

Inside

- '

20. Beforefilling a cartridge,cut a

"V"

in the end of the

n o z z l e( A )a s s h o w n .

c.. N \F1

2 m m I 'Zn l in.}I {0.08 l A 12 mm (0.47in.)

./"

U s es u c t i o nc u p st o h o l dt h e w i n d s h i e l do v e rt h e t a r k sm a d ei n o p e n i n ga , l i g ni t w i t h t h e a l i g n m e n m step 16,and set it down on the adhesive.Lightly p u s ho n t h e w i n d s h i e l du n t i li t s e d g e sa r ef u l l y s e a t e do n t h e a d h e s i v ea l l t h e w a y a r o u n d .D o n o t open or closethe doors until the adhesiveis dry.

7 mm {0.27in.)

(cont'd)

20-23

Glass WindshieldReplacement(cont'd) 23. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. To remove adhesivefrom a painted surfaceor the windshield,wipe with a soft shop towel dampensdwith alcohol.

24. Let the adhesivedry for at least t hour, then spray

27. On both sidesofthe windshield,installthe side trim (Alto the clip (B),then set the bottom edge of the side trim over the cowl cover (C),and align the c l i p s( D ) w i t ht h e r e t a i n e r (sE ) ,a n d p u s ho n t h e c l i p portionsof the trim until the trim is fully seatedon thewindshield.

water over the windshieldand checkfor leaks. Mark Ieakingareas,and let the windshielddry, then seal with sealant: . Let the vehiclestand for at least4 hours after windshieldinstallation.lf the vehiclehas to be usedwithin the first 4 hours,it must be driven slowly. . Keepthe windshielddry for the first hour after installation. Reinstallthecowl covers(seepage 20-95). NOTE:Thecowl cover clips may not set properlyif the windshieldadhesiveis too wet. Installthe clips (A, B) on both side trim {C).lf the clip (D) is damaged,replacethe side trim and clips as an assembly. A: Grey B :B l u e

28. R e i n s t a al l l l r e m a i n i n gr e m o v e dp a r t s .I n s t a l l t h e rearviewmirror afterthe adhesivehas dried thoroughly. NOTE:Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively(suchas when going i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g over rough, unevenroads).

20-24

RearWindow Replacement NOTE: . Put on glovesto protectyour hands. . Wear eye protectionwhile cuttingthe glassadhesive w i t h p i a n ow i r e . . Use seat coversto avoid damagingany surfaces. . Do not damagethe rearwindow defoggergrid lines a n dt e r m i n a l s .

6. With a helperon the outside,pull the piano wire (A) backand Jorthin a sawing motion. Holdthe piano wire as closeto the rearwindow (B)as possibleto preventdamageto the hatch,and carefullycut t h r o u g ht h e a d h e s i v e{ C }a r o u n dt h e e n t i r er e a r

1 . Removethese items: . Hatchlower trim panel (seepage 20-53) . Hatchspoiler(seepage 20-99) Removethese items: . High mount brakelight {seepage 22-821 . Rearwindow wiper motor {see page22-1461 Disconnectthe rearwindow defoggerconnectors (A).

Cutting positions:

4 . lf the old rear window is to be reinstalled,make alignmentmarksacrossthe glassand body with a g r e a s ep e n c r l , 7 . C a r e f u l l yr e m o v et h e r e a rw i n d o w . Apply protectivetape along the insideand outside e d g e so f t h e h a t c h .U s i n ga n a w l , m a k ea h o l e t h r o u g ht h e a d h e s i v ef r o m i n s i d et h e v e h i c l ea t t h e corner portionof the rearwindow. Pushthe piano w i r e t h r o u g ht h e h o l e ,a n d w r a p e a c he n d a r o u n da pieceof wood,

(cont'd)

20-25

Glass RearWindow Replacement(cont'd) With a putty kniie. scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entire rear window openingflange: . Do not scraDedown to the Daintedsurfaceof the body; damagedpaint will interferewith proper bonding . Removethe fastenersfrom the tailqate. Cleanthe hatch bonding surfacewith a sponge dampenedin alcohol.After cleaning,keepoil, greaseand water from getting on the surface,

1 0 .lf the old rearwindow is to be reinstalled,use a putty knifeto scrapeoff all of the old adhesive,the fastenersand the rubber dams from the rear window. Cleanthe insideface and the edge oi the rear window with alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis kept free of water, oil and grease.

1 1 . G l u et h e s i d eu p p e rf a s t e n e r s( A )a n d s i d e l o w e r fasteners{B)with adhesivetape {3M 5312,or e q u i v a l e n tG ) . l u et h e u p p e rr u b b e rd a m s ( C ) w i t h adhesivetape (NITTO501fM,or equivalent)and glue the lower rubberdam (D)with adhesivetape (3M 4216,or equivalent)to the insideface of the rearwindow (E)as shown. Beforeinstallingthe lower rubberdam, apply primer (3M N-200,or equivalent)to the areasbetweenthe alignment marks {F),then glue the rubberdam on. lf necessary,glue the spoilerfasteners(G)with adhesivetape (3M 5671,or equivalent)to the outsideface of the rearwindow: . Be sure the side upper fasteners,and upper r u b b e rd a m s l i n e u p w i t h a l i g n m e n m t a r k s{ H ,l ) . . Be sure both ends of the lower rubberdam line up with the edge of the glass, . Be sure the spoilerfastenersline up with a l i g n m e nm t a r k s{ J ) . . Be carefulnot to touch the rearwindow where a d h e s i v ew i l l b e a D o l i e d . 1,1,.,1,' : Applyprimerhere. G E

"6'J1r-,

20-26

12. Glue the side upperfasteners(A) andsidelower fasteners(B)with adhesivetape (3M 5312,or equivalent)tothe hatch as shown. FastonerLocations A>: Fastener, 2

2 B >: Fastener,

T-8. a r \ \ itf,

1 5 . W i t h a s p o n g ea , p p l ya l i g h tc o a to f g l a s sp r i m e r along the edge of the rear window (A),upper rubber dams (B),and lower rubberdam (C)as shown, then lightly wipe it off with gauzeor cheesecloth: . With the printeddots (D) on the rearwindow as a guide, apply the glassprimer to both side portionsof the rearwindow. . Do not apply body primer to the rearwindow, and do not get hatchand glass primer sponges m i x e du p . . Nevertouch the primed surfaceswith your hands. lf you do, the adhesivemay not bond to the rear window properly.causinga leak afterthe rear w i n d o wi s i n s t a l l e d . . Keepwater, dust, and abrasivematerialsaway from the primed surface. ..

: Applyglasspiimer here.

t 5 . Set the rearwindow in the opening,and centerit.

Align the clips (A) of the rearwindow with the holes i n t h e o p e n i n gf l a n g e .M a k ea l i g n m e n m t a r k s( B ) acrossthe rearwindow, hatch,and body with a greasepencilat the four pointsshown. Be careful not to touch the rearwindow where adhesivewill beapplied.

1 4 . R e m o v et h e r e a rw i n d o w .

(cont'd)

20-27

Glass

RearWindow Replacement(cont'd) 1 6 .With a sponge,apply a light coat of body primer to t h e o r i g i n aa l d h e s i v er e m a i n i n ga r o u n dt h e r e a r window openingflange. Letthe body primer dry for at least 10 minutes; . Do not apply glassprimer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaceswith your hands. ',,,,,': Applybodyprimerhe.e.

18. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) aroundthe edge of the rearwindow (B)as shown. With the glassprimer (C)you appliedin step 15 as a guide,apply the adhesiveto both side portionsof the rearwindow. Apply the adhesivewithin 30 minutesafter applyingthe glassprimer. fMakea slightlythicker bead at each corner. 12 mm r, 10.47in.) ,\

ii'(0.28

in.l

20 mm in.l 10.79 2mm {0.08in.)

1 7 . Beforefilling a cartridge,cut a nozzle{A} as shown.

"V" in the end ofthe

7 mm (0.27in.)

20-28

aru'.1{-----"

OuarterGlassReplacement 19. Use suctioncups to hold the rearwindow over the opening.align it with the alignmentmarks you '13, made in step and set it down on the adhesive. Lightlypush on the rearwindow until its edgesare fully seatedon the adhesiveall the way around.Do not open or closethe doors until the adhesiveis dry. 20. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. To removeadhesivefrom a painted surfaceor the rearwindow, use a soft shop towel dampenedwith alcohol. 21. Letthe adhesivedry for at least 'l hour,thenspray water over the rear window and checkfor leaks. Mark the leakingareas,let the rear window dry, then sealwith sealant.Let the vehiclestandfor at least4 hours after rearwindow installation,lf the vehiclehas to be used within the first 4 hours,it must be driven slowly.

NOTE: . Put on glovesto protectyour hands. . Wear eye protectionwhile cuftingthe glassadhesive with piano wire, . Use seatcoversto avoid damagingany surfaces. 1 . R e m o v et h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) . lf necessary,removethe rear side trim panel (see page 20-51) and B-pillarupper trim (seepage 2050). 2. Removethe front seal {A) from the front edge of the glass (B).lf necessary,cut the seal with a utility knife.

2 2 . R e i n s t a l l a lrle m a i n i n gr e m o v e dp a r t s . NOTE:Advise the customernot to do the following things for 2 to 3 days: . S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p . . Twist the body excessively(suchas when going i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g over rough, unevenroads).

(cont'd)

20-29

Glass OuarterGlassReplacement(cont'dl 3 . Apply protectivetape to along the insideand outsideedgesof the body. Using an awl, make a hole through the adhesivefrom insidethe vehicle. Pusha pieceof piano wire through the hole, and wrap each end around a pieceof wood. With a helperon the outside,pull the piano wire (A) backand forth in a sawing motion. Holdthe piano wire as closeto the quarterglass(B) as possibleto preventdamageto the body, and carefullycut through the adhesive(C)aroundthe entirequarter grass.

6 . With a putty knife,scrapethe old adhesivesmooth to a thicknessof about 2 mm (0.08in.) on the bonding surfacearoundthe entirequaner glass o p e n i n gf l a n g e : . Do not scrapedown to the paintedsurfaceof the body; damagedpaint will interferewith proper bonding . Removethe clips from the body. 7 . Cleanthe body bondingsurfacewith a sponge d a m p e n e di n a l c o h o lA . f t e rc l e a n i n gk. e e po i l , greaseand water from getting on the surface. lf the old quarter glassis to be reinstalled,use a putty knifeto scrapeoff all of the old adhesiveand the rubberdam from the glass.Cleanthe inside face and the edge of the glasswith alcoholwhere new adhesiveis to be applied.Make sure the bonding surfaceis keptfree of water, oil, and grease.

Cuttingpositions:

5. Carefullyremovethe quarterglass.

20-30

9. Set the quarterglass(A) in the opening,and center i t . F r o mi n s i d et h e v e h i c l e m , a k ea n a l i g n m e n m t ark (B)to the quarterglasswhere the rear clip will be installedwith a greasepencil.Be careful not to l o u c ht h e g l a s sw h e r ea d h e s i v ew i l l b e a p p l i e d .

11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e edge of the quarter glass(C),then anachthem with adhesivetape (NITTO571,or equivalent)to the insideface of the quarter glass,and align the center of the rearclip (D)with the alignmentmark (E)you made in step 9, and attach it with adhesivetape (3 M 4215,or equivalent)to the insideface of the quarterglassas shown. Be carefulnot to touch the glasswhere the adhesivetape will be applied. 25.5mm { 1 . 0i n . )

10. Removethe quarterglass.

(cont'd)

20-31

Glass OuarterGlassReplacement(cont'dl Firstglue the front seal (A)with adhesivetape {31\4 4 2 1 3 ,o r e q u i v a l e n t a ) .n d g l u et h e r u b b e rd a m ( B ) with adhesivetape (NITTO501M,or equivalent)to the insldeface of the quarterglass(C)as shown. Beforeinstallingthe front seal and rubber dam, a p p l yp r i m e r( 3 M N - 2 0 0 o, r e q u i v a l e n t ) t toh e i n s i d e tace of the glass.then glue the seal on: . Be sure the front seal lines upwiththe bottom and front edgesof the glass. . Be careful not to touch the glasswhere adhesive will beaoolied. .,1.,,/:/| Apply prlJnerhete.

30 mm 1 1 . 1i8n . l

-"-c

'13. With a sponge,apply a light coat of glassprimer along the edge of the rubber dam (A) and front seal (B)as shown, then lightly wipe it off with gauzeor cheesecloth: With the printeddots (C)on the quarterglass(D) as a guide, apply the glass primer to the upper and lower corner ponions of the quarterglass. Do not apply body primer to the quaner glass, and do not get body and glassprimer sponges m r x e du p . Nevertouch the primed surfaceswith your hands. lf you do, the adhesivemay not bond to the quarterglassproperly,causinga leak afterthe quarterglassis inslalled. Keepwater, dust, and abrasivematerialsaway from the primed surface.

50 mm I {1.97in.1 /

\ t

v - -

i--l '100mm {3.9i1in.) 45 mm { 1 . 7 7i n . } 6 mm (0.24in.) 3.5 mm {0.r4 in.l

1 1m m lo.i(} in.)

20-32

14, With a sponge.apply a light coat of body primer to t h e o r i g i n aa l d h e s i v er e m a i n i n ga r o u n dt h e q u a r t e r glassopeningflange.Let the body primer dry for at least 10 minutes: . Do not apply glass primer to the body, and be carefulnot to mix up glassand body primer sponges. . Nevertouch the primed surfaceswith your hands. )'/ii,/ii. I Apply bodv prime. here, 20 mm (0.79in.)

(0.08in.l

16. Packadhesiveinto the cartridgewithout air pockets to ensurecontinuousdelivery.Putthe cartridgein a caulkinggun, and run a bead of adhesive(A) around the edge of the rubber dam (B) as shown. W i t h t h e g l a s sp r i m e r( C ) y o ua p p l i e di n s t e p 1 3 o n the quarterglass (D)as a guide. apply the adhesive to the upper and lower corner portionsof the quarterglass.Apply the adhesivewithin 30 minutesafter applyingthe glass primer. lvlakea slightlythickerbead at each corner.

l.:J611, ;\

2mm {0.08in.)

7mm {0.28in.) 3mm { 0 . ' 1 2i n . }

20 mm {0.79in.)

t5.

Beforefilling a cartridge,cut a "V" in the end ofthe nozzle(A) as shown.

'10mm (0.39in.)

7 mm 10.27in.)

( c o n l ' d)

20-33

Glass OuarterGlassReplacement(cont'd) 17. Use suctioncups (A)to hold the quarterglassover the opening.align it with the clips (B)and set it down on the adhesive.Lightly push on the quarter glass until its edges are fully seatedon the adhesiveall the way around.Do not open or close the doors untilthe adhesiveis drv.

18. Scrapeor wipe the excessadhesiveoff with a putty knife or towel. To remove adhesivefrom a painted surfaceor the quarterglass,use a soft shop towel dampenedwith alcohol. 19. Let the adhesivedry for at least t hour,thenspray water over the quarterglassand checkfor leaks, Mark the leakingareas,let the quarterglassdry, then sealwith sealant.Let the vehiclestand for at least4 hours after quarterglassinstallation.lf the vehiclehasto be usedwithin the first 4 hours.it must be driven slowlv. 20. Reinstallall remainingremoved parts. NOTE:Advisethe customernot to do the following things for 2 to 3 days: . Slam the doors with all the windows rolled up. . Twist the body excessively(suchas when going in and out of drivewaysat an angle or driving over rough, unevenroads).

20-34

Moonroof ComponentLocationIndex

GLASS HeightAdjustment,page 20 37 paqe 20-37 Replacement, C l o s i n oF o r c ea n d O o e n i n" oD r a o Check;page20-48 DRAINCHANNEL page20-39 Replacement,

COVER /,BR^CKEI

_-""-\\q @?a<&, ..t'- ? .@ -@c I

LIMITSWITCH (AUTO.STOP SWITCH) page20-46 Adjustment, E R

WIND DEFLECTOR page20-38 Replacement,

CABLETUBE REARBRACKET

E @

E STOP

.a' CABLEASSEMBLY Beplacement,page20-44 page20'41 Replacement, gJ -.- REARDRA'N TUBE

*\ MOONROOF CONTROLUNIT

) REARDRAIN VAI-VE FRAME page 20-42 Replacement,

20-35

Moonroof Symptom TroubleshootingIndex Diagnosticprocedure

Symptom '1.

Also check for Gl a s sh e i g h t adJustment

Water leaks

Checkfor a cloggeddrain tube. 2. Checkfor a gap betweenthe glassweatherstripand the roof panel. 3. Checkfor a defectiveor an improperlyinstalledglass w e a t h e r s t r io p r d r a i nc h a n n e l . 4. Checkfor a gap betweenthe drain seal and the roof panel.

W i n dn o l s e

1. Checkfor excessiveclearancebetweenthe glassweatherstrip G l a s sh e i g h t adjustment and the root panel.

Deflectornoise

1. Checkfor a imDrooerclearancebetweendeflectorseal and roof panel. 2, Checkfor a insufficientdeflectorextension. 3. Checkfor a deformeddeflector.

Motor noise

1. Checkfor a loose motor. 2 . C h e c kf o r a w o r n g e a ro r b e a r i n g . 3. Checkfor a deformedcable assembly.

Glassdoes not move, 1 . C h e c kf o r a d e f e c t i v eg e a ro r i n n e rc a b l e . 2. Checkfor foreign matter stuck betweenthe guide rail and the but motor turns s l i d er . 3 . C h e c kf o r a l o o s ei n n e rc a b l e . 4. l\,4ake sure the cableassemblyis attachedproperly. Glassdoes not move and motor does nol t u r n ( g l a s sc a n b e moved with moonroofwrench)

20-36

1. 2. 3. 4. 5. 6.

Checkfor a blown fuse. Checkfor a faulty moonroof switch. Checkthe limit switch. Checkfor a run down battery. Checkfor a defectivemotor. Checkfor a faulty relay.

Checkclosingforce

GlassHeightAdjustment The roof panel (A) should be even with the glass weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l 0.04 in.) all the way around.lf not, make the following adjustment:

GlassReplacement 'L

C l o s et h e g l a s sf u l l y . S l i d et h e s u n s h a d ea l l t h e w a y b a c k . Removethe screws (A),then remove both bracket covers (B).Removethe nuts (C)and shims {D)from both glassbrackets(E).

B 2 + 0.5/ 1mm {0.08+ 0.02/-0.0i1in.}

FastengrLocations A } : Screw, 2

c O ,Nut. il

@ E

\o 1 , Removethe bracketcover from each side.

2. L o o s e nt h e n u t s{ A ) ,a n d i n s t a l l t h es h i m s( B ) betweenthe glassframe (C)and glass bracket(D) on each side. Shim ihickness: Front and rear max. 2 mm 10.08in.l

6x1.0mm 9 N.m {0.9kgf.m,7 lbf.ft} 4. Removethe glass{A) by lifting it up. Do not damagethe roof panel.

B \

Forward

A 6x1.0mm I N.m(0.9kgf.m,7lbt.ft) 3. lf necessary,repeaton the oppositeside. 5. Installthe glassin the reverseorder of the removal, a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t . 6. Checkfor water leaks.Use free-flowingwater from a hose without a nozzle.Do not use high-pressure water.

20-37

Moonroof Wind DeflectorReplacement 1 . O p e nt h e g l a s sf u l l y .

2 . Removethe screws(A, B), and releasethe hooks (C),then removethe wind deflector(D). Fastener Locations

A > : S c r e w , 2 B > : Screw, 2

3. Installthedeflector(A) in the reverseorder of removal,and checkthat lhe deflectorarm base (B) and deflectorlink pivot base (C)line up with the s a m ea l i g n m e n lti n e s( D ) .l f n e c e s s a r ya,d j u s t h e m forward or backwardso the edge of the deflector seal (E)touchesthe roof panel (F)evenly.Each base must be moved the same amount for adjustment.lf the deflectorseal and roof panel make a rubbing sound, move the deflector backwardas necessaryto positionit properly. 4il mm ( 1 . 7i n . ) _

' a -- ' -

20-38

DrainChannelReplacement 1 . Removethe moonroof glass(seepage 20-37).

4 . R e m o v et h e d r a i nc h a n n e (l A ) .

2 . With the moonroofwrench,move both glass brackets(A) to the positionwhere the moonroof normally pivots down, and removethe screws s e c u r i n gt h e d r a i nc h a n n e (l B ) . FastenerLocations ) : Screw,2

I n s t a l l t h ec h a n n e il n t h e r e v e r s eo r d e ro f r e m o v a l , and notethese items:

Releasethe drain channel(A)from both hooks{B) o f t h e d r a i nc h a n n e sl l i d e rb y p u l l i n gt h e d r a i n channelforward,

P u s ht h e d r a i nc h a n n e o l n t ot h e h o o k su n t i la faint click is heard. Checkthe glass height adjustment(seepage 2031). Checkfor water leaks.Letthe water run freely from a hose without a nozzle.Do not use a high-pressure spray.

20-39

Moonroof SunshadeReplacement 1 . R e m o v et h e d r a i nc h a n n e l . Slidethe sunshade(A) until you can see both s u n s h a d es l i d e rs p a c e r s( B ) .

4. While liftingthe front portionofthe sunshade(A), move the sunshadeforward until you can see both s u n s h a d er e a rh o o k s( B ) .D o n o t d a m a g et h e s u n s h a d ea n d h o o k s .

FastenerLocations

> : Screw,4

) : Screw,4

3. Removethe screws,then remove both spacers.

20-40

5. Removethe screws,then remove both hooks.

Motor Replacement 6. Removethe sunshade(A),

1 . Removethe headliner(seepage 20-54). Put on glovesto protectyour hands.Disconneclthe connector(A),and removethe bolts,then remove the motor (B).

::lll' =r'"'------.-.. --.,

FastenerLocations >:Bolt,2

'l'i

\ ?

@@ ,

.. 7 . Removeboth front sunshadebasesliders (A) and b o t h r e a rs u n s h a d eb a s es l i d e r s( B ) {0.9kgf.m. 7 rbf.ftl t'-^'

' a {

Installthe motor in the reverseorder of removal, and note these items: . lvlakesurethe connectoris plugged in properly. . Checkthe motor operation.

8 . I n s t a l l t h es u n s h a d ei n t h e r e v e r s eo r d e ro f r e m o v a l , and checkthe glassheight adjustment(seepage 20-37). 9 . Checkfor water leaks.Let the water run freely from a hose without a nozzle.Do not use a high-pressure spray.

20-41

Moonroof Frameand DrainTubeReplacement 1 . Removethese items: . Headliner(seepage 20-54) . Moonroof glass(seepage20-37)

2. Put on glovesto protectyou r hands.Disconnectthe motor connector(A),open/close-tilt/close switch connector {B),moonroof control unit connector{C),auto-stopswitch connector(D),and the drain tubes (Ei,and removethe

moonroofrelays(F). FastenorLocations

> : Bolt,10

{um

irl /^

6x1.0mm 9.8N.m (1.0kgf.m,7.2lbfft) Removethe interiorharness(G) by detachingthe harnessclips (H). 4 . With an assistantholdingthe frame (l). removethe bolts,startingat the rear,and releasethe rear hooks (J) by

moving the f rame forward,then removethe frame. 5 . With the help of an assistant,carefullyremovethe frame through the passenger'sdoor opening.Takecare not to scratchthe interiortrim and body, or tear the seatcovers.

20-42

6. To removea front drain valve (A)from the body, removethe kick panel,left or right (seepage 20-50). Tie a string to the end of the drain tube, then pull the front drain tube (B)down out of the front pillar.

1 . To remove a rear drain valve (A)from the cargo compartment,removethe rear side trim panel (see p a g e2 0 - 5 1 ) . D e t a tchhe c l i p s( B ) ,t h e n r e m o v et h e d r a i nt u b e ( C ) , B

8 . I n s t a l l t h ef r a m ea n d d r a i nt u b e i n t h e r e v e r s eo r d e r of removal,and note these items: . B e f o r ei n s t a l l i n g t h e f r a m e ,c l e a rt h e d r a i nt u b e s and drain valves using compressedair. . Checkthe frame seal. . C l e a nt h e s u r f a c eo f t h e f r a m e . . When installingthe frame, first attachthe rear hooks into the body holes. . Make sure the connectorsare plugged in properly. . When connectingthe drain tube, slide it overthe f r a m en o z z l ea t l e a s t1 0 m m ( 0 . 3 9i n . ) . .Installthetubeclip(A o )n t h e d r a i nt u b e( B )a s shown.

Upward

tI I

9 . Checkfor water leaks.Let the water run freely from a hosewithout a nozzle.Do not use a high-pressure spray.

20-43

Moonroof DrainChannelSliderand CableAssemblyReplacement 1. Removethe frame (seepage 20-42). 2. Removethese partsfrom the frame:

5 . P i v o t t h eg l a s sb r a c k e (t A )d o w n b y s l i d i n gt h e l i n k lifter (B) back,then slide both glassbracketsback with the link lifter.

. Sunshade(seepage 20-40) . Moonroof motor (seepage 20-41) 3. Put on glovesto protectyour hands,Removethe screws(A, B),then removethe slide stops (C)and cabletube rear brackets(D).Removethe bolts (E) from the cabletube side bracket(F)and the cable tube mounting screws(G)from both sidesof the f r a m e( H ) . FastenerLocations A> rScrew.2 B): Screw,2 E > : B o l t , 2

@ S l i d et h e c a b l ea s s e m b l y( A )a n d b o t hg l a s s brackets(B) back,then removethem from the f r a m e( C ) .

r ) : Screw 6\-'1 Position switch side: 6x1.0mm g , aN . m c A

No switch sidel

o B

6x1.0mm 9.8 N.m 11.0kgf.m,7.2 lbf.ft)

Detachthe onen switch connectorclip {l)from the frame.

20-44

7 . R e m o v et h e d r a i nc h a n n e sl l i d e r ( A )f r o m t h e g l a s s bracket(B).

8 . I n s t a l l t h es l i d e ra n d c a b l ea s s e m b l yi n t h e r e v e r s e o r d e ro f r e m o v a l a, n d n o t et h e s ei t e m s ; . D a m a g e dp a r t ss h o u l db e r e p l a c e d . ' Apply multipurposegreaseto the glassbracket ( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B ) indicatedby the arrows. . Beforereinstallingthe motor, make sure both l i n kl i f t e r sa r e p a r a l l e la, n d i n t h e f u l l y c l o s e d position. . Beforereinstallingthe motor, installtheframe a n d g l a s s t, h e nc h e c kt h e o p e n i n gd r a g ( s e ep a g e 20-481.

B \

\ ----lll

---':rdrt'Irrt fl u,t La/J' I ll l$=-r:-

20-45

Moonroof Limit Switch Adjustment 1. Removethe headliner(seepage 20-54).

Fullyclosedpositionadiustment 2. With the moonroof wrench,closethe glass(A) fully: . Make sure both link lifters(B)are parallel,and in the positionshown. . Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).

5x0.8mm 5 N.m {0.5kgf.m,4lbf.ft)

3 . W i t h a n o p e n - e n dw r e n c h ,l o o s e nt h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) . 4. Adjust the limit switch (D): ' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen the switch cam (F) pushesthe positionswitch (open/close). . Checkthat the switch plate contactsthe switch bracket(G).

20-46

Auto-stop position adiustment 5. With the moonroofwrench.operatethe glass(A)to the auto-stopposition.

/--:.!Jtr+rtl

. , G

\_-_:_t+#1 <F / \ / \ i!

5 N.m {0.5kgt.m,4 lbt ft)

With an open-endwrench, loosenthe auto-stopswitch m o u n t i n g b o l t s ( C ) . 7 . Adjustthe auto-stopswitch (D): . N 4 o v e t h se w i t c hp l a t e( E )a l i t t l e a t a t i m e , t h e n s e c u r e i t a t t h e p o s i t i o n w h e r e y o u h e a r a f a i n t c l i c k w h e n t h e switch cam (F)pushesthe switch (auto-stop). . Checkthat the switch platecontactsthe switch bracket(G). 8 . Checkthe operationof the glassby operatingthe moonroof switch:From the tilt-up positionto the fully closed position,from the fully open positionto the auto-stopposition,from the auto-stoppositionto the fully closed posltron. L Checkfor water leaks.Letthe water run fleely from a hosewithout a nozzle.Do not use a high-pressurespray

20-41

Moonroof ClosingForceand OpeningDragCheck 1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) . 2. Closingforce check: . With a shop towel {A) on the leadingedge of the g l a s s( B ) ,a f t a c ha s p r i n gs c a l e( C )a s s h o w n . . Havean assistanthold the switchto closethe glasswhile you measurethe force requiredto stop it. . Readthe force as soon as the glassstops moving, then immediatelyreleasethe switch and spring scale. Closing Force; 200 290 N (20 30 kgf,44

4. Openingdrag check:Protectthe leadingedge of the glasswith a shop towel (A).Measurethe effort requiredto open the glass using a spring scale(B) as shown.

66 tbl)

5 . lf the load is over 40 N (4 kgf,9 lbf),check; . The side clearanceand glass heightadjustment (seepage 20'37), . F o r b r o k e no r d a m a g e ds l i d i n gp a r t s .l f a n y s l i d i n gp a r t sa r e d a m a g e d r, e p l a c et h e m .

lf the force in not within specification,removethe moonroof motor (seepage 20-41),then check: . The gear portion and the inner cablefor breakage and damage.lf the gear portion is broken, r e p l a c et h e m o t o r .l f t h e i n n e rc a b l ei s d a m a g e d , removethe frame (seepage 20-42),and replace the cable assembly(seepage20-44). ' T h e m o o n r o o fm o t o r ( s e ep a g e2 2 - 1 1 2 )I .f t h e motor fails to run or doesn'ttu rn smoothlv. replaceit (seepage 20-41), . The opening drag. Go to step 4.

20-48

InteriorTrim ComponentLocationIndex

HATCHLOWERTRIM PANEL oaoe20-53 HATCHSIDETRIM page20 53

B.PILLARUPPEBTRIM page20-50

TRIM C-PILLAR page20'51

DOOROPENINGTRIM page20-50

A.PILLARTRIM page20-50 R e m o v a l / l n s t a l l a t ipoang, e2 0 5 4 KICKPANEL page20 50 Replacement, page20-55

DOORSILLTRIM page20-50

CARGOAREA FLOOR page20-52 REARSIDESHELF page20 5l REARCENTERSHELF page20-51 REARSIDETRIM PANEL page20-51

CARGOFLOORMAT page20-52 REARTRIM PANEL page 20-52

20-49

InteriorTrim Trim Removal/lnstallation- Door Area NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1 . R e m o v et h e t r i m a s s h o w n .T o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a ur p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l as necessary(seepage 20-51). 2. Installthetrim in the reverseorder of removal,and note these items: . Replace a n y d a m a g e dc l i p s . . Apply liquid thread lockto the anchor bolts before reinstallatior,. . Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts. FastenerLocations

A>: Clip,2 B > r C l i p , 3 C > : C l i p , ? (Black)

2ffi Tl|t

{White)

FRONTSEATBELT UPPER ANCHORBOLT 7/16-20 UNF 32 N m (3.3kgf m,24 lbf.ft)

,"lF \r{

A-PILLARTRIM

il-::7 KICKPANEL

ao-----

LowERANcHoRcAP

FRONTSEAT BELTLOWER ANCHORBOLT 7/16-20UNF 32 N.m (3.3kgt.m,24lbl.ftl REARSIDETRIM PANEL

20-50

Trim Removal/lnstallation- RearSideArea NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage. . Takecare not to bend or scratchthe trim and panels. '1.

To removethe rear side trim panel,removethese items: . Rearseat cushionand rear seat-back(seepage20-80) . Cargofloor mat and cargo areafloor (seepage 20-52) . R e a rt r i m p a n e l{ s e ep a g e 2 0 - 5 2 )

2 . Removethe trim as shown. On the right side,disconnectthe cargo compartmentlight connector.

3 . Installthetrim in the reverseorder of removal,and note these items: . Replace a n y d a m a g e dc l i p s . . Make sure the cargo compartmentlight connectoris pluggedin properly. . l f t h e t h r e a d s o n t h e r e a r s i d e t r i m p a n e lm o u n t i n gs e l f - t a p p i nEg Ts c r e w sa r ew o r n o u t , u s ea n o v e r s i z e sd e l f t a p p i n gE T s c r e w( P / N9 0 1 3 7 - S 1 A - E1o)1m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n . . W h e ni n s t a l l i n g t h e r e a rs i d es h e l f ,s l i pt h e r e a rs e a tb e l tt h r o u g ht h e s l i t i n t h e t r i m . ' A p p l y i i q u i dt h r e a dl o c k t ot h e a n c h o rb o l t sb e f o r er e i n s t a l l a t i o n . . Beforeinstallingthe anchorbolts,make sure there are no twists or kinks in the belt. Fasten€r Locations A>:Clip,11

B> rClip,2

c>rClap,l -..:.:' TRIM S I D ES H E L F

REARSEATSELT SIDETRIM PANEL SEAT

STRIKERCAP

S I L LT R I M SELF-TAI

scREws 5x0.8mm { 0 . 4k g f m , 3 l b f . f t )

.. F . -\ *: : :- . n: \ ,/\

\*J

R E A RB U L K H E A O COVER REARSPEAKERCOVER

FRONTSEAT AELT LOWERANCHORBOLT REARSEAT BELTLOWER \ 7/16-20UNF ANCHOF BOLT \ 32 N.m 7/16-20UNF \ { 3 . 3k g f m , 2 4 l b t . t t ) 32 N m (3.3 kgf m, 24 lbf ft, \ L O W E RANCHORCAP

20-51

lnteriorTrim - CargoFloorArea Trim Removal/lnstallation NOTE: . Put on glovesto protectyour hands. . When jrying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage' . Takecare notto bend or scratchthe trim and panels. ( s e ep a g e2 3 - 1 1 ) ' 1 . T o r e m o v et h e r e a rt r i m p a n e l ,r e m o v et h e c h i l ds e a tt e t h e ra n c h o r 2. Removethe trim as shown. , n d r e p l a c ea n y d a m a g e dc l i p s ' 3 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a Fastener Locations

A > :C l i p , 3 B > : C l i p . 4 j-= E T r

FLOORMAT

COVER REARSEAT-BACK

-t

CARGOAREA FLO

7 To rearsade trim panel.

To rearsidetrim panel.

20-52

REARTBIM PANEL

Trim Removal/lnstallation- HatchArea NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage. . Takecare not to bend or scratchthe trim and panels. 1. Removethe trim in the sequenceshown. . Hatchuppertrim panel . Left hatchside trim . Righthatchside trim . Hatchlower trim panel 2 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a , n d r e p l a c ea n y d a m a g e dc l i p s . Fastener Locations

o> A>;crip,a B>:crip,2 .>,l,l,Jil,l3

3il;1,

E>:crip.2

n l f nl t itr^ "-{q .1 \.gg

Y,]

O HATCHLowER TRrM PANEL

HATCHLOWERTRIMPANEL

a- ,,) I

t7, f.

)

HATCH UPPERTRIM PANEL

=- -1

.D HATCHUPPERTRIM PANEL

HATCHSIDETRIM

20-53

InteriorTrim HeadlinerRemovaUlnstallation NOTE: . When prying with a flat-tip screwdriver,wrap itwith protectivetape to preventdamage. . Takecare not to bend and scratchthe headliner. . Be carefulnot to damagethe dashboardand other interiortrim. 1. Removethese items:

3. From both rear passenger's,removethe caps (A), and removethe screws,then removethe grab h a n d l e s( B ) . FastenerLocations > : Screw,4 t , t;---iJ

. A-pillartrim, both sides(seepage 20-50) . B-pillau r p p e r t r i m ,b o t h s i d e s( s e ep a g e2 0 - 5 0 ) . Hatchweatherstrip,as necessary{seepage 2092\ . C - p i l l atrr i m , b o t hs i d e s( s e ep a g e2 0 - 5 1 ) . Moonroof switch (seepage22-'112) . Spotlights(seepage 22-961 . Ceilinglight (seepage 22-96) Removethe sunvisor{A) and holder {B)from both srdes. -1 Removethe caps {C). -2 Removethe screws. -3 Removethe sunvisorfrom the body and holder. -4 Using a flat-tipscrewdriver,push the hook (D), a n d t u r n t h e h o l d e r9 0 ' . t h e n p u l l i t o u t . FastenerLocations > : Screw,4

r(\'-r \)*

5x0.8mm 5 N.m {0.5kst m.4lbf ft}

20-54

)e 5x0.8mm 4 N.m {0.4 kgf.m, 3 lbf.ft}

CarpetReplacement 4. Removethe headliner. -1 Removethe socketplug (A). - 2 R e m o v et h e r e m a i n i n gd o o r o p e n i n gt r i m { B } from each roof portion. -3 Detachthe clips (C),and releasethe fasteners ( D )b y p u l l i n gt h e f r o n t p o r t i o no f t h e h e a d l i n e r (E)down. -4 With the help of an assislant,releasethe clips (F)of the headlinerfrom the moonroof frame ( G ) ,a n d r e l e a s et h e h e a d l i n efrr o m t h e c l i p s( H ) by slidingthe headlinerforward, and lowering the headliner. -5 Removethe headlinerthrough the passenger's opening. FastenerLocations C>:Clip,3

F>:Clip,2

H>:Clip,2

SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and the precautionsand procedures(seepage23-14)in the SRS sectionbefore performingrepairsor service. NOTE: . Put on glovesto protectyour hands. . Takecare not to damage,wrinkle. or twist the carpet. . Be carefulnot to damagethe dashboardor other interiortrim pieces. 1. Removethese items: . Frontseats,both sides(seepage 20-111 . Driver'sdashboardunder cover (seepage 20-60) . Passenger'sdashboardIower cover (seepage 20-631 . Rearseatcushion(seepage 20-80) . Kick panels,both sides(seepage 20-50) . Door silltrim, both sides(seepage 20-50) . Consoles,front and rear (seepage20-57) 2 . R e m o v et h e n u t ( A ) ,a n d u s i n ga h e xw r e n c h , releasethe clip (B),then removethe footrest(C). FastenerLocations Aa:Nut,1

B):Clip,'l --'1

;tt4f

tj=\-/I 5 . Installthe headlinerin the reverseorder of removal, and note these items:

-JrL

--\

l[il

A 6x1.0mm 9.8Nm 11.0kgf m,7.2 lbf.ft)

-o

. W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e passenger'sdoor opening,be carefulnot to fold or bend it, Also, be carefulnot to scratchthe DOOy. . C h e c kt h a t b o t hs i d e so f t h e h e a d l i n ear r e securelyattachedto the trim. . R e p l a c ea n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g r e m o v a lR . e i n s t a l l t h cel i p sb a c ki n t h e h e a d l i n e r before installation.

(cont'd)

20-55

InteriorTrim CarpetReplacement(cont'dl Using a utility knife,cut the carpet(A) underthe heaterareas(B),and cut out the parkingbrakelever area (C)as shown, then pull backthe carpet. A

4 . Removethe clip (A),and releasethe fasteners(B). Pullthe carpetout from both rear side trim panels (D),then removethe carpet(C). FastenerLocation A >: Clip.1 &z

20-56

5. Installthecarpetin the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g e w , r i n k l e ,o r t w i s t t h e carpeL . Make sure the seat harnessesare routed correctly. . S l i pt h e c a r p e tu n d e rt h e r e a rs i d et r i m p a n e lo n each side properly. . Replace t h e c l i p i f i t ' sd a m a g e d . . Reattachthe cut areasunder the heateraround the parkingbrakelever with a wire tie. . When installingnew carpet,cut the carpet(A) underthe heaterareas(B),and around the parkingbrakelever (C).After installingthe new carpet,slip the carpetfrom the driver's and passenger'sside through the spacebetweenthe heaterunit and body, and reattachthe cut area {C)around the parkingbrakeleverwith wire ties.

Consoles Console,Frontand RearRemoval/lnstallation NOTE:Takecare not to scratchthe front seal, dashboard,and relatedparts. 1 . R e m o v et h e r e a rc o n s o l e( A ) . -1 Slidethe front seatforward fully on each side. -2 Removethe screws{B)from the rear portionof the rearconsole, -3 Slidethe front seat rearwardfully on each side. - 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l eu p t o detachthe clips (C)and hooks (D),then release the rearconsolefrom the front console(E). - 5 S t a r t i n ga t t h e r e a r ,p u l l t h e r e a rc o n s o l eu p , then remove it.

2. Removethe front console(A). - 1 P u l lo u t t h e d a s h b o a r dc e n t e rl o w e rc o v e r{ B ) to detachthe clips (C). -2 Dlsconnectthe accessorypower socket c o n n e c t o(rD ) . 3 R e m o v et h e c o n s o l eb o x m a t ( E ) . - 4 R e m o v et h e b o l t s( F ) ,s c r e w s( G ) ,a n d c l i p s( H ) . -5 Gently pull out the front consoleto releasethe h o o k s( l ) a n dp i n s ( J ) . FastenerLocations C > : C l i p , 3 F > i B o l t , 2 G > : S c r e w . 2H ) : C l i p , 2

*..4' * q ' 4!-J - L } * fFJ \ . / -,-('E9'/ d

FastenerLocations C >: Clip,2 B >:Screw,2

6x1.0mm

98Nm (1.0kgt.m,7.2lbf.ft) Installthe consolein the reverseorder of removal, and note these ltems: . R e p l a c ea n y d a m a g e dc l i p s . . Make sure the accessorypower socketconnector i s p l u g g e di n p r o p e r l y . . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

20-57

Consoles Front ConsoleDisassembly/Reassembly NOTE;Takecare not to scratchthe consoleand relatedparts.

Fastener Locations ):Screw,8

C* FRONTCONSOLE

\ BEVERAGE HOLDER ASSEMBLY

',/ BOX CONSOLE

20-58

Dashboard InstrumentPanelRemoval/ Installation

Driver'sDashboardLower Cover Removal/lnstallation

NOTE: . When prying with a flat-tipscrewdriver,wrap it with protectivetape, and apply protectivetape aroundthe relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts.

NOTE:Takecare not to scratchthe dashboardand relatedParts.

1. Tilt the steeringcolumn down.

1. Removethe driver'sdashboardlower cover (A). -1 Turn the lock knob (B)90". -2 Gently pull out the left side to releasethe h o o k s( C ) , -3 Pull out the panelto releasethe hooks (D).

2. Removethe steeringcolumn upper cover {seepage 17,9). Removethe instrumentpanel (A). -1 Gently pull out along the bottom to releasethe c l i p s( B )a n d h o o k s( C ) . -2 Gently pull out the upper portionto releasethe c l i p s( D )a n d h o o k s( E ) . FastenerLocations

B> : c l i p . 2

D D:,C l i p , 2 ^*, Installthecover in the reverseorder of removal, and push the hook portions into placesecurely.

4 . Installthe panel in the reverseorder of removal, and push the clip and hook portionsinto place securery.

20-59

Dashboard Driver'sDashboardUnderCover Removal/lnstallation

Driver'sPocketRemoval/ lnstallation

NOTE:Takecare not to scratchthe dashboardand relatedparts.

NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe dashboardand related p an s .

1. Removethe driver'sdashboardunder cover (A). - 1 T u r nt h e l o c kk n o b( B )9 0 ' . -2 Gentlypull down the rear edgeto releasethe clip(C). -3 Pullthe cover away to releaseit from the clip {D). FastenerLocations C >: Clip.1

1. Removethe driver's pocket(A) -1 Removethe driver'sdashboardunder cover. -2 Removethe screws(B). -3 From behindthe dashboard,push the pocket b a c kb y h a n dt o r e l e a s et h e c l i p s( C ) . 4 Release t h e h o o k( D ) . FastenerLocations B):Screw,2 C>: Clip,2 ','"\5

;;t='

)

Installthecover in the reverseorder of removal, and push the clip portion into placesecurely.

20-60

2 . Installthe pocketin the reverseorder of removal, and push the clip portionsinto placesecurely.

Shift LeverTrim Removal/lnstallation NOTE: . Takecare not to scratchthe dashboardand related parts. . Put on glovesto protectyour hands. 1. Removethe glove box (seepage20-63).

4. Pull outthe shift levertrim (A) by hand to release t h e r e m a i n i n gc l l p s( 8 , C ) a n d h o o k s( D ) ,a n d disconnectthe hazardwarning switch connector(El, then removethe trim. FastenerLocations B >:Clip,1 C > : C l ; p1,

2. Removethe shift knob.

,,.;w,

D>: Hook,3

, ,

U s i n ga r a t c h ew t r e n c ha n d a n 1 1 i n c he x t e n s i o n (A)wrapped with a shop towel (B),carefullyinsert the extensionthrough the glove box opening,and push the shift levertrim (C)from underthe trim to releasethe clips (D)and hooks (E)of the left side. Fastener Locations

D>clip,2 i:F \V

E> H o o k , 2 .-a7 \rt1

Installthe trim in the reverseorder of removal,and note these rtems. . Make sure the hazardwarning switch connectot is plugged in properly. . Pushthe clip and hook portionsinto place securely,

20-61

Dashboard DashboardCenterPanelRemoval/lnstallation NOTE: . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver,wrap it with protectivetape, and apply protectivetape around the relatedparts,to preventdamage. . Takecare not to scratchthe dashboardand related parts. 1. Make sure you have the anti-theftcode for the radio, the write down the frequenciesfor the preset buttons.

4. Pull out the centerpanel (A)to releasethe clips (B) and hooks (C),and removethe harnessholder (D) from the bracket(E).Disconnectthe audio unit connector(F),antennalead (G),heaterswitch connector(H)and heatercontrol unit connectors(l). FastenerLocations B ): Clip,8

*4 , F

2 . Removethese items: . Driver'sdashboardlower cover (seepage20-59) . Passenger'sdashboardlower cover (seepage 20-63). . Glove box (seepage20-63). . Shift levertrim {seepage20-61). From the glove box and driver'sdashboardIower cover openings,loosenthe bolts (A) securingthe centerpanel (B). Fastener Locations A): Bolt,2

;.'

20-62

x 0.8 mm 5Nm

Installthe panel in the reverseorder of removal, and note these items: Make sure eachconnectoris pluggedin properly, and antennalead is connectedproperly. Pushthe clip portionsinto placesecurely. Reconnectthe negativecableto the battery. idle learn procedure{seepage Do the ECN4/PCt\4 1l-139). Enterthe anti-theftcode for the radio.then enter the customer'sradio stationpresets. Resetthe clock.

Passenger's DashboardLower CoverRemoval/lnstallation

GloveBox Removal/lnstallation

NOTE:Takecare not to scratchthe dashboardand relatedparts.

SRScomponentsare locatedin this area.Reviewthe S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a ) n dt h e p r e c a u t i o nasn d p r o c e d u r e (ss e ep a g e2 3 1 4 )i n t h e S R S sectionbeforeperformingrepairsor service.

1. Removethe passenger'sdashboardlower cover (A).

NOTE:Takecare not to scratchthe dashboardand relatedparts.

-1 Gently pull down the rear edge to releasethe c t i p s( B ) . -2 Pullthe cover away to releasethe pins (C)from t h e h o l d e r s( D ) . FastenerLocations B>: Clip,3

I jl

1. Removethe passenger'sdashboardlower cover. 2. While holding the glove box (A),removethe glove box stop (B)on each side. FastenerLocalions >Boh.2 .-6\

{Ill .-<,/fir-"b B

r-3t.oi,t-' 10.5kgf m, 4 tbf.ft)

Installthe under cover in the reverseorder of removal,and push the clip ponions into place securety.

Removethe bolts,then removethe glove box. 4 . l n s t a l l t h eg l o v eb o x i n t h e r e v e r s eo r d e ro f removal.

20-63

Dashboard DashboardSide Vent RemovaU Installation

BeverageHolderRemoval/ lnstallation

NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands.

NOTE: . Takecare not to scratchthe dashboard, . Put on glovesto protectyour hands.

1. Removethe dashboard(seepage 20-66).

1. Removethe dashboard(seepage20-66).

2. Removethe steeringhangerbeam from the dashboard(seepage 20-68).

2. Removethe screws,then removethe beverage h o l d e r( A ) .

3. Removethe screws,then removethe air duct (A) f r o m t h e d a s h b o a r d( B ) .

FastenerLocations ):Screw.2

FastenerLocations ):Screw, 7

6hD t

4 . Remove the screws, lhen remove the slde vent (A). Fastener Locations ):Screw,4

5 . l n s t a l l t h es i d ev e n t i n t h e r e v e r s eo r d e ro f r e m o v a l .

20-64

3 . Installthe beverageholder in the reverseorder of removat.

Driver'sTray Removal/lnstallation NOTE: . Takecare not to scratchthe dashboard. . Put on glovesto protectyour hands.

Passenger's Tray Removal/ Installation

1. Removethe dashboard(seepage 20-66).

NOTE: . Takecarenotto scratchthe dashboard. . Puton glovesto protectyourhands.

2. Removethe beverageholder(seepage 20-64).

1 . Removethe dashboard(seepage 20-66),

3. Removethe screws,then removethe driver'stray (A).

2 . Removethe steeringhanger beam from the dashboard(seepage 20-68).

FastenerLocations ):Screw.3

3 . Removethe air duct (seestep 3 on page20-64). 4 . Removethe screws,then removethe passenger's

tray(A). FastenerLocations ):Screw, 8

4, lnstallthe tray in the reverseorder of removal.

5. lnstallthe trav in the reverseorder of removal.

20-65

Dashboard DashboardRemoval/lnstallation SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-13)and the precautionsand procedures(seepage23-14)in the SRS sectionbeforeperformingrepairsor service.

4. From the centerpanelopening,removethe screws, then removethe centerbracket(A). FastenerLocations ):Screw,2

NOTE: . When prying with a flat-tipscrewdriver,wrap it with protectivetape, and apply protectivetape aroundthe relatedpartsto preventdamage. . Havean assistanthelp you when removing and rd. installing thedashboa . Takecare not to scratchthe dashboard,body, and other relatedparts. . Put on glovesto protectyour hands. 1. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the preset buttons. Disconnectthe negativecablefrom the battery,and wait at leastthree minutesbefore beginningwork. Removethese items: . Driver'sdashboardlower cover (seepage 20-59) . Driver'sdashboardunder cover (seepage 20-60) . Passenger'sdashboardlower cover (seepage 20-63) . Glove box (seepage 20-63) . Consoles,front and rear (seepage 20-57) . Shift levertrim {seepage 20-61) . Centerpanel (seepage 20-62) . Kick panels,both sides(seepage 20-50) . A-pillartrim. both sides(seepage 20-50) . Steeringcolumn (seepage 17-9)

20-66

Removethe shift lever (seepage 13-51). From outsideof the passenger'sdoor, gently pull out along the edge of the dashboardside cover (A) to releasethe hooks (B),then releasethe upper hook (C),to removethe cover.

Driver's side:

Middle portion:

7. From underthe dash,disconnectthe interiorwire harnessconnector(A),driver'sdoor wire harness connectors(B),side turn signallight connector(C). roof antennaconnector(D),antennalead (E).clutch switch connectors(F),and brakeswitch connector (G),and disconnectthe floor wire harness connectors(H)and engine compartmentwire harnessconnectors(l)from the under-dashfuse/ r e l a vb o x ( J ) .

8. Disconnectthe floor wire harnessconnectors(A) a n dc o m b i n a t i o n s u b h a r n e scso n n e c t o(rB ) .

Passenger'sside: 9. From under the dash,disconnectthe dashboard wire harnessconnectors(A),EPSsubharness connectors(B),enginecompartmentwire harness connectors(C),A,/Csubharnessconnectors(D), passenger'sdoor wire harnessconnectors{E),and s i d et u r n s i g n a l i g h tc o n n e c t o(rF ) .

1 0 . D e t a c ha l l o f t h e h a r n e s sa n d c o n n e c t ocr l i p s .

(cont'd)

20-67

Dashboard DashboardRemoval/lnstallation (cont'd)

SteeringHangerBeam Replacement

11. From outsidethe driver'sdoor, removethe caps (A), then removethe bolts (8, C, D),and lift up on the dashboard(E)to releaseit from the guide pins (F.G) on the body.

NOTE:Put on glovesto protectyour hands.

FastenerLocations B>rBolt.3 C>: Bolt,2 D>: Bolt,2

m6[-,,,,",",,-,F6't---'' ffi'!-v{/-

Kr*

1, Removethe dashboard(seepage 20-66). 2. Removethese items from the dashboard: . lnstrumentpanel (seepage 20-59) . Driver'spocket(seepage20-60) . G a u g ea s s e m b l y( s e ep a g e2 2 - 6 4 ) . Passenger'sairbag(seepage 23-'l14)

Removethe screws,thenremovethe glovebox striker(A). FasteneaLocations ):Screw,4

$7:

^/761: /

{2.2kgf m, 16lbf.ftl

,. r:; 8 x 1.25mm 22Nm (2.2kgf.m,16lbf.ft)

Carefullyremovethe dashboardthrough the front d o o ro p e n i n g .

1 3 .lnstallthe dashboardin the reverseorder of removal,and note these items: . Make sure the dashboardfits onto the guide pins correctly. . A p p l y l i q u i dt h r e a dl o c kt o t h e d a s h b o a r d mounting bolts of the middle portion before reinstallation. . Beforetighteningthe bolts,make sure eachwire harnessand control cablesare not pinched. . Make sure the connectorsare plugged in properly,and the antennalead is connected propeny. . Reconnectthe negativecableto the battery. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . D ot h e E C M / P C M i d l el e a r np r o c e d u r ei s e ep a g e '1-139). 1

20-68

4. Removethe bolts (A) and screws(B)securingthe d a s h b o a r d( C )a n d s t e e r i n gh a n g e rb e a m( D ) ,a n d disconnectthe power mirror switch connector(E) and cruisecontrol main switchconnector(F). S e p a r a t et h e d a s h b o a r da n d s t e e r i n gh a n g e rb e a m . FaslenerLocations

5 . I n s t a l l t h eb e a mi n t h e r e v e r s eo r d e ro f r e m o v a l , and note these items: . N 4 a kseu r et h e d a s h b o a r dw i r e h a r n e s s( G ) i s n o t pinched. . Make sure the connectorsare plugged in properly.

A>rBolt,4 B>:Screw,9

5 N.m {0.5kgf m,4lbf,ftl

20-69

Seats ComponentLocationIndex

REARSEAT page20-80 Removal/lnstallation, Seat-backLatchReplacement, page20-81 Seat-backStrikerReplacement, page20-81 Seat'backCoverReplacement, page 20-82 SeatCushionCoverReplacement, page20-84

FRONTSEAT page20-i 1 Removal/lnstallation, page20 73 Disassembly/Reassembly-Driver's, page20-74 Disassembly/Reassembly-Passenger's, SeatCoverReplacement,page20-75

20-70

Front Seat Removal/lnstallation For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service. NOTE . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage. . Takecare not to scratchthe body or tear the seat covers. . Put on glovesto protectyour hands.

4. Removethe bolts securingthe front seat. FastenerLocations

> : Bolt,

1, Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the preset butlons. Disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore beginningwork.

3 . Removethe seattrackend covers(A)from the back of both seattracks. Outef:

1 0 x 1 . 2 5m m

lnner:

(cont'd)

20-71

Seats (cont'dl FrontSeatRemoval/lnstallation Lift up the front seat,then detachthe harnessclip (A).and disconnectthe seat belt switch connector ( B )a n d s e a tb e l tb u c k l et e n s i o n ecr o n n e c t o(rC ) .l f , i s c o n n e ct th e s i d e e q u i p p e dw i t h a s i d ea i r b a g d a i r b a gc o n n e c t o (r D ) ,a n d o n t h e p a s s e n g e r 'sse a t , d i s c o n n e ct th e O P D Su n i tc o n n e c t o(rE ) .T h e p a s s e n g e r 'sse a ti s s h o w n ,t h e d r i v e r ' ss e a ti s s i m i l a re x c e p ti t h a sn o O P D Su n i tc o n n e c t o r .

6 . With the help of an assistant,carefullyremovethe front seatth rough the front door opening. , nd 7 . I n s t a l l t h es e a ti n t h e r e v e r s eo r d e ro f r e m o v a l a notethese rtems: . l\4akesure each connectoris plugged in properly. . A p p l y l i q u i dt h r e a dl o c kt o t h e s e a tm o u n t i n g bolts before reinstallatlon. . Reconnectthe negativecableto the battery. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECM/PCMidle learn procedure(seepage 11 - 1 3 9 ) .

20-72

- Driver's FrontSeat Disassembly/Reassembly For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13) and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service. NOTE: . Takecare not to tear the seamsor damagethe seatcovers, . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver.wrap it with protectivetape to preventdamage. ' Apply multipurposegreasetothe moving portion of the seattrack. . To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad. Releasethe seatcushion coverfrom the cushion f r a m es p r i n g .

SEAT-BACK

10 x 'l.25mm 47 N.m {4.8kgf.m, 35 rbt.ft)

WIRETIE

RECLINECOVER

RECLINEKNOB

20-73

Seats - Passenger's FrontSeat Disassembly/Reassembly For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13) and the precautionsand procedures(seepage 23-14)beforedoing repairsor service. NOTE; . Takecare not to tear the seamsor damagethe seatcovers . Put on glovesto protectyour hands. . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage . Apply multipurposegreaseto the moving portion of the seattrack . To Dreventwrinklesin the seat cushioncover,stretchthe materialevenlyover the pad. . lvlakesure the rear seat accesscable is connectedproperlyon each side . Replaceany damagedclips,and replacethe wire ties with new ones SIDEAIRBAG HARNESS

SEAT"BACK

Releasethe seatcushion coverfrom the cushion f r a m es p r i n g .

10 x 1.25mm 47 N.m (4.8kgf.m, 3s rbf.ft) OPDSHARNESS HANGERSPRING

CENTEBCOVER WIRETIE SEATCUSHION FRAME/SEAT TRACKS

/ REARSEAT ACC€SSCABLE

,/CLIP

*r(".o, /ACCESSKNOB ,/

I SLIDELEVER

/ H o o K RECLINEKNOB RECLINE COVER

20-74

Front SeatCoverReplacement For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23 13)and the precautionsand procedures(seepage 23-'14)in the SRSsectionbeforeperforming repairsor service,

3 . Foldthe seat-backforward. 4. Release t h e h o o k s( A ) ,a n d u n z i pt h e s e a t - b a c k

c o v e r( B ) .

NOTE: . Takecare not to tear the seamsor damagethe seat covers, . On the passenger'sseatwith side airbag,do not touch the OPDSsensorin the seat-backpad, and keep it away from oil. Oil can corrodethe sensorcausingit to fail. . Puton glovesto protectyour hands.

Seat-backCover 'L

Removethe front seat isee page 20-71).

2. W i t h s i d ea i r b a g :F r o mu n d e rt h e s e a tc u s h i o n , detachthe side airbagconnectorclip (A),and on the passenger'sseat,detachthe OPDSunit c o n n e c t ocr l i p ( B ) .R e l e a s teh e h o o ks p r i n g s( C ) f r o m t h e s e a tc u s h i o nf r a m es p r i n g{ D ) ,t h e n p u l l the guide cover (E)back,and removethe wire ties (F).The passenger'sseat is shown, the driver'sseat is svmmetricalexceptit has no OPDSunit connector.

(cont'd)

20-75

8 . Using a flat-tipscrewdriverwrappedwith protectivetape, insert it into the hook portions ( s e v e np l a c e so) f t h e h e a d r e srte a rt r i m i A ) f r o m t h e headrestfront trim side. Prv up the hooks (B)to releasethe labs (C)of the headrestfront trim (Di w h i l e p u l l i n gt h e h e a d r e sftr o n tt r i m f o r w a r d ,a n d removethe tflm.

9. Unzipthe headrestportionof the seat-backcover ( A ) ,t h e n r e m o v et h e z i p p e ri B ) ,a n d r e m o v et h e cover.

D /

1 0 .installthe cover in the reverseorder of removal, and note these items: . Fit all the hooksof the headrestfront trim into the h o l e si n t h e h e a d r e srt e a rt r i m ,t h e n p u s ho n t h e h e a d r e sttr i m u n t i lt h e h o o k ss n a pi n t o p l a c e . . To preventwrinkleswhen installinga seat back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe clips, hooks, a n d h o o ks p r i n g s . . M a k es u r et h e s i d ea i r b a gh a r n e s sO , PDS harness{passenger'sseat).and rear seataccess cable(passenger'sseati are routed properly. . lf necessary,reinitializethe OPDScontrol unit ( s e ep a g e2 3 - 1 2 4 ) .

(cont'd)

20-77

Seats Front Seat CoverReplacement{cont'd) SeatCushionCover

Outside:

1. Removethe front seat (seepage 20,71). 2. Removethese items from the front seat: . Reclinecover,driver's seat (seepage 20-73) passenger'sseat {seepage 20-74l . Frontseat belt buckle{seestep 4 on page 23-6) 3. From underthe seat cushion,detachthe side airbagconnectorclip, and on the passenger'sseat, detachthe OPDSunit connectorclip. Releasethe hook springsfrom the seat cushionframe spring, then pull the guide cover back,and removethe wire ties. 4. Releasethe hooks(A). Inside:

20-78

Releasethe seat-backcover (A)from the cushion frame spring (B),and releasethe hooks(C)from u n d e rt h e s e a tc u s h i o n .

6 . R e m o v et h e s e a tc u s h i o nc o v e r( A )w i t h t h e s e a t cushion pad from the seat cushionframe.

8. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkleswhen installlnga seat cushioncover, make sure the materialis stretchedevenlyover the pad beforesecuring t h e c l i p sa n d h o o k s . . Make sure the side airbag harnessand OPDS harness(passenger'sseat)are routed properly. . Replaceany clips you removedwith new ones ( A ) .I n s t a l l t h e mw i t h c o m m e r c i a l l a yvailable upholsteryring pliers (B).

1 . Pull backthe edge of the seatcushioncover all the way around.and releasethe clips {A),then remove the seat cushioncover (B).

r : r *

] r ?

20-79

Seats RearSeat Removal/lnstallation NOTE:Takecare not to scratchthe body or tear the seatcovers. '1.

Removethe rear seat as shown.To removethe seat-back,removethe front portion of the cargofloor mar lsee page 20-52).

2. Installthe seat in the reverseorder of removal,and note these items: 'Beforeinstallingthecenteranchorboltsontheseat-backwiththecentershoulderbelt,makesurethereareno twists or kinksin the belt. . Make sure the seat-backslock securelv. Fastener Locations

A > : B o l t , 2 B > r B o l t 1, C > : B o t t1,

D > : C l i p ,2

/-<.{\.--

K\| J ] . P F.i\-t-HAP

lltl agr f ( 1

Vt-

r_r+*.

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

CENTERPIVOTBOLT 8 x 1.25mm 22 N.m {2.2kgf.m, 16lbf.ftl RIGHTSEAT-BACK

\'7

SEAT.BACK CENTERHINGE BUSHING

LEFTSEAT.BACK

CENTERBELT

PIVOTBUSHING

PIVOT BUSHING

CENTERANCHORBOLT 7/16-20UNF 32Nm (3.3kgf m.24 lbt ftl

SEATBELTBUCKLE

6x1.0mm 9.8Nm {1.0kgf.m,7.2lbf.ft)

HOOK SEATCUSHION

20-80

RearSeat-backLatchReplacement 1 . Removethe seat-back(seepage 20-80).

RearSeat-backStriker Replacement NOTE:Takecare not to scratchthe interiortrim.

Removethe seat-backcover (seepage 20-82).

1 . R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) .

Removethe seat-backpad {A) from the seat-back frame (B).On right seat-backwith centershoulder belt,passthe centerbelt (C)through the hole in the seat-backpad.

2. Removethe bolts,then removethe seat-back striker(A). FastenerLocations ) : Bolt,2

,-;1 8 x 1.25mm 22 N m 12.2kgl rn, 16 tbf.ft)

Removethe bolts,then removethe seat-backlatch (A)from the seat-backframe (B),and releasethe pivot pin {C)of the latch lever (D)from the seat' backf rame.

3 . l n s t a l l t h es t r i k e ri n t h e r e v e r s eo r d e ro f r e m o v a l , and move the striker(A) up or down until it is centeredin the seat-backlatch {B).

FastenerLocations

lnstallthe latch in the reverseorder of removal,and make sure the seat-backlocksand unlocksproperly.

20-81

Seats RearSeat-backCoverReplacement NOTE: . Takecare not to tear the seamsor damagethe seat covers. . Put on glovesto protectyour hands. '1.

Removethe seat-back(seepage 20-80). Removethe headrest.

5. On right seat-backiUsing a Torx T30 bit, remove the bolts,then removethe belt holdertrim (A),and removethe trim from the centerbelt (B). FastenerLocations ) : Bolt, A*\./-

6x1.0mm 9.8Nm (1.0kgf.m,7.2lbf.ft)

Pull up the latchcover (A)to teleasethe clips.then remove it. Fastener Locations ) : Clip,4

1W Releasethe hook (A),and unzipthe seat-backcover (B).The right seat-backis shown. the left seat-back i ss i m i l a r .

4 . Pull up the outsideedge of the latch lever cover (A)

to releasethe clips, and releasethe cover from the p i v o tp i n s( B )o f t h e l a t c hl e v e r{ C )w h i l e p u l l j n gt h e latch lever. Fastener Locations D : Clip,2 i\r*

20-82

7. Pull backthe edge of the seat-backcover (A),and r e l e a s et h e c l i p s{ B ) .

Pull backthe edge of the seat-backcover,and pull out the seat-backframe {A) from the seat-backpad { B ) ,t h e n p u l l o u t t h e h e a d r e sgt u i d e( C )w h i l e p i n c h i n gt h e e n d o f t h e g u i d e s a, n d r e m o v et h e m .

9. Removethe seat-backcover (A)from the seat-back pad (B).On right seat-backwith centershoulder belt, passthe centerbelt (C)through the hole in the cover. seat-bacl(

1 0 ,lnstallthe cover in the reverseorder of removal, and note these items: . To preventwrinkleswhen installinga seat-back cover, make sure the materialis stretchedevenly over the pad beforesecuringthe hooksand clips . On right seat-back:When installingthe seat-back frame to the pad, slip the centerbeltthrough the hole in the seat-backcover and pad. . Replaceany clips you removedwith new ones. yvailable I n s t a ltlh e m w i t h c o m m e r c i a l l a upholsteryring pliers.

20-83

Seats RearSeat CushionCoverReplacement '1. Removethe rear seat cushion (seepage 2O-80). Releaseall the clips (A)from under the seat c u s h i o n a, n d f o l d b a c kt h e s e a tc u s h i o nc o v e r( B ) .

4. Installthecover in the reverseorder of removal, and note these items; . To preventwrinkles,make surethe materialis stretchedevenly over the pad beforesecuring t h ec l i p s . . Replaceany clips {A) you removedwith new o n e s .I n s t a ltlh e m w i t h c o m m e r c i a l l a yvailable u p h o l s t e r yr i n g p l i e r s( B ) .

B Pull backthe edge of the seat cushioncover all the way around,and releasethe clips (A),then remove the seatcushioncover.

\ iw F

1.,

ts+'

l-,+

20-84

r l

Bumpers Front BumperRemovaUlnstallation NOTE: . H a v ea n a s s i s t a nht e l py o u w h e n r e m o v i n ga n d i n s t a l l i n g t h ef r o n tb u m p e r . . Takecare not to scratchthe front bumper and body. . Puton glovesto protectyour hands. 'L

Removethe front bumper as shown.

, n d n o t et h e s ei t e m s : 2 . I n s t a l l t h eb u m p e ri n t h e r e v e r s eo r d e ro f r e m o v a l a . Make sure both front side markerlight connectorsare plugged in properly. . Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely. . Replace a n y d a m a g e dc l i p s . FastenerLocations A ) , Screw, 2

B >: Screw,2

C>:Bolt.4

k/- '

{D[]

E>:Clip,2

D>:Clip,7

*S-

=$ t

ABSORBER

SIDESPACER UPPERBEAM LEFTFRONTSIDEMARKER LIGHTCONNECTOR

' * D

;

e 3

INNER FRONT FENDER

BUMPER

ti-\

FEONTBUMPER C l

A E FRONTAIR SPOILER

SPOILER PLATE

AIR SPOILER PLATE

6 x 1 . 0m m 9.8 N.m (1.0kgt.m,7.2lbf.ft)

20-85

Bumpers RearBumperRemovaUlnstallation NOTE: ' Havean assistanthelp you when removingand installingthe rear bumper. . Takecare not to scratchthe rear bumper and body. . When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage. . Put on glovesto protectyour hands. L R e m o v et h e r e a rb u m D e ra s s h o w n . 2. Installthe bumper in the reverseorder of removal,and note these items: . Make sure both rear side marker light connectorsare pluggedin properly. 'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth sidessecurely. . Make sure the upper spacersof the rear bumper engagethe clips on the body securely. . R e p l a c ea n y d a m a g e dc l i p s . Fastener Locations

A>:Bolt,2

/h-

\-P-

: Screw, 2

ffiI"ut ^*

c >: Screw, 2

) : Clip,

? ri)

\s I

SIDEBRACKET

UPPERBRACKET

, 6 x 1 . 0m m / 9.eN.n ,/ 11.0kgl m, 1.2tbt.ttl ./ SIDESPACER

a \

A CAP

LEFTREARSIDEMARKER LIGHTCONNECTOR

A UPPERSPACER

REARBUMPER

20-86

Hood Adjustment '1. Slightly looseneach hood hinge bolt, 2 . Adjustthe hood (A) alignmentin this sequence. . A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al l s f o r w a r da n d r e a r w a r db, y u s i n gt h e e l o n g a t e dh o l e so n t h e h o o dh i n g e (B). . Turn the hood edge cushions(C),as necessary,to makethe hood iit flush with the body at the front and side edges.

6x1.0mm 9.8 N.m {1.0kgl.m,7.2 lbf.ftl

6x1.0mm 9.8 N.m {1.0kgf.m,7.2lbf.ft}

3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left until the striker(E)is centeredin the hood latch. Tighteneach bolt securely.

(contd)

20-87

Hood Adjustment(cont'd)

HoodSealReplacement

5. Checkthat the hood opens properlyand locks securely.

1 . Using a clip remover,detachthe clips,then remove the hood seal (A).Takecare not to scratchthe hood.

6. Apply body paint to the hinge mounting bolts and a r o u n dt h e h i n g e s .

Fastener Locations

7. Apply multipurposegreaseto each locationof the hood latch and hood hinge as indicatedby the arrows.

I n s t a l l t h es e a li n t h e r e v e r s eo r d e ro f r e m o v a l a, n d note these items: . R e p l a c ea n y d a m a g e dc l i p s . . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

. : I

20-88

HoodInsulatorReplacement 1 . D i s c o n n e ct h t e w i n d s h i e l dw a s h e rt u b e s( A ) . FastenerLocations '10 ) : Clip,

t*'-&

,2V..=-' (

Using a clip remover,detachthe clips. Releasethe h o o k s( B ) ,t h e n r e m o v et h e h o o di n s u l a t o (r C ) .T a k e care not to scratchthe hood. I n s t a l l t h ei n s u l a t o irn t h e r e v e r s eo r d e ro f r e m o v a l , and note these items: . R e p l a c ea n y d a m a g e dc l i p s . . Pushthe clips into placesecurely.

20-89

Hatch Adjustment 1. Removethe support strut from each side (seepage 20-91). 2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,daonw dn p tuhl le r e a r p o n i o n o f t h e h e a d l i n e r ( s e e page20-54).Takecare not to bend the headlinerexcessively. 3. Removethe reartrim panel (seepage 20-52). 4, Slightly looseneach bolt and nut. 5 . A d j u s t t h eh a t c h( A )a l i g n m e n it n t h e f o l l o w i n gs e q u e n c e . . Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes. 'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside edges. . Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).

8 x 1.25mm 22 N.m {2.2kgf.m,16lbf.ft}

8 x 1.25mm 18 N.m 11.8kgf.m, 13 lbf.ft)

20-90

HatchSupportStrut Replacement Tighteneach bolt and nut securely. 7 . Checkthat the hatchopens properlyand locks securery. Reinstallthe supportstruts securely.

1 . With the help of an assistant,use a flat-tip screwdriver(A)to pry the supportstrut clips (B) from each end of the supportstrut (C)at the hatch and body, then releasethe supportstrut from the pivot bolts (D).Do not removethe clips from the supportstrut.

9 . R e i n s t a lal l l r e m a i n i n gr e m o v e dp a r t s . 1 0 .Apply multipurposegreaseto the pivot portion of the hatch hinges{A) as indicatedby the arrows.

D 8 x 1.25mm 22 N.m(2.2kgf.m,16lbf ft) 2 . Set the clips (A) to the original position,then reattachthe supportstrut (B)on the pivot bolts (C) by pushingon the supportstrut.

20-91

Hatch HatchWeatherstripReplacement 1 . R e m o v et h e h a t c hw e a t h e r s t r i{pA ) b y p u l l i n g o u t on it.

t a r k{ B )o n t h e h a t c h 2 . L o c a t et h e p a i n t e da l i g n m e n m weatherstrip.Allgn the paintedmark with the alignmenttab in the the centerof the hatchopening, p l l t h ew a y a n d i n s t a l tl h e h a t c hw e a t h e r s t r i a around in the directionshown. Make surethere are no wrinklesin the weatherstrip. 3. Checkfor water leaks.

20-92

FuelFill Door Adjustment 1. Removethe nut (A),and removethe fuel fill door o p e ns p r i n g{ B ) .

5x0.8mm 1.8Nm (0.18kgf.m, 1.3rbf.ft) >t=-

7. Apply multipurposegreaseto each location indicatedby the arrows.

8 . Apply body paint to the hinge mounting bolts and around the hinges,

2 . S l i g h t l yl o o s e nt h e h i n g em o u n t i n gb o l t s( A ) . 3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h with the body, and up or down as necessaryto a^rr.li7a

tha

n.nc

T i g h t e nt h e h i n g em o u n t i n gb o l t s . 5 . R e i n s t a l l t h feu e lf i l l d o o r s p r i n g . 6 . Checkthat the fuel f ill door opens properlyand lockssecurely,and checkthat the rear of the door is flush with the body.

20-93

ExteriorTrim FrontGrille Replacement 1 . Removethe front bumper (seepage 20-85).

2 . Removethe front grille (A),Takecare not to scratch the front bumper (B). -1 Removethe screws (C). -2 Removethe clips (D). -3 Releasethe bottom hooks(E)ofthe grille, -4 Pull out the boftom of the grille to releasethe u p p e rh o o k s( F ) . - 5 P u l lo u t t h e g r i l l et o r e l e a s et h e s l i t s( G ) f r o m the ribs {H),then removethe grille. FastqnErLocations C >:Screw.4 D ) : Clip, 4 ll

-S---:

i")

3 . I n s t a l l t h eg r i l l ei n t h e r e v e r s eo r d e ro f r e m o v a l , a n d r e p l a c ea n y d a m a g e dc l i p s . Reinstallthe front bumper.

20-94

Cowl CoversReplacement 1 . R e m o v et h e w i n d s h i e l dw i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) . 2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19). 3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips (B)from the cowl covers.Takecare not to scratchthe cowl covers. FastenerLocations B> rClip,3 C>:Clip,8

:- :::: = - --::;-:

4 . Detachthe clips (C)by carefullypulling the passenger'scowl cover {D) upward,to releasethe hooks{E),and pull out the cover forward to releasethe hooks(F),then removethe cover.Takecare not to scratchthe body, Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to releasethe hooks(H),then removethe cover.Takecare not to scratchthe body. Installthecovers in the reverseorder of removal,and note these items: . R e p l a c ea n y d a m a g e dc l i p s . . Pushthe clip portionsinto placesecurely. . Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).

20-95

ExteriorTrim A-PillarCornerTrim Replacement 1 . Open the door. Wrap a flat-tipscrewdriverwith protectivetape, and apply protectivetape aroundlhe body to preventdamage.Carefullyinserta flat-tip screwdrivernext to the upper clip, and detachthe c l i p b y p r y i n go n t h e A - p i l l a rc o r n e rt r i m ( A ) .T a k e care not to scratchthe body and relatedparts.

5 . R e p l a c ea n y d a m a g e dc l i p s . H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .

FastenerLocation

3 . Closethe door half-way. Pullthe A-pillercornertrim (A) out to detachthe lower clips,then removethe trim. FastenerLocations

20-96

RoofMolding Replacement 1 . Apply protectivetape to the body (A).Using a flat-tipscrewdriverwrapped with protectivetape (B),pry up on the roof molding (C).Takecare not to scratchthe bodv.

4, Pull up and releasethe rear bracket(A)from the pin (B),then removethe roof molding (C).

..:.::.l. g

5 . Installthe molding in the reverseorder of removal, and note these items: . T a k ec a r en o t t o d a m a g et h e w i n d s h i e l dm o l d i n g . . Make sure the roof molding is installedsecurely. Pull up and slidethe roof molding to releasethe front bracket(D)from the pin (E). Pull up the front portion of roof molding.

20-97

ExteriorTrim RearLicenseTrim Replacement NOTE:Put on glovesto protectyour hands. 1. Removethe hatch lower trim panel (seepage 20-

3 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s( A , B ) w h i l e h o l d i n gt h e r e a rl i c e n s et r i m ( C ) ,t h e n r e m o v el h e trim, Takecare not to scratchthe hatch. FastenerLocations

2. On insidethe hatch.removethe bolts securingthe r e a rl i c e n s et r i m ( A )a n d h a t c hl o c kc y l i n d e r( B ) . FastenerLocations

A>:Clip,2 B>:Clip.2

cHl

\ ! -

€:t+

> : Bolt,2

4 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a , nd

note these rtems:

6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ftl

20-98

. Replaceany damagedclips. . Pushthe clip portionsinto placesecurely.

HatchSpoilerReplacement NOTE:Put on glovesto protectyour hands. 'l.

Removethe hatch upper trim (seepage 20-53).

2. Removethe high mount brakelight (seepage2282).

4 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s ,w h i l e p u l l i n gt h e h a t c hs p o i l e r( A )a w a y ,a n d r e l e a s et h e fasteners(B),then removethe spoiler.Takecare not to scratchthe body. FastenerLocations > : C l i p2.

3. From insidethe hatch,removethe bolts {A} and n u t s( B ) .

Fastener Locaiions

A>: Bolt,2 Bar Nut,

fi'f$t-uLt*

/,fl v_/

$. A 5 . I n s t a l l t h es p o i l e ri n t h e r e v e r s eo r d e ro f r e m o v a l , and note these items: 5x1.0mm 9.8Nm (1.0kgf.m.7.2lbf.ft)

R e p l a c ea n y d a m a g e dc l i p s . Replaceany damagedfasteners.Before installingthe fastenerto the spoiler,cleanthe spoilerbonding surfacewith a sponge d a m p e n e di n a l c o h o l G r ith . l u et h e f a s t e n e w a d h e s i v et a p e( 3 M 5 6 7 1 ,o r e q u i v a l e n t ) t toh e spoiler. Pushthe clip and fastenerportions into place securely.

20-99

ExteriorTrim EmblemReplacement NOTE:When removingthe emblem,take care not to scratchthe body. 1. To removethe front

"H" emblem and front type emblem, removethe front bumper (seepage 20-85)

2. Cleanthe bonding surfacewith a spongedampenedin alcohol.After cleaning,keepoil, grease,and water from getting on the surface. 3 . A p p l yt h e e m b l e m ,w h e r es h o w n . . Wheninstalling t h e s i d ei - V T E Ce m b l e mo n t h e b o d y ,a l i g nt h e a p p l i c a t i otna p ew i t h t h e e d g eo f t h e w h e e la r c h , then pressthe emblem into place,and removethe applicationtape. . ' 0 3 m o d e l :W h e n i n s t a l l i n g t h e L E Ve m b l e mo n t h e q u a r t e rg l a s s ,a l i g nt h e a p p l i c a t i o tna p ew i t h t h e e d g eo f t h e , n d r e m o v et h e b l a c kc e r a m i ca n d a l i g n m e n m t a r ko n t h e q u a r t e rg l a s s t, h e n p r e s st h e e m b l e mi n t o p l a c e a a p p l i c a t i o tna p e .

FRONTTYPEEMBLEM

FBONT"H" EMBLEM FRONT"H" EMBLEMBASE

FBONTGRILLE SCREWS

FRONTSi EMBLEMPLATE PUSHNUTS

PINS FRONTGRILLE

20-100

FRONTGRILLE

REARCIVICEMBLEM

LEVEMBLEM (Leftsideonly) ('03model) REARVERSIONEMBLEM SIDE|-VTECEMBLEM

REAR"H" EMBLEM Unit: mm {in.l Adhesivetape:

3M 4213E,o. equivalent Thickness:0.8mm (0.03in.) REAR"H'' EMBLEM

APPLICATION TAPE

Edoeol the blackceramic.

LEVEMBLEM Ontoinsideface

Align.

of the guarterglass. HATCHLINE

REARLICENSE TRIM REARsi EMBLEM

REARSiR EMBLEM (Canada)

34 11.3) , ilg

(1.93)

=-t

.,!!ll,'nt (1.s31

50 {'!,9?) CIVICEMBLEM

E d g eo f t h e hatch.

ADHESIVETAPE

SIDEi-VTECEMBLEM Left Side: .

SIDEi.WEC EMBLEM

Edge of the hatch.

Right Side:

63 (2.5)

114(4.49)

F.l^6

rh-

wheelarch.

.=4,

y' Li.Est

Edgeof the wheel arch.

APPLICATION TAPE

BODY LINE

112

o"f,r,ao.o"

(5'5s)

TAPE

4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.

20-101

Fenderwell FrontInnerFenderReplacement NOTE:Takecare not to scratchthe body. 1, Removethe front inner fender (A). -1 On the backofthe wheel arch,removethe screws(B). - 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r, e m o v e t h e s c r e w( B )s e c ur i n gt h e f r o n t b u m p e r .s p l a s hs h i e l d( D ) ,a n d f r o n t inner fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender. - 3 F r o m t h e w h e e la r c h ,r e m o v et h e c l i p s{ F ,G ) s e c u r i n gt h e f r o n t i n n e rf e n d e r( a n ds p l a s hs h i e l d )o n t h e b o d y . - 4 R e l e a s teh e h o o k( H )o f t h e s p l a s hs h i e l d , t h e nr e m o v e t h e f r o n it n n e r f e n d e r . FastenerLocations B):Screw,4

E>:Clip,1

0*€

,ws

F > : C l i p ,1

G):Clip,8

2. Installthe inner fender in the reverseorder of removal,and note these items: . R e p l a c ea n y d a m a g e dc l i p s . . P u s ht h e c l i p si n t o p l a c es e c u r e l y .

20-102

Front FenderFairingReplacement 1 . Removethe front inner fender as necessary(see p a g e2 0 - 1 O 2 1 . Open the front door. From outsidethe door, r e m o v et h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d et h e d o o r , removethe lower clip (A) securingthe front fender f a i r i n g( B )a n d f r o n tf e n d e r( C ) . FastenerLocations

3. From the wheel arch, removethe clip (A),and releasethe clip (B),then removethe front fender f a i r i n g( C ) . FastenerLocations A > : C l i p1,

B > : C l i p1,

J*.' -@

A>:Clip,2

J<a-'

4 . Installthe fender fairing in the reverseorder of

removal,and note these items: . R e p l a c ea n y d a m a g e dc l i p s . . R o u t et h e s i d et u r n s i g n a l i g h t h a r n e s s ( A ) through the slit (B)of the front fender fairing (C). . B e f o r ei n s t a l l i n g t h e c l i p so f t h e d o o r u p p e ra n d lower ponions, installthe front fender fairing (A) to the front fender (B) properlyas shown. . Pushthe clips into placesecurely.

o --____--

20-103

Fenderwell FuelPipeProtectorReplacement 1 . R e m o v et h e c l i p s ,t h e n r e m o v et h e f u e l p i p e

RearAir Outlet Replacement 1 . R e m o v et h e r e a rb u m p e r( s e ep a g e2 0 - 8 6 ) .

protector(A).Takecare not to scratchthe body. Fastener Locations

r n e r e a ra t r the body.

> : Clip,4

I n s t a l l t h ep r o t e c t o irn t h e r e v e r s eo r d e ro f r e m o v a l , and note these items: . R e p l a c ea n y d a m a g e dc l i p s . . P u s ht h e c l i p si n t o p l a c es e c u r e l v .

20-104

I n s t a l l t h ea i r o u t l e t sb y p u s h i n go n t h e h o o k p o r t i o n su n t i l t h eh o o k ss n a pi n t o p l a c e .

(

Openers ComponentLocationIndex

HATCHLOCK CYLINDER page20-1'l1 Replacement, HATCHHANDLE Replacement, p a g e2 0 - 1 1 0 HATCHLATCH Replacement,page20'110

FUELFILLDOORLATCH page20-107

FUELFILLDOOROPENEBCABLE page 20-107 Replacement, FUELFILLDOOROPENER Replacement,page20-109 I{OOD RELEASEHANDLE page20-'106 HOODOPENERCABLE Replacement,page20-106

z)-105

Openers Hood OpenerCableReplacement NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body and relatedparts. l. Removethese items: . Front bumper (seepage 20-85) . F r o n ti n n e rf e n d e r ,l e f t s i d e ( s e e p a g e 2 0 - 1 0 2 ) . Kick panel,left side (seepage 20-50) 2. Disconnectthe hood openercable(A) from the hood latch {B) (seepage20-108),and removethe bolts (C),then removethe hood releasehandle(D)from the body. FastenerLocations C>:Bolt,2

6x1.0mm 9,8 N.m 11.0kgl.m, 7.2 lbl.ft)

E >:Clip,3

l,.t'.

W:"

Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood openercablefrom the vehicle.Takecare not to bend the cable. 4 . I n s t a l l t h ec a b l ei n t h e r e v e r s eo r d e ro f r e m o v a l a , n d r e p l a c ea n y d a m a g e dc l i p s .

20-106

FuelFill Door OpenerCableReplacement SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and the precautions and procedures(seepage 23-14)in the SRSsectionbeforeperformingrepairsor service. NOTE; . Put on glovesto protectyour hands. . Takecare notto scratchthe body and relatedparts. 1. Removethese items from the left side of the vehicle: . D o o rs i l l t r i m { s e ep a g e2 0 - 5 0 ) . R e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 )

2 . Pullthe carpetbackas necessary(seepage 20-55). 5.

Disconnectthe fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109). FastenerLocations C > : C u s h i o n t a p e1,

D > : C l i p 1,

E > : Clip,2

4 . K C m o d e l :R e m o v e t h el e f tm i d d l ef l o o rc r o s s - m e m b egru s s e t( s e ep a g e2 0 - 1 1 3 ) . 5 . R e m o v et h e c u s h i o nt a p e{ C ) ,a n d r e l e a s et h e c a b l ef r o m t h e c l i p s( D ,E ) . 6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' . 7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable 8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s oamageo.

20-107

Openers Hood LatchReplacement NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe body. 1. Removethe bolts,then removethe hood latch (A) from the body. FastenerLocations > i Bolt,3

--------------' 6x1.0mm 9.8 N.m (1.0kgf.m,7.2lbf.ft)

Disconnectthe hood openercable (B)from the hood latch.Takecare not to bend the cable.

20-108

Installthe hood latch in the reverseorder of removal,and note these items: . Apply multipurposegreaseto each locationof the hood latch indicatedby the arrows. . Make sure the hood openercable is connected properly. . Make sure the cableactuatesthe latch beforeyou closethe hood, . Adjustthe hood latchalignment(seestep 3 on page 20-87). . M a k es u r et h e h o o do p e n sp r o p e r l ya n d l o c k s securely.

FuelFillDoorOpenerReplacement 1 . Using a flat-tipscrewdriverwrapped with protectivetape, detachthe hooks(A) by prying the front side cap (B),then remove it from the left door s i l l t r i m ( C ) ,a n d l o o s e nt h e b o l t ( D )s e c u r i n gt h e f u e lf i l l d o o r o p e n e r .

6x1.0mm 9.8 N.m 11.0kgf m,7.2 lbf.ft)

2. Removethe left door sill trim (seepage 20-50i. 3 . R e m o v et h e o p e n e r( A l f r o m t h e b o l t{ B ) .

4. Disconnectthe fuel fill door openercable (A),then removethe openeriB). Takecare not to bend the c ao t e .

5 . Installthe opener in the reverseorder of removal, and note these items: lMakesure the openercable is connected properly. lvlakesure the fuel fill door opens properlyand lockssecurely.

20-109

Openers HatchHandleReplacement

HatchLatchReplacement

NOTE:Put on glovesto protectyour hands.

1. Removethese items:

'1.

. Hatchlower trim panel (seepage 20-53) . Rear licensetrim panel (seepage 20-98) 2. Removethe rearwindow wiper motor (seepage 22-1461. 3. Disconnectthe hatch o p e n e rc a b l e1 A ) f r o mt h e h a t c hh a n d l e( B ) ,a n d removethe nuts. Fastener Locations

a : Nut,

6x1.0mm 9.8N.m

(1.0 kg{.m,7 2 tbt.{t\

Removethe hatch lowertrim panel (seepage 2053).

2. Disconnectthe hatch openercable (A),cylinder rod (B).hatchactuatorconnector(C).and hatch latch switch connector{D).and detachthe hatch actuator connectorand hatch latch switch connectorfrom the hatch. FaslenerLocations ) : Bolt,3

ttb

()rI a ,t.

4. Pull outthe hatch handle(A),then remove it.

i-'-3;li9#k g tm , 7 . 2 l bfft l 11,0

R e m o v et h e b o l t s ,t h e n p u l l t h eh a t c hl a t c h( E )o u t , then remove it. I n s t a l l t h el a t c hi n t h e r e v e r s eo r d e ro f r e m o v a l a, n d notethese items: . Make sure each connectoris plugged in properly, and the rod and cableare connectedproperly. . l\4akesure the cable actuatesthe latch beforeyou c l o s et h e h a t c h . . Make sure the hatch opens properlyand locks securely. I n s t a l l t h eh a n d l ei n t h e r e v e r s eo r d e ro f r e m o v a l . and note these items:

lMake surethe hatchopenercableis connected securely. M a k es u r et h eh a t c ho p e n sp r o p e r l y .

20-110

HatchLockCylinderReplacement NOTE;Put on glovesto protectyour hands. '1.

Removethese items: . Hatchlower trim panel (seepage 20-53). . Rearlicensetrim (seepage 20-98).

4. Installthe lock cylinder in the reverseorder of removal,and note these items: . Make sure the rod is connectedproperly. . Make sure the hatchopens properlyand locks securely.

2. Disconnectthe cylinder rod (A)

- . .

From outsidethe hatch,removethe bolt securing the lock cylinder{A}.From insidethe hatch,pull the l o c kc y l i n d e ro u t b y r e l e a s i n tgh e h o o k( B ) . Fastener Location 6 x 1 . 0m m 9.8Nm (1.0kgf m,7.2lbt.ftl

> : Bolt,1

rS'l-. u-ar

*/t

20-111

Frame SubframeReplacement SubframeTorque NOTE:After looseningthe subframemounting bolts,be sureto replacethem with new ones.

Referenceholesalignment:

SUBFRAME

REFERENCE HOLE ( B o d yS i d e )

INSTALLATION REFERENCE HOLE (Subframe side)

INSTALLATION REFERENCE HOLE

SCREWDRIVER or TAPEREDPUNCH

FRONTSUSPENSION To body.

INSTALLATION REFERENCE HOLE

To body. I

n E SPECIAL ' 1 4x 1 . 5mBOLTS m 103 N.m (10.5kgf.m,75lbf.ft) Replace.

20-112

FrameStiffener,Brace,and GussetReplacement FrameStiffener,Brace,and GussetTorque NOTE:When installingthe middle floor cross member braceor gussets,torque the mounting hardwarein the following sequenceto avoid damageto the quarterpanel.

MIDDLE FLOOR CROSS-MEMgER BRACE/GUSSET SIDEFRAMESTIFFENER

8 x 1 . 2 5m m 29 N.m (3.0kgf m,22 lbf ft)

To body. model: Canada

U.S.model: 1 0x 1 . 2 5m m 38 N.m (3.9kgf.m.28lbf.ftl

MIODLE FLOOR CROSS-MEMBER BRACE

__!:::-| -

1 0 x 1 . 2 5m m 38 N m (3.9 kgt.m, 28 lbf.ftl

MIDDLE FLOOR CROSS.MEMBER GUSSET

1 0 x 1 . 2 5m m 38Nm (3.9kgf.m,28 lbl.ftl

20-113

Frame FrameRepairChart Top view

Unit:mm {in.} o: Inner diametel

a b1 b2 b3 cl c2 c3

Forsublrameo1510.59) Forenginemount e13 (0.511 Forenginemount o13 (0.51) Forenginemount rl3 (0.51) Formanualtransmission mouoto13{0.5' Formanualtransmission mounto13 10.5' Formanualt.ansmission mo!nt d13{0.51)

o I g h

Fordampermounts11.5{0.45} For damper centero78 (3.07) Fordampermounts11.5(0.451 Fordampeimountd11.510.45) Forsubframeo15 {0.591 Localinghole s25 {0.98} Locatingholee50 (1.97)

VEFTICAL UNE

20-114

m n p q

Locatinghole d25 (0.981 Fortrailing.rm rl3 10.51) Locatinghole o25 (0.981 Locatinghole s20 (0.79) Trailingarm center Reardampercenter For upperarm o13 (0.51)

t1, t2

x1 x2

Fortrailingarm d13 (0.511 For upper arm bracketcenterrl5 {0.59) Locatingholes13 (0.51) Foruppe.arm o13{0.511 For rear lower arm cent€r Locatingholes50 (1.97) Locatinghole s20 (0.79) Locatinghole o25 (0.981

(cont'd)

20-115

Frame

FrameRepairChart(cont'dl Sideview

Unitrmm {in.) o: InnerdiameteJ

a b1 b2 b3 cl c2 c3

For subframe015 {0.59} Forenginemount o13 (0.511 Forenginemount 01310.51) Forenginemount 113(0.511 Formanualtransmission mount 013{0.51) Formanualtrensmission mount 613{0.51} Formanualtrrnsmissionmounro13{0.51}

o e I

s h i

Fordampermounto11.5{0.45) For damper centerr78 {3.07} Fordampermounto11.5(0.45) Fordampermountr11.5{0./t5l Forsubtrameel5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)

SECTIOiIAA

BASE UNE

trr2xt.6

VERTICAI LINE

20-116

Frame

FrameRepairChart(cont'dl Sideview

Unitrmm {in.) o: InnerdiameteJ

a b1 b2 b3 cl c2 c3

o e I

s h i

Fordampermounto11.5{0.45) For damper centerr78 {3.07} Fordampermounto11.5(0.45) Fordampermountr11.5{0./t5l Forsubtrameel5 10.591 Locatinghole o25 (0.98) Locatinghole s 11.97)

SECTIOiIAA

BASE UNE

trr2xt.6

VERTICAI LINE

20-116

m p q

Locatinghole o25 {0.98) Fortrailingarm 613 {0.511 Locatinghole d25 {0.98} Locatinghole r20 {0.79) Trailingarm center Reardamper centel Forupperarm o13 (0.51)

11,t2

xl x2

Fortrailingarm s13 {0.51} For upper arm bracketcenter o15 {0.591 Locatingholeo13{0.51} Forupperarm d13{0.51) For rear lower arm centei Locatingholeo50{1.97} Locatinghole a20 {0.79} Locetinghole s25 (0.98)

20-117

HVAC(Heating, Ventilation, andAir Gonditioningl HeatingandAir Conditioning 21-2 SpecialTools Comoonent Location lndex ........z t-'5 A/CService Tiosand z t-o Precautions A,/CRefrigerant Oil z t-o ReDlacement Troubleshooting General 21-8 lnformation Index .......21-9 DTCTroubleshooting SymptomTroubleshooting 21-10 1ndex.............. 21-11 SystemDescription..................... 21-14 CircuitDiagram D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o Recirculation ControlMotor .......... CircuitTroubleshooting 21-25 HeaterControlPowerandGround Troubleshooting ........21-27 Circuits Condenser FanCircuit Troubleshooting ...................... 21-28 Fans Radiator andCondenser CommonCircuit ...................... 21-29 Troubfeshooting Compressor ClutchCircuit T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2 . .1. .-.3. .0 A,/CPressureSwitchCircuit ...................... 21-32 Troubleshooting Air Mix ControlMotor ............. 21-34 TestandReolacement ModeControlMotor ............. 21-35 TestandReplacement Recirculation ControlMotor ............. 21-36 TestandReolacement Evaporator Temperature Sensor andTest ............. 21-31 Reolacement Test ................. 21-38 PowerTransistor HeaterControlPaneland PushSwitchAssemblv RemovalandInstallation........21-38

DustandPollenFilter Reolacement ..21-39 BlowerUnitRemovaland ......21-39 lnstallation BlowerUnitComoonents R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . . Evaporator Core ..21-42 Reolacement *HeaterUnit/Core ..21-43 ReDlacement HeaterValveCable .....21-46 Adjustment .......... 21-47 CompressorReplacement 21-48 Comoressor ClutchCheck .......... Comoressor ClutchOverhaul.....21-49 ThermalProtector Compressor R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . . ReliefValve Comoressor R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . . 21-52 Reolacement............ Condenser Recovery .................. 21-53 Refrigerant ...................... 21-54 SystemEvacuation 21-55 SystemCharginS......................... 21-56 LeakTest.................. Refrigerant 21-57 A,/CSvstemTests ........................

HVAC{Heating,Ventilation,and Air Conditioning) SpecialTools Ret.No.

Tool Number

DescriDtion

07sAz-001000A

BackprobeSet

---2

att-,,/'Tt e^t"'

T 21-2

KCe

"-t--'

Otv 2

Heatingand Air Gonditioning ComponentLocationIndex

VALVE SERVICE {LOW.PRESSUBE SIDEI

EVAPORATOR CORE (Built-in theheaterunit) B e p l a c e m epnat ,g e2 1 4 2

SERVICE VALVE {HIGH-PRESSURE SIDEI

RECEIVER/DRYER

COMPRESSOR Beplacement,page21 47 CONOENSEB ClutchCheck,page21-48 page 21-52 Replacement, C l u t c hO v e r h a u lp, a g e2 1 - 4 9 ThermalProtectorCheck,page21-48 page21 51 ThermalProtectorReplacement, R e l i eV f a l v eR e p l a c e m e npta, g e2 1 5 1

Heatingand Air Conditioning ComponentLocationIndex(cont'dl

RADIATORFAN RELAY Test,page22-51 CLUTCHRELAY

Tesl, page 22-51

MOTORRELAY

Test, page 22-5I

'-t

-::--

t_]]l

BOX UNDER.HOOD FUSE/RELAY

-l

CONDENSERFAN Test, page 22-51

.\\

... A/C PRESSURE SWITCH

RADIATORFAN CONOENSERFAN

21-4

HEATER UNIT/CORE page21-43 Beplacement,

BLOWEN UNIT page21-39 Removal andInstallation, BLOWERUNITCOMPONENTS page21-41 Replacement,

HEATERVALVECABLE page21-46 Adjustment,

DUSTAND POLLEN FILTER page21'39 Replacement, RECIRCULATION CONTROLMOTOR Test,page21-36 page21-36 Replacement, MODE CONTROLMOTOR Test,page21-35 page21-35 Replacement, POWERTRANSISTOR Test,page 21-38

AIR MIX CONTROLMOTOR Test,page21'34 page21'34 Replacement, EVAPORATORTEMPERATURE SENSOR page 21-37 Replacement, Test,page21-37

PUSH SWITCHASSEMBLY Removaland Installation,page21'38

HEATERCONTROLPANEL RemovalandInstallation,page21 38

21-5

HeatingandAir Conditioning A/C ServiceTips and Precautions

A/C Refrigerant Oll Replacement R e c o m m e n d eP d A Go i l : K E I H I NS P 1 0 :

Compressedair mixed with R-134aforms a combustible vapor. T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s injury. Never use compressedair to pressuretest R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n sg y s t e m s .

A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor. T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a ) r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l , w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t w h i c ha r e n o t c o m p a t i b l e r e f r i g e r a not r m i n e r a l l i l .D o n o t u s eR - ' 1 2 andminerao oil in this system,and do not aftemptto use R 12 s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g t ill result. s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s certifiedto meet the requirementsof SAE J2210to r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m . lf accidentalsystem dischargeoccurs,ventilatethe w o r k a r e ab e f o r er e s u m i n gs e r v i c e .

. P/N38897-Pl3-A01AH:'120m0 i4 fl oz) . P/N38899-P13'A01: 40 m0 i1 1/3fl oz) Add the recommendedrefrigerantoil in the amount listedif you replaceany of the following parts. . T o a v o i dc o n t a m i n a t i o nd.o n o t r e t u r nt h e o i l t o t h e c o n t a i n eor n c ed i s p e n s e da, n d n e v e rm i x i t w i t h o t h e r refrigerantoils. . l m m e d i a t e la y f'teu r s i n gt h e o i l , r e i n s t a l l t h e c a po n the container,and seal it to avoid moisture aosorpron. . D o n o t s p i l lt h e r e f r i g e r a not i l o n t h e v e h i c l e i;t m a y damagethe paint. lf it gets on the paint,wash it off immediately. , . 9l m p . o z ) C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0 '1.4 E v a p o r a t o r. . . . . . . . .4. 5 . m0 (1113Il.oz, lmp.oz) '10 L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z ) '10 R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z ) Leakagerepair ....25 m0,1516 Il oz,0.9 lmp.oz) . .o rc o m p r e s s orre p l a c e m e n l , C o m p r e s s o r. . . . . . . F s u b t r a ctth e v o l u m eo f o i l d r a i n e d from the removedcompressorfrom 1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d d r a i nt h e c a l c u l a t e vdo l u m eo f o i l '130 f rom the new compressor: m0 i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f removedcompressor= Volume to d r a i nf r o m n e w c o m p r e s s o r .

R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretested or leaktested withcompressed air.

NOTE:Evenif no oil is drainedfrom the removedcompressor,don't d rain more than 50 m0 \1 2/3 fl.oz, ' 1 . 8l m p o z ) f r o mt h e n e w compressor.

A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e obtainedfrom the refrigerantand lubricant manufacturers. . Always disconnectthe negativecablefrom the parts. b a t t e r yw h e n e v e r e p l a c i n ga i r c o n d i t i o n i n g . Keepmoistureand dirt out of the system.When d i s c o n n e c t i nagn y l i n e s ,p l u g o r c a pt h e f i t t i n g s immediately;don't removethe caps or plugs until iust be{oreyou reconnecteach line. ' B e f o r ec o n n e c t i n g a n y h o s eo r l i n e ,a p p l ya f e w d r o p s of relrigerantoil to the O-ring. . W h e nt i g h t e n i n go r l o o s e n i n ga f i t t i n g ,u s ea s e c o n d wrench to supportthe matchingfitting. . W h e n d i s c h a r g i ntgh e s y s t e m u , s ea R - ' 1 3 4 a station;don't refrigerantrecovery/recycling/charging releaserefrigerantinto the atmosphere.

21-6

REMOVED COMPBESSOR

l i

\..

\tb

NEW COMPRESSOR

/- a\

r /

\:)-) -/

'r:l_

_ 0L

I "o*tttu" _*lH I I II DRAINING voLUME ],^ ,lEL.A: 130 m0 {4 l/3 tl.oz,4.6lmp.oz)

RECEIVER LINEA

RECEIVER/DRYER CONDENSER LINE

Dischargehoseto the compressor{6 x 1.0 mm) : 9.8 N.m {1.0kgf.m,7.2 lbl.ft} Dischargehoseto the condenser(5 x 1.0mml : 9.8 N.m {1.0kgt.m,7.2 lbf ft) Condenserline to the condenser(6 x 1.0mm) : 9.8 N.m {1.0kgf,m,7.2 lbt.ft} Condenserfine to the receiver/dryer{6 x 1.0mm} : 9.8 N.m (1.0kgt.fi,7.2lbt.ltl ReceiverlineAtothe receiver/dryer{6 x 1.0mm} : 9.8 N.m {1.0kgf.m. 7.2 lbf.ft} Receiverline A to the receiveiline B : 13 N.m (1.3kgr.m,9.4 lbf.ft) Receiverline B and the suctionline to the evaporator(6 x 1.0mm) :9.8 N.m 11.0kgf.m,7,2 lbf.ft) Suction line to the suction hose : 3l N m {3.2 kgf.m, 23 lbf ftl Suctionhose1o the compressor(6 x 1.0mm) : 9.8 N.m 11.0kgf.m.?.2 lbf.lt) Compressorto the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2 kgt.m, 16 lbf.ft) Compr€ssorbracketto the engineblock {10 x 1.25mm} : ,14N.m 14.5kgf.m,33 lbf.ft)

21-7

Heatingand Air Conditioning GeneralTroubleshootingInformation How to Retrievea DTC The heatercontrol panel has a self-diagnosisfunction.To run the self-diagnosisfunction,do the following: 1 . T u r nt h e f a n s w i t c hO F F . 2. Pressandholdthe recirculationcontrol switch andthe rearwindow defoooerswitch down. 3 . T u r nt h e i g n i t i o ns w i t c ho N { l l i . 4. Releaseboth switches.The recirculationindicatorand the rearwindow defoggerindicatorcome on. The recirculationindicatorgoes off 3 secondslater and the Ay'Cindicatorcomes on. then the self-diagnosiswill begin. About 10 secondslater,the self-diagnosiswill finish and the A,/Cindicatorgoes off. .lfanytroubleisfound.therecirculationindicatorblinksthediagnostictroublecode(DTC)toindicateafaulty circuil or comDonent. . lf the system is OK, the recirculationindicatorstaysoff.

atc INOICATOR BECIRCULATION INDICATOB

/A\

-:@

RECIRCULATION CONTROLSWITCH

REARWINDOW INDICATOR OEFOGGER

REARWINDOW DEFOGGER SWITCH

Examole of DTC indication Pattern IDTC7)

DTC 7 Recirculation + indicatot Recirculation+ indicalor go6s oft

----->

Reseiting the Selt-diagnosis Function Turn the ignition switch OFFto cancelthe self-diagnosisfunction.After completingrepairwork, run the self-diagnosis f u n c t i o na o a i nt o m a k es u r et h a t t h e r ea r e n o o t h e rm a l f u n c t i o n s .

21-8

DTCTroubleshootingIndex DTC{Recirculation IndicationBlinks)

Detection ltem

7 8 9

A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t A short ln the air mix control motor circuit A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r An open or shon in the mode control motor circuit A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t A problem in the EEPROMin the heatercontrol panel; the control oanel must be reolaced An ooen in the evaDoratortemDeraturesensorcircuit A short in the evaDoralortemoeraturesensorcircuit

10 11

12 13 14

Page ( s e ep a q e2 1 - 1 6 ) ( s e eD a o e2 1 - ' 1 6 ) ( s e ep a q e2 1 -1 7 ) ( s e eo a q e2 1 - 1 8 ) ( s e ep a q e2 1 1 9 1 ( s e ep a q e2 1 - 2 0 ) ( s e ep a g e2 1 - 3 8 ) (seepaqe 21-23) ( s e eo a q e2 1 - 2 4 1

In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks. ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.

21-9

Heatingand Air Conditioning \

Index SymptomTroubleshooting

{

Also check for Svmptom Diagnosticprocedure RecirculationControl Motor C l e a n l i n e sasn d t i g h t n e s so f a l l Recirculationcontrol doors do not changebetweenFreshand Recirculate CircuitTroubleshooting(seepage connectors 21 251 HeaterControlPowerandGround B l o w nf u s eN o .' 1 4( 1 0 Ai)n t h e Both heaterand Ay'Cdo not work

(see CircuitsTroubleshooting page21-27) Condenserfan does not run at all (but radiatorfan runs with the Ay'Con) Both fans do not run with the A,/Con

Compressorclutchdoes not engage (both fans run with A,/Con) A/C system does not come on (both fans and compressor)

fuse/relay box under-dash Poorgroundat G501 C l e a n l i n easns dt i g h t n e sosf a l l conneclors

. P o o rg r o u n da t G 3 0 1 . C l e a n l i n e sasn d t i g h t n e s so f a l l connectors R a d i a t oarn dC o n d e n s e Fra n s B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4 CommonCircuitTroubleshooting (20A)in the under-hoodfuse/relay ( s e ep a g e2 1 - 2 9 ) box P o o rg r o u n da t G 3 0 l C l e a n l i n e sasn dt i g h t n e s so f a l l connectors CompressorClutchCircuit C l e a n l i n e sasn dt i g h t n e s so f a l l T r o u b l e s h o o t i n(qs e eD a q e2 1 - 3 0 ) connectors Ay'CPressureSwitch Circuit B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4 (20A)in the under-hoodfuse/relay T r o u b l e s h o o t i n(gs e ep a g e2 1 - 3 2 ) box Poor ground at G301 C l e a n l i n e sasn dt i g h t n e s so f a l l connectors

C o n d e n s eFr a nC i r c u i t Troubleshooting{seepage 21-28)

! 21-10

SystemDescription HeaterControlPanelInputsandOutputs HEATERCONTFOLPANELCONNECIORS

CONNECTOR A {r/rP)

CONNECTORB (22P)

W res deoitema eterm nals

CONNECTOR Cavity _|

Wire color \ln Y

2 3

LT GRN PNK/BLU BLU GRNA/EL GRNA/VHT BLUI/EL BLU/RED

5 6 7 8 I

GRN

10 11

YEL/RED YEVBTU YEL/BLK BLK BLK/YEL

CONNECTOR B Cavity

Sional AIRMIXPOTENTIAL +5V S E N S OC RO M M O N GROUND

OUTPUT

AIR MIX HOT

OUTPUT INPUT INPUT INPUT OUTPUT INPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT INPUT

INPUT

A,/CPRESSURE SWITCH RECIRCULATE FRESH

POWER TRANSISTOR BLOWERFEEDBACK AIR MIX COOL MODEDEF MODEVENT REARWINDOWDEFOGGER RELAY GROUND l G 2( P o w e r )

on Wire color

Siqnal

2 3 4

5 6 7 8 9

BLIVRED

--T

PNVBLK

R E A RW I N D O WD E F O G G ES RW I T C HL E D A./CSWITCHLED RECIRCULATIO CN ONTROL S W I T C HL E D AIR MIX POTENTIAL

BRN

EVAPORATOR TEIMPERATURE SENSOR

INPUT INPUT INPUT OUTPUT OUTPUT

GAUGE ASSEMBLY

al' 'TDr ri

LT GRN L TG R N / B L K

10 11

14 ic

16 17 18 19 20

RED RED/BLK BLU LT GRN/RED YEVRED YEUGRN WHT/BLU RED/BLU RED/YEL BRN^,^/HT

REDA/r'HT

TAILLIGHTSRELAY

INPUT

REARWINDOWDEFOGGER SWITCH

INPUT

A/C SWITCH RECIRCULATIO CN ONTROL SWITCH

INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT

MODE4 MODE3 M O D E2 M O D E1 I G N( P o w e d (Not used)

(cont'd)

21-11

Heatingand Air Gonditioning SystemDescription(cont'dl The air conditioningsystem removesheatfrom the passengercompartmentby circulatingrefrigerantthrough the system as shown below.

BLOWER FAN \

\ r\,u

EXPANSIONVALVE

(Metersthe required amount of refrigerant into the evaporator)

APOBATORTEMPERATURE SENSOR THERMALPROTECTOR (Opensthe compressorclutchcircuit when the compressottemperature becomestoo high)

A/C PRESSURESWITCH When the refriqerantis below 196kPa(2.0kgi/cm',28psi) or above3,140kPa(32 kgf/cm' 455 psi),the Py'cpressure switchopensthe circuitto the Py'Cswitch and stopsthe air conditioningto protectthe compressor-

RELIEF VALVE (Relieves pressure at thecompressor w h e nt h ep r e s s u ri e st o oh i g h )

A/C COMPRESSOR (Suctionand comoression)

RECEIVER/DRYER (Trapsdebris,and \-^ removesmorsturel

/CONDENSER (Radiationof heat)

vAPoR HrcHPRESSURE

[ '.... tffi

-:--l

Low PREsSUBE LrourD Low PREssURE vAPoR

refrigerantwhich does not containchlorofluorocarbons.Pay attentionto the This vehicleuses HFC-134a(R-'134a) following serviceitems: . D o n o t m i x r e f r i g e r a n tCs F C - 1 2 ( R - 1 2a) n d H F C - 1 3 4(aR - 1 3 4 aT) .h e ya r e n o t c o m p a t i b l e . '!0) . U s eo n l y t h e r e c o m m e n d e p d o l y a l k y l e n e g l y c(oPl A G) r e f r i g e r na t o i l ( K E l H l NS P designedfortheR-134a (PAG) recommended refrigerant with retrigerant oil will resultin compressor.Intermixingthe oil any other compressorfailure. . AllAy'Csystem parts (compressor,dischargeline, suction line,evaporator,condenser,receiver/dryer. expansion valve,O-ringsfor joints) have to be designedfor refrigerantR 134a.Do not exchangewith R-'12parts. . Use a halogengas leakdetectordesignedfor refrigerantR-134a. . R-12and R-134arefrigerantservicingequipmentare not interchangeable. Use only a recovery/recycling/charging s t a t i o nt h a t i s U . L . - l i s t eadn d i s c e r t i f i e dt o m e e tt h e r e q u i r e m e n tosf S A EJ 2 2 1 0t o s e r v i c eR - 1 3 4 a i r c o n d i t i o n i n g system. . Always recoverthe refrigerantR-134awith an approvedrecovery/recycling/charging stationbeforedisconnecting any Ay'Cfifting.

21-12

HeatingandAir Conditioning GircuitDiagram UNDEN rcODFUSVRELIYSOX

UNOER DASN fUSE/8EIlYBOX

|GNUION SWTCfi lG2HoI ii 0l\lllll

+. \

C}F rG2/

BLK/RED

;

\ IHEFMAI

PBorEcro8 I

*n*,*, lTl | <l I CLUTCH tf

G301

MUITIPLD( CONTFOI UNITI

-!10.

RADIATOS\ NADIATOS ) tAl'/ / swtlcll oT0n

B LX

G301

21-14

19S"F 193"C) l

I I n A/CPnESSUEt swTOt

irgF 8Ll

t...iCF

BLU

CONDEN$N MOTOB

I I 8u(

I ilnthoundor dasiluse/lelay box

BU/YEL

-8lU/wH'I

EVAPORATOB TEMPERATUNESENSOR

sn 4-Lrenil

m ::-:::: ., . a/c

YEUBLU YEL/NED

M DEF MODEl

BED/YEI

Mq)EI

RED/8LU

M00€2 M00t3

WHT/8LU

MOOE3

YEL/GRN

MOOEI

M00l co TnoL MOTOS

LTGRI'l

ffftH,, F*u,*

GNNMHT

GRN/YEL

8LK--..-...-l ( f

coNNEcroFrir.Pt mxr{EcroB ! {2P) G5'1

G602

21-15

Heatingand Air Conditioning DTCTroubleshooting DTC7:An Openin theAir Mix ControlMotor Circuit

DTC8:A Shortin theAir Mix ControlMotor Circuit

1. Test the air mix control motor {seepage 2'l-341.

1. Testthe air mix control motor(see page 21-341.

ls the air mix control motor OK? YES-Go to step 2. N O - R e p l a c et h e a i r m i x c o n t r o lm o t o r . l 2. Disconnectthe air mix control motor 5P connector. 3. Disconnectheatercontrol panel connectorsA {14P) a n dB ( 2 2 P ) . 4. Checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorsA (14P)and B (22P)and the air mix control motor 5P connector, 14P: 5P: No.5 N o .1 No.4 No.2 No.2 No.3 N o .1 No.9

ls the ait mix control motor OK? YES-Go to step 2. NO-Replace the air mix contorol motor.I 2. Disconnectthe air mix control motor 5P connector. 3. Disconnectheatercontrol panelconnectorsA (14P) andB (22P). 4. Checkfor continuitybetweenbody ground and heatercontrol panelconnectorA (14P)terminals No. 1, 2, 3, and 9 individually,and betweenbody ground and heatercontrol panelconnectorB (22P) t e r m i n a lN o . 6 .

A {I4PI HEATERCONTROL PANELCONNECTOR

22P: No.6

5P: No.3

W i r e s i d eo f f e m a l et e r m i n a l s

HEATERCONTFOL PANELCONNECTORB I22P1

Wire side ol lem.letehi.6ls

ls there continuity? YES-Check for loosewires or poor connectionsat heatercontrol oanel connectorsA (14P)and B (22P) and at the air mix control motor 5P connector.lf the connectionsare good. substitutea known-goodair mix control motor, and recheck,lf the symptom/ indicationgoes away, replacethe originalair mix control motor. lf the symptom/indicationcontinues, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e heatercontrol panel and the air mix control motor.l

21-16

W i r e s i d eo i l e m a e l e r m i n a l s

ls therc continuity? Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e wire(s)betweenthe heatercontrol panel and the air mix control motor.l N O - G o t o s t e p5 .

5. Turn the ignition switch ON (ll),and checkthe same terminalsfor voltage. HEATERCONTROLPANELCONNECTOR A {14PI

DTC9: A Problemin the Air Mix Control Linkage, Door,or Motor 1, Test the air mix control motor (seepage 21-34). ls the air mix control motor OK? YES-Substitute a known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO-Replace the air mix control motor, or repair t h e l i n k a g ea n d d o o r . l

Wire side of femaleterminals

HEATERCONTROLPANELCONNECTOR B I22PI

Wiresideof femaleterminals

ls there any voltage? YES-Repair any short to power in the wire(s) betweenthe heatercontrol panel and the air mix control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacingthe heatercontrol panel.l NO Substitutea known-goodair mix control motor, and recheck.lf the symptom/indicationgoes away, replacethe originalair mix control motor. lf the symptom/indicationcontinues,substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe originah l e a t e rc o n t r o lp a n e l . I

21-17

Heatingand Air Conditioning DTCTroubleshooting.(cont'd) DTC10:An Openor Shortin the Mode ControlMotorCircuit 1. Test the mode control motor (seepage 21-35).

5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e t e r m i n a l sf o r v o l t a g e . HEATEB CONTROL PANEL CONNECTOR A {14P)

ls the mode cottol motor OK? YES Go to step 2. NO Replacethe mode control motor.I

2. Disconnectthe mode control motor 10Pconnector. s (14P) 3 . D i s c o n n e cht e a t e rc o n t r o lp a n e lc o n n e c t o r A and B \22P1. Checkfor continuitybetweenbody ground and h e a t e rc o n t r o lp a n e lc o n n e c t oA r ( 1 4 P t)e r m i n a l s N o . 2 , 1 0 ,a n d 1 1 i n d i v i d u a l l ya,n d b e t w e e nb o d y g r o u n da n d h e a t e rc o n t r o lp a n e lc o n n e c t o B r (22P) '17, 1 8 ,1 9 ,a n d 2 0 i n d i v i d u a l l y . t e r m i n a l sN o . HEATER CONTROL PANEL CONNECTOR A {14PI

Wire side of femaleterminal

HEATERCONTROLPANELCONNECTOR B {22PI 3 tl

15 T6

1 1 1 8 t 9 2A 21 22

RED/YEL WHT

Wiresideof femaleterminals

Wire side ol lemale terminals

HEATERCONTROLPANELCONNECTOR B {22P)

ls there any voltage? YES-. Repairany short to power in the wire(s) betweenthe heatercontrol panel and the mode control motor. This short may also damagethe heatercontrol panel.Repairthe short to power before replacingthe heatercontrol panel.l NO- Go to step 6.

W i r e s i d e o f f e m a L el e r m i n a l s

ls there continuity? Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e wire(s)betweenthe heatercontrol panel and the mode control motor.l NO

21-18

Go to step 5.

Turn the ignition switch OFF,and checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorsA (14P)and B (22P) and the mode control motor 10Pconnector. 14P: 10P: '10 N o .2 No. No.10 No,1 N o .1 1 No.2 22P: N o .1 7 N o .1 8 No.19 N o .2 0

10P: No.8 No.6,9 No.5 N o .4 , 7

DTC11:A Problemin the ModeControl Linkage, Doors,or Motor 1. Testthe mode control motor (seepage 21-35). ls the mode control motor OK? YES Substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO Replacethe mode control motor, or repairthe l i n k a g ea n d d o o r s . l

HEATER PANELCONNECTOR A (14PI CONTROL Wiresideof lemaleterminals

MODECONTROLMOTORlOPCONNECTOR Wiresideof femaleterminals

HEATERCONTROLPANELCONNECTORB {22PI Wire side of femaleterminals

ls there continuity? YES-Check for loosewires or poor connectionsat heatercontrol panelconnectorsA (14P)and B (22P), and at the mode control motor 10Pconnector.lf the connectionsare good, substitutea known-good mode control motor, and recheck.lf the symptom/ indicationgoes away. replacethe original mode control motor.lfthe symptom/indicationcontinues, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe originalheatercontrol panel.l NO Repairany open in the wire(s)betweenthe heatercontrol Daneland the mode control motor.l

21-19

HeatingandAir Gonditioning DTCTroubleshooting{cont'd) DTC12:A Problemin the BlowerMotor Circuit '1. C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d fuse/relaybox, and the No. 14 (10A)fuse in the under-dashf use/relaybox.

7. Checkfor continuitybetweenthe No. 3 terminal of the power transistor4P connectorand body ground. POWERTRANSISTOR4P CONNECTOR

2 Are the tuses OK?

NO Replacethe fuse(s),and recheck.l 2. Connectthe No. 2 terminal of the blower motor 2P connectorto body ground with a jumper wire. BLOWERMOTOB2PCONNECTOR

BLK

YES-Go to step 2.

Wire side ol temaleterminals

ls there continuity? YES-Go to step 8.

JUMPER] BLU/BLK

NO-Check for an open in the wire betweenthe power transistorand body ground. lf the wire is OK, checkfor poor ground at G502.I

8 . Connectthe No. 1 and No. 3 terminalsof the power transistor4P connectorwith a jumper wire. Wiresideol femaleterminals TRANSISTOR 4PCONNECTOR POWER 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the blowet motor run? YES Go to step 4, NO Go to step 17. 4. Turn the ignition switch OFF. Wiresideof femaleterminals 5. Disconnectthe jumper wire. 6. Disconnectthe power transistor4P connector.

9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . Does the blower motor tun at high speed? Y E S - G o t o s t e p1 0 . NO-Repair open in the wire betweenthe power transistorand the blower motor.l 1 0 . Turn the ignition switch OFF. 1 1 . Disconnectlhe jumper wire.

21-20

Disconnectheatercontrol panelconnectorA (14P).

1 3 .Checkfor continuitybetweenthe No. 7 and No. 8 terminalsof heatercontrol panel connectorA (14P) a n d b o d y g r o u n di n d i v i d u a l l y . HEATER CONTNOL PANEL CONNECTOR A {14PI

1 5 . Reconnectheatercontrol panel connectorA (14P). lo.

Test the power transistor(seepage 21-38). ls the power transistorOK? YES Checkfor loosewires or poor connectionsat heatercontrol panel connectorA (14P)and at the power transistor4P connector.lf the connections are good, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l NO

Replacethe power transistor.I

1 7 . Disconnectthe jumper wire. 1 8 . Disconnectthe blower motor 2P connector. 1 9 . Measurethe voltagebetweenthe No, 1 terminal of the blower motor 2P connectorand body ground.

ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the power transistor.I

BLOWERMOTOR2PCONNECTOR BLU/WHT

NO Go to step 14, 1 4 . Checkfor continuitybetweenthe following terminalsof heatercontrol panelconnectorA ( 14P) and power transistor4P connector. 'l4Pt 4P: No.4 No.7 No.8 No.2 HEATER CONTROL PANEL CONNECTOR A (14P)

Wiresideof femaleterminals

Wire side ot femaleterminals

z 3

T 8

4 1 5 1 6

r ol x l I

ls thete battery voltage?

1 2 l1 3l 1 4

BLU/YEL

YES- Replacethe blower motor.l

) 8LU/RED

NO Go to step 20.

20. Turn the ignitionswitch OFF. ILU/YEL 4PCONNECTOR POWER TRANSISTOR Wiresideof femaleterminals

2 1 .Removethe blower motor relayfrom the underhood fuse/relaybox, and test it (seepage 22-511. ls the relay OK?

ls thete continuity?

YES Go to step 22.

YES Go to step 15.

NO- Replacethe blower motor relay.l

NO Repairany open in the wire(s)betweenthe heatercontrol paneland the power transistor.l (cont'd)

21-21

Heatingand Air Conditioning DTCTroubleshootinglcont'd) 22. Measurethe voltage betweenthe No. 3 terminal of the blower motor relay 4P socketand body ground.

25. Turn the ignition switch OFF, 26. Checkfor continuitybetweenthe No. 1 terminal of the blower motor relay 4P socketand body ground.

BLOWERMOTORRELAY4PSOCKET

2 4

BLOWERMOTORRELAY4PSOCKET

ls there battety voltage? YES-Go to step 23.

ls there continuity?

NO Replacethe under-hoodfuse/relaybox.t

YES-Repair open in the BLUIr'/HTwire between the blower motor relay and the blower motor.l

23. Turn the ignitionswitch ON {ll). Measurethe voltage betweenthe No. 2 terminal of the blower motor relay 4P socketand body ground,

BLOWERMOTORRELAY4PSOCKET

ls therebattery voltage? YES-Go to step25. NO Repairopenin thewire betweenthe No.14 fusein the under-dash fuse/relay boxandthe blowermotorrelay.I

21-22

NO Checkfor an open in the wire betweenthe blower motor relay and body ground. lf the wire is O K ,c h e c kf o r p o o r g r o u n da t G 3 0 1 . 1

DTC14:An Openin the Evaporator Temperature SensorCircuit 1. Removethe evaporatortemperaturesensor(see p a g e2 1 - 3 7 ) . 2. Measurethe resistancebetweenthe No. l and No. 2 terminalsof the evaporatortemperature sensor. x D i pt h e s e n s o ri n i c ew a t e r ,a n d m e a s u r e resistance.Then pour hot water on the sensor,and c h e c kf o r c h a n g ei n r e s i s t a n c e .

4. Checkfor continuitybetweenthe No. 7 terminal of heatercontrol panelconnectorB (22P)and the No. 1 terminal of the evaporalortemperature s e n s o r2 P c o n n e c t o r . B {22P) HEATERCONTROLPANELCONNECTOR Wiresideof femaleterminals

EVAPORA TORTEMPERATURE SENSOR

ll#l

t-l SENSOR 2PCONNECTOR EVAPORATOR TEMPERATURE Wiresideof femaleterminals

lI UT-TU l , l , l l ---r---T--I t

11c))-l

ls there continuity?

\9/

T e r m i n asl i d eo f m a l et e r m i n a l s

YES Go to step 5. NO Repairopen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I 5. Disconnectheatercontrol panelconnectorA (14P).

RESISTANCE k0

50 10

68 20

86'F

30'c

TEMPERATURE ls the tesistancewithin the specificationsshown on the graph? Y E S - G o t o s t e p3 . NO Replacethe evaporatortemperature sensor.I 3. Disconnectheatercontrol panelconnectorB {22P).

(cont'd)

21-23

Heatingand Air Gonditioning DTCTroubleshooting{cont'd) 6. Checkfor continuitybetweenthe No. 2 terminal of heatercontrol panel connectorA (14P)and the No, 2 terminal of the evaporalortemperature sensor2P connector. HEATER CONTROL PANELCONNECTOR A {14PI Wiresideof femaleterminals LT GRN

DTC15:A Shortin the Evaporator Temperature SensorCircuit 1. Removethe evaporatortemperaturesensor(see p a g e2 1 - 3 7 ) . 2. Testthe evaporatortemperaturesensor(seepage 21-37J. ls the resistance within the specifications shown on the graph? YES Go to step 3. NO Replacethe evaporatortemperature sensor.!

EVAFORATOR TEMPERATURE SENSOR 2PCONNECTOR Wiresideof femaleterminals

Disconnectheatercontrol panel connectorB l22Pl. 4. Checkfor continuitybetweenthe No. 7 terminal of

ls there continuity? YES-Check for loosewires or Doorconnectionsat heatercontrol panel connectorA ('l4P)and B l22Pl and at the evaporatortemperaturesensor2P connector.lf the connectionsare good, substitutea known-goodheatercontrol panel,and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.l

heatercontrol panel connectorB {22P)and body ground. HEATER CONTROL PANELCONNECTOR B (22P)

NO Reoairooen in the wire betweenthe heater control panel and the evaporatortemperature sensor.I Wire side of femaleterminals

ls there continuity? YES Repairshort to body ground in the wire betvveenthe heatercontrol paneland the evaporatortemperaturesensor.I NO-Substitute a known-goodheatercontrol panel, and recheck.lf the symptom/indicationgoes away, replacethe original heatercontrol panel.I

21-24

RecirculationControlMotor CircuitTroubleshooting 1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e / relay box.

8. Checkfor continuitybetweenthe No. 5 and No. 6 terminalsof heatercontrol panelconnectorA (14P) and body ground individually.

ls the f use OK? YES Go to step 2.

A I14P) HEATER CONTROL PANELCONNECTOR

NO- Replacethe fuse, and recheck.l 2. Disconnectthe recirculationcontrol motor 5P conneclor.

3 . Turn the ignitionswitch ON (ll). lvleasurethe voltage betweenthe No. 5 terminal of the recirculationcontrol motor 5P connectorand body ground. RECIRCULATIONCONTROLMOTOR 5P CONNECTOR

Wire side of femaleterminals

ls there continuity? YES Repairany shortto body ground in the wire(s)betweenthe heatercontrol panel and the recirculationcontrol motor.l NO-Go to step 9. 9. Turn the ignition switch ON (ll),and checkthe same wires for voltage.

Wiresideof femaleterminals

A Il4PI PANELCONNECTOR HEATER CONTROL

ls there battery voltage? YES Go to step 5. NO- Repairopen in the wire betweenthe No. 14 fuse in the under-dashfuse/relaybox and the recirculationcontrol motor .l 5 . Turn the ignitionswitch OFF. 6 . Testthe recirculationcontrol motor {seepage 2136), ls the recirculationcontrol motor OK? YES Go to step7. NO- Replacethe recirculationcontrol motor, or r e p a i rt h e l i n k a g ea n d d o o r s . I 7 . Disconnectheatercontrol panel connectorA (14P).

Wiresideof lemaleterminals

ls therc any voltage? Y E S R e p a i ra n y s h o n t o p o w e ri n t h e w i r e ( s ) betweenthe heatercontrol panel and the recirculationcontrol motor. This shon may also d a m a g et h e h e a t e rc o n t r o lp a n e l .R e p a i rt h e s h o n to power before replacingthe heatercontrol p an e l .I N O - G o t o s t e p1 0 .

{cont d r

21-25

Heatingand Air Conditioning RecirculationControl Motor CircuitTroubleshooting(cont'd! 10. Turn the ignition swirchOFF. 11. Checkfor continuitybetweenthe following terminalsof heatercontrol panel connectorA ( 14P) and the recirculationcontrol motor 5P connector. 'l4Pt 5P: No.5 N o .1 No.6 No.2 HEATER CONTROL PANEL CONNECTOR A {14P} Wiresideol temaleterminats

RECIRCULATION CONTROL MOTOR5PCONNECTOR Wiresideol lemaleterminals ls there continuity? YES Checkfor loosewires or poor connectionsat heatercontrol panel connectorA ( 14P)and at the recirculationcontrol motor 5P conneclor.lf the connectionsare good, substitutea known-good heatercontrol panel,and recheck.lf the symptom/ indicationgoes away, replacethe original heater control panel,I NO Repairany open in the wire{s)betweenthe heatercontrol panel and the recirculationcontrol motor.l

21-26

HeaterControlPowerand GroundCircuitsTroubleshooting 1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h fuse/relaybox.

6. Checkfor continuitybetweenthe No. l3terminal of heatercontrol panelconnectorA (14P)and body g round.

ls the f use OK? A (1ilP) HEATER CONTRoLPANELCONNEcToR

YES-Go to step 2. N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l 2. Disconnectheatercontrol panelconnectorA{'14P).

1 2 3 I

8 9 r0 t,

4 5 6 1 l 12

BLK

3. Turn the ignition switch oN (ll). 4. Measurethe voltage betweenthe No. l4terminal of heatercontrol panelconnectorA (14P)and body grouno. A {14P} PANELCONNECTOR HEATER CONTROL

2 3

5 6

7 8 I 1 0l ,

11 12

BLK/YEL

Wire side of temaleterminals

ls therc continuity? YES Checkfor loosewires or poor connectionsat healercontrol panel connectorA (14P).lfthe connectionsare good, substitutea known-good heatercontrol panel,and recheck.lf the symptom/ indicationgoes away, replacethe original heater control panel.l NO Checkfor an open in the wire betweenthe heatercontrol paneland body ground. lf the wire is O K ,c h e c kf o r p o o r g r o u n da t G 5 0 1I.

ls there battery voltage? YES-Go to step 5. NO Repairopen in the wire betvveenthe No. 14 fuse in the under-dashfuse/relaybox and the heatercontrol panel.l Turn the ignitionswitch OFF.

21-27

Heatingand Air Conditioning CondenserFanCircuitTroubleshooting NOTE:lf neitherthe condenserfan nor the radiatorfan work, go to Radiatorand CondenserFansCommon CircuitTroubleshooting(seepage21-29). 1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a yb o x ,a n d t h e N o . 1 4 ( 1 0 A ) f u s ei n t h e under-dashf use/relaybox.

4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e condenserfan relay 4P socketwith a jumper wire. CONDENSERFAN RELAYitP SOCKET

Are the tuses OK?

JUMPERWIRE

YES-Go to step 2. NO Replacethe fuse(s),and recheck.t 2. Removethe condenserfan relayfrom the under-hoodfuse/relaybox, and test it ( s e ep a g e2 2 - 5 1 ) . Does the condenser lan tun? ls the relay OK? YES-Go to step 5. YES Go to step 3. NO Go to step8. NO- Replacethe condenserfan relay.l 5. Disconnectthe jumper wire. 3. Measurethe voltage betweenthe No, 2 terminal of the condenserfan relay 4P socketand body ground. CONDENSERFAN RELAYilP SOCKET

6. Turn the ignition switch ON (ll). 7. Measurethe voltage betweenthe No, 3 terminal of the condenserfan relay 4P socketand body ground. CONDENSER FAN FELAY4PSOCKET

r-,_-l 1

2 |

Flr \----1--rl

IELK/YEL

d, ls thete battery voltage?

YES-Go to step 4. ls there battery voltage? NO-Replace the under-hoodfuse/relaybox.l YES Replacethe under-hoodfuse/relaybox.t N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4 fuse in the under-dashfuse/relaybox and the c o n d e n s efra n r e l a y . l Disconnectthe jumper wire.

21-28

Radiatorand CondenserFans CommonCircuitTroubleshooting 9 . Disconnectthe condenserfan 2P connector, 1 0 .Checkfor continuitybetweenthe No. 1 terminal of the condenserfan relay 4P socketand the No. 2 terminal of the condenserfan 2P connector. CONDENSER FANRELAY4PSOCKET

NOTE;lf both fans and the Ay'Ccompressorclutchdo not work when the Ay'Cswitch is on, go to Ay'CPressure Switch CircuitTroubleshooting(seepage 21-32l,. 1. Checkthe No. 1 {20A}and No. 4 (20A)fuses in the under-hoodfuse/relaybox, and the No. 14 (10A) fuse in the under-dashfuse/relaybox. Are the tuses OK? YES Go to steD2. NO Replacethe fuse(s),and recheck.l

CONDENSERFAN 2P CONNECTOR Wire side of femaleterminals

2. Removethe condenserfan relavfrom the under-hoodf use/relaybox. 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ; .

Is there continuity? 4. Measurethe voltage betweenthe No. 3 terminal of the condenserfan relay 4P socketand body ground.

YES Go to step 11. NO- Repairopen in the wire betweenthe c o n d e n s efra n r e l a ya n d t h e c o n d e n s efra n , I '11. Checkfor continuitybetweenthe No. 1 terminal of the condenserfan 2P connectorand body ground. FAN2PCONNECTOR CONDENSER

-l r-,

FANRELAY4PSOCKET CONDENSER

1 2 l f---r---

l,l,l lar-vverl

BLK

ls there battery voltage? YES Go to step 5.

Wire side of {emaleterminals

ls there continuity?

NO Repairopen in the wire betweenthe No. 14 fuse in the under-dashfuse/relaybox and the radiatorfan relay,and the condenserfan relay.l

YES- Replacethe condenserfan motor.I

5. Turn the ignition switch OFF.

NO Checkfor an open in the wire betweenthe condenserfan and body ground. lf the wire is oK, c h e c kf o r p o o rg r o u n da t G 3 0 1 . 1

l e c o n d e n s efra n r e l a y . 6 . R e i n s t a tl h 7 . M a k es u r et h e I V Cs w i t c hi s O F F . 8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

(cont'd)

21-29

HeatingandAir Conditioning Radiatorand CondenserFans CommonCircuitTroubleshooting

(cont'dl

9. Using a BackprobeSet, measurethe voltage betweenthe No. 6 terminal of ECN4 connectorB {24P)and body ground with the ECMconnectors connecteo. ECMCONNECTOR B {24P}

CompressorClutchCircuit Troubleshooting 1. Checkthe No. 1 (20A)fuse in the under-hood f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e under-dashfuse/relaybox. Are the tuses OK? YES Go to step 2. NO Replacethe fuse(s),and recheck.I 2. Checkthe enginecoolanttemperature,the throttle positionsensor,and the idle speed (usethe Honda PGMTesterPGM-Fldata list if possible). ls the coolant temperaturc above nomal, the throttle position sensor rcading too high, or the idle speed too low?

Wire side of femaleterminals

ls there battery voltage? YES UDdatethe ECM if it does not have the latest so{tware,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECM,replacethe originaE l CM.I NO Repairopen in the wire betweenthe radiator fan relay,the condenserfan relay and the ECM.t

YES Troubleshootand repairthe causeof the high enginecoolanttemperature,high throttle positionsensor reading,or low idle speed.l NO-Go to step 3. 3. Removethe compressorclutchrelay from the under-hoodfuse/relaybox, and test it (seepage 225 1) . ls the relay OK? YES Go to step 4. NO Replacethe compressorclutch relay.I 4. Measurethe voltage betweenthe No. 2 terminal of the compressorclutch relay 4P socketand body ground. COMPfiESSON CLUTCHBELAY'P SOCKET

ls there battery voltage? YES Go to step 5. NO Replacethe under-hoodfuse/relaybox.I

21-30

5. Connectthe No. 1 and No. 2 terminalsof the compressorclutch relay 4P socketwith a jumper wire. COMPRESSORCLUTCHRELAY4P SOCKET

L Turn the ignition switch OFF. 10. Reinstallthecompressorclutch relay. 11. l\4akesure the Ay'Cswitch is OFF. 1 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .

JUMPERWIRE

13. Uslng the BackprobeSet, measurethe voltage betweenthe No. 18 termina!of ECI\4connector E {31P)and body ground with the ECMconnectors connected. ECMCONNECTOR E 131P} 2

3 t 4 5

Does the compressor clutch click ?

22 23 24

m 21

1 4 1 5 16

RED

YES Go to step 6. N O - G o t o s t e p1 4 . 6. Disconnectthe jumper wire.

Wire side of femaleterminals

7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . ls there battery voltage? 8. Measurethe voltagebetweenthe No. 3 terminal of the compressorclutch relay 4P socketand body ground. COMPRESSOR CLUTCHRELAY4PSOCKET

YES Updatethe ECM if it does not have the latest software,or substitutea known-goodECM,then recheck(seepage 11-6).lf the symptom/indication goes away with a known-goodECIM,replacethe o r i g i n aE l CM.I NO Repairopen in the wire betweenthe c o m p r e s s ocr l u t c hr e l a ya n d t h e E C M . I 1 4 . D i s c o n n e ct h t e j u m p e rw i r e . 15. Disconnectthe compressorclutch lPconnector.

ls there battery voltage? YES-Go to step 9. NO Repairopen in the wire betweenthe No. 1 4 fuse in the under-dashfuse/relaybox and the compressorclutch relay,I

{cont'd)

21-31

Heatingand Air Conditioning Compressor ClutchCircuit Troubleshooting(cont'dl 16. Checkfor continuitybetweenthe No. lterminal of the compressorclutch relav 4P socketand the No. l terminal of the compressorclutch 1Pconneclor. COMPRESSON CLUTCHRELAY4PSOCKET

A/C PressureSwitch Circuit Troubleshooting '1.

Turn the ignition switch ON {ll).

2. Turn the blower switch on, and checkfor blower motor operatron. Does the blower motor run on all speeds? YES Go to step 3. NO Troubleshootthe blower motor circuit(see page21-20). 3. Turn the ignition switch OFF. 4. Disconnectheatercontrol panelconnectorA ('14P).

COMPRESSORCLUTCH1P CONNECTOR Terminalside of male terminals

ls therc continuity? YES-Check the compressorclutchclearance,the thermal protector,and the compressorclutchfield c o i l ( s e ep a g e2 1 - 4 8 ) . I

5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 6. Measurethe voltage betweenthe No, 4 terminal of heatercontrol panelconnectorA {14P)and body ground. HEATER CONTROL PANELCONNECTOR A (I4P}

NO-Repair open in the wire betweenthe compressorclutch relay and the compressor clutch.l

Wire side of femaletermina's

ls there battety voltage? YES Go to step 7. N O - G o t o s t e p9 . 1 . S t a nt h e e n g i n e .

21-32

8. Connectthe No.4terminal ofheatercontrol connectorA (14P)to body ground with a jumper wire,

11. Checkfor continuitybetweenthe No. 2 terminal of the A,/Cpressureswitch 2P connectorand the No. 9 terminal of under-dashfuse relav box connector F t12Pt.

HEATER CONTROLPANELCONNECTOR A I14P}

A/C PRESSURE SWITCH2PCONNECTOR W i r e s i d eo f f e m a l et e r m i n a l s

BLU 2 3 7 8 I

5 6

r 0 l x 11 12 l 3 t 4 JUMPER WIBE

UNDER.OASHFUSE/RELAYBOX CONNECTORF (12P) W i r es i d eo f f e n a l e l e r r r i n a l '

Wiresideoffemale terminals

Does the A/C system come on?

ls there continuity?

YES Replacethe heatercontrol panel.!

YES Go to step 12.

NO Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1

NO Repairopen in the wire betweenthe pressure under-dashfuse/relaybox and the A,,/C switch.I

9 . Usingthe BackprobeSet,connectthe No. 9 terminal of under-dashfuse/relaybox connector F ( 1 2 P t)o b o d y g r o u n dw i t h a j u m p e rw i r e .

1 2 . Checkfor continuitybetweenthe No. 1 and No. 2 terminalsof the A,/Cpressureswitch. A/C PRESSURE SWITCH

BOXCONNECTOR F{12P} UNOER.DASH FUSE/RELAY 2 6 1

B g l r ot l l 2 BLU/WHT JUMPER WIRE

Wire side of female terminals

ls there continuity? Does the NC system come on? YES Go to step 10. NO- Referto the multiplexcontrol system (see p a g e2 2 - 1 6 8 ) . 1 '1. N O T EC : h e c kf o r m u l t i p l e xc o d e si n m o d e F o l l o w the troubleshooting{or any codesfound. lf no codesare found, subsititutea known-9ood m u l t i p l e xc o n t r o lu n i ta n d a E C Mo n e a t a t i m e . 1 0 . Disconnectthe Ay'Cpressureswitch 2P connector and under-dashfuse/relaybox connectorF { 12P).

YES Repairopen in the wire betweenthe heater control panel and the A,/Cpressureswitch.l N O G o t o s t e p1 3 .

'13.check for properAy'Csystem pressure. ls the pressure within specitications? YES Replacethe AilCpressureswitch.l NO

Repairthe AilCpressureproblem.I

21-33

HeatingandAir Conditioning Air Mix ControlMotorTest 1. Disconnectthe 5P connectorfrom the air mix control motor. 2. Connectbatterypowertothe No. l terminal ofthe air mix control motor, and ground the No. 2 t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d stop at Max Cool.lf it doesn't,reversethe connections;theair mix control motor should run, and stop at Max Hot. lf the air mix control motor does not run, remove it. then checkthe air mix control linkageand door for smooth movement.

Air Mix ControlMotor Replacement 1 . Removethe under-dashfuse/relaybox (seepage 22-491. Disconnectthe 5P connector{A) from the air mix control motor (B).Removethe self-tappingscrews and the air mix control motor from the heaterunit. R e m o v et h e r o d ( C )f r o m t h e a r m ( D )o f t h e a i r m i x controi motor.

,.,:l'

. lf the linkageand door move smoothly,replace the air mix control motor. . l f t h e l i n k a g eo r d o o r s t i c k o rb i n d ,r e p a i r t h e ma s needed. . lf the air mix control motor runs smoothly,go to step 3. AIRMIX CONTROLMOTOR

3 . Installthe motor in the reverseorder of removal. After installation,make surethe motor runs smoothly.

3 . Measurethe resistancebetweenthe No. 4 and No. 5 terminals.lt should be between2.1 k to 3 . 9k Q . 4 . Reconnectthe air mix control motor 5P connector,

t h e nt u r n t h e i g n i t i o ns w i t c hO N { l l ) . Using the BackprobeSet, measurethe voltage betweenthe No. 3 and No. 4 terminals. Max Cool about 1V Max Hot about 4 V lf eitherthe resistanceor voltage readingsare not as specified,replacethe air mix cotrol motor.

21-34

Mode ControlMotor Test '1.

Disconnectthe 10Pconnectorfrom the mode control motor.

Mode ControlMotor Replacement 1 . R e m o v et h e E C M( s e ep a g e 1 1 - 4 ) .

2. Removethe relay mount bracketbolt, and move Connectbatterypower to the No. 1 terminal of the mode control motor, and groundthe No. 2 terminal;the mode control motor should run smoothly and stop at Defrost.lf it doesn't,reverse the connections;the mode control motor should run smoothly and stop at Vent.When the mode control motor stops running,disconnectbattery power immediately.

the relaysout of the way.

3 . Disconnectthe 10Pconnector{A) from the mode control motor (B).Removethe self-tappingscrews and the mode control motor from the heaterunit.

MODECONTROLMOTOR

3. lfthe mode control motor does not run in step 2, remove it, then checkthe mode control linkageand doors for smooth movement.

4 . lnstallthe motor in the reverseorder of removal. lvlakesure the pin on the linkageis properly engagedwith the motor. After installation.make sure the motor runs smoothly.

. lf the linkageand doors move smoothly. replace the mode control motor. . l f t h e l i n k a g eo r d o o r s s t i c ko r b i n d ,r e p a i r t h e m as neeoeo. . lfthe mode control motor runs smoothly,go to step 4. 4 . Use a digital multimeterwith an output of 1 mA or lessat the 20 k Q range.With the mode control motor running as in step 2, checkfor continuity b e t w e e nt h e N o . 4 , 5 , 6 , 7 , 8 , a n d 9 t e r m i n a l sa n d t h e N o . 1 0t e r m i n a li n d i v i d u a l l yT.h e r es h o u l db e c o n t i n u i t yf o r a m o m e n ta t e a c ht e r m i n a la s t h e motor moves past each mode position. lf there is no continuityfor a moment at each terminal. replacethe mode control motor.

21-35

HeatingandAir Conditioning RecirculationControlMotor Test

RecirculationControlMotor Replacement

1. Disconnectthe 5P connectorfrom the recirculation control motor. 1 . R e m o v et h e E C M( s e ep a g e1 1 - 4 ) . Incorrectlyapplying power and ground to the recirculationcontrol motor will damge it. Follow the instructionscarefullv. 2. Connectbattervoower to the No. 5 terminal ofthe recirculationcontrol motor, and ground the No. 1 and No. 2 terminals;the recirculationcontrol motor should run smoothly.To avoid damagingthe recirculationcontrol motor, do not reversepower and ground. Disconnectthe No. 1 or No. 2 terminalsfrom ground;the recirculationcontrol motor should stop at Freshor Recirculate.Don't cyclethe recirculationcontrol motor {or a long time.

Removethe relay mount bracketbolt.and move the relaysout of the way, Disconnectthe 5P connector(A)from the recirculationcontrol motor (B),Removethe selftapping screwsand the recirculationcontrol motor from the blower unit.

RECIRCULATION CONTROL MOTOR

Installthe motor in the reverseorder of removal. Make sure the pin on the motor is properly engagedwith the linkage.After installation.make sure the motor runs smoothly.

lf the recirculationcontrol motor does not run in step 2, remove it, then checkthe recirculation control linkageand doors for smooth movement. . lfthe linkageand doors move smoothly,replace the recirculationcontrol motor. . l f t h e l i n k a g e o r d o o r s s t i c k obr i n d ,r e p a i r t h e m as neeoeo.

21-36

EvaporatorTemperatureSensor Replacement

EvaporatorTemperatureSensor Test

1 . Removethe driver'sdashboardlower cover (see page 20-59)and the under cover (seepage 20-60).

l. Dip the sensorin ice water, and measurethe resistancebetweenits terminals

Removethe under-dashfuse/relaybox (seepage 22-491.

EVAPORATOR TEMPERATURE SENSOR

Disconnectthe 2P connector(A)from the evaporatortemperaturesensor(B),then remove the connectorclip (C).Removethe self-tapping screw,and carefullypull out the evaporator temperature.

Terminalside ol male terminals

2 . Then pour hot water on the sensor,and check{or a changein resistance.

3 . Comparethe resistancereadingswith the specificationsshown in the graph;the resistance should be within the specifications

4. Installthe sensorin the reverseorder of removal, RESISTANCE k9

32 0

50 10

68 20

86 'F 30'c

TEMPERATURE

21-37

HeatingandAir Gonditioning PowerTransistorTest 1. Disconnectthe 4P connectorfrom the power Iranslslor. 2, Measurethe resistancebetweenthe No. 1 and No. 2 terminalsof the power transistor.lt should be '1.4 1 . 5k Q . about . lf the resistanceiswithln the specifications, go to step 3. . lf the resistanceis notwithin the specifications, replacethe power transistor.

HeaterControlPaneland Push Switch AssemblyRemovaland Installation 1 . Removethe centerpanel (seepage 20-62). Removethe dials (A),then removethe self-tapping screwsand the heatercontrol panel (B)from the centerpanel (Cl. Removethe self-tappingscrews and the push switch assembly(D)from the center panel.

POWERTRANSISTOB

C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l (BLUI/EL)(A) in the 4P connector,then removethe terminaa l n d i n s u l a t ei t f r o m b o d y g r o u n d .

\ 3 . lnstallthe control panel and push switch assembly in the reverseorder of removal.After installation, operatethe control panel controlsto see whether it worKspropeny. functionto confirm that 4 . Runthe self-diagnosis there are no problemsin the system (seepage218).

(To112 power o w e rssource 2V p o u r c eo n vvehicle) ehicle) on Reconnectthe 4P connectorto the power transistor. S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r wire. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e b l o w e rm o t o r r u n s . . lf the blower motor does not run, replacethe power rranstsror. . l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s

oK.

21-38

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

BlowerUnit Removaland lnstallation For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand procedures(seepage 23-14) in the SRSsectionbeforeperforming repairsor service. 1. Make sure you havethe anti-theftcode for the radio, then write down the frequenciesfor the preset buttons. 2. Disconnectthe batterynegativecable,and wait 3 minutesbefore beginningworK. 3. Removethe right kick panel (see page 20-50), passenger'sdashboardlower cover,and the glove box {seepage 20-63). 4. Cut the plasticcross bracein the glove box opening with diagonalcuttersin the area shown. Remove and discardthe plasticcross brace,

Removethe filter {A) from the housing (B),and replacethe filter.

Cut heare.

4. Installthe filters in the reverseorder of removal.

{cont'd)

21-39

Heatingand Air Gonditioning Blower Unit Removaland Installation{cont'd} Removethe steeringhangerbeam bracketcover from the right side of the glove box opening,then removethe bolts and the olove box frame.

10. Disconnecttheconnector{A) from the recirculation control motor, then removethe wire harnessclip {B).Removethe mounting bolts,the mounting nuts a n d t h e b l o w e ru n i t ( C ) .

Removethe ECM(seepage 11-4). 1 . Removethe EPScontrol unit (seepage 17-67).

6 x 1 . 0m m I 9.8N.m(1.0kgt.m, 7.2tbt.ftl

8 . Disconnectand removethe PGM-Flmain relays and bracketassembly,then removethe ECM bracket. 9 . Disconnectthe connectors{A) from the blower motor and the power transistor,then removethe wire harnessclips (B)and the connectors(C). Removethe self-tappingscrewsand the bracket(D). A

6x1.0mm 9.8 N.m (1.0kgf.m, ?.2 tbf.ft)

1 1 .I n s t a l l l h eu n i t i n t h e r e v e r s eo r d e ro f r e m o v a l . M a k es u r et h a tt h e r ei s n o a i r l e a k a g e . Reconnectthe negativebatteryterminal.

'13.

D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n procedure { s e ep a g e1 1 - 1 3 9 ) .

1 4 . Enterthe anti-theftcode for the radio,then enter the customer'sradio station presets.

21-40

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

21-41

Heatingand Air Gonditioning

EvaporatorCoreReplacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53).

5. Carefullypull out the evaporatorcore without bendingthe pipes.

Removethe bolt,then disconnectthe suctionline (A) and the receiverline (B)from the evaporator core.

6x10mm 9.8N.m(1.0kgt.m,7.2lbf.ft) Removethe blower unit (seepage 21-39). Removethe self-tappingscrewsand the expansion valve cover.

21-42

6 . Installthecore in the reverseorder of removal,and note these items. . lfyou're installinga new evaporatorcore, add r e f r i g e r a not i l ( K E l H l NS P - ] 0 )( s e ep a g e2 1 - 6 ) . . Replacethe O-ringswith new ones at eachfitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings f o r H F C - 1 3 4(aR - ' 1 3 4 tao) a v o i dl e a k a g e . . l m m e d i a t e l y a f t eurs i n g t h eo i l , r e i n s t a l l t h e c a p on the container,and seal it to avoid moisture absorotion. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrigerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55).

HeaterUnit/CoreReplacement SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23'13),and precautionsand procedures(seepage 23-14)in the SRS sectionbefore performingrepairsor service. 1. Make sure you have the anti-theftcode forthe radio, then write down the freouenciesfor the radio's Dresetbuttons.

6. Slidethe hose clamps (A) back,then d isconnectthe inlet heaterhose (B)and the outlet heaterhose (C) from the heatercore. Enginecoolantwill run out when the hosesare disconnected;drain it into a clean drip pan. Be sure not to let coolantspill on the electricalpartsor the paintedsurfaces.lf any coolantspills,rinse it off immediately.

Disconnectthe negativecablefrom the battery, Disconnectthe suctionand receiverlinesfrom the evaporator core (see page 21-42). 4 . From underthe hood, open the cableclamp (A), then disconnectthe heatervalve cable (B)from the heatervalve arm (C).Turn the heatervalve arm to the fully openedpositionas shown

7 . Removethe bolt and the heatervalve,then remove the mounting nut from the heaterunit.Takecare not to damageor bend the fuel lines and the brake lines,etc.

W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t from the radiator(seepage 10-6).

8 x 1.25mm 12 N.m (1.2kgf.m,8.7lbf.ft)

(cont'd)

21-43

Heatingand Air Conditioning HeaterUnit/CoreReplacement(cont'd) 8. Removethe dashboard{seepage 20-66).

1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s , and the heaterunit.

9. Disconnecttheconnectors(A) from the blower motor, the recirculationcontrol motor, the mode control motor, and the power transistor,then removethe wire harnessclips (B)and the connector(C).Removethe self-tappingscrewsand the bracket(D).

7 t , 5 x 1 . 0m m 9.8 N.m 11.0kgl m, 7.2 tbf.ftl

12. Removethe self-tappingscrewsand the expansion

1 0 ,Disconnectthe connectors(A) from the evaporator temperaturesensorand the air mix control motor, then removethe wire harnessclips (B) and the connector(C).Removethe self-tappingscrew and the cover (D).Disconnectthe heatervalve cable (E).

valve cover (A).Carefullypull out the evaporator core (B)so you don't bendthe inlet and outlet pipes. Removethe grommet (C),then removethe selftapping screwsand the flange cover (D).Bemove the self-tappingscrewsand the pipe cover (E),then carefullypull out the heatercore (F)so you don't bend the inlet and outlet oioes.

21-44

13. Installthe heatercore and the evaporatorcore in the reverseorder of removal. 14. Installthe heaterunit in the reverseorder of removal,and note these items: . Do not interchangethe inlet and outlet heater hoses,and installthe hoseclamps securely. . Refillthecooling systemwith engine coolant(see page 10-6). . Adjust the heatervalve cable (see page2'l-461. . Make sure that there is no coolantleakage. . Make sure that there is no air leakage. . Referto evaporatorcore replacement{seestep 6 o n p a g e2 1 - 4 2 ) . . Do the enginecontrol module (ECl\4)idle learn p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) . . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationDresets.

21-45

Heatingand Air Conditioning HeaterValveCableAdjustment 1 . F r o mu n d e r t h eh o o d ,o p e nt h e c a b l ec l a m p{ A ) , then disconnectthe heatervalve cable (B)from the heatervalve arm {C).

5, From under the hood,turn the heatervalve arm {C) to the fully closedpositionas shown, and hold it. Attachthe heatervalve cable (B)to the heatervalve a r m ,a n d g e n t l yp u l l o n t h e h e a t e rv a l v ec a b l e housingto take up any slack,then installthe heater v a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .

.'.-:',, - " l l

...... t

From under the dash,disconnectthe heatervalve c a b l eh o u s i n gf r o m t h e c a b l ec l a m p( A ) ,a n d disconnectthe heatervalve cable (B)from the air m i x c o n t r o l i n k a g e{ C ) .

\ t.- l

\'r2t'

''' ' ::"'

Set the temperaturecontrol dial on Max Cool with the ignition switch ON (ll). Attachthe heatervalve cable (B)to the air mix control linkage(C)as shown above,then snap the h e a t e rv a l v ec a b l eh o u s i n gi n t ot h e c a b l ec l a m p( A ) .

21-46

CompressorReplacement 1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e engineat idle speed,and let the air conditioning work for a few minutes,then shut the engine off.

8. Removethe mounting bolts and the compressor.

2. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the radio's presetbuttons. 3. Disconnectthe negativecablefrom the battery. 4. Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). 5. Removethe alternator(seepage 4-29). 6. Removethe Ay'Ccondenserfan assembly(seepage 10-10). 7. Disconnectthecompressorclutchconnector(A), removethe bolts,then disconnectthe suction line ( B )a n d t h e d i s c h a r g el i n e( C ) f r o mt h e c o m p r e s s o r . Plug or cap the lines immediatelyafter disconnectingthem to avoid moistureand dust contamination. 6 x '1.0mm 9.8 N.m 11.0kgt.m, 7.2 tbl.ttl

u1/ (

8 x 1 . 2 5m m 22 N.m12.2kgf.m. 9 . I n s t a l l t h ec o m p r e s s oirn t h e r e v e r s eo r d e ro f removal,and note these items: . Beforeinstallingthe new compressor,checkfor m e t a lo r o t h e rc o n t a m i n a t i o inn t h e l i n e .R e p l a c e any contaminatedparts. . lf you're installinga newcompressor,you must calculatethe amount of refrigerantoil to be removedfrom it (seepage 21-6). . Replacethe O-ringswith new ones at each fitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to use the correctO-rings f o r H F C - 1 3 4{aR - 1 3 4 at o ) a v o i dl e a k a g e , . U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o ) r HFC-134a K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y . . To avoid contaminatlon,do not returnthe oilto the containeronce dispensed,and never mix it with other refrigerantoils. . l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p on the container,and seal it to avoid moisture absorption. . Do not spill the refrigerantoil on the vehicle;it may damagethe paint. lf the refrlgerantoil contactsthe paint,wash it off immediately. . Chargethe system (seepage 21-55). . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) . . Enterthe antitheft code for the radio,then enter the customer'sradio station presets.

21-47

HeatingandAir Gonditioning

CompressorClutchCheck 1 . Checkthe armatureplatefor discoloration,peeling, or other damage.lf there is damage,replacethe clutch set (seepage 21-49), Checkthe rotor pulley bearingplay and drag by rotatingthe rotor pulley by hand.Beplacethe clutchset with a new one if it is noisy or has excessiveplay/drag(seepage 21-49).

4. Releasethe field coil connectorf rom the holder, then disconnectit. Checkthe thermal protectorfor continuity.lf there is no continuity,replacethe t h e r m a lp r o t e c t o (r s e ep a g e2 1 - 5 1 ) . NOTE:The thermal Drotectorwill have no . hen c o n t i n u i t ya b o v e2 5 2 t o 2 7 0 " F\ 1 2 2 l o 1 3 2 ' C )W t h et e m p e r a t u r e d r o p sb e l o w2 4 1t o 2 1 9 ' F( 1 1 6t o 104'C),the thermal protectorwill have continuity.

,\. Measurethe clearancebetweenthe rotor pulley (A) and the armatureplate (B)all the way around.lf the clearanceis not within specifiedlimits, removethe armatureplate (seepage 21-49)and add or remove shims as neededto increaseor decreaseclearance.

Checkresistanceof the field coil. lf resistanceis not within specifications,replacethe field coil ( s e ep a g e2 1 - 4 9 ) . FieldCoil Resistance: 3.05 3.35ohmsat68"F

Clearance: 0.510.15 mm {0.02010.006in.) N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s : 0 . 1m m . 0 . 2m m , 0 . 4m m , a n d0 . 5m m .

21-48

t20"c)

Compressor ClutchOverhaul Special Tool Required A,/Cclutch holder,Robinair10204.Kent-MooreJ37872, or HondaTool and EquipmentKMT-J33939, c o m m e r c i a l la yvailable 1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e armatureplatewith a commerciallyavailableA,/C c l u t c hh o l d e r( B ) . 1 7 . 6N . m {1.8kgf.m, 13 tbt.ft)

3. lf you are replacingthe field coil, removethe snap ring (A) with snap ring pliers,then removethe rotor pulley (B).Be careful not to damagethe rotor pulley or tne compressor.

\ot

-@ /@h"

.ffi Removethe armatureplate (A) and shim(s)(B), taking care not to losethe shim(s).lf the clutch needsadjustment,increaseor decreasethe number and thicknessof shims as necessary,then reinstallthearmatureDlate,and recheckits clearance(see page21-481.

4. Removethe bolt and holder (A).then disconnect the field coil connector(B).Loosenthe clamp screw (C)to iree the field coil wire. Removethe snap ring { D ) w i t hs n a pr i n g p l i e r s t, h e n r e m o v et h e f i e l dc o i l (E).Be careful not to damagethe field coil or the comoressor.

N O T ET : h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s : 0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .

9-=-g

7.4 N.m (0.75kgf m, 5 tbf.ft) ----------------

"\)

(cont'd)

21-49

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

21-50

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

CompressorReliefValve Replacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53).

2 . Removethe reliefvalve (A) and the O-ring (B).Plug the openingto keepforeign mafterfrom entering the system and the compressoroil from running out.

7.4 N.m (0.75kgf.m, 5 rbf.ftl

9,8 N.m (1.0kgf m,7.2lbf.ft)

Replacethe thermal protector(A)with a new one, and apply siliconesealant(B)to the bottom of the thermal Drotector.

Clean the mating surfaces. 4 . Installa new O-ringon the reliefvalve, and apply a

thin coat of refrigerantoil to the O-ring. Removethe plug, and installand tightenthe relief valve. Chargethe system (seepage21-55).

A 3. lnstall in the reverse order of removal.

21-51

Heatingand Air Conditioning GondenserReplacement 1 . Recoverthe refrigerantwith a recovery/recycling/ chargingstation(seepage 21-53). Removethe front bumper {seepage 20-85). Removethe bolts,then disconnectthe discharge line (A) and the condenserline (B)from the condenser.Plug or cap the lines immediatelyafter disconnectingthem to avoid moistureand dust conlamtnaflon.

4, Removethe mounting bolts,then removethe condenserby lifting it up. Be carefulnot to damage the radiatoo r r t h e c o n d e n s efri n s w h e n r e m o v i n o the condenser.

6 x '1.0mm 9.8 N.m ('1.0kgf.m, 7.2 tbl.ftl

-"'. f,

-li

:.--\ ----

.:)-

- -'

5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f removal,and note these items. 6x1.0mm 9.8 N.m ('1.0kgf.m,7.2lbf.ft)

,t\

6x1.0mm 9.8 N.m (1.0kgt.m.7.2lbf.ft)

21-52

. l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) . . Replacethe O-ringswith new ones at eachfitting, and apply a thin coat of refrigerantoil before installingthem. Be sure to usethe correctO-rings t ov o i dl e a k a g e . f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a . lmmediatelyafter using the oil, reinstallthecap on the container,and seal it to avoid moisture absorption. . D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t may damagethe paint.lf the refrigerantoil contactsthe paint,wash it off immediately. . Be carefulnot to damagethe radiatoror the condenserfins when installingthe condenser. . Chargethe system (seepage 21-55).

RefrigerantRecovery

Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose.or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor

1. Connecta R-134arefrigerantrecovery/recycling/ chargingstation{A) to the high-pressureservice port (B)and the low-pressureserviceport (C),as shown, following the equipmentmanufacturer's instructions. 1!l

Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystemdischargeoccurs,ventilatethe work area before resumingservice

-'',

'=i

( -

Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers.

lvleasurethe amount of refrigerantoil removed from the Ay'Csystem after the recoveryprocessis completed.Be sure to put the same amount of new refrigerantoil backinto the Ay'Csystem before chargrng.

21-53

Heatingand Air Conditioning SystemEvacuation

. Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. . Be carefulwhen connectingserviceequipment. . Do not breatherefrigerantor vapor.

Use only serviceequipmentthat is U.L.-listedand is certifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 a ) f r o m t h e a i rc o n d i t i o n i n q system.

2. Connecta R-134arefrigerantrecovery/recycling/ chargingstation(A)to the high-pressureservice pon (B)and the low-pressureserviceport (C),as shown,following the equipmentmanufacturer's instructions.Evacuatethe system.

-i -

r4.t

lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. 1. When an Ay'Csystem has been openedto the atmosphere,such as during installationor repair,it must be evacuatedusing a R-134arefrigerant recovery/recycling/charging station(lf the system has been open for severaldays,the receiver/dryer should be replaced,and the system should be evacuatedfor severalhours.)

lf the low-pressuredoes not reachmore than 93.3 k P a{ 7 0 0m m H g ,2 7 . 6i n . H g )i n 1 5 m i n u t e st,h e r ei s probablya leak in the system.Partiallychargethe system,and checkfor leaks(seestep 3 on page 2156).

21-54

SystemCharging 2 . Evacuatethe system(seepage 21'54). Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor,

3 . Add the same amount of new refrigerantoil to the systemthat was removedduring recovery.Use only KEIHINSP-10refrigerantoil. 4 . Chargethe system with the specifiedamount of

dn di s U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a certifiedto meet the requirementsof SAEJ2210to r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice Additionalhealthand safetyinformationmay be obtainedfrom the refrigerantand lubricant manufacturers.

R-134arefrigerant.Do not overchargethe system; the compressorwill be damaged. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55 kg 1 . 1 0t o 1 . 2 1l b s 17.6to 19.4oz Checkfor refrigerantleaks(seepage 21'56).

1. Connecta R-134arefrigerantrecovery/recycling/ c h a r g i n gs t a t i o n( A )t o t h e h i g h - p r e s s u rsee r v i c e pon (B)and the low-pressureserviceport {C),as shown, following the equipmentmanufacturer's instructions.

Checkfor system performance(seepage 21-58).

21-55

HeatingandAir Conditioning RefrigerantLeakTest Special Tool Required Leakdetector,HondaTool and EquipmentYGK-H-10PM c o m m e r c i a l la vvailable

1. Connecta R-134arefrigerantrecovery/recycling/ chargingstation(A)to the high-pressureservice port (B)and the low-pressureserviceport (C),as shown, following the equipmentmanufacturer's anstructions.

Compressedair mixed with R-134aforms a combustiblevapor. The vapor can burn or explodecausingserious

injury. Neverusecompressed airto pressure test R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r conditioningsystem.

A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r can irritateyour eyes,nose,or throat. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor

Use only serviceequipmentthat is U.L.-listedand is certiifiedto meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice. R - 1 3 4 as e r v i c ee q u i p m e n o t r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretestedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers.

Open the high pressurevalve to chargethe system to the specifiedcapacity,then closethe supply valve,and removethe chargingsystem couplers. Selectthe appropriateunits of measurefor your refrigerantchargingstation. Refrigerant capacity: 500 to 550 g 0.50to 0.55kg 1 . 1 0t o 1 . 2 1l b s 17.6to 19.4oz

3 . Checkthe systemfor leaksusing a R-134a refrigerantleak detectorwith an accuracyof 14 g (0.5oz) per year or better. lf you find leaksthat requirethe systemto be opened(to repair or replacehoses,fittings,etc.), recoverthe system. After checkingand repairingleaks,evacuatethe system.

21-56

A/C SystemTests Pressure Test Test results (high) Discharge pressure abnormallyhigh

svmotom3 pressure Afterstoppingcompressor, to dropsquickly,andthencontinues Beduced or no airflow through condenser hot. Lineto condenser is excessively

DGaUSe

Air in system Cloggedcondenser or radiator fins or radiatorfan not Condenser Restrictedflow of refrigerantin

discharge pressure Highand low pressures arebalanced . Faultycompressor Discharge valve Low soonafterstoppingcompressor, . Faultvcomoressor seal sideis hioherthannormal. valve Faultyexpansion Outletof expansionvalve is not gaugeindicates Moisturein system frosted,low pressure

(low) Suction pressure low abnormally

Suctionpressure high abnormally

Expansion valveis not frosted,and lineis not cold.Low low-pressure pressure gaugeindicates vacuum,

is low,andthe Frozenevaporator Discharge temperature air flow from vents is restricted. Exoansion valveis frosted. Receivetdryer outletis cool,and inlet Cloggedreceiver/dryer is warm (shouldbe warm during ooeralton), Low pressure hoseandcheckjointare E x p a n s i o nv a l v e o p e n t o o l o n g around coolerthanthetemperature evaoorator, in system refrigerant Excessive is loweredwhen Suctionpressure ..nrlenser

is cooled bv water.

areequalized Highand low pressure is stopped, assoonasthecompressor while andbothgaugesfluctuate Reduced airflow throughcondenser. Suctionand dascharge pressures abnormallv hioh hoseand metalend Low-pressure Suctionand pressure areasarecoolerthanevaoorator, discharge valve Temperature aroundexpansion abnormally low is too low comparedwith thataround leaks Fefrigerant

' Frozenexpansion valve (Moisturein system) . Faultyexpansion valve

:omoressor clulchis dirtv. lomoressorbolt(s)aredirtv. ; o m D r e s s o ro a s k e t i s w e t w i t h o i l .

Faultygasket valve Faultyhigh pressure Foreignpaniclestuckin high . Cloggedcondenser or radiator fins ' Condenser or radiatorfan not workinoorooerlv Cloggedor kinkedlow-pressure hoseoarts

Recover,evacuate(seepage21-54), and rechargewith specifiedamount {seeoaoe21 55). Clean Checkfan voltageand rpm. Checkfan direction. restricted lines. Replace the compressor. Beplace . Replace valve. the expansion . Recover,evacuatefor at least 30 minutes,and rechargewith sDecified amount. Recover,evacuatefor at least with 30 minutes,and recharge amount. specified valve. the expansion Beplace Runthe fan with compressoroff, then checkevaooratottemoeraturesensor. eanor reolace, Replacereceaver/dryer. Bepairor replace. Recover,evacuate,and rechargewith qnp.ifie.lamo'rnr

Replace the compressor.

Clean Checkvoltageand fan rpm. Checkfan direction. Repairor replace.

C l o g g e d h i g h - p r e s s u r el i n e

Repairor replace,

:omoressor shaftsealleakinq no aroundbolt(s) iet no

Reolace the comDressor, Tiohtenbolt{s)ot reolacecomDressor, acethe comoressor.

(cont'd)

21-57

Heatingand Air Conditioning A/C SystemTests(cont'd) PerformanceTest

' Compressedair mixed with R-134aforms a combustiblevapor. . T h e v a p o rc a n b u r n o r e x p l o d ec a u s i n gs e r i o u s Injury. . Never use compressedair to pressuretest R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r conditioning systems.

Open the glove box. Removeboth glove box stops, then let the glove box hang down (seepage 20-63). 4 . Inserta thermometer(A) in the centervent, and placeanotherthermometer{B) nearthe blower unit.

Air conditioningrefrigerantor lubricantvapor can irritateyour eyes,nose,or throar. Be carefulwhen connectingserviceequipment. Do not breatherefrigerantor vapor.

The performancetest will help determineif the air conditionersystem is operatingwithin specifications. Use only serviceequipmentthat is U.L.-listedand is cenified to meet the requirementsof SAE J2210to r e m o v eH F C - 1 3 4(aR - 1 3 4 a l f r o m t h e a i rc o n d i t i o n i n g system. lf accidentalsystem dischargeoccurs,ventilatethe work area before resumingservice R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r c o n d i t i o n i n g systemsshould not be pressuretestedor leaktested with compressedair. Additionalhealthand safety informationmay be obtainedfrom the refrigerantand lubricant manufacturers. 1 . Connecta R-134arefrigerantrecover/recycling/

chargingstationto the high-pressureserviceport and the low-pressureserviceport, following the equipmentmanufacturer'sinstructions. D e t e r m i n et h e r e l a t i v eh u m i d i t ya n d a i r Iemperarure.

21-58

Test conditions: . Avoid direct sunlight. . Open the hood. . Open the front doors. . Sel the temperaturecontrol dial on Max Cool,the mode control dial on Vent,and the recirculation control switch on Recirculate. . Turn the A,/Cswitch on and the fan switch on Max. . R u nt h e e n g i n ea t 7 5 0 r p m . . N o d r i v e ro r p a s s e n g e risn v e h i c l e . A f t e r r u n n i n gt h e a i r c o n d i t i o n i n fgo r I 0 m i n u t e s underthe above test conditjons,read the delivery temperaturefrom the thermometerin the center vent, the intaketemperaturenear the blower unit, and the high and low system pressurefrom the Ay'C g au g e s .

7. To completethe charts: . M a r k t h ed e l i v e r y t e m p e r a t u a r el o n gt h e v e r t i c a l i n e . . Mark the intaketemperature(ambientair temperature)along the bottom line. . Draw a line straightup from the air temperatureto the humidity. . M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l . . From each point. drawa horizontalline acrossthe deliverytemperature. . The delivervtemperatureshould fall betweenthetwo lines . Completethe low-sidepressuretest and high-sidepressuretest in the same way. . Anv measurementsoutsidethe line may indicatethe needfor further inspection. kPa (ksl{cm') Lpsrl 2500[25) _ 360l

{kgflcm') Lpsil 600 {6t

80 yo a0 0/"

tssl

2000 (201 1280

HUMIDITY LEVEL 30 9o

fcl 1500{1s} ,21o)

30% 80%

1000(101 :1401 500 {5) 171l DELIVERY PRESSURE 100 {11 h4l INTAKE PRESSURE

OELIVERY TEMPERATURE 68 t20l

I I 86 77 t30) t25l INTAKETEMPEBATURE

95 (35)

104 {40)

{'cl

21-59

BodyElectrical

Body Electrical SpecialTools GeneralTroubleshooting tntorrnaiion.'...... 22,3

RelayandControlUnit Locations.....22-7 Connectors and Harnesses

22-13

Fuse/Relay Boxes............................... 22-44 PowerDistribution............................. 22-46 GroundDistribution........................... 22-4A Under-dash Fuse/Relay Box .............. 22-49 Battery ..............

22-50

Relays................ *lgnitionSwitch ..............

22-51 22-53

*Gauges C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-54 ....... S e l f - d i a g n o sPt irco c e d u r .e. . . . . . . . . . . . . . . . . 22-56 ........ CircuitDiagram 22-54 G a u g eB u l bR e p l a c e m e n. .t . . . . . . . . . . . . . . . .22 . . . .63 .... GaugeAssemblyReplacement 22-64 CoolantTemperature ...... G a u g eT r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . 22-64 VehicleSpeedSignalCircuit Troubleshooting 22-65 VSSReplacement 22 61

ExteriorLights C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . 22-68 ....... C i r c u iD t iagram 22--71 DaytimeRunningLightsControi U n i tI n p u tT e s t( C a n a d a .). . . . . . . . . . . . . . . .22-7 . . . . .6. . H e a d l i g hAtd , u s t m e n .t . . . . . . . . . . . . . . . . . . 22-74 H e a d l i g hRr e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .22-79 ......... CombinationLightSwitch Test/Replacement 22-AO B u l bR e p l a c e m e n t 22-41 T a i l l i g hRt e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . .22-82 .... HighMountBrakeLightReplacement......22-42 LicensePlateLightReplacement.............. 22-43 S i d eM a r k e L r i g h tR e p l a c e m e n. .t. . . . . . . . . .22-43 .... BrakePedalPositionSwitchTest .............. 22-44 SideTurn SignalLightReplacement........22-84 Turn Signal/Hazard Flasher System C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-85 ....... C i r c u iD t iagram 22 A6 Turn Signal/Hazard RelaylnputTest ........22-87 HazardWarningSwitchTest 22-88

Entry Lightscontrol system ComponentLocationIndex ....................... 22-89 C i r c u iD t iagram . . . . . . . 2. .2 9 0 lgnitionKeySwitchTest .....................,...... 22-9'l l g n i t i o nK e yL i g h tT e s t . . . . . . . . . . . . . . . . . . . . . 2 . .2. .-.9. .1. . . C o n t r oUl n i tI n p u tT e s t . . . . . . . . . . , . . . . . . . . . . 2 . .2. .9. 2 .....

InteriorLights ComponentLocationIndex ....................... 22-94 CircuitDiagram .........22-95 CeilingLighVSpotlights T e s V R e p l a c e m e. n . .t. . . . . . . . . . . . . . . . . . . . .2. .2. -. .9.6. . . . . RearCeilingLightTesVReplacem ent ........22-96 CargoAreaLightTest/Replacem ent .........22-97 HatchLatchSwitchTest ..,..,....................... 22-97

*Audio System ComponentLocationIndex ....................... 22-98 CircuitDiagram .........22,99 AudioUnit Removal/lnstallation ............... 22-1OO Audio Unit ConnectorReplacement.........22-101 SpeakerReplacement................................ 22-102 RoofAntennaRep1acement ....................-.. 22-103 Rear Window Defogger ComponentLocationIndex ........... 22-104 C i r c u iD t i a s r a m. . . . . . . . . . . . . . . . . . . . . : : : : : . : :22-105 .::. FunctionTest D e f o g g eW r i r eR e p a i r. . . . . . . . . . . . . . . . . . . . . . .22-106 .......... N o i s eC o n d e n s eCra p a c i t y T e s. t. . . . . . . . . . .22-107 ....

Moonroof C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 2. .2. .-.1. .O B CircuitDiagram .........22-109 MoonroofControlUnitInputTest ............. 22-'l10 S w i t c hT e s V R e p l a c e m e. n . .t. . . . . , . . . . . , . . .2. .2. .- .11. .2. MotorTest ................. 22-112 LimitSwilchTest ......22-'l'13 Auto-stopSwitchTest ................................ 22-113

PowerMirrors ComponentLocationIndex ....................... 22-114 CircuitDiagram .........22-115 FunctionTest ............. 22-116 P o w e rM i r r o rS w i t c hT e s t . . . . . . . . . . . . . . . . . . 2. .2. .-.l .l .7. PowerMirrorActuatorTest ....................... 22-117 PowerMirrorActuatorReplacement........22-11A

* Horns ComponentLocationIndex ....................... 22-120 CircuitDiagram .........22-121 H o r nT e s V R e p l a c e m e. n . .t. . . . . . . . . . . . . . . . .2. .2. -. .1. 2. -2. HornSwitchTest .,....22-122

PowerWindows 22 124 ComponentLocationIndex .......... ::::.: c i r c u i tD i a g r a m. . . . . . . . . . . . . . . . . . . . . . : . : : : : .22-125 M a s t eS r w i t c hI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-126 ........ 22-128 MasterSwitchTest ...... D r i v e r 'W s i n d o wM o t o rT e s t . . . . . . . . . . . . . . .22-129 Passenger's WindowSwitchlnputTest ... 22- t30 Passenger's WindowSwitchTest ............. 22-132 22 132 Passenger's WindowMotorTest .............. 22-133 lMaster SwitchReplacement...................... Passenger's WindowSwitch 22-133 Replacement

Wipers/Washers 22-134 ComponentLocationIndex ....................... C i r c u iD t iagram RearWindowWiperIntermiftent ........ C o n t r oU l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-138 Wiper/Washer Switch 22-140 TesVReplacement .. C o n t r oU l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . . . . .2.2. .-.1. .4. 1 22-143 WiperMotorTest 22-144 WasherMotorTest WasherFluidLevelSwitchTesV ....... R e p l a c e m e(nCt a n a d a.l . . . . . . . . . . . . . . . . . .22-144 WindshieldWiperMotor Replacement.... 22-145 RearWindowWiperMotor Replacement 22-146 .... W a s h eR r e s e r v oR i r e p l a c e m e n. .t. . . . . . . . . .22-146 . . . 147 ... W a s h eTr u b e sB e p l a c e m e n. .t. . . . . . . . . . . . . .22 Accessory Power Socket .........22-149 CircuitDiagram AccessoryPowerSocket . .t. . . . . . . . . . . . . . . . . . . . .2. .2. .- .14. .9. . . . T e s V R e p l a c e m e. n Keyless/Power Door Lock System 22-150 ComponentLocationIndex ....................... .........22-151 CircuitDiagram 22-153 KeylessReceiver Unit InputTest ............... 22-155 ControlUnit InputTest ............................... D o o rL o c k A c t u a t o r T e s. .t. . . . . . . , . . . . . . . , . .2, 2. ,-.1. .5. .8 . .5. .9 H a t c hL o c k A c t u a t o r T e s. .t. . . . . . . . . . . . . . . . .2. .2. -. 1 22-160 DoorLockKnobSwitchTest ...................... 22-160 DoorLockSwitchTest ................................ .......22-161 TransmitterTest T r a n s m i t t ePrr o g r a m m i n .g. . . . . . . . . . . . . . . . .2. 2. .-.1. .6. 1

lmmobilizerSystem 22-162 componentLocationIndex ........... ... S y s t e mD e s c r i p t i o .n. . . . . . . . . . . . . . . :. . . : . . : . :22-163 22-164 CircuitDiagram Troubleshooting lmmobilizerControlUnit - R e c e i v eRre p l a c e m e n. .t. . . . . . . . . . . . . . . . .22-167 ........

Multiplex ControlSystem 22,164 ComponentLocationIndex ........... :.:..:.::.: c i r c u i tD i a g r a m. . . . .... . . . . . . . . . . . . . . . . . . . . . . :22-169 22-17'l SvstemDescriDtion 22,112 Troubleshooting M u l t i o l eC x o n t r oUl n i tI n D uTt e s t . . . . . . . . . . .2.2. - 1 7 5

BodyElectrical SpecialTools Ref. No. Q)

o) o

Tool Number 07wAz-001010A O7LAJ-PT3O2OA 07TAz-001020A

Description MPCSServiceConnector Test Harness BackProbeAdaotet

1 1 1

22-2

Otv

GeneralTroubleshootingInformation Tipsand Precautions Before Troubleshooting 1. Checkapplicablefuses in the appropriatefuse/relay oox.

Some connectorshave a clip on their side used to attachthem to a mount bracketon the body or on a n o t h e rc o m p o n e n tT. h i sc l i p h a sa p u l lt y p e l o c k . Some mountedconnectorscannot be disconnected unlessyou first releasethe lock and removethe connectorfrom its mount bracket(A).

2. Checkthe batteryfor damage.stateof charge,and cleanand tight connections.

. Do not quick-chargea batteryunlessthe battery ground cable has been disconnected,otherwise you will damagethe alternatordiodes. . Do not attemptto crankthe enginewith the batteryground cable looselyconnectedor you w i l l s e v e r e l yd a m a g et h e w i r i n g . Handling Connectors . Make surethe connectorsare clean and have no l o o s ew i r e t e r m i n a l s . . Make sure multiplecavity connectorsare packedwith dielectricgrease(exceptwatertight connectors). . All connectorshave push-downreleasetype locks(A).

Nevertry to disconnectconnectorsby pulling on their wires; pull on the connectorhalvesinstead. Alwavs reinstallDlasticcovers,

Beforeconnectingconnectors,make sure the terminals(A) are in placeand not bent.

(cont'd)

22-3

BodyElectrical GeneralTroubleshootingInformation(cont'd) Checkfor looseretainer(A)andrubberseals(B).

The backsof some connectorsare packedwith dielectricgrease.Add greaseif necessary.lf the greaseis contaminated,replaceit.

HandlingWires and Harnesses . Securewires and wire harnessesto lhe frame with their respectivewire ties at the designatedlocations. . Removeclips carefully;don't damagetheir locks(A).

S l i p p l i e r s( A ) u n d e rt h e c l i p b a s ea n dt h r o u g ht h e hole at an angle,then squeezethe expansiontabs to r e l e a s et h e c l i p .

lnsertthe connectorall the way and make sure it is securelvlocked. Positionwires so that the open end of the cover faces oown.

After installingharnessclips, make sure the harness doesn't interferewith any moving pans. Keepwire harnessesaway from exhaustpipes and other hot parts,from sharp edgesof bracketsand holes,and from exposedscrewsand bolts. Seatgrommets in their grooves properly{A). Do not leavegrommets distorted(B).

| . , ./ f

.ll ----E;

22-4

lwtl"//

'l/ F.

\--------\

tflr'---'..-

Testingand Repairs . Do not usewires or harnesseswith brokeninsulation. Replacethem or repairthem by wrappingthe break withelectricaltape. . After installingparts,make surethat no wires are o i n c h e du n d e rt h e m . . When using electricaltestequipment,followthe manufacturer'sinstructionsand those describedin t h i sm a n u a l . . l f p o s s i b l ei ,n s e r t t h ep r o b eo f t h e t e s t e r f r o m t h ew i r e side (exceptwaterproofconnector).

UsebackDrobeadaotor07TM-0010204.

Referto the instructionsin the HondaTerminal Kit for identificationand reolacementof connectorterminals.

( c o n td )

22-5

BodyElectrical GeneralTroubleshootingInformation(cont'dl Five-stepTroubleshooting '1.

Verify The Complaint T u r n o n a l l t h e c o m p o n e n t si n t h e p r o b l e mc i r c u i t to verify the customercomplaint.Note the symptoms.Do not begin disassemblyor testing until you have narroweddown the problem area.

2. AnalyzeThe Schematic Look up the schematicfor the problem circuit. Determinehow the circuit is supposedto work by tracingthe currentpathsfrom the power feed through the circuitcomponentsto ground. lf severalcircuitsfail at the same time, the fuse or g r o u n di s a I i k e l yc a u s e . Basedon the symptoms and your understandingof the circuitoperation,identifyone or more possible causesof the problem. 3. lsolateThe ProblemBy TestingThe Circuit Make circuitteststo checkthe diagnosisyou made i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls, i m p l e procedureis the key to efficienttroubleshooting. Testfor the most likelycauseof failure first, Try to make tests at pointsthat are easilyaccessible. 4. Fix The Problem Oncethe specificproblem is identified.make the repair.Be sure to use propertools and safe proceoures. 5. Make Sure The CircuitWorks Turn on all componentsin the repairedcircuit in all modes to make sure you've fixed the entire problem.lf the problemwas a blown fuse, be sure to test all of the circuitson the fuse. Make sure no n e w p r o b l e m st u r n u p a n d t h e o r i g i n a p l roblem does not recur.

22-6

Wire Color Codes The following abbreviationsare usedto identifywire colors in the circuitschematics:

w H T . . . . . . . . . . . . . . . . . . . . , . , . White ............ Y E L . . . . . . . . . . . . . . . . . . . . . . , , .Y. .e.l.l .o. w ,...... B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B . .l.a. .c. k. . . . . B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . . G R N . . . . . . . . . . . . . . . . . . . . . . . .G . .r.e. .e.n. . . . . . . R E D. . . . . . . . . . . . . . . . . . . . . . . . . . . .Red ........, o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange ............. P N K . . . . . . . . . . . . . . . . . . . . . . . .P . .i,n. k. . . . . . . . . B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown ............. G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray ............, P U R . . . . . . . . . . . . . . . . . . . . . . . .P . .u. .r .p.l.e. . . . . . 1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . Light . . . . . ,Blue ..... 1TGRN....................L . .i.g. h . .G t. ,r.e. .e n The wire insulationhas one color or one color with anothercolor stripe.The secondcolor is the stripe.

Relayand Control Unit Locations EngineCompartment

BLOWERMOTORRELAY

RADIATORFAN RELAY HORNRELAY CONDENSERFAN RELAY

ELDUNIT UNDER-HOOD FUSE/RELAY BOX

\...

,-:1-'...

22-7

Relayand GontrolUnit Locations Dashboard RUNNINGLIGHTSEELAYlCanada) _DAYTIME lWirecolorsrRED,RED/YEL,I andRED/8LU LRED/BLK I BEAMCUTRELAYlcanada) _ _LOW RED/BLK,I lWirecolors:REDMHT, andRED/BLU LBEDA/EL I KEYLESSRECEIVER UNIT CRUISECONTROLUNIT

' ':

'-.:-

..? ;,

POWERWINOOW RELAY TURN SIGNAL/HAZARDRELAY

TAILLIGHTRELAY

;

.[:_- -

-l:r

UNDER.DASH FUSE/RELAY BOX

MULTIPLEXCONTROLUNIT

22-8

(cont'd)

22-9

Relayand Control Unit Locations

Dashboard(cont'd)

L \

SRSUNIT

EPSCONTROLUNIT AIR/FUEL RATIOSENSOR RELAY [WirecolorsrWHT,WHT/RED, I OBNandBLK/ORN I

22-10

PGM.FIMAINRELAY1 lWirecolors:YEUBLK, WHT/BLKand RED/YEL LWHT/BLK, PGM.FIMAN RELAY2 fwirecolors:YEUBLK, I YEUBLKand GRN/YELI LYEUGRN,

Rearand Roof

OPENRELAY MOONROOF Wirecolors:GRNI/EL, GRN, I BLKandYEL/GRNI LRED/YEL, MOONROOF CLOSERELAY GRN, l fwire colors:GRN/BLK, BLKand YEL/GRNI IGRN,AtVHT,

REARWINDOWWIPERINTERMITTENT CONTBOL UNIT

22-11

Relayand ControlUnit Locations Door and Seat Driver'sDoor:

l\:

].\ POWERWINDOWMASTERSWITCH lHasbuilt-incontrolunit)

Passenger's Seat:

22-12

Gonnectors and Harnesses

GonnectorIndex "G" for ground ldentification numbershavebeenassigned to in-lineconnectors. The numberis preceded by the letter"C" for connectors, terminalsor "T" for non groundterminals. Hamess

Location

EngineCompartment

Dashboard

Others{Floor,Door, Trunk.and Roo{l

Not€s

Startersubharness

C 1 0 2a n dC 1 0 3 T1 andT2 T 1 0 1a n dT 1 0 2

(seepage22-15)

Batterygroundcable

T3 G'l and ( T4

{seepage22-l!)

Enginegroundcable

{seepage22-14)

Enginewire harness

C l 0 l t h r o u g hC 1 0 4 G1 0 1 Enginecompartment wire harness G201andG202 {riohtbranchi Enginecompartment wire harness G301 (leftbrench) Enginecompartment wire harness (dashboard)

(seepage22 16) (seepage22 18) (seepage22 18) (seepage22-18) c401 C451and C452 C501throughC503 c551 c851 G402

EPSsubharness

C 1 5 1a n d C 1 5 2 G'151

\seepage22 241

Dashboard wire harness A lleftbranch)

C504throughC510 G501andG503

(seepage22-26)

L e f ts i d et u r n s i g n a l l i g h t

c506

(seepage22-26)

Dashboard wire harness A (rightbranch)

C50lthroughC503 C 5 l l t h r o u g hC 5 1 5 C852andC853 G502

(seepage22-26)

lseepage22-26)

Rightside turn si9nal light sub harness

Dashboard wire harnessB ECMwire harness

(seepage22-30)

C40lthrough C403 c510 G40l c101 cl52 C451 through C453 c511

{seepage22-32}

G451

Floorwireharness(frontside)

C402 andC403 c453 C508 andC509 c512

G551

(see page 22'34)

Floorwire harness(rearside)

C553and C554

(seepage22-34)

Roo{wire harness Hatchwire harness Driver'sdoorwire harness

(seepaqe22-38)

P a s s e n q e r ' sd o o r w i . e h a r n e s s T eh a r n e s s

c507 C553andC554 C504andC505 5 1 4a n dC 5 1 5 )552

( s 6 ep a q e 2 2 ' 3 9 ) (see paqe 22-40) ( s e eo a o e 2 2 - 4 1

/C wire harness

c851 rhrouoh c853

( s e ep a q e 2 2 . 4 3 i

C 5 5 1a n . l C 5 5 ?

(seeoaqe22-42i

22-13

and Harnesses Connectors Gonnectorto Harnesslndex BatteryGroundCable Connectoror Terminal

Cavities

T3 2

Location Left side of enqinecompartment Left side of enginecompartment Batterv

Connectsto

Notes

Bodygroundviabattery qroundcar)le B a t t e r vn e o a t i v et e r m i n a l

EngineGround Cable

Connectoror Terminal

Cavities 5 4

focation Riohtsideof enoine Rightsideof enginecompartment

Connec{sto Bodygroundviaengine

ENGINEGROUNDCABLE

BATTERYGROUNDCABLE

\.....

22-14

Notes

StarterSubharness Connectoror Terminal Alternator Knocksensor Startersolenoid c102

Ret 10 8 5 7

c103

T101

4 1 I

r2 r102

Cavities Location 4 R i g h t s i d e o f e n g ; n ec o m p a r t m e n t Front of engine 1 1 Middle of enginecompartment Front of enginecompartment 6 1

F r o n t o f e n g a n ec o m p a r t m e n t

L€tt sideof enginecompartment Middleor enoinecomDanment Under-hood fuse/relay box Alternator Batterv

Connoc,ts to

Notes

Enginewire harness(see page22 16) Enginewire harness(see o a a e2 2 - 1 6 ) Underhoodfuse/relay box Stanermotor Battervpositiveterminal

STARTERSUB HARNESS

22-15

Connectorsand Harnesses Connectorto HarnessIndex(cont'dl EngineWireHarness

position(CMP)sensor Camshaft Lllr sensor EC[,4connectorA ECI/lconnectorB (ECT) Enginecoolanttemperature sensor Engineoil pressure switch EVAPcanisterpurgevalve ldleair control(lAC)valve lgnitioncoilNo. l lgnitioncoil No.2 lgnitioncoilNo.3 lgnitioncoilNo.4 IniectorNo. 1 InlectorNo.2 IniectorNo.3 IniectorNo.4 Intakeairtemperature {lAT)sensor

2 3 3 24 2 28 18 4 5 6 7 25 24 20 19 12

TDCsensor Throttleposition(TP)sensor Vehiclespeedsensor(VSSI VTCoil controlsolenoidvalve VTECoil pressureswitch VTECsolenoidvalve c 101

8 11 10 27 29 30 3

c102

1 2 3 3 3 3 3 2 2 2 2 2 3 3 3 2 2 2 20

Transmission housing Leftsideof engine Rightsideofengine Underglovebox Underglovebox Leftside of engine BightsideoI engine Leftside of intakemanifold Left sideof intakemanifold Middleof enginecompartment Middleof enginecompartment Middleof enginecompartment Middleof enginecompartment Middleof enginecompartment Middleof enginecompartment Middleof enginecompartment Middleof enginecompanment Leftsideof intakemanifold Leftsideof engine Left side of intakemanifold housing Transmission Rightsideo{ engine Rightsideof engine Rightsideof engine Underrightsideof dash Frontof enginecompanment Frontof enginecompartment

22-16

ECMwire harness{seepage 22-321 (seepage Startersubharness 22-15) (seepage Startersubharness 22 151

....-

10 11

13 14

22-17

Connectorsand Harnesses Connectorto HarnessIndex{cont'dl EngineCompartmentWire Harness(Rightbranch) Connsctoror Terminal ABSmodulator-control unit Bearwasher motor RightfrontABSwheelsensor Rightfrontairbags€nsor Bightfrontparkinglight Rightfrontsidemarkerlight Rightfrontturn signallight Rightheadlight Righthorn wash€rfluidlevelswitch Windshield washermotor

G201 G202

Cavitiss 8 12 1 10 11 2 7 6

2 2 2 2 2 2 I 2 2

Location Bightsideo{ enginecompartment Behindrightsideof {rontbumper Rightsideot enginecompartment Behindrightsideof frontbumper Behindrightheadlight Behindrightsideof Jrontbumper Behindrightheadlight Behindrightheadlight Behindfrontbumper Behindrightsideof trontbumper Behindriohtsideof frontbumoer Behindrightsideof trontbumper Behindrightsideof Jrontbumper

Connectsto

Notes

Canada Bodygroundvia€ngine compartment wtreharness Bodygroundviaengine .omnerhent

wire harness

22-18

ENGINECOMPARTMENT WIRE HARNESS

(cont'd)

22-19

Connectors and Harnesses Connectorto HarnessIndex (cont'dl EngineCompartmentWire Harness(Left branch)

AirJuel(A,,/F) ratiosensor Brakefluidlevelswitch Condenser fan motor Cruisecontrolactuator ELDunit Foglightconnector LeftfrontABSwheelsensor Leftfrontairbagsensor Leftfrontparkinglight Leftfrontsidemarkerlight Leftlrontturnsignallight Leftheadlight Lefthorn Radiatorfan motor Radiator fan switch Secondary heatedoxygen(SHO2S) Testtachometer connector Windshield wipermotor Under'hood fuse/relay box connector A {seepage22-44) Under-hood f use/relay box connectorB (seepage22-44) Underhoodfuse/relay box connector C (seepage22-44) Underhoodfuse/relay box D (seepage22 44) connector fuse/relay Under-hood box

24 22 2

25 1 9

2 2 4 3 ,l

Frontof enginecompanment Leftsideof enginecompartment Leftsideof enginecompartment Leftsideo{ enginecompartment Frontof enginecompartment Underrightsideof cowlcover Under'hood f use/relay box Leftsideof enginecompartment Leftsideof enginecompanment Behindleftsideof frontbumper Behindleftheadlight Behindleftsideof frontbumper Eehindleftheadlight Behindleftheadlight Behindfrontbumper Leftsideof enginecompartment Frontof enginecompartment Leftsideof enginecompartment

11 7

2 5 2

Leftsideof enginecompanment L.Jnder leftsideof cowlcover L.Jnder hoodfuse/relay box

L.Jnder hoodfuse/relay box

L.Jnder'hood f use/relay box

12 17 13 20 21 23

2 2 2 2 2 3 l

2 2

underhoodfuse/relay box

fuse/relay Under-hood box

22-20

ENGINECOMPARTMENTWIRE HARNESS

(conr'd)

22-21

and Harnesses Connectors Connectorto HarnessIndex (cont'd) EngineCompartmentWire Harness(Dashboard)lcont'dl Connectoror Terminal

Cavities Location Undermaddle of dash 1 Underleftsideof dash 12

Foglightconnector Under'dash fuse/relay box connector F (seepage22-45) Underdash fuse/relay box G (seepage22-45) connector Underdash fuse/relay box connector H (seepage22'45) fuse/relay Under-dash box connector | (seepage22'45) Under-dash fuse/relay box connector J (seepage22-45) c151 c401

Underrightsideot dash

c451

Underrightsideot dash

c452

UnderrightsideoJdash

c501

'10

UnderrightsideoI dash

c502

Underrightsideol dash

c502

UnderrightsideoJdash

Undermiddleof dash

Underrightsideof dash

Underleftsideof dash

Underleftsideol dash

Underrightsideof dash

c503

c851

'14

G402

1' I

Connectsto

EPSsubharness {seepage2224) wire harnessB Dashboard (seepage22-30) ECMwire harness(seepage 22-321 ECMwire harness(seopage 22 32) Dashboard wire harnessA (seepage22-26) Dashboard wire harnessA USA lsee page 22-261 Dashboard wire harnessA Canada (seepage22-26) Dashboard wire harnessA (seepage22-26) Floorwireharness(seepage 22-34l' ,VCwire harnesslsee page 22-43\ Eodygroundviaengine ..mdarlma.t

22-22

Notes Oplion

w,rc harncss

BOX FUSE/RELAY UNDER-DASH WIRE ENGINECOMPARTMENT

D '

' 1_-1.:,

-.,.i

ifa.: ,, ..j

. -

-g'-.t

, -,,

';.-a

22-23

Connectorsand Harnesses Connectorto Harnesslndex (cont'dl EPSSubharness Connectoror Terminal EPScontrolunitconnectorA EPScontrolunitconnectorB EPScontrolunitconnector C EPSmotor EPStorquesensor c151

2 ,l 3 1 6

c152

G151

22-24

Cavities Location Underrightsideofdash 2 2 Underrightsideof dash 20 Underrighrsideof dash 2 Middleof enginecompanment Middleof enginecompartment 6 2 Underrightsideof dash I

Underrightsideof dash

Connectsto

Enginecompartment wire harness(seepage22-18) ECI\,4 wire harness(seepage 22-321 aodygroundvia EPS

Notes

EPSSUB HARNESS

22-25

Connectorsand Harnesses Connectorto HarnessIndex (cont'd) DashboardWire HarnessA {Leftbranchl Connectoror Terminal Accessorypower socket Audioantenna Brakepedalpositionswitch Clutchinterlockswitch Clutchpedalpoistionswitch Cruisecontrolunit Cruisemainswitch Daytimer!nning lightscontrolunit Daytimerunninglightsrelay Gaugeassembly connector A GaugeassemblyconnectorB Hazardwarningswitch Heatercontrol panelconnectorA Heatercontrol panelconnectorB HVACpush switch assembly Keyless receiverunit Low beamcut relay Optionalsecurityconnector Powermirrorswitch Under-dash fuse/relay box connector K (seepage22-45) Under'dashfuse/relaybox L {seepage22-45} Underdashfuse/relay box connectorM lsee page22'45) Under-dash fuse/relay box connectorN (seepage22-45) UndeFdash fuse/relay box connector O (seepage22-45) UndeFdash fuse/relay box connectorY(seepage22 45) c504

22 2 26 30 29 6 28 I 8

20 11 18 19 10 5 3 27 ,I4

2 2 4 2 2 14 5 14 4 22 22 10 22 '14 10 5 5 16 13 17

Undermiddleof dash Underleftsideof dash ] Underleftsideof dash ] Underleftsrdeof dash | Underleftsideof dash I Underleftsideof dash Underleftsideof dash Underlettsideof dash Underlettsideof dash I Behindgaugeassembly i Behindgaugeassembly Behindhazardwarnningswitch Behindheatercontrolpanel Behindheatercontrolpanel ] BehindHVACswitchassembly I Undermiddleof dash lUnderleftsideofdash Underlefrsideof dash UnderleftsideoI dash ln the under-dash fuse/relay box

In the under-dash fuse/relay box

ffi

Canada Canada

In the undeFdash fuse/relay box In the underdashfuse/relay box 12

Inthe under-dash fuse/relay box

In the under-dash fuse/relay box Underleftsideof dash

c505

Underleftsideot dash

c506

Underleftsideof dash

c507

Underleftsideof dash

c508

Undermiddleof dash

Driver'sdoorwire harness (seepage22'40) Driver'sdoorwire harness (seepage22-40) Leftsideturo signallight suonarness Roofwire harness(seepage 22 3Al Floorwire harness{seepage 22-341 Floorwire harness(seepage 22 34J Dashboard wire harnessB (seeoaoe22-30)

c509

c510

G501

Undergaugeassembly

G503

Underleftsideof dash

Body ground via dashboard

Cavities Location 2 B e h i n d l e f t s i d e t u r n s i g n a ll i g h t 2 Under left side of dash

Connectsto

Undermiddleof dash 12

Undermiddleol dash

Body ground via dashboard

Left Side Turn Signal Light Sub harness Connectoror Terminal Leftsideturn signallight c506

22-26

35 34

Dashboard wire harnessA

Noles

WIRE DASHBOARD A HARNESS

,./

-19

34 LEFTSIDETURN SIGNAL LIGHT SUB HARNESS

). \'u )t

(cont'd)

22-27

Connectorsand Harnesses Connectorto HarnessIndex (cont'd) DashboardWire HarnessA (Rightbranch) Connecloror Terminal

Cavities Location 20 Eehindaudiounit 10 Underrightsideof dash

Audiounitconnector c501

c502

Underrightsideof dash

c502

Underrightsideof dash

c503

tJnderrightsideof dash

c5' 11 c512

c514

ca52 c853

Undermiddleof dash 12

Undermiddleof dash

Underrightsideof dash

Undermiddleofdash

G502

Undermiddleof dash Underrightsideof dash

Connectsto Enginecompartment wire harness(seepage22,18) Enginecompanmentwire harness(seepage22-18) Enginecompartment wire harness(seepage22-18) Enginecompartment wire harness(seepage22-18) ECN4 wire harness(seepage 22-321 Floorwire harness{seepage 22-341 Rightsideturn signallight suonarness Passenger's doorwire harness(seepage22 4l) Passenger's doorwire harness(seepage22 4'l) A,/Cwire harness(seepage 22-43) ly'Cwire harness(seepage 22-431 Eodygroundvia dashboard

Notes

USA Canada

Right Side Turn Signal Light Sub harness ConnectororTorminal Rightsideturn signallight c5't3

22-28

1 8

Cavities Location 2 Eehindrightsideturn signallight 2 Underriohtsideof dash

Connectsto Dashboard wire harnessA

Not€s

WIBE DASHBOARO HARNESS A

'---/...'

22-29

Connectors and Harnesses Connectorto HarnessIndex(cont'd) DashboardWire HarnessB Collqctor or Terminal C a b l e reel

2 1 17 16 't9

Cavities Locatiol| In steeringcolumncover 5 In steeringcolumncover In steeringcolumncover 4 In steeringcolumncover 1 In steeringcolumncover 1 In steeringcolumncover 4 Undermiddleof dash 18 Undermiddleofdash 14 In steeringcolumncover 5 Underleft sideof dash

Combination lightswitch Driver'sairbaginflator lgnitionkey switch lgnitionswitch lmmobilizer controlunit receiver Passenger's airbaginflator SRSunitconnector A Wiper/washerswitch Underdashfuse/relay box connectorAlseepage22,45) Under dashluse/relaybox connectorB (seepage22-45) Under'dash fuse/relay box connectorC (seepage22-45) Under-dash fuse/relay box connector S lseepage22-45) Under'dash fuse/relay box connectorX(seepage22 45) c401

c402

Undermiddleof dash

c403

Undermiddleof dash

G510

Undermiddlesideof dash

G40l

22-30

18 I 3 5 6

Underleftsideofdash

Underleftsideof dash

Underlettsideof dash

Under left sideof dash Underrightsideof dash

Undergaugeassembly

Connectsto

Enginecompartment wire harness(seepage22-'18) Floorwire harness(seepage 22-34J Floorwire harness(seepage 22-341 Dashboard wire harnessA (seeoaoe22-26) Bodygroundviadashboard

Notes

WIRE OASHBOARD HARNESS B

22-31

Connectors and Harnesses Connectorto HarnessIndex(cont'd) ECMWire Harness Connectoror TerminiF Arrruert/vrl ralo sensorretay Datalinkconnector EC[/lconnectorE PGM-Flmainrelay1 PGM-Flmainrelay2 Under-dash fuse/relay box connector D (seepage22 45) Underdashfuse/relay box connectorE lsee page22-45) under-dashfuse/relaybox connectorR lsee page22-45) c10'1

I Re- lcavities L 8 7 6 1

4 4

Location

Eehindglovebox Undermiddleof dash Behindglovebox Behindglovebox Behindglovebox In the under-dash fuse/relay box Inthe under-dash fuse/relay box

In the under-dash fuse/relay box

Underrlghtsideof dash

c152

1' I

Underrightsideof dash

c451

c452

Underrightsideot dash

c453

UndermiddleoI dash

c511

G451

22-32

Connectsto

Underrightsideof dash

Undermiddleof dash Undergaugeassembly

Enginewire harness(see page22'16) EPSsubharness(seepage 22-24) Enginecompanment wire harness{seepage22-18) Enginecompartment wire harness{seepage22-18) Floorwire harness(seepage 22-34) Dashboard wire harness A {seeoaoe22-26) Bodygroundvia ECMwire harness

Notes

ECMWIREHARNESS

22-33

Connectorsand Harnesses Connectorto Harnesslndex (cont'd) FloorWire Harness(Frontsidel Connec-tor or Terminal Location I Ref uavftres Driver'sseatbeltswitch 11 3 I Underdriver'sseat Driver'ssideairbaginflator l0 2 i Underdriver'sseat Driver'ssideimpactsensor 13 2 I Leftside offloor Leftside seatbelt buckletensioner 12 4 Underdriver'sseat Memoryerasesignal(MES)connector 1 9 2 Underdashfuse/relay box Parkingbrakeswitch 1 9 1Middleoffloor Passenger's seatbelt switch 3 5 Underpassenger's seat Passenger's sideairbaginflator 3 2 Underpassenger's seat Passenger's sideimpactsensor 7 2 Rightsideoffloor Rightsideseatbeltbuckletensioner 4 4 Underpassenger's seat SRSunitconnector B 20 18 I Undermiddleof dash SRSunitconnector C 21 8 Undermiddleof dash Under-dashfuse/relaybox 11 18 Underdashfuse/relay box connector P {seepage22-45) 'r8 Under-dash fuse/relay box 8 Underdashfuse/relay box connectorO (seepage22,45) ] c402 22 10 Undermiddleof dash I c403 23 4 Undermiddleof dash c453

Undermiddleof dash

c508

Undermiddleof dash

c509

Undermiddleofdash

c512

8 10

6 G551

22-34

Undermiddleof dash I

Undermiddleof dash

] Unaermiddleof aasn L,nderpassenger's seat

connects to

Dashboard wire harnessB {seepage22 30) Dashboard wire harnessB (seepage22-30) ECMwire harness(seepage 22-321 Dashboard wire harnessA (seepage22-26) Dashboard wire harnessA \see page 22-26) Dashboard wire harnessA {seepage22-26) Enginecompartment wire harness(seepage22 18) OPDSunitharness(seepage 22-421 Bodygroundviafloorwire

Nol6s

- 10 11

FLOORWIREHARNESS

( c o n t ' d)

22-35

Gonnectors and Harnesses

Connectorto HarnessIndex (cont'dl Floor Wire Harness {Rear side}(cont'dl Cargoarea Driver'sdoorswitch EVAPemissionbypasssolenoidvalve EVAPemissioncontrolcanistervent shutvalve Fuelpump/sending unit Fueltankpressure sensor Left back-uplight Left rearABS wheel sensor Leftrearsidemarkerlight Left rear speaker Leftrearturn signallight Leftsideseatbelttensioner LefttaillighVbrake light (rearwindow Noisecondenser defogger) (rearwindowwiper) Noisecondenser Passenger's door switch Rearwindowwiperintermiftent controlunit Rightback-uplight Righttaillighvbrake tight Rightrearturn signallight BightrearABSwheelsensor Rightrearsidemarkerlight Rightrearspeaker Rightsideseatbelttensioner c554

6 2 24

2 1 2 2

LeftB pillar Fueltank Fueltank

I 3 25 1 26 4 2A 5 27 '13

5 3 2 2 2 2 2 2 3 2

Fueltank Fueltank Lefttaillight Left rear offloor Behindleftsideof rearbumper Leftquarterpanel Lefttaillight LeftB-pillar Lefttaillight Rightquarterpanel

18 10 11

2 1 20

Rightquarterpanel R i g hB t pillar Rightq uarterpanel

22 20 21 15 19 12 11 7

2 3 2 2 2 2 2 12

Righttai ight Righttaillight Righttaillight Rightsideof cargoarea Behindrightsideof rearbumper Rightquanerpanel RightB-pillar Rightquanerpanel

Rightquanerpanel

side of cargo area

rearseal bdcl

Rightsideof cargoarea

22-36

H a t c hw i r e h a r n e s s( s e ep a g e 22 39) H a t c hw i r e h a r n e s s( s e e p a g e Bodv ground vta

Bodygroundviafloorwire

FLOORWIREHARNESS

22-37

Connectors and Harnesses Connectorto HarnessIndex(cont'd) RoofWire Harnsss Connectoror Terminal Moonroofclose relay Moonrool control unit Moonroofmotor Moonrootopenrelay Moonroofpositionsensor1 N4oonroofpositionsensor2 Moonroofswitch Rearceilinglight SpotlighVceiling light c507

22-38

6 I 7 8 5 1 2 10

Cavities 5 5 2 5 2 4 5 3 4 8

tocation Middleof roof Middleof roof Middleof roof Middleof roof MiddleoI roof Middleof roof Frontof roof N4iddleof roof Frontof roof Underleftsideof dash

Connectsto

Dashboard wire harnessA (seeoaoe22-261

Notes

HatchWire Harness Connectoror Torminal Hatchlatchswitch Hatchlockactuator Highmountbrakelight Licenseplatelight connectorA Licenseplatelight connectorB Rearwindowde{ogger connector A

I 3

Cavities 2 2 2 2 2 1

B Bearwindowdetoggerconnector

LeftC-pillar

Bearwindowwipermoto. c553

6 2

4 12

Middleof hatch Rightquanerpanel

c554

Rightquanerpanel

( )

7 8

Location Middleo{ hatch Middleof hatch Behindhighmountbrakelight Middleof hatch Middleof hatch RightC-pillar

Connects to

Notes

Floorwire harness(seepage 22-341 Floorwire harness(seepage )2-34\

22-39

Connectors and Harnesses Connectorto Harnesslndex (cont'd)

Driver'sDoorWire Harness Connectoror Terminal Driver'sdoor lockactuator Driver'sdoorlockknobswitch Driver'sdoor lockswitch Driver'sdoorspeaker Driver'spowerwindow motor Left power mirror actuator Left tlveeter Powerwindow masterswitch c504 c505

ReI 9 10 1 7 2 3

Cavities 2 3 3 2

Location

8 5

Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdooa Driver'sdoor Driver'sdoor Driver'sdoor Driver'sdoor Underleftsideof dash

't3

Underleftsideof dash

6 2

DRIVER'SOOORWIREHABNESS

22-40

Connectsto

A Dashboard wire harness \seepage22-261 A Dashboard wire harness

Notes

Passenger'sDoor Wire Harness Connectoror Terminal Passenger's doorlockactuator Passenger's doorspeaker powerwindowmotor Passenger's powerwindowswitch Passenger's Rightpowermirroractuator Righttweeter c514

Rel 6 I 5 1 4 3 2

Cavities

2 2 2 5 6 2 13

Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Passenger's door Underrightsideof dash

Underrightsideof dash

Location

Connectsto

Notes

Dashboard wire harnessA (seepage22'26) Dashboard wire harnessA lsee oeoe 22-26\

PASSENGER'S DOORWIREHABNESS

22-41

and Harnesses Gonnectors Connectorto Harnesslndex {cont'dl OPDSUnit Harness ConnoctororTorminal OPDSunit

Cavitios 2 1

Location In frontpassenger's seat Underfrontpassenger's seat

FLOORWIBEHARNESS

22-42

Connectsto Floorwareharness(seepage 22-34)

Notes

A/C Wire Harness Connoctoror Terminal Air mix controlmotor Blowermotor Evaporator temperature sensor Modecontrol motor Powertransistor Recirculation controlmotor c851

Rel I 2 8 3 4 1 1

Cavities 5 2 2 10 5 1

Undermaddle of dash Underrightsideof dash Undermiddleof dash Underrightsideof dash Underrightsideof dash Underrightsideof dash Undermiddleol dash

c852

Undermiddleofdash

c853

Undermiddleo{ dash

Location

Connec'tsto

Notes

Enginecompartment wire harness(seepage22-18) Dashboard wire harnessA {seepage22 26i Dashboard wire harnessA lsee oaoe 22-261

22-43

Fuse/Relay Boxes Connectorto Fuse/RelayBox Index Under-hoodFuse/RelayBox Socket

Ref 14 2

Ay'Ccompressorclutch relay B Blower motor relay

15 9

C o n d e n s efra n r e l a y D E E L Du n i t H e a d l i g hrte l a y1 Headlightrelay 2 Horn relay Radiatorfan relay Rearwindow defoqqerrelay T1 (Batterv) T101 (Alternator)

11 to

5 6 10 'l J

T---r .-:-

t L _ _| . 1 I t

tr T T tTt Tr ,/^-------lFr -/1-l szl:!)

lrt

lview of tront sidel

22-44

Startersubharness(seeoaqe22-15) Startersubharness{seeoaoe22-'15}

8 7

a-------) | -

4 4 4

t t-l t t_l t tIl L l L l t l ' " . -

""""-l-

r^l

Terminal Connects to Enginecompartmentwire harness(seepage 22-18) 2 4 Enginecompartmentwire harness(seepage22-18) 5 4 Enginecompartmentwire harness(seepage 22-18) 4 14 Enginecompartmentwire harness(seepage 22-18) 7 E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 ) 3 Enginecompartmentwire harness{seepage 22-18) 4

{View of back side)

Under-dashFuse/RelayBox Socket

D E F G H

Ref

Terminal

2 3 1

5 6 14

5 19 9 I 20

13 12 10 3

J K

24 22 27 26 7

M N

o P Powerwindow relay

6 10 25 14 18

R S Startercut relay T Taillightrelay Turn signal/hazardrelay U

1: .o^

;; 4 8

Floorwire harness(seepage 22-34) ECMwire harness(seepage 22-32) Dashboardwire harnessB (seepage 22-30)

2 in l

Multiplexcontrol unit servicecheckconnector

Optionalconnector Optionalconnector Floorwire harness(seepage22-34)

I 13

{Plugsdirectly into the multiplexcontrol unat) ( P l u q sd i r e c t l vi n t ot h e m u l t i D l e cx o n t r o lunrl)

l5 to

W ( M e m o r ye r a s es i g n a l( M E S ) connector) X Y

: 11 '10

Connects to Dashboardwire harnessB {seepage 22-30) Dashboardwire harnessB {seepage 22-30) Dashboardwire harnessB (seepage 22-30) ECMwire harness(seepage 22-32) ECI\4wire harness(seepage 22-32) Enginecompartmentwire harness(seepage 22-'l8l Enginecompartmentwire harness(see page 22-181 E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 ) Enginecompartmentwire harness(see page 22-18) Enginecompartmentwire harness(seepage 22-18) Dashboardwire harnessA (seepage 22-26) Dashboardwire harnessA (seepage 22-26) Dashboardwire harnessA (seepage 22-26) Dashboardwire harnessA (seepage 22-26) Dashboardwire harnessA (seepage 22-26) Floorwire harness(seepage 22-34)

l t

tn--rl I U LI L.]L.J h - - n UL]L]UL] I] L] L] LI L]

22-45

PowerDistribution Fuseto Componentslndex Under-hoodFuse/RelayBox Fuse Number 'I

Amps

WireColor

204

BLUI/EL Condenserfan motor BLU/RED Ay'Ccompressorclutch WHT/GRN Dashlights,Front parkinglights,Frontside marker lights,Licenseplate

15A

Component(sl or Circuit(s) Protected

l i q h t ,R e a rs i d em a r k e rl i q h t s T , ailliqhts

15A

WHT/BLU C a r q oa r e al i q h t ,C e i l i n ql i q h t s l. q n i t i o nK e v l i q h t .S o o t l i o h t s BLU/BLK Radiatorfan motor WHT/BLK Turn siqnal/hazardrelav,Turn siqnal liqhts WHT/BLK CKPsensor,ECM,IACvalve, lmmobilizercontrol unit-receiver,Injectors,

15A

WHT/GRN Brakelights,Brakesignals(to ABS modulator-controlunit, Cruisecontrol

20A 10A

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

7.5A 5

204 10A

P G M - Fm I a i n r e l a v1 a n d 2 . T D Cs e n s o r 7

unit, ECM) 8 9

control unit-receiver,lmmobilizerindicatorlight. Keylessreceiverunil, lvlultiDlexcontrol unit

40A

30A

40A 40A

40A

15A

16 17

204

WHT/RED ABSmodulator-control unit BLK/YEL Noisecondenser,Rearwindow defoqqer BLU^^/HT Blower motor WHT/BLK No. 7 fuse (in the under-dashfuse/relavbox), Powerwindow relav WHT/RED No.2 and No.3 fuses (in the under-dashfuse/relavbox) REDI/EL Daytimerunning lightscontrol unit (Canada),Daytimerunning lights relay { C a n a d a )H, i o hb e a mi n d i c a t o lri q h t .L e f th e a d l i q h t

18 19 20

15A 60A

WHT Multiplexcontrol unit RED D a v t i m er u n n i n ql i q h t sc o n t r o lu n i t ( C a n a d a )R. i o h th e a d l i o h t WHTiBLU EPScontrol unit

80A 40A' 50A'?

WHT

Batterv.Power distribution lgnition switch (BAT)

* 1 :U S A " 2. Canada

E'l

22-46

t4 " t |

l - - -

E,l E,l r--r r---rt__J i; i6'!/'

E,l E,l E,l

l'lr]n r L__J,a ,..r^{-------l^-,

n[:]$"Lrt

O: Sparefuse

" N2,

Eol E l f__--l | |

- r^l

Under-dashFuse/RelayBox Fuse Number

Amps

Wire Color

15A

2 3

204

BLKA/VHT l g n i t i o nc o i l s WHT/RED Airlfuelratiosensor,ECM RED/BLU D a y t i m er u n n i n gI i g h t sc o n t r o lu n i t{ C a n a d a ) BLI(ORN Air/fuel ratio sensorrelay,Alternator,CMP sensor,Cruisecontrol main

10A

7.5A

204

7.5A

10A

7.54

7.5A 7.5A

12 13 't4

10A 10A

Component(s) or Circuit(s) Protected

switch,Cruisecontrol unit. ELDunit, Evaporativeemission(EVAP)bypass solenoidvalve, Evaporativeemission(EVAP)canisterpurge valve, Evaporativeemission(EVAP)canistervent shut valve,SecondaryH02S, Vehiclespeed sensor Not used Y E U G R N Moonroof control unit, Moonroof open and close relay,Powerwindow relaV GRN Moonroof motor YEURED A u d i o u n i t GRN OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rear window wiper intermittentcontrol unit YEL Back-uplights,Cruiseindicatorlight, EPScontrol unit, Gaugeassembly, Keylessreceiverunit, Multiplexcontrol unit, Securitycontrol unit connector(optional) BLIVORN ABS modulator-controlunit YEURED D a y t i m er u n n i n ol i o h t sc o n t r o lu n i t ( C a n a d a ) PNK S R Su n i t BLK/YEL A,,/C compressorclutch relay,Blower motor relay,Condenserfan relay, Heatercontrol panel,Power mirror actuator,Power mirror defogger (Canada),Radiatorfan relay,Rearwindow defoggerrelay,Recirculation control motor Not used

15A

18 19

15A 7.5A

20 21 22 23 24 25

30A

Notused YEL/BLK E C M ,F u e lp u m p BLK/YEL >H> Unrr Y E U G R N Accessorypower socket Y E U B L K T u r ns i q n a l / h a z a rrde l a v T , u r ns i q n a l i o h t s G R N / B L K M u l t i p l e xc o n t r o lu n i t ,W i n d s h i e l dw a s h e rm o t o r .W i n d s h i e l dw i o e r m o t o r

204 20A.

G R N / B L K Passenqer'swindow motor GRN,A/VHT Driver'swindow motor

Not used

Notused

_ _ ^ : Hr tl_l f at-t at\t I

r^,rl fl

!!;r -

!f 3 3 9: , i ; s ! ! s Fnf

|rnITf

22-47

GroundDistribution Groundto ComponentsIndex Componentor circuit qrounded

Ground Batterv,Transmissionhousinq En g i n e G1 0 1

G 15' ]

ECM(PGis BLK;LGis BRN/YEL) BLK:IACvalve,lgnitioncoils,Vehiclespeedsensor,VTECsolenoidvalve switch BRNA/EL: Camshaft oosition(CMP)sensor.CKPsensor,TDCsensor.VTECoil pressure EPScontrolunit

G201

ELDunit. Multiplexcontrol inspectionconnector,Multiplexcontrol unit, Powerwindow relay,Rear window washer motor, Rightfront parkinglight, Rightfront side marker light, Rightfront turn signal light,Turn signal/hazardrelay,Washerfluid level sensor(Canada), Windshieldwasher motor, WindshieldwiDer motor

G202 G301

ABSmodulator-control unit

G401 G402 G4 5 1 G501

G502 G503 G551

G552

22-48

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

Under-dashFuse/RelayBox Removaland Installation SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations{seepage 23-13)and precautionsand procedures(seepage23-14)in the SRS sectionbeforeperformingrepairsor service.

Removal 1. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the radio's presetbuttons.

5. Removethe mounting bolt, and slidethe underdash fuse/relaybox (A) down from the bracket{B). 6. Disconnectthe backside from connectorsfrom the back of the under-dashfuse/relaybox, and remove the fuse/relaybox. N O T E : T h eS R Sc o n n e c t o irs a s p r i n g - l o a d eldo c k type (seepage 23-11).

lnstallation 2. Disconnectthebatterynegativecable,then disconnectthe positivecable,and wait at least three minutes.

1. Installthe under-dashfuse/relaybox in the reverse order of removal and connectall connectorsto the under-dashfuse/relaybox.

3. Removethe driver'sdashboardlower cover (see page 20-59).

2 . I n s t a l l t h ed r i v e r ' sd a s h b o a r dl o w e rc o v e r .

4. Disconnectthe connectorsfrom the fuse side of the under-dashfuse/relaybox.

3. Connectboth the negativecable and positivecable to the battery. 4. Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. 5. Confirmthat all systemswork properly, 6 . D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .

22-49

Battery Battery Test

A batterycan explodeif you do not follow the proper procedure,causingseriousinjury to anyone nearby.Follow all procedurescarefullyand keep sparksand open flames away from the battery. Use eithera JCI or BearARBSTtester,and follow the manufacturer'sprocedures.lf Vou don't have one of these computerizedtesters,follow this conventional test procedure: 1. Be sure the temperatureof the electrolyteis between70'F (21"C)and 100'F(38'C). 2. Inspectthe batterycasefor cracksor leaks. . l f t h e c a s ei s d a m a g e d r, e p l a c e t h eb a t t e r y . l . lf the case looksOK, go to step 3. 3. Checkthe indicatorEYE. . lf the EYEindicatesthebafteryischarged,goto step 4. . l f t h e E Y Ei n d i c a t e s al o w c h a r g e ,g o t o s t e p 7 . 4. Apply a 300 amp load for 15 secondsto removethe surfacecharge. 5, Wait 15 seconds,then apply a test load of 280 amps for 15 seconds. 6. Recordbatteryvoltage. . l f v o l t a g ei s a b o v e 9 . 6 v o l t s , t h e b a t t e r yi s O K . l . l f v o l t a g ei s b e l o w 9 . 6 v o l t sg, o t o s t e p T . 7 . C h a r g et h e b a t t e r yo n H i g h( 4 0a m p s )u n t i lt h e E Y E shows the batteryis charged,plus an additional30 minutes.lf the batterychargeis very low, it may be necessaryto bypassthe charger'spolarity protectioncircuitry. . l f t h e E Y Ei n d i c a t e s t h eb a t t e r yi s c h a r g e d w i t h i n 3 hours,the batteryis OK.l . lf the EYEindicatesthebatteryis notcharged within 3 hours,replacethe battery.l

22-50

{

Relays PowerRelayTest Usethischanto identifythetypeof relay,thendo the testlistedfor it.

type 1:

NOTE:Turnsignal/hazard relayinputtest(seepage2287). Relay

A'lCcomoressor clutchrelav Airlfuel ratio sensorrelav Condenserfan relay H e a d l i o hrte l a v1 H e a d l i q hrte l a v2 H o r nr e l a v Powerwindow relay R a d i a t oIra n r e l a y Reverserelav Startercut relav T a i l l i q h rt e l a V D a y t i m er u n n i n gl i g h t sr e l a y { C a n a d)a

Test Normally-open type A

type 2:

P G M - FmI a i nr e l a v1 P G M - Fm l a i n r e l a v2 Blower motor relav Rearwindow defoqoerrelav Moonroofclose relay Moonroof oDenrelav Low beam cut relav {Canada)

Normally-open tvpe B F i v et e r m i n a l type

Normally-open type A:

PGM-FImain relay 1 PGM-FImain relay 2 type 1:

Checkfor continuitvbetweenthe terminals. . Thereshould be continuitybetweenthe No. 1 and N o , 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e connectedto the No. 3 and No. 4 terminals. . Thereshould be no continuitybetweenthe No. 1 and N o . 2 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .

type 2:

(cont'd)

22-51

Relays PowerRelayTest (confdl Normally-open type B:

Five-terminal type

Checkfor continuitybetweenthe terminals.

C h e c kf o r c o n t i n u i t yb e t w e e nt h e t e r m i n a l s .

. Thereshould be continuitybetweenthe No. 1 and N o . 3 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e connected t o t h e N o .2 a n d N o . 4 t e r m i n a l s . ' Thereshould be no continuitybetweenthe No, 'l and No. 3 terminalswhen power is disconnected.

. T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e c o n n e c t e tdo t h e N o . 3 a n d N o . 5 t e r m i n a l s . . T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 4 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .

tF-gr tJ 1l Rearwindow defonn* *O,

type 1:

6:) rc*V

.r{{ (n F, t )\

s3.

Blower motor relay type 1:

type2:

type 2;

22-52

lgnitionSwitch Test SRScomponentsare locatedin this area.Reviewthe S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a ) nd precautionsand procedures{seepage 23-'l4)in the SRS sectionbefore performingrepairsor service. 1, Removethe driver's dashboardlower cover {see page 20-59). 2. Disconnectthe 5P connectorfrom the under-dash fuse/relaybox. WHT/RED Wiresideof f e m a l tee r m i n a l s BLK/YEL

BLK/WHT BLK/RED

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. \

Terminal WHT/

BLK/ BLK/ BLK/

RED WHT YEL RED WHT p.J,i""-\ (ACC) (BAT) flGl) trc2t (sr) o (LocK) | (ACC) o- --o _H c)[ (oN) III (START) o _H

lf the continuitychecksdo not agreewith the table, replacethe steeringlock assembly(seepage'17-121.

22-53

Gauges \-

ComponentLocationIndex

PARKINGBRAKESWITCH p a g e1 9 - 1 0

FUELGAUGESENDING p a g e1 1 - 1 5 6

SWITCH ENGINEOILPRESSURE page8-4

GAUGEASSEMBLY Procedure,page22-56 SelJ-diaqnostic page22 63 Gauqedulb Replacement, Rep6cement,page22-64 CoolantTemperatureGauge page22'64 TroLrbleshooting,

VEHICLESPEEDSENSOR{VSS) page22-65 Troubleshooting, Beplacement,page22-67

BRAKEFLUIDLEVELSWITCH p a g e1 9 - 1 0

22-54

CONNECTOR B lgreenJ

CONNECTORA (bluel

SPEEDOMETER VehicleSpeedSignalCircuit page22-65 Troubleshooting, TACHOMETEB

\7 t----/

\ _ / \

i . . _ ODO/TRIPMETER

FUELGAUGE Test,page11-156

22-55

Gauges

Self-diagnosticProcedure The gaugeassemblyhas a self-diagnosisfunction. . T h e B e e p e rD r i v eC i r c u i C t heck . The IndicatorDrive CircuitChecL . The LCDSegmentsCheck . The GaugesDrive CircuitCheck(Speedometer,Tachometer,Fuelgauge,Coolanttemperaturegauge) . T h e C o m m u n i c a t i oLni n eC h e c k( t h ec o o l a n t t e m p e r a t u rsei g n a l i n e b e t w e e nt h e g a u g ea n d E C M ) NOTE:Indicatorsare also controlledvia the communicationline.

Enteringthe self-diagnosis f unction: Beforedoing the self-diagnosisfunction,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A) fuse in the under'dashfuse/relaybox. 1. Pushand hold the trip/resetbutton. 2 . T u r nt h e l i g h t i n gs w i t c hO N . 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 4 . W i t h i n5 s e c . ,t u r n t h e l i g h t i n gs w i t c hO F F t, h e n O N a n d O F Fa g a i n . 5. Within 5 sec.,releasethe trip/resetbutton,then push and releasethe buttonfour times reDeatedlv. NOTE: . While in the self-diagnosismode, the dash lights brightnesscontrolleroperatesnormally. 'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge drive cicuit check. . lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diagnosis mode ends.

oN flrl lgnition OFF Switch Lighting Switch Trip/Reset Switch

-> 5 sec.

Move to selt-diagnosis mode.

5 sec.

The BeeperDriveCircuitCheck: When enteringthe self-diagnosismode, the beepersoundsfive times

TheIndicatorDriveCircuitCheck: When enteringthe self-diagnosismode,the following indicatorsblink. Seatbelt indicator,Door/hatchindicator,Brakesystem,Lowfuel indicator,Maintenancerequiredindicator(USA), ) , i l p r e s s u r el i g h t . W a s h e rf l u i d l e v e li n d i c a t o (r C a n a d a O

22-56

The LCDSegmentCheck: W h e ne n t e r i n gt h e s e l f - d i a g n o s m i s o d e ,t h e o d o / t r i ps e g m e n tb l i n k sf i v et i m e s .

TheGaugeDriveCircuitCheck: W h e ne n t e r i n gt h e s e l f - d i a g n o s m i s o d e ,t h e s p e e d o m e t e trh, e t a c h o m e t e rt ,h e f u e l g a u g e ,a n d t h e c o o l a n t g a u g en e e d l e ss w e e pf r o m t h e m i n i m u mp o s i t i o nt o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m temperature posrtron. NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton s t a r t st h e b e e p e rd r i v ec i r c u i tc h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i tc h e c ka g a i n . T h e c h e c kc a n n o tb e s t a r t e du n t i l t h en e e d l e sr e t u r nt o t h e m i n i m u mp o s i t i o n . Self-diagnosis mode

ON OFF

Trip/Reset switch

9loFF _---

causeneedlesXl" Beeper

;;

n =--llJL--

f---U---------l r-r r-r r-r .-1 r-r

r-r

lll u u l_lL__l I

[-----l

l-l

The needlessweepfrom the minimum positionto the maximum position,then return t o t h e m i n i m u mp o s i t i o n -

5 sec

The Communication Line Check: In the self-diagnosismode, after the odo/trip LCDsegmentscheck,the self-diagnosisstartsthe communicationline cnecK. l f a l l s e g m e n t sc o m e so n , t h e c o m m u n i c a t i o lni n e i s O K . " E r r o r "i s i n d i c a t e d , l f t h ew o r d t h e r ei s a m a l f u n c t i o ni n t h e c o m m u n i c a t i o lni n e b e t w e e nt h e g a u g ea s s e m b l yt.h e m u l t i D l e cx o n t r o lu n i t .a n d t h e E C M .

Faulty:

Normal: iD

:-l!:!!JlJ!J t l i-

f l

O i -

t --

| | | t t f i-

Endingthe self-diagnosisfunction: T u r nt h e i g n i t i o ns w i t c hO F F . N O T E lrf t h e v e h i c l es p e e de x c e e d s1 . 2m p h { 2 k m / h ) t, h e s e l f d i a g n o s i sf u n c t i o ne n d s .

22-57

Gauges CircuitDiagram ' UflOEN fiOOOFUSE/8ILAY 8OX

ECM/PCM

V I -r'

r--l

l J , I

I 8|

COOLANI TEMPfNAIUFT SPIEDOMEIENTACHOMEIIR FUTLGAUGI GAUGE

Norll0AlFUSE

8L(

-o-

22-58

ii-ciorurnn

coNNECron

N o 2 0 i o A: lU S A

ti) l To mxr I

MAi{IIiIANCE

ft0unlD [{0tcaTo8 LIGH] (LEDI

(cont'd)

22-59

Gauges

CircuitDiagram(cont'dl

No2il5AlFUSE ilnlh.undi hooq llu!./rcl.ybox r

DASH LGHTS

-t

WASHEF Itut0 I!VEL 6t0tc ToR UGHT (tDl

ls?2

BLUIYEL I

J cSutsE m n0L

a 22-60

ib-n'rnoL

UNIT

tNGniEorL PRESSUBE swtTcH lCld.d Eisin.3topp.d l iopd Ersin.runni.s i

--t

I ! i I I

DAYTIME BUNN|NG LIGHTS @NTROL UNII

I ; I

-.-..

icmadd

(cont'd)

22-61

Gauges CircuitDiagram(cont'dl

GRNIfiED I \""'7

GAUGIASSEi|BLY

LEFTTUN SIGI'IAL II'{DICATOR LTCHTS

HIGHSEAM

-|.

IMMOBITIZER

f,il

vll9i,]

CoME|NAT|ON LtctlTswtTclt

tMf,tOBtUZEn @l\tTRoL UN|I ftCtIVER

ltDtcATon r/: \ tilucaToB

J 22-62

GaugeBulb Replacement

LIGHT{1.4WI RIGHTTURNSIGNALINDICATOR

CRUISE HIGHBEAMINOICATOR LIGHT{1.4W)

ITORLIGHT{I.4W) LEFTTURNSIGNALINDICATORLIGHTl1.il wl GAUG€LIGHT{1.4WI

GAUGELIGHT{1.4W}

IMMOBILIZENINDICATOR LTGHT {1.4Wl

22-63

Gauges GaugeAssemblyReplacement

CoolantTemperature Gauge Troubleshooting

1 . Removethe instrumentpanel (seepage 20-59), t h e n r e m o v et h e u p p e rc o l u m nc o v e r{ s e ep a g e1 7 -

2. P l a c ea c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e assemblyto preventscratchingthe steering c o l u mn o r d a s hp a n e l .

Beforetesting,checkthe No. I { 10A)fuse in the underhood fuse/relaybox and the No. '10(7.5A)fuse in the under dash fuse/relaybox. 1. Startthe engine,and checkthe malfunction i n d i c a t o lra m p ( M l L ) .

3 . Removethe screwsfrom the gauge assembly(B). Does the MIL come on? YES- Troubleshootthe causeof the ECM DTC(see p a g e11 - 5 7 )a, n d r e c h e c k . NO-Go to step 2. 2. Checkfor a multiplexcontrol unit DTC(seepage 22,168). ls a DTC indicated? YES Troubleshootingthe causeof the multiplex control unit DTC{seepage 22-168),and recheck. NO Go to step 3.

4. Disconnectthe connectors(C),and removethe

g a u g ea s s e m D r y . I n s t a l l t h eg a u g ea s s e m b l yi n t h e r e v e r s eo r d e ro f removal.

3 . D o t h e c o m m u n i c a t i o lni n ec h e c kw i t h t h e s e l f diagnosisprocedure(seepage 22-56). ls the word "Error" indicated on the odo/ttip d isplay ? YES The gaugecannot receivethe signalfrom the multiplexcontrol unit and the ECI\,4. Checkfor an open in the WHT/GRNwire (gaugeconnector t e r m i n a lB1 3 ) .l f n o o p e ni s f o u n d ,g o t o s t e p5 . NO Go to step 4. 4. Do the gaugedrive circuitcheckwith the selfd i a g n o s i sp r o c e d u r e( s e ep a g e2 2 - 5 6 ) . Does the temperaturegauge needle sweep lrom the minimum position to the maximum, then tetutn to the minimumposition? YES Go to step 5. NO Replace t h e g a u g ea s s e m b l y . l 5. Substitutea known-goodECM and recheck. Did the symptom/ ind ication go away? YES Replace theECM. NO Substitutea known good gaugeassembly.lf the symptom/indicationgoes away, replacethe g a u g ea s s e m b l y . l

22-64

VehicleSpeedSignalCircuitTroubleshooting Special Tools Required: Test Harness07LAJ-PT3020A

5. Connectthe WHT test harnesscliD(B)to the positiveprobe of a voltmeter,and connectthe RED test harnessclip (C)to the negativeprobe.

Beforetesting,inspectthe No. 4 (10A)and No. 10 (7.5A) fuses in the under-dashfuse/relaybox. 1. Disconnectthe 3P connectorfrom the vehicle speedsensor(VSS){A).

T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . le thara

h2ltarv

v^ltada?

Y E S - G o t o s t e p7 . Connectthe test harnessonly to the enginewire harness.

wire betweenthe NO Repairopen in the BLK,/YEL VSS and the under-dashfuse/relaybox.l

3 . Connectthe REDtest harnessclip (B)to the positive probe of an ohmmeter.Coverthe white (C)and green {D)test harnessleadswith protectivetape (E). 4 . Checkfor continuitybetweenthe REDtest harness c l i p a n d b o d yg r o u n d ,

7 . Disconnectthe WHT test harnessclip (B). 8 . C o n n e ctth e G R Nt e s th a r n e s sc l i p{ D )t o t h e positiveprobe of a voltmeter.

ls there continuity? YES Go to step 5. N O R e p a i ro p e ni n t h e B L Kw i r e b e t w e e nt h e V S S a n dG1 0 1 . I

Is there 5 V or more? YES- Go to step 9. NO Repairshort or open in the BLUMHT or WHT/ GRNwire betweenthe VSS and the cruisecontrol u n i t ,o r t h e E C M . I

(cont'd)

22-65

Gauges VehicleSpeedSignalCircuitTroubleshooting(cont'dl 9 . Turn the ignitionswitch OFF.

14. Disconnectthe 22Pconnector"8" from the gauge assemDry.

1 0 .Connectthe other test harnessconnector(A)to the V S S( B ) ,

GAUGE ASSEMBLY CONNECTOR B (22P)

Wire side ot femaleterminals

'15. Connectthe positiveprobe of a voltmeterto the BLU/WHTwire and the negativeprobeto ground. 1 1 .R aisethe front of the vehicle,and make sure it is securelysupported.

' t 2 .Put

t5.

'16.

Slowly rotateone wheel with the other wheel blocked.

the vehiclein neutralwith the ignitionswitch

o N { |)| ,

Does voltage pulse f rom 0 to about 5 V or more?

Slowly rotateone wheel with the other wheel blocked.

YES- Replacethe speedometerassembly.I

Does voltage pulse ttom 0 to about 5 V ot morc? YES Go to step 14. NO Replacethe VSS.I

22-66

NO Repairopen in the BLUMHTwiTe between the VSS and the speedometer.l

VSS Replacement 1. Removethe intakeresonator. 2. Disconnectthe 3P connectorfrom the vehicle speed sensor{VSS)(A).

Removethe mounting bolt, then removethe VSS. 4 . lnstallthe VSS in the reverseorder of removal.

22-67

ExteriorLights GomponentLocationIndex

UNDER.HOOD FUSE/RELAY BOX HEADLIGHT RELAY1 Test,page22-51

HEADLIGHT RELAY2 Test,page22-5'l

BRAKEPEDALPOSITION

swtTcH

Test,page22-84 Adjustment,page l9'6

SIDETURN SIGNAL LIGHT page22-84 Replacement,

/ FRONTTURNSIGNAL LIGHT , g e2 2 8 1 B u l bB e p l a c e m e npt a

HEADLIGHTS page22 79 Replacement, Adjustment.page22-78 page22-81 Eulb Replacement,

22-68

PARKINGLIGHT B u l bR e p l a c e m e npt a, g e2 2 - 8 1 FRONTSIDEMARKERLIGHT Bulb Replacement,page22 83

-a-.,_ z HIGHMOUNTBRAKELIGHT page22-82 Replacement,

LICENSE PLATELIGHTS page22-83 Replacement,

BACK.UPLIGHT page22-82 Replacement,

REARSIDEMARKERLIGHT page22-83 Replacement,

TAILLIGHTSsnd BRAKELIGHTS page22-82 Replacement, REARTURNSIGNALLIGHT Beplacement,page22-82

(cont'd)

22-69

ExteriorLights

ComponentLocationIndex(cont'dl DAYTIMERUNNINGLIGHTSRELAY{Canadal [Wirecolors:RED,REDryEL, I andRED/BLU I LRED/BLK Test,page22-51 BEAMCUTRELAY {Canadal_ _LOW WirecolorsrREDMHT, RED/BLK,I andRED/BLU I LREDryEL Test,page22-51 DASH LIGHTSBRIGHTNESS CONTROLLER

. . i ' :'

--,': -

' i,-'-'l

DRLINDICATOR LIGHT{Canadal HIGH BEAM INDICATORLIGHT page22-63 Bulb Replacement,

COMBINATION LIGHTSWITCH page22-80 TesVReplacement, oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada) InputTest,page22-76 I

FUSE/ UNDER.DASH RELAYBOX

22-70

LET] FBOIII SIDE MAiKEE L.IGHT

f,IGHT TSONT

s]0E

MANXtF IJGIIT

IETT NEANSIDE MAircN IIGHT

I ucEr\6E I PI.ATE

|fiIli I 8L.l(

22-71

ExteriorLights CircuitDiagram- Canada

UNOEN HOOO FUSE/8ELAY BOX N ol 9 l 8 0 A l

) to.o - i50Al

No.1'l

loa)

WHT ED

IT N o . ! 0S( 7A lusE r d.3hl

RED,I

I- _ l '2

/', t-\ \ rc|'/moN . rcz/ swfrcH

I EAr

,'orrro" -.

vG2Horin0N{ll)

) INDICAIOF

-/ l'lcli; *01

I I BED BU1

'l'I I

= .| A

DNL

TIGHT luDl

RED/ BLU

{ r-

oorr,",rr.,ro

uctrrscournoLu,'r" J l

I I

8 SLU/BID

||MoS|UZEn CONTNOL UNIT RECEIVEB

SYSIIMUGHI

VY I

--t

GNfl/FEO

DAYTIME BUNNINC LIGHTS EfLAY

HT/BI

fifili{*1l,.H' I

) No12 i l7.5Al

BI(

G8N

17 Y

GRI\/NED

II I

88A(E I FiUrD

( 2 , LTVEL

[./ SWITCH

F\ PANKNG ; } BNAXE

+./ swrTcH

'nddoM I

22-72

G301

cl.1 G501

J DASH LIGHTS

COMEINATION LIGHT SWIqI

TTFT TRONT 3r0E MABKER LIG}IT

LEFT PAfiX*'IG LIG}IT

BLI(

BL](

G301

BIGHT PANKNG LIGIIT

FIGIIT FBONT SIDE MAfircF LJGHT l5w)

LEFT TAIILGl T

LEFT BEAFSIDE LJGHT

RIGHT RIAFSIDI I/IAFrc8 UCHT

NEHI I LICENSE IAILUOHI I PLAII I LIGNTS (twr2l | 8LI

G301

G552

I 22-73

ExteriorLights CircuitDiagram- BrakeLights UiDENHOOD FUSE/NEUYBOX SATIISY \

22-74

r!o7l15A) I | ,r-T-v--rrni'citr

CircuitDiagram- Back-upLights

UiDEN H@DFUSI/8EIAY 80)(

22-75

ExteriorLights DaytimeRunningLightsControlUnit InputTest- Canada T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l yw i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o ns w i t c ht o O N ( l l )w i t h t h e headlightswitch off and the parkingbrakese1.lt should go off when you turn on the headlightswitch and releasethe parkingbrake.lf it comes on at any other time, do the control unit input test. r i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y . N O T EW : h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow 1. Removethe driver'sdashboardlower cover (seepage 20-60). 2 , D i s c o n n e c t t hle4 P c o n n e c t o r ( Af)r o m t h e d a y t i m er u n n i n gl i g h t s c o n t r oul n i t ( B ) .

RED/BLU RED/BLU GRN/BLK

GNN/BLK GRN/ORN

BLU/RED

RED/YEL

YEL/RED

Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent,loose orcorroded, repairthem as necessary,and recheckthesystem. ' lf the terminalslook OK, go to step 4.

22-76

4. Makethese input tests at the connector, .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the input tests prove OK,the control unit must be faulty. Replaceit.

Wire Test condition RED/BLU U n d e a r ll conditions

YEL/RED

Cavity

lgnitionswitch

o N( r )

BLK

U n d e ra l l conditions BLK U n d e ra l l conditions REDI/EL C o m b i n a t i o n light switch ON / =f\\

'11

3 5

6 8

RED/BLU

Combination light switch ON {iD), and dimmer switch inHIGH RED/BLK C o m b i n a t i o n light switch ON (iD), and dimmer switch inHIGH G R N / B L K C o mb i n a t i o n light switch ON (iD), and dimmer switch inHIGH G R N / O R NParkingbrake l e v e ro u l l e d B L U / R E DC o m b i n a t i o n l i g h ts w i t c hO F F

WHT/BLU lgnitionswitch

o N0 r ) t5

GR N / R E D lgnition switch

o N( | | )

Test:Desiredresult

Possiblecauseif resultis not obtained Blown No. 14 (40A)fuse in the under-hoodfuse/relaybox B l o w nN o . 3 { 1 0 A ) f u s ei n t h e under-dashfuse/relaybox A n o p e ni n t h e w i r e Checkfor voltageto ground: B l o w nN o . l 2 ( 7 . 5 A ) f u s ei n t h e Thereshould be batteryvoltage. under-dashfuse/relaybox An open in the wire C h e c kf o r c o n t i n u i t yt o g r o u n d : . P o o rg r o u n d{ G 5 0 ' 1 ) . An oDenin the wire T h e r es h o u l db e c o n t i n u i t v . . P o o rg r o u n d( G 5 0 1 ) Checkfor continuityto ground: ' A n o p e ni n t h e w i r e Thereshould be continuitv. Checkfor voltageto ground: B l o w nN o . 1 5 ( 1 5 A )f u s ei n t h e Thereshould be batteryvoltage. under-hoodfuse/relaybox Faultyheadlightrelay 2 Faultycombinationlight switch An open in the wire Connecta jumper wire between B l o w nb u l b No.3 andNo.1terminals. Faultylow beam cut relay B o t hh e a d l i g h t (sH I G H a) n d Faultycombinationlight switch h i g h b e a mi n d i c a t o lri g h t Poor ground (G50'l) s h o u l dc o m eo n . An open in the wire Connecta jumper wire between . B l o w nb u l b . Faultycombinationlight switch N o . 5 a n d N o . 1 1t e r m i n a l s . . ( H I G H ) R i g h th e a d l i g h t should Poor ground (G50'1) . A n o p e ni n t h e w i r e c o m eo n . Checkfor voltageto ground: Thereshould be batteryvoltage.

C h e c kf o r c o n t i n u l t yt o g r o u n d T h e r es h o u l db e c o n t i n u i t y .

. Faultycombinationlight switch . P o o rg r o un d { G 5 0 1 ) . A n o p e ni n t h e w i r e

C h e c kf o r c o n t i n u i t yt o g r o u n d : There should be continuitv. Checkfor voltageto ground: Thereshould be batteryvoltage.

Faultyparkingbrakeswitch A n o p e ni n t h e w i r e F a u l t yh e a d l i g hrt e l a y s Short to ground A n o o e ni n t h e w i r e . B l o w nN o . 1 0 ( 7 . 5 A f)u s e i n t h e under-dashfuse/relaybox . FaultyDRLindicator . A n o o e ni n t h e w i r e Faultybrakesystem indicator A n o p e ni n t h e w i r e

Attachto ground: T h e D R Li n d i c a t o lri g h ts h o u l d c o m eo n . Attachto ground: T h e b r a k es y s t e ml i g h ts h o u l d c o m eo n .

22-77

ExteriorLights \

HeadlightAdjustment 2. Parkthe vehicle7.5 m (25 ft) away from a wall or a screen(A). Headlightsbecomevery hot during use;do not touch them or any attachinghardwareimmediately afterthey have beenturned off.

7.5m {25ftl

Beforeadiustingthe headlights: . Parkthevehicleon a levelsurface. . Makesurethetire pressures arecorrect. . Thedriveror someonewho weighsthe sameshould sit in the driver'sseat. '1.

Cleanthe outer lens so that you can seethe center of the headlights(A).

3 . O p e nt h e h o o d .

22-78

HeadlightReplacement

T u r nt h e l o w b e a m so n .

'1.

Determineifthe headlightsare aimed properly.

2 . Disconnectthe connectors(A)from the headlight (B).

Removethe front bumper (seepage 20-85).

Verticaladjustment: Measurethe height ofthe headlights(A).The lights should reflect52 mm (2.'1in.) below headljght h e i g h t( B ) .

6. lf necessary,adjustthe headlightsto local requirementsby turning the verticaladjuster. Removethe five mounting bolts,then removethe corner upper beam (C)and headlightassembly. Installin the reverseorder of removal. 5 . After replacement,adjustthe headlightsto local requirements.

22-79

ExteriorLights CombinationLight Switch Test/Replacement 1. Removethe driver's dashboardlower cover (seepage 20-60). 2. Removethe steeringcolumn covers(seepage 17-9). 3 , D i s c o n n e c t t hle6 P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o nl i g h ts w i t c h( B ) .

4 . Removethe tlvo screws,then slide out the combinationlight switch. 5 . Inspectthe connectorterminalsto be surethey are all makinggood contact. . lf the terminalsare bent, looseor corroded,repair them as necessary, a nd recheckthe system. .lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositionaccordingtothe tables. - lf the continuityis not as specified,replacethe switch. Light switch: \

Telmint

Position OFF Headlight switch

o--

LOW

Passingswitch

HIGH OFF

o--

Turn signalswitch: Terminal

Position

LEFT

----o

NEUTRAL RIGHT

22-80

o--

Bulb Replacement Headlight:

FrontTurn SignalLight: ParkingLight:

1. Disconnectthe 3P connector(A)from the headlight. 1 . R e m o v et h e i n n e rf e n d e r( s e ep a g e2 0 - 1 0 2 ) . Headlight{high/low): 60/55 W 2. Disconnecttheconnectors(A) from the lights.

Frontturn signallight: Parkinglight:

21W 5W

f-rI

A-

-'-+l

2. Removethe rubbercover (B). Pullthe retainingspring (C)away from the bulb (D), then removethe bulb. Installa new bulb in the reverseorder of removal. Make sure the notchesin the bulb align with the t a b sl n t h e h e a d l i g h t .

Turn the bulb sockets(B) 45'counterclockwiseto removethem from the headlighthousing. 4 . Installthe new bulb(s)in the reverseorder of

removat.

22-81

ExteriorLights TaillightReplacement

HighMount BrakeLight Replacement

1 . Removethe rearbumper(seepage20-86). 2 . Openthetailgate,anddisconnect the connectors

1. Open the hatch.

(A)fromthetaillight(B). 2. Removethe plastictrim.

Brako/Taillight; 2115W TurnSignalLight: 21 W Back-upLight: 21W

3. Disconnectthe2P connectors(A)from the high m o u n tb r a k el i g h t( B ) . High Mounl BrakeLight:

5W x 5

=\\ ili--- _\

, \ . r B ---'a

\ Removethe mounting nuts and bolts,then remove t h et a i l l i g h t .

Carefullyremovethe high mount brakelight. 5 . lnstallthe light in the reverseorder of removal.

Turn the bulb socket45' counterclockwise to removethe bulb socket. When installingthe taillight.checkthe gasket;if it is distortedor stayscompressed,replaceit. After installingthe taillight.run water over the taillightto make sure it does not leak.

22-82

LicensePlateLight Replacement 1 . Removethe hatch lower trim panel (seepage20-

P u l l t h el i c e n s ep l a l el i g h ta s s e m b l yo u t . a n d disconnectthe 2P connector(A) from the light.

Side Marker Light Replacement 1. Carefullyprythe light(A)outofthe rearbumper, (B)fromthe light. anddisconnect the 2Pconnector Becarefulnotto damagethe rearbumper. Side Marker Light:

LicensePlateLight: 5Wx2

'[-J^

,^f , t lo \

+tiP'-

' f l ^ t

\-J

"/ \==-^

3 . S e p a r a t et h e l e n s( B )a n d h o u s i n g( C ) ,t h e n r e m o v e

2 . Removethe bulbsocket(A)by turningit 45' counterclockwise. thenreolace the bulb.

the bulb. 4 . l n s t a l l t h el i g h ti n t h e r e v e r s eo r d e ro f r e m o v a l .

22-83

ExteriorLights BrakePedalPositionSwitch Test

SideTurn SignalLight Replacement

1. Disconnectthe4P connector(A) from the brake pedal positionswitch {B).

NOTE:Be careful nol to damagethe fender. 1 . P u s ht h e r e t a i n i n gs p r i n g( A ) .a n d r e m o v et h e s i d e t u r n s i g n a l i g h t( B ) , Side Turn Signal Light:

Checkfor continuitybetweenthe No. 1 and No. 2 termtnals. . T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l rs presseo. . Thereshould be no continuitywhen the brake pedal is released. Checkfor continuitybetweenthe No. 3 and No. 4 terminals{with cruisecontrol). T h e r es h o u l db e n o c o n t i n u i t yw h e n t h e b r a k e pedal is pressed. T h e r es h o u l db e c o n t i n u i t yw h e n t h e b r a k ep e d a l is released. lf necessary,adjustor replacethe switch,or adjust t h e p e d a lh e i g h t( s e ep a g e1 9 - 6 ) .

22-84

2. Disconnectthe 2P connector{C)from the light.

TurnSignal/Hazard Flasher ComponentLocationIndex

COMBINATION LIGHT/TURN SIGNALSWITCH Test,page22-80 page22-80 Beplacement, TURNSIGNALINDICATOR LIGHTS (lnthegaugeassembly) page22'63 BulbReplacement,

HAZARDWARNINGSWITCH Test,page22-88 page22-88 Replacement,

TURNSIGNAL/HAZARDRELAY InputTest,page22-87

FUSE/RELAY BOX UNDER.DASH

22-85

TurnSignal/Hazard Flasher CircuitDiagram

DASH Ut\toEB TUSVRILAY 8OX

UNDff HOOD FUSUftIIY8OX

'No20lr0A USA No.2{ l50A):Cmada

fiIGHTT

INDICATON IIGHT 11.1W)

FBONT

! 22-86

RelayInputTest TurnSignal/Hazard 1 . R e m o v e t h e t u r ns i g n a l / h a z a rrde l a y( A )f r o m t h e u n d e r - d a sfhu s e / r e l a yb o x ( B ) .

000i0!1000

00u!u0

Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact . lf the terminalsare bent.loose,or corroded,repairthem as necessary,and recheckthesystem. . lf the terminalslook OK, go to step 3. Make these input tests at the fuse/relaybox. .lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . l f a l l t h e i n p u t t e s t sp r o v eO K , t h e t u r ns i g n a l / h a z a rrde l a ym u s t b e f a u l t y .R e p l a c ei t

Cavitv 1

Possiblecauseil resultis not obtained Test: Desired result . P o o rg r o u n d( G 2 0 1 ) Checkfor continuityto ground: . An ooenin thewire Thereshould be continuiw. ' ( ground: Blown No. 19 (7.5A)fuse in the for voltage to Check ON ll) lgnitionswitch under-dashfuse/relaybox Hazardwarning switch Thereshould be batteryvoltage. . Faultyhazardwarning switch OFF . A n o o e ni n t h e w i r e . Blown No. 5 {10A)fuse in the ground: warningswitch Checkfor voltageto Hazard voltage. under-hoodfuse/relaybox There be battery should ON . Faultyhazardwarning switch lgnitionswitchOFF . An ooen in the wire . , 3 0 1 ,G 5 0 1 , ( P o o rg r o u n d( G 2 0 1G C o n n e cN t o . 2 t e r m i n a l t oN o . 3 l g n i t i o ns w i t c hO N l l ) G553) G502, terminal: and turn signal switch . Faultyturn signalswitch in Rightor Left position R i g h to r l e f tt u r n s i g n a l i g h t s . A n o D e ni n t h e w i r e s h o u l dc o m e o n . . P o o rg r o u n d( G 2 0 1G , 3 0 1 ,G 5 0 1 , C o n n e cN t o . 2 t e r m i n a tl o N o . 3 lgnitionswitch OFF G502, G553) Hazardwarning switch t e r m r n a l : . Faultyhazardwarning switch H a z a r dw a r n i n gl i g h t ss h o u l d ON . An open in lhe wire c o m eo n . Tesl condition U n d e ra l l c o n d i t i o n s

22-87

TurnSignal/Hazard Flasher HazardWarningSwitch Test 1 . Removethe centerpanel (seepage 20-62). 2 . Disconnectthe 10Pconnector(A)from the hazard w a r n i n gs w i t c h( B ) .

3 . Pushout the hazardwarning switch from behind t h e c e n t e rp a n e l( C ) . 4 . Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. lf the continuityis not as specified,replacethe bulb ( D )o r t h e h a z a r dw a r n i n gs w i t c h .

Termin6l 1

;;;-_-\ OFF ON

22-88

Entry Light ControlSystem ComponentLocationIndex

CEILINGLIGHT/SPOTLIGHTS Test,page22-96 page22-96 Replacement,

REARCEILING LIGHT Test,page22-96 page22-96 Replacement, FRONTPASSENGER'S DOORSWITCH

IGNITIONKEYLIGHT Test,page22-91 IGNITIONKEY SWITCH lest, page22-91

HATCHLATCHSWITCH Test,page22-97 DRIVER'SDOORSWITCH

AREALIGHT CARGO Test,page22-97 page22 97 Replacement,

22-89

EntryLightControlSystem CircuitDiagram

'No.20({0A) USA UiIOTf,HOOD fUSE/8ELAY BOX

EiIIpN SMTqI

lGlHoTin0Nilll nd STAnT 0D

CEILING UGHT

Y I I

DtrVTN'S DOOR

Locx

(NOB s!t/tTc8

ORIVEBS DOOR SWITCH

PASSTNGERS DOOB SWITCH

i9r"..d l

IGNIlx)N KEY SWtTCH

G()t

J 22-90

lgnition KeySwitch Test NOTE:For more key-inbeeperinformation,referto the circuitdiagram (seepage 22-90)and input test (see page 22-921.

lgnition Key Light Test 1 . Removethe steeringcolumn upper and lower covers(seepage 17-9). Disconnectthe 6P connector,

When the ignition key is in the ignition switchthe multiplexcontrol unit sensesground through the closedignition key switch.When you open the driver's door, the multiplexcontrol unit sensesground through the closeddoor switch and soundsthe beeper. 1. Removethe steeringcolumn upper and lower c o v e r s( s e ep a g e ' 1 7 - 9 ) .

i' /.'

2. Disconnectthe 6P connector.

The LEDshouldcome on when power is connected to the No. 6 terminal and ground is connectedto N o .5 t e r m i n a l . lf the LEDdoes not come on, replacethe ignition swrtch.

3 . Checkfor continuitybetweenthe No. 1 and No. 2 termrnars. . There should be continuitywith the key in the ignition switch. . Thereshould be no continuitywith the key removedfrom the ignitionswitch. lf the continuityis not as specfied,replacethe ignition switch.

22-91

EntryLightControlSystem Control Unit Input Test 1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172). 2. Removethe dashboardlower cover. 3. Disconnectthe under-dashfuse/relaybox connectors. NOTE:All connectorsare wire side of femaleterminals. UNDER.DASH FUSE/RELAY BOXCONNECTOR K Il7PI

UNDEB-DASIJ FUSE/RELAYBOX CONNECTOR O {,I2PI

GRN/RED UNDEB.DASH FUSE/RELAY BOXCONNECTOR P {18PI

6),/18.

GRN LT GRN/REO UNOER.DASHFUSE/REI"AY BOX CONNECTOBX I8PI

,/13 4

8ED/WHT WHT/BLK UNDER.DASH FUSE/RELAY BOXCONNECTOR Y {13PI

YEL/RED 4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseorcorroded, repairthem as necessary,and recheckthe system. . lf the terminalslook OK, go to step 5.

22-92

I maketheseinputtestsat theconnector' stilldisconnected, 5. Withtheconnectors . lf anvtestindicates the system a problem,find andcorrectthe cause,then recheck . lf allthe inpultestsproveOK,go to step6. Cavitv K2

Test:Desiredresult Test condition Wire 8LU/ORN lJnderallconditions Checkfor continuitybetweenthe K2 terminalandthe keylessreceiver No.2 terminal: unit5Pconnector Thereshouldbecontinuitv. GRN/RED C e j l i n gl i g h t s w i t c h i n Attachto ground: comeon. Ceilinglight(s)should middle position.

r l l c o n d i t i o n s Attachto ground: WHT/BLK U n d e a lgnitionkeylightshouldcomeon.

Possiblecquseil resultis not obtained An open in the wire

BlownNo.3 (7.5A)fusein the underhood Blownbulb Faultyceilinglight An ooenin the wire in the underhood ElownNo.3 (7.5A)fuse fuse/relay box Faultyignitionkeylight(LED) An ooenin the wire

on the under-dash connectors box,and maketheseinputtestsat the appropriate to the underdashfuse/relaV the connectors 6. Reconnect fuse/relay box. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. .lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder'dashfuse/relaYboxassemblY Cavitv P18

Wire RED

Test condition

Test:Desiredresult

Posq!!!c sq!!ej1!.9!!!!j Poorground(G552) Fauhyhatchlatchswitch An openinthewire Faultyhatchlatchswitch Shorttooround Faultydrlver'sdoorswitch An oDenin thewire Faultydriver'sdoorswitch

H a t c ho p e n

C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 1 V or less.

H a t c hc l o s e d

Checkfor voltageto ground: Thereshouldbe 5 v or more.

Driver'sdooropen

C h e c kf o r v o l t a g e t o g r o u n d : Thereshould be 1 V or less.

Driver'sdoorclosed

Passenger's door croseo RED^vHT lgnitionkey inserted intothe ignition

Checkfor voltageto ground: Thar. shoul.lhe 5 V or more. Checkfor voltageto ground: Thereshouldbe 1 V or less. Checkforvoltageto ground: Thereshouldbe 5 Vor more. Checkfor voltageto ground: Thereshouldbe 1 V or less.

lgnitionkey removed from the ignition

C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 5 V or more.

F a u l t yi g n i t i o n k e y s w i t c h Short to ground

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Poorground{G501) Faultydriver'sdoorlockknobswitch An ooenin thewire Faultydriver'sdoorlockknobswitch Shortto oround

GRN

door LTGRN/ Passenger's BED

YEURED Driver'sdoorlock knob switchlocked Driver'sdoorlock kn6h cwirch Inl6cke.l

Checkfor voltageto ground: Thereshouldbe 5 V or more.

€d

' Faultypassenger's doorswitch ' An oneninthewire . Faultypassenger's doorswitch . Shor o oround Poorground(G401) Faultyignitionkeyswitch An ooenin the wire

22-93

InteriorLights

u J

ComponentLocationIndex

CEILING LIGHT/SPOTLIGHTS Test,page22-96 page22-96 Replacement, REARCEILING LIGHT Test,page22-96 page22-96 Replacement,

HATCHLATCHSWITCH Test,page22-97 CARGOAREALIGHT fesl, page 22-97 page22-97 Replacement,

22-94

CircuitDiagram

STAB ctu[G

LIGHT

MUITIPLEX c0NTlot UIIIT

HATCH LATClI swtTcH

22-95

Interior Lights CeilingLight/SpotlightsTest/ Replacement

RearCeilingLight Test/ Replacement

1 . Turn the ceiling lighvspotlightsswitchesOFF.

1 . Turn the light switch OFF.

2 . Carefullypry off the lens {A) wilh a small screwdnver,

2 . Carefullypry offthe lens (A) with a small screwdriver.

CeilingLight: Spotlight:

5W 5Wx2

CeilingLight: 8 W

x 1-0 mm 5x1.0mm \A

3. Removethe two screwsand the housing(B). 4 . D i s c o n n e ct h t e 4 Pc o n n e c t o(rC )f r o m t h e h o u s i n g .

3. Removethe two mounting screws.

5. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

4. Disconnectthe 3P connector(B)from the housing

P."lil;-

Terminal -----_l

oFF celL,"ca,c", MIDDLE isoottiohts\ 'uir a}-+4 oN

SPOTLIGHTS I C e i l i n ql i o h t r o F F - - i

-o -o

o (.F.O

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. Terminal Position

G-

OFF

MIDDLE

OFF

{c).

o G -@- O

OFF

lf the continuityis not as specified,checkthe bulb. l f t h e b u l bi s O K , r e p l a c et h e c e i l i n gl i g h v s p o t l ihgt s .

22-96

lf the continuityis not as specified,checkthe bulb. l f t h e b u l b i s O K , r e p l a c et h e r e a rc e i l i n gl i g h t .

CargoArea Light Test/Replacement Hatch Latch Switch Test 1 . Open the hatch. Carefullypry out the cargo area light (A).

'1. Open the hatch. Removethe hatch lower trim panel (seepage 20-

s3).

CargoArea Light: 5W Disconnectthe 2P connector{A) from the hatch l a t c h( B ) ,

Disconnectthe 2P connector(B)from the light. Checkfor continuitybetweenthe No. 1 (+) and N o . 2 ( ) t e r m i n a l sT. h e r es h o u l db e c o n t i n u i t y . lf there is no continuitv,checkthe bulb. lf the bulb is OK, replacethe cargo area light.

4 . Checkfor continuitybetweenthe No. 1 and No. 2 terminals. . Thereshould be continuitywith the hatch open . Thereshould be no continuitywith the hatch ctoseo. lf the continuityis not as specified,replacethe hatch latch.

22-97

AudioSystem ComponentLocationIndex

AUOIOUNIT Removal/f nstallation, Daoe22-100 pa-ge Connector Terminals, 22-101 RIGHTDOOBTWEETER page22-102 Replacement,

ROOFANTENNA page22-'1 Replacement, 03

ANTENNA SUB LEAD

DRIVER'SDOORSPEAKER page22 102 Replacement,

LEFTREARSPEAKER page22-102 Replacement, RIGHT REARSPEAKER page22-102 Replacement, ANTENNA LEAD

22-98

CircuitDiagram '

/ 8AT

--------F

\ f!tACC /

No.20ioA) :USA

WHT/FED

ACC HoTinACC lllmd0Nllll

AUDIO UflIT

DRIVER'S DOORSPEArcF

IEFITWEETER

PASSE!{GIF'S DOOB SPEAKES

SIGIITTWEETEB

LEFTFEAB SPEA(I8

NrcBTREAF SPEAKEF

22-99

AudioSystem

!\,

Audio Unit Removal/lnstallation NOTE: . Put on glovesto protectyour hands. . Takecare not to scratchthe dashboardand related parts.

Removethe heatercontrol panel (seepage 21 38). R e m o v et h e f o u r m o u n t i n gb o l t sa n d t h e a u d i ou n i t from the radio brackets.

1. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the radio's presetbuttons. 2. Removethe driver's dashboardlower cover (see page20-59). 3. Removethe two mounting bolts,then pull out the centerpanel (A).

7 . I n s t a l l t h ea u d i ou n i ti n t h e r e v e r s eo r d e ro f removal,and note these items:

4 . Disconnectthe audio connector(B)and antenna lead (C),heatercontrol panelconnectors(D) and HAVCpush switch assembly(E),then removethe center panel.

22-100

. Make sure the audio unit and A/C connectorsare pluggedin properly,and the antennalead is connectedproperly. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets.

Audio Unit ConnectorReplacement Cavity 1

Wire YEUGRN YEURED

Connectsto

4 5

PNK

Roof antenna ACC (Power) Not used Not used R i o h tr e a rs D e a k e(r+ I

BLU^/vHT

(+) LeftrearsDeaker

7 8

GRN/YEL

Front oassenqer'sdoor sDeaker{+)/Riqht tweeter (+) Driver'sdoor speaker{ + )/Lefttweeter (+ ) Liqhts on siqnal Constantpower Not used Not used Not used

2 3

9 10

GRN/BLK RED/BLK WHT/RED

Notused

14 ta to

11 18 19

BLU/YEL BLU/BLK GRY/RED LT GRN RED BLK

R i o h tr e a rs o e a k e (r Left rear sDeaker( Front passenqer'sdoor speaker( )/Riqhttweeter{ Driver'sdoor sDeaker( )/Lefttweetr ( Dashliqhts briqhtnesscontroller

Gr o u n d( G 5 0 3 )

AUDIOUNIT2OPCONNECTOR

22-101

AudioSystem SpeakerReplacement DoorSpeaker:

Rear:

1 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) .

1 . Removethe speakercover (A).

2. Pullthe top of the speaker{A) straightout, just enoughto releasethe upper clip. lf you pull the speakerout too far, you will damagethe lower clips (C).Then lifi the speakerstraightup to releasethe lower clips.

2. Removethe three screws,then disconnectthe 2P

3. Disconnectthe 2P connector(B),and removethe speaKer.

Tweeter: Carefullypry the tweeter (A) out of the mirror mount cover,then disconnectthe 2P connector(B)from the tweeter.

'-----d

22-102

connector(B)from the speaker(C).

RoofAntennaReplacement 1. Removethe rear part of headliner(seepage20-54). 2, Disconnectthe antennalead connector(A) and 1P connector(B)from the roof antenna(C).

3. Removethe mounting nut and the antenna.

22-103

RearWindow Defogger

ComponentLocationIndex *:Rearwindow defoggerswitch is built into the heatercontrol panel. UNDER.HOOD FUSE/RELAY BOX

REARWINDOWDEFOGGER RELAY Test,page22-51

REARWINDOW DEFOGGER SWITCH+

u I

NOISE CONDENSER page22 107 CapacityTest,

REARWINDOWDEFOGGEB Function Test,page22 106

DefoggerWire Repair,page22 106

J 22-104

CircuitDiagram

;Hl}lj.'fl,1fl1fi"

T f,rAiwrxDow ,74 DEfOGGES

BEATERcoNrf,oLpANrL(\iP\/ I SWrcfl L

INDIATOR ILEDI

22-105

RearWindowDefogger FunctionTest

DefoggerWire Repair

NOTE: . Be carefulnot to scratchor damagethe defogger wires with the testerprobe. . Beforetesting,checkthe No. 11 (30A)fuse in the '14('10A) under-hoodfuse/relaybox and No. fuse in the under-dashfuse/relaybox.

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

1. Checkfor voltage betweenthe verticaI dividersand body ground with the ignitionswitch and defogger switch ON. There should be voltageas shown. . lf there is no voltage.checkfor: - faulty defoggerrelay. - an open in the BLK,BLK,/YEL, or YEL/BLKwire. - taulty heatercontrol panel. . lf there is batteryvoltage,goto step 2.

2. Carefullymask above and below the brokenportion of the defoggerwire (B)with transparenttape {C). Mix the silverconductivepaint thoroughly.Using a small brush,apply a heavy coat of paint extending about 1/8 inch on both sidesof the break.Allow 30 minutesto dry. 6V

2 . Checkfor continuitybetweenthe negativeterminal ( B )a n d b o d y g r o u n d . lf there is no continuity,checkfor: . a n o p e n i n t h e B L Kw i r e . . Poor body ground at the window antennacoil mounting bolt. Touchthe voltmeterpositiveprobe to the halfway point of each defoggerwire. and the negative probeto the negativeterminal, Thereshould be about 6 V with the ignitionswitch and the defoggerswitch ON. . l f t h e v o l t a g ei s a s s p e c i f i e dt ,h e d e f o g g e r w l r ei s

oK. . lf the voltage is not as specified,repairthe defoggerwire. - l f i t i s m o r et h a n 6 V , t h e r ei s a b r e a ki n t h e n e g a t i v eh a l fo f t h e w i r e . - lf it is lessthan 6 V, there is a breakin the positivehalf of the wire.

22-106

Checkfor continuityin the repairedwire. 5 . Apply a secondcoat of paint in the same way. Let it dry 3 hours before removingthe tape.

NoiseGondenserCapacityTest 1 . Removethe right rear side trim panel (seepage 2066). Disconnectthe 2P connector(A)from the noise condenser. Noise condenser capacity: 0.47 a 0.09 microfarads Wiresideol femaleterminals

Use a commerciallyavailablecondensertester. Connectthe condensertester probes,and the measurecondensercapacity. 4. lf it is not within the specification,replacethe noise

condenser.

22-107

Moonroof ComponentLocationIndex

MOONROOF SWITCH f e $ , p a g e2 2 - 1 1 2 R e p l a c e m epnat ,g e2 2 - 1 2 T e s tp. a g e 2 2 - 1 1 2 page20-41 Replacement, MOONROOFLIMIT SWITCH Test,page22-113

\|.

MOONROOF CONTROLUNIT InputTest,page22-'l10

MOONROOFAUTO-STOPSWITCH Test,page22'113

22-108

MOONROOF OPENRELAY GRN, I lwire colors:GRN/YEL, BLKandYEUGRNI LRED/YEL, Test,page22-51 MOONROOF CLOSERELAY GRN, I lwire colorsrGRN/BLK, BLKand YEL/GRNI LGRN/WHT, Test,page22-51

CircuitDiagram UNDIR OAS8FUSE/NILAY MX

No.20lOAl:US No.20150 ) :Canda

A Clos.dfom lh€ ruto nop poshio. to lh€ doed porhion B Clo!.d in th€ lilt or do3.d poilion C : Clo!.d in anyop.n (io! riltl posirion D Clos.d in th€ tilt po6iiion

BL|(

8LI

G50t

G5{1

22-109

Moonroof MoonroofControlUnit Input Test

1 . R e m o vteh eh e a d l i n e( sr e ep a g e2 0 - 5 4 ) . (A)fromthecontrolunit(B). 2 . Disconnect the 5Pconnector

GRN/WHT

LT GRN

Wire sideof f e m a l et e r m i n a l s

RED/YEL BLK Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseor corroded,repairthem asnecessary.and recheckthesystem. . lf the terminalslook OK, go to step 4.

$ J 22-110

4- Reconnect the moonroolcontrolunit5Pconnector, andmaketheseinputtestsattheconnector. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtestsproveOK,go to step5. Caviiy

Wire

Test condition

BLK

Underallconditions

Checkfor continuityto ground: Thereshouldbe continuity.

Poorground(G501) An openin the wire

YEUGRN lgnitionswitchON (ll)

C h e c kf o r v o l t a g e t o g r o u n d : There should be baftery voltage.

BlownNo.6 (7.54)tusein the under dashfuse/relaybox An openin the wire

lgnitionswitchON (ll) Moonroofclosed

C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 1V or less.

Poorground(G501) Faultymoonroof auto-stopswitch An openinthewire

Moonroof open

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

Shorttoground Faultymoonroofauto-stop switch

LT GRN

Test:Desiredresuh

Possiblecaus6if result is not obtained

Disconnectthe moonroofcontrolunit5Pconnector, andmakethese;nputtests at the connector 'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtestsproveOK,the controlunit mustbefaultv.Replace it. Cavity

Wire

Test condition

Test:Desiredrosult

Possiblecauseif resultis not obtained Poorground(G501) BlownNo.6 (7.5Aifusein the under' dashfuse/relaybox BlownNo.7120Alfuse inthe under dashfuse/relay box Faultymoonroofopenrelay Faultymoonroofcloserelay FaultymoonrooJmotor A n o p e n ; nt h e w i r e

RED//EL lgnitionswitchON lll)

Connecta jumperwire betweenNo, 3 and No.5 terminals. Moonroofmotorshouldrun (opened).

cRN,4/VHTl g n i t i o n s w i t c h O N ( l l )

Connecta jumperwire betweenNo. Poorground(G501) 2 and No.5 terminals. BlownNo.6 (7.5Aifusein the under I\,4oonroof motorshouldrun {closed). dashfuse/relay box ElownNo.7 (20A)fusein the under dashfuse/relaybox Faultymoonroofopenrelay Faultymoonroolcloserelay Faultymoonroof motor An openin thewire

22-111

Moonroof Motor Test

Switch Test/Replacement '1 . Carefullypry the moonroof switch (A) out of the headlin er.

1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) . 2. Disconnectthe 2P connectorfrom the moonroof motor.

2. Disconnectthe5P connector(Blfrom the moonroof swtrcn. 3. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. Terminal \ --\ Pi.iti..

Terminal

pl.iri""---\ OPEN

lf the motor does not run. replaceit,

TILT

-o

4 . lf the continuityis not as specified.replacethe moonroof switch.

22-112

OPEN

3. Checkthe motor by connectingpower and ground accordinoto the table.

NOTE:See closingforce check(seepage20-48)for motor clutchtest.

Limit Switch Test

Auto-stopSwitch Test

l . Removethe headliner(seepage 20-54).

1 . Removethe headliner(seepage 20-54).

2. Disconnectthe 4P connectorfrom the moonroof

2 . Disconnectthe 2P connectorfrom the moonroof auto-stopswitch.

limit switch.

Checkfor continuily betweenthe terminalsin each switch positionaccordingto the table.

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

NOTE:Turn the motor by hand with the wrench.

NOTE: . Turn the motor by hand with the wrench, . The auto-stoppositionis about 145 mm (5.75in.) from fully closed.

Terminal \ Position

TILT

Terminal

OPEN

Position

BotwoenAUTO-STOP andCLOSE

lf the continuityis not as specified,replacethe moonroof limit switch.

Between OPEN and AUTO.STOP

lf the continuityis not as specified,repairor replace the auto-stopswitch.

22-113

PowerMirrors ComponentLocationIndex POWERMIRRORS FunctionTest,page22-116 page20-15 Replacement, ActuatorTest,page22-117 ActuatorReplacemenl,page22-118

q3:.[

---\,--,-'/

j-' ',i.

-:,)

it .i/

'\ \, -,''

-o t: '

-lo'

,.'7

POWERMIRRORand MIRRORDEFOGGERSWITCH lesl, page22-111 page22-117 Replacement,

$r22-114

CircuitDiagram '1 UiIDTSrcODR]SE/R€LAY 8OX

rcilmoN s1/vtTcH

UiD$ DASH N'SUnIIAY8OX

ih.a i|0At :Usa

22-115

PowerMirrors FunctionTest 1. Removethe driver's pocket(seepage 20-60).

Left mirror

2. Reachthrough the pocketopening,and push out the power mirror switch (A).

7 . C o n n e ctth e N o . 2 t e r m i n a tl o t h e N o . l 0 t e r m i n a l , a n dt h e N o . 5 ( o r N o . 1 2 )t e r m i n a tl o t h e N o . 6 t e r m i n aw l i t h j u m p e rw i r e s .T h e l e f tm i r r o rs h o u l d t i l t d o w n ( o r s w i n gl e f t ) w i t ht h e i g n i t i o ns w i t c hO N

, \

flr).

. l f t h e m i r r o r d o e sn o t t i l t d o w n ( o r d o e sn o t s w i n g left),checkfor an open in the GRN/WHT(or BLU/ Wl-lT)wirebetweenthe left mirror and the 13P conneclor,lf the wire is OK, checkthe left m irror actualor. . lf the mirror neithertiltsdown nor swings left. r e p a i rt h e B L U / B L K wire. . l f t h e m i r r o r w o r k sp r o p e r l yc, h e c k t h em i r r o r

RED B

SWIICN,

Right mirror W i r es i d eo f t e m a l et e r m i n a l s

WHT/RED RED/BLK

RED/YEL

o n n e c t o(rB )f r o m t h e s w i t c h . 3 . D i s c o n n e c t t h e ' 1 3cP 4. Choosethe appropriatetest basedon the symptom: . Both mirrors don't work, go to step 5. . Left mirror doesn'twork, go to step 7. . Rightmirror doesn'twork, go to step 8. . Defoggerdoesn'twork (Canada),go to step 9.

8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l , a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a tl o t h e N o . 6 terminaw l i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d tilt down (or swing left)with the ignition switch ON ( ). . lf the mirror does not tilt down (or does not swing left),checkfor an open in the GRN/WHT(or WHT/ R E D ) w i r eb e t w e e nt h e r i g h tm i r r o ra n d t h e 1 3 P connector. lf the wire is OK, checkthe right mirror actuator. . l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t , repalrthe RED|YELwire. ' l f t h e m i r r o r w o r k sp r o p e r l yc. h e c k t h em i r r o r swrrcn.

Both mirrors Defogger(Canada) 5. Checkfor voltage betweenthe No. 2 terminal and b o d y g r o u n dw i t h t h e i g n i t l o ns w i t c hO N ( l l ) . There should be batteryvoltage. . lf there is no batteryvoltage,checkfor: - b l o w n N o . 1 4 ( 1 0 A )f u s e i n t h e u n d e r ' d a s h fuse/relaybox. - a n o p e ni n t h e B L K r y E L wire. . lf there is batteryvoltage,goto step 6. 6. Checkfor continuitybetweenthe No. 6 terminal a n d b o d yg r o u n d . T h e r es h o u l db e c o n t i n u i t y . . lf there is no continuity,checkfor: - a n o p e ni n t h e B L Kw i r e . - p o o r g r o u n d( G 5 0 1 ) . . lf there is continuity,checkboth mirrors i n d i v i d u a l la y s d e s c r i b e di n t h e n e x tc o l u m n .

22-116

9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l sw i t h a jumper wire, and checkfor voltage betweenthe N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oar n d b o d y ground.Thereshould be batteryvoltageand both m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o ns w i t c h

oN t). . l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m su p , c h e c k for: - a n o p e n i n t h e B L K I / E Lo r o R N w i r e . - b l o w n N o . 1 4 ( ' l 0 A ) f u s ei n t h e u n d e r - d a s h fuse/relaybox. . l f o n l y o n e f a i l st o w a r m u p , c h e c k : - its defogger. - p o o r g r o u n d( G 5 0 1G , 502) . l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .

PowerMirror Switch Test

Power Mirror ActuatorTest

1 . Removethe driver'spocket(seepage 20-60).

1 , Removethe door panel (seepage 20-4).

2 . Reachthrough the pocketopening,and push out the power mirror switch (A).

2 . Disconnectthe 6P connector(A) from the power m i r r o ra c t u a t o (r B ) .

3 . Disconnectthe 13Pconnector(B)f rom the switch. Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table. Checkactuatoroperationby connectingpower and ground accordingto the table.

Mirror Switch:

\.f9.-'"1L Position

--o

-c)

TILTDOWN

SWINGLEFT

SWING RIGHT

o o

-o RIGHT

TILTUP

-o

Terminal \ Position

-o

4. lf the mirror fails to work properly,replacethe mtrror actuator. DefoggerTest {Canada);

"[T

5 . C h e c kf o r c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2 terminalsof the 6P connector.Thereshould be continuity.lf there is no continuity,checkfor an open circuit.

RIGHT

Defogger Switch (Canadal: \

Te.minal

tlf

il;;; ON

OFF

5 . lf the continuityis not as specified,replacethe power mirror switch.

22-117

PowerMirrors PowerMirror Actuator Replacement '1.

Removethe power mirror (seepage 20-15).

8. Removethe three Torx screws,and separatelhe actuator(A)from the mirror housing{B).

2 . Carefullyremovethe mirror holderfrom the mirror h o u s i n gG . e n t l yp u l l i t o u t b y h a n d( s e ep a g e2 0 - 1 5 ) .

3 . Disconnectthe connector. 4 . Removethe cover,then removethe two Torx screwsfrom the mirror connector. 5 . Recordthe terminal locationsand wire colors. 6 . Cut the wire harnesswith the wire cutter.

9 . Routethe wire harness{A) ofthe new actuator t h r o u g ht h e h o l ei n t h e b r a c k e (t B ) .

7. Removethe three screws,and separatethe mirror housinqfrom the mirror base.

J 22-118

10. lnsertthe terminalsinto the connectorin the o r i g i n aa l r r a n g e m e nat s s h o w n b e l o w .

LEFTMIRROR CONNECTOR RIGHTMIRROR CONNECTOR

*:Canada 'l'1.

Wiresideof femaleterminals

Reassemblein the reverseorder of disassembly. Be carefulnot to breakthe mirror holderwhen reinstallingit to the actuator.

1 2 .R e i n s t a l l t h m e i r r o ra s s e m b l yo n t h e d o o r . tJ.

Operatethe power mirror to ensuresmooth operation.

22-119

Horns \

ComponentLocationIndex UNDER-HOOD FUSE/RELAY BOX

HORNRELAY Test,page22-51

:.."'

HORNSWITCH fesl, page22-122

HORNS Test,page22 122 B e p l a c e m e npt a , g e2 2 1 2 2

CABLEREEL page23,119 Replacement,

*r 22-120

GircuitDiagram

22-121

Horns Horn Test/Replacement

Horn Switch Test

1 . Removethe front bumper {seepage 20-85).

1 . Removethe steeringcolumn covers(seepage '179).

Disconnectthe 1Pconnector(B),and removethe horn (A).

Disconneclthe dashboardwire harnessB 5P connector(A) from the cable reel (B).

|. . . . : .../.. ...,

3 . Testthe horn by connectingbatterypower to the terminal (A) and ground to the bracket(B).The horn s h o u l ds o u n d .

Using a jumper wire . connectthe dashboardwire harnessB 5P connector(A) No. 2 terminal to body g r o u n d. . lf the horns sound,goto step 4. . l f t h e h o r n sd o n o t s o u n d ,c h e c k t h e s ei t e m s : - Horn relay - N o . 7 ( 1 5 A ) f u s ei n t h e u n d e r - h o o fdu s e / r e l a y box - Horns (see page 22-122). - An open in the wire 4. lf it fails to sound, replaceit.

22-122

I wire harnessB 5P 4. Reconnect the dashboard the hornswitch connector {A),anddisconnect (B). positive1Pconnector

wheelto 1 . Usinga jumperwire,connentthe steering b o d yg r o u n d . 8 . Closethecontactsbetweenthe hornplateandthe contactplate. . lf the hornssound,replacethesteeringcolumn. . l f t h eh o r n s d on o t s o u n dr,e p l a c e t hheo r na n d contactplate.

Using a jumperwire, connectthehorn switch positive1Pconnector(B)to ground . lf the horns sound,go to step 6. . l f t h e h o r n sd o n o t s o u n d ,r e p l a c e t h e c a b lree e l . 6 , Reconnectthe horn switch positive1Pconector(B).

22-123

PowerWindows ComponentLocationIndex

UNDER.DASH FUSE/RELAY BOX

al.l ' -f..--.-L - . : :

POWERWINDOWRELAY Iest, page22-51

FRONTPASSENGER'S WINDOWMOTOR Test,page22-132

DRIVER'SWINDOWMOTOR Test,page22-129 POWERWINDOW MASIER SWITCH InputTest.Daqe22.126 Test,page22--128 page22-133 Replacement,

FRONTPASSENGER'SWINDOW SWITCH I n D uT t e s l ,p a q e2 2 - 1 3 0 f est, page 22-132 Beplacement,page22-133

22-124

CircuitDiagram 'No.20il0A) : USA UNOERHMO FUSI/8tLAY8OI

tGt'TtoitswtTcfi

--+r

o'F

BTTYEL

lGl HOTin 0N {ll) tnd STABT{llll

WHT/BU

22-125

PowerWindows MasterSwitch Input Test NOTE:Thepowerwindowcontrolunitis builtintothe powerwindowmasterswitch,andit onlycontrolsthe driver's windowoperations. 1. Removethe windowmasterswitch{A)(seepage22-133). (B)from the masterswitch. 2. Disconnect the 14Pconnector

GRN/WHT

3. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf theterminals are bent, looseorcorroded, repairthem as necessary,and recheckthesystem. . lf the terminalslook OK, go to step 4.

22-126

4. Withthe connectorstill disconnected,maketheseinputtests attheconnector. .lfanytestindicatesaproblem,findandcorrectthecause.thenrecheckthesystem. . l f a l l t h e i n p u t t e s t sp r o v eO K ,g o t o s t e p5 .

Cavity

Wire

Test condition

BLK

U n d e ra l l c o n d i t i o n s

14 11

GRN^,^/HT l g n i t i o ns w i t c hO N ( l l )

GRN/BLK

RED/YEL C o n n e ctth e N o . RED/BLK

Test:Desiredresult

Checkfor continuityto grouno: Thereshould be continuity. Checkfor voltageto ground: Thereshould be battery voltage.

'l'1 Checkfor driver'swindow and molor operaflon: N o . 7 t e r m i n a l sa, n d t h e N o , 4 a n d N o . 1 4t e r m i n a l s , I t s h o u l dr u n ( t h ed r i v e r ' s and turn the ignition switch w i n d o w m o v e sd o w n ) .

Possiblecauseif result is not obtained . P o o rg r o u n d{ G 5 0 ' 1 ) . An openin thewire B l o w nN o . 6 ( 7 . 5 A f)u s ei n the under-dashfuse/relay box Blown No. 22,23 l2OA)tuse in the under-dashfuse/ relay Dox Faultypower window relay P o o rg r o u n d( G 2 0 1 ) An open in the wire . Faultydriver'swindow motor . An open in the wire

oN flr). 3

B L U / R E DConnectthe No. 2 and No. 1 Checkfor passenger's t e r m i n a l sa, n dt h e N o . 3 BLU/WHT a n d N o . 1 0t e r m i n a l sa, n d t u r n t h e i g n i t i o ns w i t c hO N

fir),

window motor operation: I t s h o u l dr u n ( t h e passenger'swindow moves oown).

Faultypassenger'swindow motor Faultypassenger'swindow swatch An open in the wire

5. Reconnectthe 14Pconnectorto the switch,and performthe following input tests. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the input tests prove OK, the control unit must be faulty. Replacethe power window masterswitch.

Cavity

Wire

ORN

Test condition

Test: Desired result

Checkfor voltagebetween C o n n e ctth e N o . 1 1 a n d t h e N o . 1 3a n d N o . 1 4 N o . 7 t e r m i n a l sa, n d t h e N o . 4 a n d N o . 1 4t e r m i n a l s , t e r m t n a l s : and turn the ignition switch A b o u t 6 V s h o u l d b e indicatedwith the driver's o N0 r ) . window motor running.

Possible cause if result is not obtained . Faultydriver'swindow molor . A n o p e ni n t h e w i r e

22-127

Driver'sWindow Motor Test PulserTest:

Motor Test: 1 . Removethe door panel (seepage 20-4).

Disconnectthe 4P connector(A)from the driver's window motor.

1 . Reconnectthe 4P connectorto the driver'swindow motor, and reconnectthe 20Pconnectorto the power window masterswitch. Connectthe test leadsof a voltmeterto the No, 3 and No. 4 terminalsof the driver'swindow motor 4P connector. Run the motor usingthe masterswitch.The voltmetershould read about 6 V. lf the voltageis not as specified,checkfor an open in the wires. lf the wires are OK, replacethe driver's window motor.

Testthe motor in each directionby connecting batterypower and ground accordingto the table. When the motor stops running,disconnectone lead immediatelv. \

Terminal

il;;'-\

DOWN

o e

4 . lf the motor does not run or fails to run smoothly, replacerL

22-129

PowerWindows Passenger's Window Switch Input Test 1 . Removethe switch panel (seepage 20-4). 2 . Disconnectthe 5P connector(A)from the switch (B).

'' "'"1. Wire side of femaleterminals

BLU/WHT

GRN/BLK

Inputthe connectorand socketterminalsto be sure they are all making good contact. . lf theterminals are bent, looseor corroded,repairthem as necessary,and recheckthesystem. . lf the terminalslook OK, go to step 4. 4 . Reconnectthe connector,and using a back probe, makethese input tests at the connector.lf any test indicatesa

problem,find and correctthe cause,then recheckthe svstem,

Cavitv 3

Wire Test condition G R N / B L K lgnitionswitch ON {l l )

BLD,A/VHT lgnitionswitch ON ( ) At the master window switch, pressand hold down the passenger'sswitch BLU/RED lgnitionswitch ON (||) At the master window switch, p u l lu p a n d h o l d the passenger's switch

22-130

Test:Desiredresult Checkfor voltageto grouno: There should be battery voltage.

Checkfor voltageto ground: Thereshould be battery voltage.

Checkfor voltageto grouno: Thereshould be battery voltage.

Possiblecauseif resultis not obtained B l o w nN o . 6 ( 7 , 5 A ) f u s ei n t h e under-dashfuse/relaybox B l o w nN o . 2 2 { 2 0 A ) f u s ei n t h e under-dashfuse/relaybox Faultypower window relay An open in the wire P o o rq r o u n d( G 2 0 1 ) Faultymasterwindow switch An open in the wire

Faultymasterwindow switch An open in the wire

5. Disconnect the 5Pconnector, andmaketheseinputtests. Cavitv 1

Wire Test condition Test: Desired result RED Checkfor passenger's Connectthe No. 2 RED/BLU t e r m i n a tl o t h e N o . window motor operation:lf

Possiblecauseil resultis not obtained Faultymaster'swindow switch An open in the wire 1 t e r m i n a la , n dt h e should run (the passenger's Faultypassenger'swindow window moves down), N o . 4 t e r m i n a tl o moror. t h e N o . 5 t e r m i n a l , There should be battery a n dt u r n t h e voltage. ignition switch ON {ll),and pressthe down button on the power window masterswitch for the passenger's window.

6. lf allthe tests prove OK, the switch must be faulty. Replaceit.

22-131

PowerWindows Passenger's Window Switch Test 1 . Removethe switch panel (seepage 20-4). Removethe power window switch (A) from the doorpanel.

Passenger's Window Motor Test 1 . Removethe passenger'sdoor panel (seepage204). Disconnectthe 2P connector(A)from the passenger'spower window motor.

Disconnectthe 5P connector(B)from the passenger'spower window switch. Terminalside of m a l et e r m i n a l s

tfiTtTtT;Etl '-r--r-,Jl l'

Checkfor continuitybetweenthe terminalsin each switch positionaccordingto the table.

Testthe motor in each directionby connecting batterypower and ground accordingto the table. When the motor stops running,disconnectone l e a di m m e d i a t e l y . \

\Torminal Poiition\

Terminal Dl*;;;__\

UP DOWN

I o

o o

OFF

DOWN

lf the continuityis not as specified,replacethe swtlcn.

22-132

lf the motor does not run or fails to run smoothly, reptacert.

MasterSwitch Replacement '1.

Passenger's Window Switch Replacement

Removethe door grip (seepage 20-4).

2 . Removethe power window masterswitch (A)f rom t h e d o o rp a n e l .

1 . Removethe door grip {seepage 20-4). 2 . Removethe power window switch (A) from the o o o rp a n e r .

3 . Disconnectthe 14Pconnector(B)from the switch. Removethe three screwsand the switch from the switch panel.

3 . Disconnectlhe 5P connector(B)from the switch. 4 . Removethe two screwsand the switch from the

switch panel.

22-133

Wipers/Washers ComponentLocationIndex WINDSHIELD WIPERARMS and LINKAGE page22-'145 Replacement,

WIPER/WASHERSWITCH Test,page22-140 Replacement,page 22 140

WINDSHIELD WIPERMOTOR Test,page22-'143 page22-145 Replacement,

UNDER.DASH FUSE/RELAY BOX

INTERMITTENT WIPERCIRCUIT l l nt h em u l t i p l ecxo n t r oul n i t ) InputTest,page22-138

22-134

WASHER TUBES page22-147 Replacement,

WASHER RESERVOIB page22'146 Replacement,

WASHERFLUIDLEVELSWITCH{Canada) TesI,page22-144 page22-144 Replacement,

REARWINOOWWASHERMOTOR Test,page22-144 page22 146 Replacement,

WINDSHIELD WASHERMOTOR fesl, page22 144 page22-146 Beplacement,

CONDENSER CapacityTest,page22 107

REARWINDOWWIPERINTERMITTENT CONTROL UNIT InputTest,page22'138

REARWINDOWWIPERMOTOR f e$, page22-143 page22 146 Replacement,

BEARWINDOWWIPERARM page22 146 Replacement,

22-135

Wipers/Washers

\ 1

CircuitDiagram- Windshield

'7{

FL]SE/8ELAY BOX UNOENHOOD

F;^--il

U-I^--

I -':-;--u,Hr-

IGNITIONSWITCN

6\ o,f-''*""

MULTIPIIX coiln0L UNIT

L\'

\,! 22-136

CircuitDiagram- RearWindow UI\IOIF H@OFUSE/RELAY MX

BATTERY -;i r--------------l No'g,soA, ro2o. | (-;1_=l----_--_fww{"-'

No2olaoAl :USA

GNMOIIISW|ICH

/,^1\

\+y

lErHorb0Ni||l

andsra8r 0

ffAn w$tDowwtPEE INTE$'ITTEI'IT C{)NNOL UI'/IT

f---------------

22-137

Wipers/Washers RearWindowWiperIntermittentGontrolUnit InputTest 1 . Remove the rightrearsidetrim panel{seepage20-51).

(A)fromthe rearwindow.wiDer the 20Pconnector intermittent controlunit(B). 2 . Disconnect

Wire side of femaleterminals LTGRN/REO

WHT/RED WHT/RED

LT GRN

LT GRN/BLK

Inspecttheconnector andsocketterminalsto be suretheyareall makinggoodcontact. . lf theterminalsare bent,looseorcorroded,repairthemas necessary, andrecheckthe system. . lf theterminalslookOK,go to step4.

22-138

\ 4. With the connectorstill disconnected,maketheseinput tests at the connecrors. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. ' lf all the input tests prove OK, the control unit must be faultv. Replaceit.

Cavitv

Wire GRN

Tesl condition lgnitionswitch ON

flr) 10 6

BLK

U n d e ra l l conditions

WHT/RED lgnitionswitch ON

LT GRN/ RED LT GRN

( l l )a n d r e a r window washer switch ON lgnition switch ON ( l l )a n d r e a r window wiper switch ON lgnition switch ON

flr) 20

LT GRN/ BLK

lgnitionswitch ON (ll)

Test: Desired result Checkfor voltageto ground: Thereshould be battery voltaqe.

Possiblecauseif resultis not obtained

. B l o w nN o . 9( 1 0 A ) f u sien t h e under-dash fuse/relay box . An openin thewire

Checkfor continuity to grouno: Thereshouldbe continuitv.

Poor ground (G553) A n o p e ni n t h e w i r e

Checkfor voltageto ground: Thereshould be battery vortage.

B l o w nN o . 9 ( 1 0 A )f u s ei n t h e under-dashfuse/relaybox Faultyrearwlndow wiper/ washer switch A n o p e ni n t h e w i r e

Attachto groundl The rearwindow wiper motor s h o u l dr u n . Attachto ground: The rear window wiper motor s h o u l dr u n . Checkfor voltageto ground: Thereshould be battery voltage.

B l o w nN o . 9 ( 1 0 A ) f u s ei n t h e under-dashfuse/relaybox Faultyrearwindow wiper motor An open in the wire B l o w nN o . 9 ( 1 0 A )f u s ei n t h e under-dashfuse/relaybox Faultyrearwindow wiper motor A n o D e ni n t h e w i r e

22-139

Wipers/Washers Wiper/WasherSwitch Test/Replacement lowercover{seepage20-60). 1 . Remove the driver'sdashboard Removethesteeringcolumncovers(seepage17-9). (A)fromthewiper/washer switch{B) Disconnecl the 14Pconnector

Removethe two screws,then pull out the wiper/washerswitch. Inspectthe connectorterminalsto be sure they are all making good contact. . lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthe system. .lftheterminalslookOK,checkforcontinuitybetweentheterminalsineachswitchpositlonaccordingtothe tables, - lf the continuityis not as speciiied,replacethe switch. Terminal Position

o- -{ o-

OFF tNl

HI Mist switchON

Washor 3witch ON

22-140

ControlUnit InputTest l . Beforetesting,troubleshootthe multiplexcontrol system lsee page22-jj2).

2 . Removethe dashboardlower cover, 3 . Disconnectthe under-dashfuse/relaybox connectorsB, G, J, X and y NOTE:All connectorsare wire side of female terminals. UNDER-DASH FUSE/RELAY BOX CONNECTOR B I6PI

UNDER.DASH FUSE/RELAY BOX CONNECTOR G {1OP)

UNDER-DASH FUSE/RELAY BOX CONNECTOR J {8PI

WHT/BLU \

l-,1 € l l

l-rl

l-,1 - llTtl F_j-JF-#

1 4 1 5 1 76 l 8 l

lslrlzlol \ BLU/RED

BLU/WHT

UNDER.DASH FUSE/RELAY BOX CONNECTOR X I8PI

BLU/BLK 4. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact. . lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthesystem. . l f t h e t e r m i n a l sa r e O K ,g o t o s t e p5 .

(cont'd)

22-141

Wipers/Washers ControlUnit Input Test (cont'dl

5. Reconnectthe connectors,and make these input tests at the connector. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . l f a l l t h e i n p u t t e s t s p r o v e O K , t h e m u l t i p l e x c o n t r ou ln i tm u s t b e f a u l t y .R e p l a c e t h e u n d e r - d a sfhu s e / r e l a yb o x assembly. Cavity J4

Y6 BI

E'0

Wire BLK

Test condition U n d e ra l l conditlons BLK U n d e ra l l conditions WHTiBLU lgnitionswitch ON { l l )a n d w a s h e r switch ON

BLU/RED lgnitionswitch ON ( l l )a n d w i p e r switch OFF(wiper motor stopped)

BLUA/VHT lgnitionswitch ON ( l l )a n d w i p e r si n p a r kp o s i t i o n

B L U / B L K l g n i t i o ns w i t c hO N ( l l )a n d w i p e r switch in INT

Test:Desiredresult C h e c kf o r v o l t a g et o g r o u n d : T h e r es h o u l db e 1 V o r l e s s . Checkfor voltageto ground: T h e r es h o u l db e 1 V o r l e s s . Checkfor voltageto ground: Thereshould be battery vortage. Checkfor voltageto ground: There should be battery voltage.

Checkfor voltageto ground: There should be battery voltage. Checkfor voltageto ground: There should be battery voltage.

Possiblecauseif resultis not obtained . P o o rg r o u n d( G 5 0 1 ) . AnoDeninthewire . Poor ground (G502) . A n o D e ni n t h e w i r e Blown No. 20 (20A)fuse in the under-dashfuse/relaybox Faultywiper/washerswitch An open in the wire Blown No. 20 (20A)fuse in the under-dashfuse/relaybox Faultywiper/washerswitch F a u l t yw i n d s h i e l dw i p e r m o t o r An open in the wire B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e under-dashfuse/relaybox F a u l t yw i n d s h i e l dw i p e r m o t o r An ooen in the wire B l o w nN o . 2 0 ( 2 0 A ) f u s ei n t h e under-dashfuse/relaybox Faultywiper/washerswitch An oDenin the wire

L J 22-142

Wiper Motor Test Windshield:

RearWindow:

1. Open the hood,and carefullyremovethe cap nuts and the wiper arms. Make surethey do not touch the hood.

1. Open the hatch,and removethe hatchtrim panel (seepage 20-53). 2. Disconnectthe4P connector{A) from the motor {B).

2, Removethe hood seal andcowl cover. 3 . D i s c o n n e c t t h5eP c o n n e c t o(rA ) f r o mt h e m o t o r ( B ) .

Testthe motor by connectingbatterypower and ground accordingto the table. lf the motor does not run or fails to run smoothly,replaceit. Testthe motor by connectingbatterypower and ground accordingto the table. lf the motor does not run or fails to run smoothly,replaceit. Terminal P-"-,tion

LOWSPEED HIGHSPEED

Telminal Battery Connected

5 . Testthe wiper motor park switch by connectingan a n a l o gv o l t m e t e rb e t w e e nt h e N o , 5 ( + ) t e r m i n a l a n d g r o u n d ,a n d r u n t h e m o t o ra t l o w o r h i g hs p e e d . T h ev o l t m e t e rs h o u l di n d i c a t e1 2V a n d 4 V o r l e s s alternately.lf it does not, replacethe motor.

4 . Testthe wiper motor park switch by connectingan a n a l o gv o l t m e t e rb e t w e e nt h e N o . 4 ( + ) t e r m i n a l and ground, and run the motor. The voltmeter should indicate12 V and 4 V or lessalternatelv.lf it does not, reolacethe motor.

.l J

22-143

Wipers/Washers WasherFluidLevelSwitch Test/ - Canada Replacement

WasherMotorTest 1. Partiallyremovethe right inner fender (seepage 20-'t021. 2. Disconnectthe 2P connectors(A) from the washer motors (B).

1 . Partiallyremovethe right innerfender (seepage 20-102). Disconnectthe 2P connector{A) from the washer level switch.

Testthe washer motor by connectingbattery power and ground accordingto the lable.

3 . Removethe washer fluid level switchfrom the Terminal

Battery Connected

reservoir. NOTEF : l u i dm a y f l o w o u t t h e o p e n i n g . 4 . Checkfor continuitybetweenthe terminalsin each float (B) positionaccordingto the table.

4. lf the motor does not run, replaceit,

Terminal

Position

FLOATUP FLOATDOWN

o- ---o

lf the continuityis not as specified.replacethe swtTcn.

22-144

WindshieldWiper Motor Replacement 1 . Open the hood. Removethe nuts (A) and the w i n d s h i e l dw i p e ra r m s ( B ) .

5 . S c r i b ea l i n e ( A )a c r o s st h e l i n ka n d w l n d s h i e l d wiper linkageto show the original adjustment. Separate t h e w i n d s h i e l dw i p e r l i n k a g e( B )f r o m t h e w i p e r m o t o r( C ) . N.m

(3.2ksf.m,23 lbt.ft)

Removethe hood seal and cowl cover. Djsconnectthe 5P connector(A)from the wiper motor (B). 9.8 N.m (1.0

Installin the reverseorder of removal,and note lhese items. Apply multipurposegreaseto the moving parts. Beforereinstallingthe wiper arms,turn the wiper switch ON, then OFFto returnthe wiper shaftsto the oark oosition. lf necessary,replaceany damagedclips, Checkthe wioer motor oDeration.

R e m o v et h e b o l t s( C ) ,m o v ew i n d s h i e l dw i p e r l i n k a g ea s s e m b l y{ D ) t o w a r dt h e p a s s e n g e r 'ssi d e of the vehicle until it slidesoff of the pin (E),then removethe assembly.

22-145

Wipers/Washers RearWindow Wiper Motor Replacement

WasherReservoirReplacement 1 . Partiallyremovethe right inner fender.

1 . Open the hatch,and removethe hatchtrim panel (seepage 20-53).

Disconnectthe 2P connectors(A)irom the washer motors (B) and level switch (Canada).

Removethe mounting nut (A),the wiper arm (B) and the specialnut (C).

A 9.8N.m {1.0kgf.m, 7.2rbf.ftl B 8 N.m 10.8kgt.m, 6.0rbf.ft)

3 . Disconneclthe tubes (C)from the washer motors. Removethe three bolts (A) and the washer reservoir(B).

Disconnect the 4Pconnector {A),removethethree mountingbolts(B),thenremovethe rearwindow wiDermotor(C).

A 9.8 N.m (1.0kgt.m, 7.2 tbf.tt)

B 9.8 N.m

{1.0kgt.m,7.2lbfftl

4 , Installin the reverseorder oI removal,and note

these items. Apply multipurposegreaseto the moving parts. Beforereinstallingthe wiper arm, turn the wiper switch ON, then turn OFFto returnthe wiper shaft to the Darkoositon. lf necessary,replaceany damagedclips. Checkthe wiDer motor operation.

22-146

WasherTubesReplacement 1 . Removethe rightinnerfender{seepage20-102). 2 . Remove the washernozzles andclips,thenremovethetubes.

<=>

r"-----------='

--==':?-

L-!

(cont'd)

22-147

Wipers/Washers WasherTubesReplacement(cont'dl

3 . I n s t a l il n t h e r e v e r s e o r d e r orf e m o v a lT. a k ec a r en o t t o p l n c h t h e w a s h e r t u b e sC. h e c kt h e w a s h e ro p er a t i o n .

22-148

AccessoryPowerSocket CircuitDiagram

AccessoryPower Socket Test/ Replacement 1 . Carefullypry the accessorypower socket(A) out from the centerlower cover. Disconnectthe 2P connector(B)from the socket.

Inspectthe connectorterminalsto be sure they are all making good contact. . lf the terminalsare bent, loose orcorroded, repairthem as necessary,and recheckthe system. . lf the terminalslook OK, go to step 4. 4 . Turn the ignition switchACC (l), and checkfor

voltage betweenthe No. 'l and No. 2 terminals. . Thereshould be batteryvoltage. . lf there is no baneryvoltage,checkfor: - p o o r g r o u n d{ G 5 0 2 ) . - an open in the wire. - b l o w n N o . 1 8 ( 1 5 A ) f u s ei n t h e u n d e r - d a s h fuse/relaybox.

22-149

DoorLockSystem Keyless/Power ComponentLocationIndex

Test,page22-161 P r o g r a m m i n gp,a g e2 2 - 1 6 1

DRIVER'SDOORLOCKSWITCH Test,page22-160 RECEIVER UNIT

lnput Test,page22-153

IGNITIONKEYSWITCH Test,page22-91

PASSENGER'S DOORLOCKACTUATOR Test,page22 158

MUTIPLEXCONTROLUNIT InputTest,page22-155

DRIVER'SDOORSWITCH

DRIVER'S DOORLOCK SWTICH ACTUATOR/KNOB Actuator Test,page22-158 KnobSwitchTest,page22 160

HATCHLATCHSWITCH Test,page22-97 HATCHLOOKACTUATOR Test,page22 159 PASSENGER'SDOORSWITCH

22-150

CircuitDiagram UNOEE DASH fUSE/SELAYBOX

8OX UiDENHooDFUSE/RETIY

/ 8Ar \

cl-

lG1,/

lG1HoTin0N(lllaidSTAfft(llll

l3 IT

BLK

G502

UI'IDE8DASH f USE/RETAY 80X MULTIPUX CONTNo! Uflfi

000R Loc(KNOE

tl xtY

\"2

PASSTNGtrS 0008100( ACTUATOi

t'-F> Li___JDBt!'t8'S 000R100( ACTUATOB

t (cont'd)

22-151

Keyless/PowerDoor LockSystem CircuitDiagram(cont'dl

HOOD UNDEN FU8E/BELAY MX l\br t15a)FUSE

t"-

HORN SWTCH

UNDEN DAS}I FUSE/8ELAY 8OX

t J

Y,,, mMErNAllofl LIGHISWITCH

DFIVES'S DOOB TOCK 6WTCH

Df,IVEB'S 0008 swtrcH plo'.d l

tG tltot\t IGY stvrTcH

HATCH LATCH

swlrol

22-152

KeylessReceiverUnit Input Test 1. Removethe driver'sdashboardlower cover (seepage 20-59). 2 . R e m o v et h e a u d i ou n i t ( s e ep a g e2 2 - 1 0 0 ) . 3. Disconnectthe 5P connector(A)from the keylessreceiverunit (B).

WHT/RED Wiresideof femaleterminals e a kl li n gg o o dc o n t a c t . 4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm . lf the terminalsare bent.Iooseorcorroded, repairthem as necessary,and recheckthesystem. . lf the terminalsare OK, go to step 5.

t (cont'd)

22-153

Keyless/PowerDoor LockSystem KeylessReceiverUnit Input Test (cont'dl With the connectorstill disconnecled,makethe input test at the connector. .lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf the inputtest provesOK, goto step 6. Cavity

Wire Test condition BLU/ORN U n d e ra l l conditions

Test:Desiredresult Checkfor continuitybetween t h e N o . 2 t e r m i n a la n dt h e N o . 2 t e r m i n a lo f t h e under-dashfuse/relaybox connectorK { 17P). There should be continuitv.

Possiblecauseil resultis not obtained An open in the wire

Reconnectthe 5P connector,and make these input tests at the connector. .lfanytestindicalesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtests prove OK, replacethekeylessreceiverunit.

Cavitv 1

Wire BLK YEL

Test condition U n d e ra l l conditions lgnition switch

o N( | | )

WHT/RED U n d e a r ll conditions

22-154

Test:Desiredresult Checkfor voltageto ground: There should be 1 V or less. Checkfor voltageto ground: There should be battery voltaqe. Checkfor voltageto ground: There should be battery voltaqe.

Possiblecauseif resultis not obtained . Poor ground (G502) . An oDenin the wire Blown No. 10 {7.5A)fuse in lhe under-dashfuse/relaybox An ooen in the wire ' B l o w nN o . 9 ( 1 0 A )f u s ei n t h e under-hoodfuse/relaybox . A n o o e ni n t h e w i r e

Control Unit Input Test 1. Beforetesting,trou bleshootthe m u ltiplexcontroI system (seepage 22-172). 2, Removethe dashboardlower cover. 3. Disconnectthe under-dashfuse/relaybox connectors. NOTE:All connectorsare wire side of female terminals. FUSE/RELAY BOX UNDER.DASH CONNECTOR C {1itPl

BLU

UNDER.DASH FUSE/RELAY BOX CONNECTOR O (8P)

GRN

BOX UNDER-OASH FUSE/RELAY CONNECTOR J {8PI

BLU/RED

FUSE/RELAY BOX UNDER.DASH CONNECTOR K {17PI BLU/ORN

,/1,/ 3 4 5 6

UNDER.DASH FUSE/RELAY BOX CONNECTOR F I12P)

UNDER.DASH FUSE/RELAY BOX CONNECTOR M Il2PI

FUSE/RELAY BOX UNDER.OASH P I18PI CONNECTOR

YEL/BLKYEL/BLK YEL YEL

YEL YEL/BLK

UNDER-DAsH FUsE/neLeY sbx X (8P) CONNECTOR

FUSE/RELAY BOX UNDER.DASH Y {13P) CONNECTOR

LT GRN/RED

RED/WHT

WHT/BLK YEL/RED WHT/GRN WHT/BLU

4. Inspectthe connectorand socketterminalsto be sure they are all making good contact. . lf the terminalsare bent, loose orcorroded, repairthem as necessary,and recheckthesystem. . lf the terminalslook OK, go to step 5.

(cont'd)

22-155

Keyless/PowerDoor LockSystem Control Unit Input Test (cont'dl 5. Reconnect all connections to the underdashfuse/relay box,and maketheseinputtestsat the appropriate connectors on the under-dash fuse/relay box. 'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. . lf all the inputtestsproveOK,goto step6. Cavitv

c1'l

Wire 8LU

Test condition

Underall conditions

Test:Desiredresult Aftachto ground: Parking, sidemarker,license platelights,andtajllightsshould comeon.

Possible causeif resultis notobtained B l o w nN o . 2( 1 5 A ) f u si en t h eu n d e r hoodfuse/relaybox Faultytaillightrelay Faultyunder-dash fuse/relay box An onen in rhc wire

BLU/BEO Underall conditions

Attachto ground: Headlights shouldcomeon.

WHT/RED Underall conditions

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

B l o w nN o .1 5o r 1 7( 1 5 A ) f u si en t h e underhoodfuse/relay box Faultyheadlight relay'1or 2 An ooen in the wire

B l o w nN o . 9( 1 5 A ) f u si e n t h eu n d e r hoodfuse/relay box An oncn in thc wirc

BLK

Underall conditaons

Checkfor voltageto ground: Thcreshoulnhc 1 V or lpqs

OBN

Under allconditions

Attachto ground: The horns should sound.

Poorground(G501) An ooenin the wire BlownNo.7 (15A)fuse in the under hoodfuse/relay box Faultyhornrelay Faultyhorns

Under all conditions

Checkfor voltageto ground: Thereshouldbe batteryvoltage.

ElownNo.16(20A)fusein the under hood fuse/relaybox

H a t c ho p e n

Checkfor voltageto ground: Thereshouldbe 1 V or less.

H a t c hc l o s e d

Checkfor voltageto groundl Thereshoul.lhe 5 V or more

Driver'sdooropen

C h e c kf o r v o l t a g et o g . o u n d : There should be 1 V or less C h e c kf o r v o l t a g e t o g r o u n d : Thereshould be 5 V or more.

An 6nen in rhe wire

An oocn in ihc wi.c

P18

BED

Poorground(G552) Faultyhatchlatchswitch An oncn in rhc wirF

GBN

Driver'sdoorclosed

LT GRN /RED

Passenger's dooropen

Checkfor voltageto ground: Thereshouldbe 1 V or less.

Passenger's doorclosed

C h e c kf o r v o l t a g e t o g r o u n d l There should be sVor more C h e c kf o r v o l t a g e t o g r o u n d : There should be 1 V or less.

REDAVHT lgnition key inserted into the ignitionswhch

lgnitionkeyremovedfrom rhe ionitionswitch WHT/BLK Driver'sdoorlockknob switchunlocked Driver'sdoorlockknob

YEURED Driver'sdoorlockknob switch locked

C h e c kf o r v o l t a g e t o g r o u n d : There should be 5 V or more. C h e c kf o r v o l t a g e t o g r o u n d l There should be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d l Ihere should be 5 V or more. C h e c kf o r v o l t a g e t o g r o u n d l There should be 1 V or less.

Faulty hatch latch switch

. Faultydriver'sdoorswitch . An ooenin thewire Faultydriver'sdoorswitch Shortto oround Faultypassenger's doorswitch An ooeninthewire . Faultypassenger's doorswitch . Shortto oround Poorground{G401) Faultyignitionkeyswitch An ooeninthewire Faultyignitionkeyswitch Shortto oround Poorground(G50'l) Faultydriver'sdoorlockknobswitch An openin thewire Faultydriver'sdoorlockknobswitch Shortto oround Poorground(G50'l) Faultydriver'sdoorlockknobswitch An oncn inihewire

Driver'sdoorlockknob switch unlocked Y10

WHT/GRN Drtver's door lock switch unlocked

Driver'sdoorlockswitchin Y12

WHT/BLU Driver'sdoorlockswitch locked Driver'sdoorlockswitchin

C h e c kf o r v o l t a g e t o g r o u n d : There should be 5Vor more C h e c kf o r v o l t a g e t o g r o u n d l There should be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : Therc shorl.l be 5V or m6rp C h e c kf o r v o l t a g e t o g r o u n d : 'l There should be V or less. C h e c kt o r v o l t a g e t o g r o u n d : There should be 5Vor more

' Faultydriver'sdoorlockknobsw;tch . Shorrto oround Poorground(G501i Faultydriver'sdoorlockswitch An ooenin the wire Faultydriver'sdoorlockswitch Short to o rolrnd Poorground(G501) Faultydriver'sdoorlockswitch An oDenin the wire F a u l t yd r i v e r ' s d o o r l o c k s w i t c h

22-156

6. Disconnect the M, P,K andJ connectors fromthe underdashfuse/relay box,and maketheseinputtestsat the connectors. .lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem. .lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly. Cavitv K2

Wire Test condition BLU/ORN Underall conditions

M7 M9

YEUBLK

M6 M8

YEUBLK

P16 P17

YEL YEUBLK

YEL

ConnectJ7 terminalto [,47 lMgl terminal,and Mg lMTl terminaltoJ4

Test:Desiredresult Checkfor continuitybetween the K2terminalandthe keyless receiver unit5Pconnector disconnected: Thereshouldbe continuitv. Checkactuatoroperation: Thedriver'sdoorlockactuator shouldlock lunlockl

ConnectJ7 terminalto M6 lMSl terminal,and M8 lM6l terminaltoJ4

Checkactuatoroperation: The passenger's doorlock actuatorshouldlock iunlockl

Connect J7 terminalto P17 lP16l terminal,and P16 l P 1 7 l t e r m i n a l t Jo4

Checkactuatoroperation: The hatchlockactuatorshould lock lunlockl

Pdsiblo c6useif resultis not obtain€d

An openin the wire

Faultydriver'sdoorlockactuator An openin the wire Faultypassenger's doorlockactuator An openin the wire . Faultyhatchlockactuator . An openin the wire

22-157

I Keyless/Power DoorLockSystem Door LockActuatorTest Driver'sdoor:

Passenger'sdoor:

1 . R e m o v et h e d r i v e r ' sd o o r p a n e l( s e e p a g e 2 0 - 4 ) .

1 . R e m o v et h e p a s s e n g e r 'dso o r p a n e l( s e e p a g e 2 0 4).

2. Disconnectthe 2P connectorfrom the actuator. 2. Disconnectthe 2P connectorfrom the actuator,

Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltageonly momenlanry. \

Terminal

ilil;lll LOCK UNLOCK

e e

Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltageonly momenlanty. \

Terminal

P."I,l.;--\

LOCK UNLOCK

e e

e o

4 . lf the actuatordoes not operateas specified,

repracerr.

22-158

lf the actuatordoes not operateas specified, reprace[,

Hatch Lock Actuator Test 1. Open the hatch. 2. Removethe hatch lower trim panel lsee page 2053). 3. Disconnectthe 2P connectorfrom the hatch lock actualor.

Terminalside of m a l et e r m i n a l s

J 4. Checkactuatoroperationby connectingpower and ground accordingto the table.To preventdamage to the actuator,apply batteryvoltage only momentaflty. \Terminal Po.irion\

LOCK UNLOCK

22-159

Keyless/Power DoorLockSystem Door LockKnob Switch Test 1 . Remove the driver'sdoorpanel(seepage20-4).

Disconnect fromthe actuator. the3Pconnector

Door LockSwitch Test

'1.

Removethe driver'sdoor panel (seepage 20-4).

Removethe two mounting screwsand the door lock switch.

. t i

. l I

( . 1

Checkfor continuitybetweenthe No. 1 and No. 2 term anals. . Thereshould be continuitywhen the door lock knob switch is in the LOCKEDposition. . Thereshould be no continuitywhen the door lock knob switch is in the UNLOCKEDposition. Checkfor continuitybetweenthe No. 2 and No. 3 termtnals. . Thereshould be continuitywhen the door lock knob switch is in the UNLOCKEDposition. . Thereshould be no continuitywhen the door lock knob switch is in the LOCKEDposition. 5. lf the continuityis not as specified,replacethe door locl(actuator.

22-160

Checkfor continuitybetweenthe terminals. . Thereshould be continuitybetweenthe No. 1 and No. 2 terminalswhen the door lock switch is in the LOCKEDposition. . Thereshould be continuitybetweenthe No. 2 and No. 3 terminalswhen the door lock switch is in the UNLOCKEDposition. lf the continuityis not as specified.replacethe door lock switch.

TransmitterTest

TransmitterProgramming

NOTE: . l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t ebru, t the LEDon the transmitterdoes not come on, the LED is faulty. Replacethe transmitter, . l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e transmrtter. . lf you unlockedthe doors with the transmitter,but do not open any of the doors within 30 seconds,the doors relockautomatically. . The doors do not lock or unlockwith the transmitterif the ignition key is insertedin the ignition switch.

Storingtransmittercodes: The codes of up to three transmitterscan be storedin the keylessreceiverunit memory. (lf a fourth code is stored.the code which was input first will be erased.) NOTE:lt is importantto maintainthe time limits betweenthe steps.Make sure the doors and the hatch are closed. 1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .

1. Pressthe lock or unlock buttonfive or six times to resetthe transmitter. . lf the lockswork, the transmitteris OK. . lf the locksdon't work, go to step 2. 2. Open the transmitterand checkfor water damage. . lf you find any water damage,replacethe transmrtter. . lf there is no waterdamage,go to step 3.

2. Within 1 to 4 sec.,push the transmitterlock or unlockbutton with the transmitteraimed at the receiverin the multiplexcontrol unit behindthe d r i v e r ' ss i d eo f t h e d a s h . 3. Within 1 to 4 sec.,turn the ignition switch OFF. 4. Within 1 to 4 sec.,turn the ignition switch ON (ll). 'l 5. Within to 4 sec.,push the transmitterlock or unlockbuttonwith the transmitteraimed at the receiverin the multiplexcontrol unit behindthe d r i v e r ' ss i d eo f t h e d a s h . 6. Within 1 to 4 sec.,turn the ignitionswitch OFF.

3. Replacethe transmitterbattery(A)with a new one, and try to lock and unlockthe doors with the transmitterby pressingthe lock or unlockbutton five or six times. . lf the doors lock and unlock,the transmifteris OK. . lf the doors don't lock and unlock,go to step 4.

7 . W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) . 8. Within 1 to 4 sec.,push the transmitterlock or unlockbuttonwith the transmifteraimed at the receiverin the mupltiplexcontrol unit behindthe driver's side of the dash. 9. Within 1 to 4 sec.,turn the ignition switch OFF, '10. W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) . 1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r unlockbutton with the transmitteraimed at the r e c e i v e irn t h e m u l t i p l e xc o n t r o lu n i t b e h i n dt h e driver'sside of the dash. 1 2 . C o n f i r my o u c a n h e a r t h es o u n do f t h e d o o r l o c k actuators.Within 1 to 4 sec.,push the transmitter lock or unlockbutton again,

4 . Reprogramthe transmitter,then try to lock and u n l o c kt h e d o o r s . . l f t h e d o o r sl o c k a n du n l o c k . t h e t r a n s m i t t e i srO K . . l f t h e d o o r sd o n ' t l o c k a n du n l o c k r, e p l a c e t h e transmitter.

13, Within 10 sec.,aim the transmitters(up to two additionalones)whose codesyou want to store at the receiver,and pressthe transmitterlock or unlockbuttons. Confirmthat you can hear the sound of the door lock actuatorsafter eachtransmittercode is stored. 1 4 . T u r nt h e i g n i t i o ns w i t c hO F F ,a n d p u l l o u t t h e k e y . '15. Confirm proper operationofthe transmitter.

22-161

lmmobilizerSystem ComponentLocationIndex

INOICATOR LIGHT page 22 63 Bulb Replacement,

ECM page 11-4 Replacement, Substituteknown-goodfor testing, p a g e1 1 - 5

IMMOBILIZER CONTROLUNIT.RECEIVER page22-165 Troubleshooting, page22-167 Replacement,

TRANSPONDER (8uiltintothe ignitionkey)

22-162

SystemDescription The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used. This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver,an indicator l i g h t ,a n d t h e E C M . When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver sendspower to the transponderin the ignition key.The transponderthen sendsa coded signal backto the immobilizer control unit-receiverwhich then sendsa coded signalto the ECI\4. IMMOBILIZER CONTROLUNIT.RECEIVER

KEYCYLTNDER iEl'JUiliii'tlun"oona"|.r

lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds,then go off. lf the wrong key has been used or the code was not receivedor recognizedby the unit,the indicatorlight will come on for about 2 seconds,then it will blink until the ignition switch is turned OFF. lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset correctly,then the indicatorwill go off. lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.

IMMOBILIZER INDICATOR LIGHTBLINKING PATTERN:

IGNITIONSWITCH

ON OFF

PROPER KEY INSERTED

INDICATOR LIGHT

WRONGKEY INSERTED

INDICATOR ON LIGHT

OFF

(| i.,

)

22-163

lmmobilizerSystem CircuitDiagram '

UNDTRrcODFUSE/RELAY 8OX

No20(LAl r USA

rGNtTt0i/ swlrcH lct HoTin0N{ll) .ndSIAnTl|l)

F G N 8ELAY1

YEUBIJ(

0R8

itAWStY

tct

tGPl

tGPz

EC LGI

22-164

LG2

LG3

|M0CD . PA8(II'IG DATA LIN( SMIG CONNECIOR SWITCH .8nA{E {0Lcl FTUID I!VEL SWTfi

)

Troubleshooting Beforetroubleshootingthe immobilizersystem, troubleshootany EClvlDiagnosticTroubleCodes(DTCS) ( s e ep a g e1 1 - 3 )a, n d m a k es u r et h e E C Mh a s n o malfunction.

5. Disconnectthe 7P connector(A)from the i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e( B r ),

Note these items beforetroubleshooting: . Due to the actionof the immobilizersystem,the enginetakesslightly more time to startthan on a vehiclewithout an immobilizersystem. . When the system is normal,and the proper key is inserted,the indicatorlight comes on for 2 seconds, then it will go off. . If the indicatorstartstoblink after 2 seconds,or if the enginedoes not start.removeany other immobilizer keysor large key fobs on the key ring,then repeatthe startingprocedure. lf the engine still does not start,continuewith this procedure.

Checkfor voltage betweenthe immobilizercontrol unit-receiver7P connectorNo. 7 terminal and body ground.

1. Turn the ignitionswitch ON {ll) with proper key. ls there battery voltage?

2. Checkto see if the immobilizerindicatorlight c o m e so n .

YES-Go to step 7.

Does the indicator light blink?

NO Checkfor these problems;

YES Disconnectthe 7P connectorfrom the immobilizercontrol unit-receiver,then go to step 9.

. B l o w nN o . 9 { 1 0 A ) f u s ei n t h e u n d e r - h o o fdu s e / relay box.l . An open in the WHT/REDwire.l

NO Checkfor these problems,then go to step 3. . Blown No. 9 (10A)fusein the under-hood fuse/relaybox.I . An open in the wire betweenthe gaugeassembly a n d t h e i m m o b i l i z ecr o n t r o lu n i t - r e c e i v e r . l . A f a u l t yi m m o b i l i z eirn d i c a t o lri g h t , I . An open in the wire betweenthe gauge assembly and the under-hoodfuse/relaybox.l

1 . Checkfor voltage betweenthe immobilizercontrol unit-receiver7P connectorNo. 6 terminal and body ground with the ignition switch ON {ll). ls there battery voltage? YES- Go to step 8. NO Checkfor these problems:

Removethe driver'sdashboardlower cover (see page 20-59). Removethe steeringcolumn lower cover (seepage 11-9).

. B l o w nN o . 6 ( 1 5 A ) f u s ei n t h e u n d e r - h o o d fuse/relaybox,I . F a u l t yP G M - Fm l a i n r e l a y1 , t . A n o p e ni n t h e Y E U B L Kw i r e . l

l (cont'd)

22-165

lmmobilizerSystem Troubleshooting(cont'dl 8. Checkfor voltage betvveenthe immobilizercontrol unit-receiver7P connectorNo. 6 terminal and No. 1 rermlnat.

Checkfor continuitybetweenthe immobilizer control unit-receiver7P connectorNo. 2 terminal a n d E C Mt e r m i n a lE 2 7 .

ls thete battery voltage?

ls there continuity?

YES Go to step 12.

Y E S - G o t o s t e p1 3 .

NO Checkfor these problems,

wire.I N O - R e p a i tr h e o p e ni n t h e R E D / B L U

. Open on the BRNI/ELwire.l . F a u l t yE C M . I

1 3 .Reconnectthe 7P connectorto the immobilizer

9. Removethe driver's dashboardlower cover (see page20-59). 10. Removethe steeringcolumn lower cover (seepage 17-9).

control unit-receiver. 1 4 . Checkfor voltage betweenthe immobilizercontrol unit-receiver7P connectorNo. 4 terminal and body ground with the parkingbrakelever pulled,then released. ls there 1 V or less,then 5 V or more?

11. Disconnectthe 7P connector(A) from the immobilizercontrol unit-receiver(B).

YES Replacethe immobilizercontrol unit-receiver. After replacingthe immobillzercontrol unitreceiver,rewritethe unit with a HondaPGM Tester.l NO Checkfor these problems:

{

. Faultyparkingbrakeswitch or a poor body ground of the parkingbrakeswitch.l . R e p a i rs h o r to r o p e ni n t h e G R N / O R N w i r e .I

22-166

lmmobilizerControl Unit-ReceiverReplacement 'L

Removethe driver'sdashboardlower cover (see page20-59).

2 . Removethe steeringcolumn covers(seepage 17-

3 . Disconnectthe 7P connector(A)from the immobilizercontrol unit-receiver(B).

Removethe two screwsand the immobilizer control unit-receiverfrom the ignition key cylinder

(c).

5 . Installthe immobilizercontrol unit-receiverin the reverseorder of removal. 6 . After replacement,rewritethe unit with a Honda PGM Tester,then checkthe immobilizersystem.

22-167

MultiplexControlSystem

lr,

ComponentLocationIndex

REARCEILINGLIGHT Test,page22'96 LIGHT/SPOTLIGHTS Test,page22-96

ASSEMBLY GAUGE

IGNITIONKEYLIGHT Test,page22'91

ECM

MULTIPLEXCONTROLUNIT {Builtinto the under-dash fus6/relav boxl Troubleshooting,page22'172 InputTest,page22-175

22-168

CircuitDiagram

UiIDM HOOD IUSE/NEUY BOX

' I'10.20 :usA {a0AJ UNDEf, DASH ib.a)l50A):C.nd. FUSE/NEUYBOX

IGNITiON SWITCH

--_to

/ BAI \ oJ\ tcl ./

BLI,'YEL

MULTIPLEX c0NT80r tNsPECTror! CONNECIOF HAICII LATCH SWITCH

G201

{cont'd)

22-169

MultiplexControlSystem CircuitDiagram(cont'd)

l'1o.3 tUSt l7.5AJ lln$.uidt hoodr itutefd4bor I

V I

wHTPLU l0 t--t---

lrfl |

lE lnv*| > | ucHT lt A l'*' Y l I'

CIILINGLIGHT

I.l|MOBItEER @NTIOL UIIIT RECEIVEE

VI I

{

22-170

SystemDescriptions The MultiplexControlSystem hasfour internal functions: . Multiplexing ( s e n dm u l t i p l es i g n a l so v e rs h a r e d wtres) . Wake up/sleep(runsat full power only on demandto reducebatterydraw) . Fail-safe(fixesor ignoresfaulty signals) . Self-diagnosis(Mode 1 for the system,Mode 2 for i n p u tl i n e s ) The systemcontrolsthe functionof these circuits: . E n t r yl i g h t c o n t r o(l i g n i t i o nk e y l i g h t a n d c e i t i n gl i g h t ) . Wiper/washerintermittentwipe and park functions . Keyless/powerdoor lock . Meter assembly,temperaturegauge,and indicator lights . HVAC(compressorand fan control) . K e y - i nr e m i n d e r . H e a d l i g hrte m i n d e r . Seatbeltreminder

MultiplexCommunication To reducethe number of wire harnesses,digital signals a r e s e n tv i a s h a r e dm u l t i p l e xc o m m u n i c a t i o lni n e s r a t h e rt h a n s e n d i n gn o r m a le l e c t r i c asl i g n a l st h r o u g h i n d i v i d u awl i r e s . . The input signalsfrom each switch are convertedto digital signalsat the centralprocessingunit (CpU). . T h e d i g i t a ls i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i nu gn i t t o t h e r e c e i v i n gu n i t a s s e r i a ls i g n a l s . . The transmittedsignalis convertedto a switch signal at the receivingunit, and it operatesthe related componentor monitors a swltch. . There are exclusivecommunicalionlines between the ECM,the gauge assembly,and the under,dash fuse/relaybox.

Wake-upand Sleep The multiplexcontrol system has "wake-up" and "sleep" functions to decreaseparasiticdraw on the batterywhen the ignitionswitch is OFF. . ln the sleep mode,the multiplexcontrol unit stops functioning(communicationand CPUcontrol)when it is not necessaryfor the systemto operate. . As soon as any operationis requested(for example,a door is unlocked),the relatedcontrol unit in the sleep mode immediatelywakes up and beginsto function. . When the ignition switch is turned OFF,and the driver'sor front passenger'sdoor is opened,then closed,there is about a 10 seconddelay beforethe control unit goes from the wake-upmode to the sleep mode. . lf any door is open,the sleep mode will not function. . l f a k e y i s i n t h e i g n i t i o ns w i t c h ,t h e s l e e pm o d ew i l l not function. . When in sleep mode,the draw is reducedfrom 70 80 mA to lessthan 10 mA.

Fail-safe To preventimproper operation,the multiplexcontrol system has a fail-safefunction.In the fail-safemode, the output signal js fixed when any part of the system malfunctions(for examplea faulty control unit or c o m m u n i c a t i o lni n e ) . Eachcontrol unit has a hardwarefail-safefunctionthat fixes the output signalwhen there is any CPU malfunction,and a softwarefail-safefunctionthat i g n o r e st h e s i g n a lf r o m t h e m a l f u n c t i o n i ncgo n t r o lu n i t and allowsthe systemto operatenormally.

22-171 /ar

Multiplex ControlSystem Troubleshooting Mode 1 Tset 1. Removethe driver's dashboardlower cover {see page 20-59).

7. Checkfor continuitybetweenterminal 4ofthe under-dashfuse/relaybox connectorJ and body ground. ls there continuity?

2. Checkthe No. 9 ( 10A)fuse in the under-hoodfuse/ relay box and the No. 10 (7.5A)fuse in the underdash fuse/relaybox. Are the fuses OK? YES-Go to step 2. N O - F i n d a n d r e p a i r t h ec a u s eo f t h e b l o w nf u s e . ! 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . l tf h e d r i v e r ' s seatbeltis unbuckledthe seat belt reminderwill c h i m e6 t i m e s .

YES Replacethe under-dashfuse/relaybox.l N O- R e p a i tr h e o p e n i n t h e w i r e . l ft h e w i r e i s o k , r e p a i rG 3 0 1 . 1 8. lf ther are any DTCSpresent,the spotlightand lf more ceiling light will blink to indicatethe DTC(S). than one DTCis present,the DTCSwill be displayed in ascendingorder,lf there are no DTCSthe s p o t l i g h at n d c e i l i n gl i g h tw i l l n o t b l i n ka g a i na f t e r the mode1 indication. Are there any DTCg?

4. Set the ceiling light to the centerpositionand close a l l t h ed o o r s . 5. Connectthe specialtoolto the multiplex inspection conneclor. 6. After about 5 secondsthe spotlightand ceiling light should come on for 2 seconds,go out, then blink on for 0.2 secondto show the system is now in mode 1. Did the spotlight and ceiling light indicate mode 1? YES-Go to step 8.

YES Go to step 9. NO Go to the Mode 2 test. 9. Troubleshootthe DTC(S)in the order indicated u s i n gt h e f o l l o w i n gc h a r t s . lf a faulty control unit is suspected,substituteit with a known food part and recheckfor DTCS, . lf the DTC(s)isstill present.go to the next step listedfor the DTC. . lf the DTC(S)is no longer presentreplacethe originap l art.

NO Go to step 7.

22-172

I Individual

Multiplex DTC

Probable Cause The multiplexcontrol unit cannot receivesignalsfrom the gauge assemDty. 'l

Faultypoweror groundto the gaugeassembly

2 . Faultygauge assemblv 3 . Faultyunder-dashf use/relay box The multiplexcontrol unit cannot receivesignalsfrom the ECM 1 Faultypower or ground to the ECM 2 . F a u l t yE C M ?

Faultyunder-dash fuse/relay box

Internalfailure of the multiplex control unit 1 Faultyunder-dash fuse/relay

box 5

I 6

The gaugeassemblycannot receive signalsfrom the multiplexcontrol u n i ta n d t h e E C M Faultypower or ground to the g a u g ea s s e m b t v F a u l t yq a u g ea s s e m b l v The ECMcannot receivesignals from multiplexcontrol unit and the gaugeassembty 1 Faultypower or ground to the ECM F a u l t yE C M '

DTCs Multiplex DTC 1 , 2a n d3

Probable Cause

Short to ground on one of the

& communicationwires. ECMDTC Short to ground on the YELwire P0600 betweenthe PCMterminal E24 Simultane and the under-dashfuse/relay ously b o x t e r m i n a lE 1 0 2 . Short to ground on the WHT/ GRNwire betweenthe Gauge assemblyterminal A2 and under-dashfuse/relaybox t e r m i n a lK 1 0 1 a n d 6 Open in the communicationwire Simultane I Open in WHT/GRNwire o u sl y betweenthe under-dashfuse/ relay box terminal K10 and the GauqeassemblVterminal 42 2 a n d 5 O p e ni n t h e c o m m u n i c a t i o w n ire S i m u l t a n e 1 Open in the YELwire between ously the under-dashfuse/relaybox t e r m i n a lE 1 0a n d E C Mt e r m i n a l

'Before

replacinga FaultyECM/PCMmake sure it has the latestsoftwarerevision.UDdateif necessarybeforeswappingor replacing.

(cont'd)

22-173

MultiplexControlUnit Input Test 1 . Removethe driver'sdashboardlower cover (seepage20-59). 2 . Disconnectthe under-dashfuse/relaybox connectorsC, E, F, J, K, O, p, O, X and y. NOTE:All connectorsare wire side of female terminals. CONNECTOR C {14P}

CONNECTOR E I13P)

GRN/ORN

BLU

4 10

1 0) . / 12

1 4

GRN/RED

,/1,/l,/ 12

WHT/BLK

RED/WHT

CONNECTORY {13P) BRN/YEL

BLU/RED BLU/RED

RED

CONNECTOR X {8P)

LTGRN/RED GRN/ORN

GRN/RED

CONNECTOR O (8P}

coNNECTOR P (18P)

,/ l,/

2 5

BLK

CONNECTOR O I12P)

WHT/GBN

CONNECTOR J {8PI WHT/RED

YEL

CONNECTOR K {17P)

CONNECTOR F {12P} GRN/RED {USAI (Canada) GRN/ORN

,/1,/ r0

BLK

{cont'd)

22-175

MultiplexControlSystem MultiplexControl Unit lnput Test (cont'd) andsocketterminals to be suretheyareall makinggoodcontact the connector 3. Inspect .lftheterminalsarebent,looseorcorroded,repairthemasnecessary,andrecheckthesystem . llthe terminalslookOK,go to step4. Test condition

Wire BLK

[ Jn d e r a l l c o n d i t i o n s

BLK

lJnderall conditions

Cavitv

Test:Desired.esult Check{or voltage1oground: Therc sholl.l he 1V or less

C h e c kf o r v o l t a g et o g r o u n d : There should bc 1 V or less.

Checkfor voltageto ground: Thereshouldbe batteryvoltage down,turn the igntionswitchON (ll) whilethe Brakesystemindicatoris on forthe buldcheck. Checkfor voltageto ground: Thereshouldbe 1V or lesswhenthe

BFNryEL Parkingbrakelever

r l l c o n d i t i o n s Checkfor voltageto groundi WHT/RED U n d e a Thereshouldbe bafteryvoltage.

Possible causeif resullEqS!q!!e!!ed Poorground(G20'l) An ooenin the wire Poorground1G501) An ooenin thewire An openin thewire Shorttoground unit FaultyABSmodulatorcontrol

in the under'hood BlownNo.9 (10A)fuse box fuse/relay An oncnin rhc wire

connectors on lhe underunderdashfuserelaybox,andmakesuretheseinputtestsatthe appropriate 4. Reconnectthe connectorstothe box. dashfuse/relav . lf anytestindicates the system a problem,{ind andcorrectthe cause,then recheck fuse/relay box assembly . lf alltheinputtestsproveOK,the multiplexcontrolunit mustbe faulty.Replace the under_dash Cavitv

GRN

Test condition Driver'sdooropen Driver'sdoorclosed

door LT GRN/RED Passenger's

door Passenger's

osI]l .

GRN/ORN Parkingbrakelever

4.,

GRN/ORN

GRN/RED (USA) GRN/ORN (Canada)

Tesi: Oesiredresult C h e c kf o r v o l t a g e t o g r o u n d : There should be 1 V or lessC h e c kf o r v o l t a g e t o g r o u n d : There should be 5 V or more. C h e c k. f o rv o l t a g e 1 0 g r o u n d : There should be 1 V or less.

Checkfor voltageto ground: Thereshouldbe 5 V or more. C h e c kf o r v o l t a g et o g r o L r n d : Thereshorl.l be 1 V or less. C h e c kf o r v o l t a g e t o g r o u n d : There should be 5 V or more.

BLU/RED lgnitionswitchON (ll), C h e c kf o r v o l t a g et o g r o u n d : Thereshould be 1V or less. driver'sseatbeltis

BLU/RED lgnitionswitchON (ll) Check{or voltageto ground: Thereshouldbe 6 V or more. driver'sseatbeltis buckled. Checkfor voltageto ground: RED Theresho0ldbe 1V or less-

P18

H",=

f-9*:li:'^:**:':s*:*

22-176

l g n i r i o nk e y i n t h e ignit on switch

C h e c kf o r v o l i a g e t o g t o u n d : Thpre should be I V or lcss

l g n r t r o nk e v o u r o { t h e

C h e c kf o r v o l l a g e t o g r o u n d :

Possible causeifresultis notobtained Faultydriver'sdoorswitch An ooenin the wire Faultydriver'sdoorswitch Shortto qround doorswitch Faultypassenger's An ooeninthewire doorswitch Faultypassenger's Shortto oround F a u l t yp a r k i n gb r a k e s w i t c h . An ooen in thewire

. Faultyparkingbrakeswitch Shorttoground

Faultydriver'sseatbeltswitch P o o r g r o u n(dG 5 5 1 ) An oDenin the wire Faultydriver'sseatbeltswitch Shorttoground Faultyhatchlatchswrtch Poorground(G552) An openin the wire F a u l t yh a t c h l a t c hs w i t c h . F a u l t yi g n i t i o n k e y s w i t c h . Poorground (G401) . An open in the wire

**6 I : [11y.'::i':::1"'

J Cavitv X8

Wire WHT/BLK

GRN/RED Ceilinglightswitchin A t t a c h t o g r o u n d : T h e c e i l i n g l i g h t , the middleposition, s p o t l i g h t ss h o u l d c o m e o n . all doorsclosed

c]1

BLU

GRN/RED

E10

Test condition Test:Desiredresult Underallconditions Attachto ground:Theignitionkey lightshouldcomeon.

YEL

Underall conditions Attachto ground:Dashlightsshould

Brakefluidreservoir C h e c kf o r v o l t a g et o g r o u n d : float in down T h e r e s h o u l d b e l e s st h a n I V . position(brakefluid Brakelluid reservoir Checkfor voltageto ground: floatin up position Thereshouldbe 5 V or more. (brakefluidat full level) Underall conditions C h e c kf o r v o l t a g et o g r o u n d :

Possible causeif resukis notobtained BlownNo.3 (7.5A)fuse in the under,hood BlownLED An ooenin the wire ElownNo.3 (7.54)fusein the undeFhood Faultyceilinglight An oDenin the wire BlownNo.2 (15Aifusein the under-hood fuse/relaybox Faultytaillightrelay An ooenin the wire Faultybrakefluidlevelswitch An openin thewire Faultybrakefluid levelswitch Shorttoground . An openor shortin thewire

T h e r e s h o u l d b e b a t t e r yv o l t a g e i n t h e s l e e pm o d e a n d 3 T v o l t s w h e n

K10

WHT/GRN Underall conditions Checkfor voltageto ground: Thereshouldbe batteryvoltagein the sleepmodeand3 Tvoltswhen

An openor shortin the wire

I J 22-177

I Restraints Restraints SpecialTools

............. 23-2

SeatBelts Component LocationIndex ......................................... 23-3 FrontSeatBeltReplacement ....................................... 23-4 RearSeatBeltReplacement ........................................ 23-6 Inspection .................. 23-8 ChildSeatTetherAnchorRemoval/lnstallation ........23-9

SRS(SupplementalRestraintSysteml

Component LocationIndex ......................................... 23-13 Precautions and Procedures ,,.,......... 23-14 General Troubleshooting Information....................... 23-23 DTCTroubleshooting Index .............. 23-28 SymptomTroubleshooting Index............................... 23-30 SystemDescription................. ........... 23-31 CircuitDiagram .........23-34 DTCTroubleshooting ............... .......... 23-36 Indicator SRS CircuitTroubleshooting ....................... 23-105 ComponentReplacemen(/lnspection After Deployment ..............23-112 Driver'sAirbagReplacement ............ 23-113 FrontPassenger's AirbagReplacement ..................... 23-114 SideAirbagReplacement .................. 23-115 A i r b a gD i s p o s a.l . . . . . . . . . . . . . . . . . . . . . . ........2 . .3. - 1 1 6 l eplacement C a b l eR e eR . . . . . . . . . . . . . .2. .3. .- .1. 1 9 SRSUnitRepfacement ....................... 23-122 SidefmpactSensorReplacement ..........,.................... 23-123 OPDSUnitReplacement .................... 23-124 FrontfmpactSensorReplacement .............................. 23-125

Restraints SpecialTools '

07HAZ-SG00500

oTPM-oo101oo

€

oTsM-TB4o114

oTTM-sz5o114

o-'

07TM-0010204

@ -1

o7xAz-s140200 07xAz-s230100

DeploymentTool SCSServiceConnector r i mu l a t o r S R SI n f l a t o S S R SS i m u l a t o rL e a dC B a c k p r o bA e dapter1 , 7m m S R SS i m u l a t o rL e a dE S R SS i m u l a t o rL e a dF S R SS i m u l a t o rL e a dH

* 1 : I n c l u d e di n S R ST o o l S e t0 7 M M ' S M 5 0 0 0 8 *2: Use with the stackingpatchcords from T/N 07SAZ-0010004, BackprobeSet.

L . 23-2

SeatBelts

ComponentLocationIndex REARCENTER BELTand REARSEATBELTBUCKLES step1 on page23-8 page23 9 Inspection,

SHOULDER ANCHOR ADJUSTER step8 on page23-4 FRONTSEATBELT page23-4 Replacement, page23 9 Inspection,

I CHILDSEATTETHER ANCHORS Removal/lnstallation, page23-11

REARSEATBELT page23.7 Beplacement, page23-9 Inspection, FRONTSEAT BELTBUCKLES step1 on page23'6

23-3

SeatBelts FrontSeat Belt Replacement SRScomDonentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-13)and the precautionsand procedures(seepage23-14)in the SRS sectionbefore performingrepairsor service,

6. Removethe upper anchorcover {A),and remove t h e u p p e ra n c h o rb o l t( B ) . B 7/16-20 UNF 32N m (3.3kgf.m,24lbt.ft)

NOTE:Checkthe front seat beltsfor damage,and replacethem if necessary.Be careful not to damage them during removaland installation.

Front Seat Belt 1 . Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the preset buttons. Disconnectthe negativecablefrom the battery,and wait at least3 minutes beforebeginningwork.

3 . Slidethe front seatforward fully. Removethe lower anchorcap (A),and removethe lower anchor bolt (B).

7. Disconnectthe seat belt tensionerconnector(A). Removethe retractormounting self-tappingET screw {B),and the retractorbolt (C),then remove the front seat belt (D) and retractor(E). 6x1.0mm 3.4N m {0.35kgf.m,2.5lbf.ft)

5 . R e m o v et h e r e a rs i d et r i m p a n e l( s e e p a g e 2 0 - 5 1 ) .

7/16-20 UNF 32 N.m(3.3kgf m,2irlbf.ft) 8. lf necessary,removethe front seat belt protecto (F).

23-4

9 . Removethe B-pillaruppertrim {seepage20-50) 1 0 .Removethe shoulderanchoradjuster{A).

Upperanchorbolt construction: UPPERANCHOR BOLT

UPPERANCHOR

BUSHING

COLLAR

TOOTHED LOCKWASHER

Lower anchor bolt construction: 8 x 1.25mm

WASHER

22 N.m(2.2kgf.m,16lbf.ftl 1 1 .Installtheseat belt in the reverseorder of removal, and note these items: . lf thethreads on the retractormounting selftapping ET screw are worn out, use an oversized self-tappingET screw (P/N90133-SZ4-0030) made specificallyfor this application. . Checkthat the retractorlockingmechanism functions(seepage 23-9). . A s s e m b l et h e w a s h e r sc, o l l a r s a, n d b u s h i n go n the upper and lower anchorbolts as shown. . lf the seat belt tensionerhas been deployed replacethe front seat belt protectorwith a new one. . A p p l y l i q u i dt h r e a dl o c kt o t h e a n c h o rb o l t s beforereinstallation. . Beforeinstallingthe anchorbolts,make sure there are no twists or kinksin the front seat belt. . Make sure the seat belt tensionerconnectoris pluggedin properly. . Reconnectthe negativecableto the battery. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECM/PCMidle learn procedure{seepage 11,139).

LOWERANCHORBOLT

TOOTHEDLOCKWASHER

{cont'd)

23-5

Seat Belts Front Seat Belt Replacement(cont'd) SeatBelt Buckle 1. Make sure you have the anti-theftcode for the radio, then write down the frequenciesfor the preset buttons. 2. Disconnectthe negativecablefrom the battery, and wait at least3 minutesbefore beginningwork. 3. Removethe front seat (seepage 20-7'1). 4. Detachthe seat belt switch connectorclip (A),seat belt buckletensionerconnectorclip (B),and h a r n e s sc l i p ( C ) .

.-..:.a--

5. Removethe centeranchor bolt (A),and removethe seat belt buckle{B).

7/16-20 UNF 32N m {3.3kgf m,24lbf.ft) 6. Pullthe seat belt switch/tensionerharness(C)out through the hole on the seattrack.

23-6

7. Installthe bucklein the reverseorder of removal, and note these items: . Assemblethe washerson the centeranchor bolt as shown. . Apply liquid thread lockto the centeranchor bolt before reinstallation. . lf the seatbelt tensionerhas been deployed, replacethe front seatbelt protectorwith a new one. . Apply liquid thread lockto the seat mounting bolts before reinstallation . Reconnectthe negativecableto the battery. . Enterthe anti-theftcode for the radio,then enter the customer'sradio stationpresets. . Resetthe clock. . Do the ECMiPCMidle learn procedure(seepage 11 _ 1 3 9 ) .

COLLAR

RearSeat Belt Replacement NOTE:Checkthe rear seat beltsfor damage,and replacethem if necessary.Be carefulnot to damage l n di n s t a l l a t i o n . t h e m d u r i n gr e m o v a a

RearSeatBelt 1 . R e m o v et h e r e a rs e a tc u s h i o n( s e ep a g e2 0 8 0 ) . 2. Removethe lower anchor bolt {A}. A 7/16-20UNF 32 N.m (3.3kgf.m, 24 tbf.ftl

5. Installtheseat belt in the reverseorder of removal, and note these items: . lf the threadson the retractormounting selftapping ET screw are worn out, use an oversized self-tappingET screw (P/N90133-524-0030) m a d es p e c i f i c a l lfyo r t h i s a p p l i c a t i o n . . Apply liquid thread lockto the anchorbolt before reinstallation. ' Checkthat the retractorlockingmechanism functions{seepage 23-9). . Beforeinstallingthe anchor bolt, make sure there are no twists or kinksin the rear seat belt.

3 , R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) . 4 . Removethe retractormounting self-tappingET screw (A),and the retractorbolt (B),then remove the rear seat belt (C)and retractor{D). B 7/16-20 UNF

N m {3.3kgf.m,2irlbf.ft)

A 6x1.0mm 3.4 N.m {0.35kgl m,2.5 lbf.ftl

(cont'd)

23-7

SeatBelts RearSeat Belt Replacement{cont'd) CenterBelt and Seat Belt Buckles 1. Removethe seatcushion{seepage 20-80).

7. Removethe seat belt guide (A)from the pin (B), and releasethe centerbelt (C)from the seat belt g ui d e .

2. Removethe centeranchor bolts (A),and remove the seat belt buckles(B)and centerbeh (C). A 7/16-20 UNF 32N.m13.3kgf.m, 24 tbt.ft)

'.;r'"

1-..i, ,

<i.. -"':'' "':

Removethe retractormounting bolt (A),and the retractorbolt (B),then removethe centerbelt (C) and retractor(D)from the seat-backframe (E).

3. Removethe right seat-back(seepage 20-80).

A 6x1.0mm 9.8 N.m (1.0kgf m, 7.2 tbl.ttl

7/16-20UNF 32 N.m(3.3kgf m, 24 tbf.ftl

4. Removethe seat-backcover (seepage20-82). 5, Removethe seat-backpad from the seat-back frame (seestep 3 on page 20-81). 6. Removethe screw,and releasethe hooks (A),then removethe retractorcover (B). FastenerLocation

.:.',

t.) 23-8

Inspec'tion 9. lnstallthe seat belt and bucklesin the reverseorder of removal,and note these items: . Checkthat the retractorlockingmechanism functions(seestep 1 on page 23-10). . Assemblethe washerson the centeranchor bolt as shown (exceptcentershoulderbelt). . Apply liquidthread lock to the anchor bolts beforereinstallation. . Beforeinstallingthe centeranchor bolt, make sure there are no twlsts or kinksin the centerbelt, Canler anchor bolt construction:

WASHER

with seatbelttensioners. Forfrontseatbeltretractors locations(seepage23-13) reviewtheSRScomponent (seepsge23-14)in andprocedures andthe precautions the SRSsectionbeforeperformingrepairsor service.

Retractor,Front and Rear 1. Beforeinstallingthe retractor,checkthat the seat belt can be pulled out freely. 2. l\4akesure that the seat belt does not lockwhen the retractor(A) is leanedslowly up to 15'from the mounted position.The seat belt should lock when the retractoris leanedover 40'. Do not attemDtto disassemblethe retractor. Front:

Forward

lnside

Forward

Inside

Rear:

Replacethe seat belt with a new assemblyif there is any abnormality.Do not disassembleany pan of the seat belt for any reason,

(cont'd)

23-9

Seat Belts Inspection(cont'd) In-vehicle

RetraEtor,RearCenter 1. Beforeinstallingthe retractor,checkthat the seat belt can be pulled out freely.

1. Checkthat the seat belt is not twisted or caught on anything.

2, Make sure that the seat belt does not lockwhen the retractor(A) is leanedslowly up to 15' from the mounted position.

2. After installingthe anchors.checkfor free movementon the anchorbolts. lf necessary, removethe anchor bolts and checkthat the washersand other partsare not damagedor i m p r o p e r l yi n s t a l l e d . 3. Checkthe seat beltsfor damageor discoloration. Cleanwith a shop towel if necessary.Use only soap and water to clean. NOTE:Dirt build-upin the loops of the upper anchorscan causethe seat beltsto retractslowly. Wipe the insideof the loops with a cleancloth d a m p e n e di n l s o p r o p yal l c o h o l .

lnside

Forward

3 , Leanthe retractorover 40', and make sure that the seat belt does not lockwhen pulled out over 900 mm (35.4in.).Do not aftemptto disassemblethe retractor. 4 . Replacethe seat belt with a new assemblyif there is any abnormality.Do not disassembleany part of the seat belt for any reason.

Checkthat the seat belt does not lockwhen pulled out slowly. The seatbelt is designedto lock only during a sudden stop or impact. For rearcentershoulderbelt, checkthat the seat b e l tl o c k sw h e n p u l l e do u t o v e r 4 0 0m m ( 1 5 . 7i n . ) with the seat-backfolded down. Make sure that the seat belt will retract automaticallywhen released. 7 . For each passenger'sseat belt,checkthe seat belt retractorlockingmechanismALR (automatic lockingretractor).This function is for securingchild seats. - 1 P u l l t h es e a tb e l ta l l t h e w a y o u t t o e n g a g et h e ALR.The seat belt should retractwith a ratchetingsound, but not extend.This is normal. -2 To disengagethe ALR, releasethe seat belt and a l l o w i t t o f u l l y r e t r a c tt,h e n p u l l t h es e a tb e l t out part-way.The seat belt should retractand extend normally. 8 . Replacethe seat belt with a new assemblyif there is any abnormality.Do not disassembleany part of the seat belt for any reason.

\,J 23-10

ChildSeatTetherAnchorRemovaUlnstallation Side

Middle 1. Removethe child seattether anchorcover (A) in t h e r e a rt r i m p a n e l( B ) .

1. Removethe rear bulkheadcoversfrom both sides ( s e ep a g e2 0 - 5 1 ) . 2. Removethe anchorbolt (A),then removethe child seattether anchor (B)from behindthe seat-backon each side ofthe cargo compartment.Do not removethe toothedwasher (C)from the tether anchor.

f-..- t" .i..].-

,tltl 8 x 1.25mm 22 N m {2.2ksf.m, 16lbf.ft)

2 . R e m o v et h e a n c h o rb o l t( C ) ,t h e n r e m o v et h e c h i l d seattether anchor(D).Do not removethe toothed washer (E)from the tether anchor.

8 x 1 . 2 5m m 22 N.m {2.2kgt m. 16lbfft)

l n s t a l l t h ea n c h o r si n t h e r e v e r s eo r d e ro f r e m o v a l .

3 . I n s t a l l t h ea n c h o ri n t h e r e v e r s eo r d e ro f r e m o v a l .

I J 23-11

sRs ComponentLocationIndex

LEFTFRONTIMPACTSENSOB RIGHTFRONTIMPACTSENSOR

SRSINOICATOR page23-105 Troubleshooting, SIDEAIRBAG CUTOFFINDICATOR

AIRBAG DRIVER'S page23-113 Replacement, page Disposal, 23 1'16

FRONTPASSENGER'SAIRBAG page23-114 Replacement, Disposap l , a g e2 3 ' 1 1 6

SENSOR/

SEATBACK Replacement, page20-75 FRONTPASSENGER'S SIDEAIRBAG Replacement, p a g e2 3 ' 1 ' 1 5 Disposal, p a g e2 3 ' 1 1 6

FRONTPASSENGER'S SEATBELT TENSIONER Beplacement, page23-4 Disposal, page23-'116

CABLEREEL Beplacement, p a g e2 3 - 1 1 9

MEMORYERASE (MES} SIGNAL CONNECTOR I2PI

OPDSUNIT page23-27 Initialization, page23-124 Replacement, SIOE PASSENGER'S IMPACTSENSOR Replacement, p a g e2 3 - 1 2 3

DATA LINK CONNECTOR (DLCI16P

FRONTPASSENGER'SSEAT BELTBUCKLETENSIONER

DRIVER'SSEATBELTTENSIONER page23 4 Replacement, D i s p o s a pl ,a g e2 3 - 1 1 6

23-13

sRs Precautionsand Procedures GeneralPrecautions

Steering-related Plecautions

Pleaseread the following precautionscarefullybefore performingairbagsystem service.Observethe instructionsdescribedin this manual.or the airbags could accidentallydeploy and causedamageor injuries.

CableReelAlignment

. Exceptwhen performingelectricalinspections. alwaysturn the ignition switch OFF,disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore beginningwork. NOTE:The memory is not erasedeven if the ignition switch is turned OFFor the batterycablesare disconnectedfrom the battery. . Use replacementpans which are manufacturedto the same standardsand quality as the original parts.Do not installused SRSpartsfrom anothervehicle.Use only new pans when making SRS repairs. . Carefullyinspectany SRS part beforeyou installit. Do not installany part that shows signs of being droppedor improperlyhandled,such as dents,cracks, or deformation.

. Beforeremoving any SRSparts (includingthe disconnectionof connectors),alwaysdisconnectthe SRSconnector. . Use only a digital multimeterto checkthe system.lf it is not a Honda multimeter,make sure its outout is 10 mA (0.01A)or lesswhen switchedto the lowestvalue in the ohmmeter range.A testerwith a higheroutput could causeaccidentaldeploymentand possible injury. . Do not put objectson the front passenger'sairbag. . The original radio has a coded theft protectioncircuit. Be sure to get the customer'sradio code and write down the frequenciesfor the radio's presetstations beforedisconnectingthe batterycable. . Beforereturningthe vehicleto the customer,enter the radio code.then enter the customer'sradio stationpresets,and set the clock.Do the engine control module (ECM)idle learn procedure(seepage 11-139).

23-14

. M i s a l i g n m e not f t h e c a b l er e e lc o u l dc a u s ea n o p e ni n t h e w i r i n g ,m a k i n gt h e S R Ss y s t e ma n d t h e h o r n s inoperative.Centerthe cable reelwheneverthe following is performed(seestep 6 on page23-121). - Installationof the steeringwheel - Installationof the cable reel - I n s t a l l a t i oonf t h e s t e e r i n gc o l u m n - Other steering-related adjustmentor installation . Do not disassemblethe cable reel. . Do not apply greaseto the cable reel. . lf the cable reel shows any signs of damageor contamination.replaceit with a new one. For example,it does not rotatesmoothly.

\rc

AirbagHandlingand Storage

. Storethe removedairbagon a secure, flat surface 200'Fi awayfrom any highheatsource(exceeding

Do not disassemblean airbag,lt has no serviceable parts.Oncean airbag has been deployed,it cannot be repairedor reused. For temporarystorageof an airbagduring service, observethe following precautions. . Storethe removedairbagwith the pad surfaceup. Never put anythingon the airbag.

Never perform electricalinspectionsto the airbags, such as measuringresistance. Do not positionyourselfin front of the airbagduring removal,inspection,or replacement.

To preventdamageto the airbag,keep it free from any oil, grease,detergent,or water,

Referto the scrappingproceduresfor disposalof a d a m a g e da i r b a g .

(cont'd)

23-15

sRs .j

Precautionsand Procedures{cont'dl SRSUnit, Front lmpact Sensors,and Side lmpact Sensors

. Do not disassemblethe SRS unit,front impactsensors,

. Be careful not to bump or impactthe SRS unit, front impact sensors,or side impactsensorswheneverthe ignition switch is ON (ll),or for at least3 minules after the ignition switch is turned OFF.

. Turn the ignition switch OFF,disconnectthe battery negativecable,and wait at least3 minules before beginninginstallationor replacementof the SBS unit, or disconnectingthe connectorsfrom the SRSunit.

. During installationorreplacement,be carefulnotto bump (by impactwrench, hammer,etc.)the area aroundthe SRS unit, front impact sensors,and sjde impact sensor.The airbagscould accidentallydeploy and causedamageor injury.

. Be sure the SRSunit,front impactsensors,and side impact sensorsare installedsecurely.with the mounting bolts torquedto 9.8 N.m (1.0kgf.m,7.2 lbf.ft)

or side impact sensors.

. Do not spill wateroroil on the SRSunit, front impact sensors,or the side impact sensors,and keepthem away from dust. . Store the SRS unit, front imDactsensorsand side impactsensorsin a cool (lessthan 104"F/40'C)and dry (lessthan 80 % relativehumidity,no moisture) area.

After a collisionin which any airbagsor seat belt tensionerswere deployed.replacethe SRSunit, front impact sensors,and other relatedcomponents(see page 23-112).After a collision in which a side airbag was deployed.replacethe side impact sensoron the deployedside and the SRS unit. After a collisionin which the airbagsor the side airbagsdid not deploy, inspectfor any damageor any deformationon the SRS unit, front impact sensors,and the side impact s e n s o r sl.f t h e r ei s a n y d a m a g e r, e p l a c et h e S R Su n i t and/orthe sensors.

23-16

I WiringPrecautions

Precautions for ElectricalInspections

Some of the SRSwiring can be identifiedby a special yellow outer covering,and the SRSconnectorscan be identifiedby their yellow color. Observethe instructionsdescribedin this section.

. When using electricaltestequipment,insertthe probe of the tester into the wire side of the connector. Do not insertthe probe of the testerinto the terminal side of the connector,and do not tamper with the connector.

. Neverattemptto modify. splice,or repairSRSwiring. l f t h e r ei s a n o p e no r d a m a g ei n S R Sw i r i n g ,r e p l a c e the harness.

Use a U-shapedprobe.Do not insertthe probe forcibly.

Be sure to installthe harnesswires so they do not get Dinchedor interferewith other Darts.

Use specifiedserviceconnectorsin tro u bleshooting. U s i n gi m p r o p e rt o o l sc o ul d c a u s ea n e r r o ri n inspectiondue to poor metal-to-metalcontact. M a k es u r ea l l S R Sg r o u n dl o c a t i o n sa r e c l e a n ,a n d groundsare securelyfastenedfor optimum metal-tometal contact.Poorgroundingcan causeintermittent problemsthat are difficultto diagnose.

(cont'd)

23-17

sRs Precautionsand Procedures(cont'dl Spring-loaded LockConnector

Side Airbag Connector:

Some SRSsystemconnectorshave a spring-loaded lock.

Disconnecting T o r e l e a s et h e l o c k ,p u l l t h es p r i n g - l o a d esdl e e v e( A ) a n dt h e s l i d e r{ B )w h i l e h o l d i n gt h e o p p o s i t eh a l fo f t h e connector.Then pullthe connectorhalvesapart.Be sure to pull on the sleeveand not on the connectorhalf.

Front Airbag Connectors: Disconnecting To releasethe lock.pullthe spring-loadedsleeve(A) toward the stop (B)while holdingthe oppositehalf of the connector.Then pullthe connectorhalvesapart,Be sure to pull on the sleeveand not on lhe connector.

Connecting 1. To reconnect,hold the pawl-sideconnector,and presson the backof the sleeve-sideconnectorin the directionshown. As the two connectorhalves are pressedtogether,the sleeve(A) is pushedback by the pawl (C).Do not touch the sleeve.

Connecting Hold both connectorhalves,and pressthem firmly togetheruntil the projection(C)of the sleeveside connectorclicks.

When the connectorhalvesare completelV connected,the pawl is released,and the springloadedsleevelocksthe connector.

\ J 23-18

Backprobing Spring-loaded LockConnectors

Seatswith SideAirbags

When checkingvoltageor resistanceon this type of connectorthe first time, you must removethe retainer to insertthe tester orobe from the wire side.

"SIDEAIRBAG" label Seatswith side airbagshave a on the seat-back.Becausethe componentpans (seat-back cover,cushion,etc.)of seatswith and without airbags are different,make sure you installonly the correct replacementparts.

NOTE:lt is not necessaryto reinstallthe removed retainer;theterminalswill stay lockedin the connector housrno.

A To removethe retainer(A),inserta flat-tipscrewdriver (B) betweenthe connectorbody and the retainer,then carefullypry out the retainer.Takecare not to breakthe connector.

W h e n c l e a n i n gd, o n o t s a t u r a t e t h es e a t w i t hl i q u i d , and do not sDravsteam on the seal Do not reoalra torn or fraved seat-backcover. ReDlacethe seat-backcover. A f t e ra c o l l i s i o ni n w h i c ht h e s i d ea i r b a gw a s deployed,replacethe side airbagwith new parts.lf the seat-backcushion is split, it must be replaced.lf the seat-backframe is deformed,it must be replaced. Never put aftermarketaccessorieson the seat{covers, pads,seat heaters,lights,etc.).

(cont'd)

23-19

sRs Precautionsand Procedures(cont'dl DisconnectingSystemConnectors Beforeremoving a front airbag.side airbag,or other SRS relateddevices{the SRS unit,the cable reel,the front impact sensors,the side impact sensors,the seat belt buckletensioners,and the seat belt tensionerconnector),disconnecting connectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbagconnectors or the side airbagconnectorsto preventaccidentaldeploVment. Turn the ignition switch OFF,disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore beginningthe following procedures. 'BeforedisconnectingSRSunitconnectorA(1)fromtheSRSunit,disconnectthedriver'sairbag4Pconnector(3). the front passenger'sairbag4P connector(4),the driver'sseat belt tensioner2P connector(6),and the front passenger'sseatbelt tensioner2P connector(7). . BeforedisconnectingSRS unit connectorB (8)from the SRS unit, disconnectboth side airbag2P connectors(11.'12), and both seat belt buckletensioner4P connectors(9, 10). . Beforedisconnectingthe cable reel 4P connector(2),disconnectthe driver'sairbag4P connector(3). 'Beforedisconnectingthefloorwireharness4Pconnector(5),disconnectbothseatbelttensioner2Pconnectors (6.7).

23-20

1. Disconnectthe batterynegativecable,and wait at least3 minutes. Driver's Airbag

Side Airbag 4. Disconnectboth side airbag2P connectors(Alfrom the floor wire harness.

2. Removethe accesspanel (A)from the steering wheel, then disconneclthe driver'sairbag 4P connector(B)from the cable reer.

Front Passenger'sAirbag 3. Disconnectthe front passenger'sairbag4P connector(A)from dashboardwire harnessB.

(cont'd)

23-21

sRs Precautionsand Procedures(cont'd)

SeatBelt Tensioner

SRS Unit

bothseatbelttensioner2Pconnectors 5. Disconnect (A)fromthefloorwire harness

7. DisconnectSRS unit connectorA, SRS unit connectorB, and/or SRS unit connectorC from the S R Su n i t .

Seat Belt Buckle Tensioner 6. Disconnectboth seat belt buckletensioner4P connectors(A).

\ J 23-22

GeneralTroubleshooting Information DTC(Diagnostic TroubleCodesl

Readingthe DTC

The self-diagnostic function of the SRSsystem allows it to locatethe causesof system problemsand then store this informationin memory. For easiertroubleshooting, this data can be retrievedvia a data link circuit.

When the SRSindicatoris on, read the DTCusing either of the following methods:

. W h e ny o u t u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,t h e S R S indicatorwill come on. lf it goes off after 6 seconds, the system is normal. . lf there is an abnormality,the svstem locatesand definesthe problem,storesthis informationin memory, and turns the SRS indicatoron. The data w i l l r e m a i ni n t h e m e m o r ye v e nw h e n t h e i g n i t i o n switch is turned off or if the batteryis disconnected. . When you connectthe HondaPGlMTesterto the 16P d a t al i n kc o n n e c t o(rD L C ) t os h o r tt h e S C St e r m i n a l , a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .t h e S R Si n d i c a t o r will indicatethe diagnostictrouble code (DTC)by the n u m b e ro f b l i n k s . . When you connectthe HondaPGM Testerto the 16P data link Connector(DLC),you can retrievethe DTCin t h e H o n d aS y s t e m s" S R S " m e n u . . After readingand recordingthe DTC,proceedwith the troubleshootingprocedurefor th is code.

PGM Tester "SRS" Menu Method: Connectthe Honda PGM Tester{A)to the 16Pdata link connector{DLC)(B), and follow the Tester'sDromptsin "SRS" the menu. lf the Testerindicatesno DTC,no communication.DTC 3-6 to 3-'10,DTC4-6 to 4-10,DTC9-1,or DTC9-2, double-checkby usingthe "SCS" menu method.

Precautions . U s eo n l y a d i g i t a lm u l t i m e t etro c h e c kt h e s y s t e m .l f it's not a Hondamultimeter,make sure its output is 1 0 m A ( 0 . 0 1 Ao) r l e s sw h e n s w i t c h e dt o t h e s m a l l e s t v a l u ei n t h e o h m m e t e rr a n g e A , t e s t e rw i t h a h i g h e r o u t p u tc o u l dd a m a g et h e a i r b a gc i r c u i to r c a u s e a c c i d e n t aal i r b a gd e p l o y m e nat n d p o s s i b l ei n j u r y . . Wheneverthe ignition switch is ON (ll),or has been turned OFFfor lessthan 3 minutes,be careful not to b u m pt h e S R Su n i Ut h e a i r b a g sc o u l da c c i d e n t a l l y d e p l o ya n d c a u s ed a m a g eo r i n j u r i e s . . Beforeyou removethe SRSharness,disconnectthe driver's airbagconnector.the front passenger's airbagconnector,both side airbagconnectors,both seat belt buckletensionerconnectors,and both seat b e l tt e n s i o n ecr o n n e c t o r s . . Make sure the batteryis sufficientlycharged.lf the batteryis dead or low, measuringvalueswon't be correct. . Do not touch a tester probe to the terminalsin the SRSunit or harnessconnectors,and do not connect t h e t e r m i n a l sw i t h a j u m p e rw i r e . U s eo n l y t h e backprobeset and the HondaPGM Tester.Backprobe spring loadedlocktype connectorscorrectly.

(cont'd)

23-23

sRs L

GeneralTroubleshootingInformation(cont'd) PGM Tester "SCS" Menu Method {retrieving the flash codes): The SRSindicator(A) indicatesthe DTCby lhe number of blinkswhen the Honda PGM Tester(B) is connected to the DLC(datalink connector)( 16P)(1). '1.

Readingthe main code: I nc a s eo f 1 - 1 0 Countthe numberof blinks. Examplo: 1 . 2S r . 2S 1 . 2S 1 . 2S 1 . 2S

*t**t*l*l

""_f]_flfl

Make sure the ionition switch is OFF.

2. Connectthe HondaPGN4Tester(B)to the DLC(C), "SCS" menu and follow the Tester'soromDtsin the (see ground to the SCS line the HondaPGM Tester ODerator'sManual).

Maincodo= 1

In caseot 11..'15 Fourfastblinkscountas 10. Add anyfunherblinkstogetheras shown. Example: 0 . 1s

/// t\\\

1.rs r.2s r.2s 1.2s *t* - L'- - * l

//lii\\ |

""ffi Main code=

3 . Make sure the SCS line is grounded,then turn the ignitionswitch ON (ll).The SRS indicatorcomes on for about 6 seconds,and then goes off. Then it will blinkto indicatethe DTC(seethe table below).

=12

l n c a s eo f 2 0 o r m o r e T w o s e t s o f f o u r f a s t b l i n k sc o u n t a s 2 0 . A d d a n y f u n h e r b l i n k s t o g e t h e ra s s h o w n . Examplo:

0 . 1s

4. Readthe DTC.

0.1s

12s12s ,y'fl\,,. /[N *l*FtftffN*+fH-t-ff

5 . Turn the ignition switch OFF,and wait for 10 seconds. 6, Disconnectthe Honda PGMTesterfrom the DLC. 7. Do the troubleshootingprocedurefor the DTC.

Main code=

Readingthe subcode:

Patteins of DTC Indications:

Count thenumber of blinks.

T h e D T C c o n s i s t so f a m a i n c o d e a n d s u b c o d e .

Example: S: Second 6S

o N [ l I t l - l- - - -|- L [l - - - l I oFFl First emitting Main code

0.3s 0.3s 0.3s 0.3s 0.3s 0.3s 0.3s

l**t**t*t*t*l

Subcode

""ffi S

lf the main code is DTC 3 4.

'3',

a n d t h e s u b c o d ei s

' 4 ' , r e c o r da

\ J 23-24

Includingthe most recentproblem,up to three differentDTCScan be indicated(seeexample 1 below). ln case of a continuousfailure,the DTCwill be indicatedrepeatedly{seeexample 1 below). In caseof an intermittentfailure,the SRS indicatorwill indicatethe DTCSone time, then it will stay on (seeexample 2 below). lf both a continuousand an intermittentfailure occur,both DTCSwill be indicatedas continuousfailures. When the system is normal (no DTCS),the SRS indicatorwill stay on (seeexample3). lf the SRSindicatorcomes on continuouslywithout a DTC,there mav be a problemwith the svstem. lf the SRSindicatordoes not come on as indicatedabove,alwayscheckfor an open or a short to ground in the SCS circuitbeforetroubleshootingthe system. Example of DTC Indications: 1. Continuousfailure,SRSIndic6torblink$likethis: 1 . 2S 1 , 2S

0.3s

0.3s 0.3s

S: Second

ON OFF Bulb check period

Maincode(21 Subcode l1)

Main code l1l Subcode(3) Main code {11 Subcode{'l) Indications are lepeated DTC2-l tn cese ot DTC1-3 DTC1-1 Most recentp.oblem continuous Sscond-mostrecent Third-mostrocent failure. problem problem 2. Intermittent failure, SRS lndicator blinks like this:

ON OFF Bulb check DTC 5-1 period (no 3. Normal failure|,SRSIndicatorblinks like this:

lndicator stays on in case of i nterm ittent failu re.

ON OFF Bulb chock period

No DTC,systom is normal, the indicator stays on.

(cont'd)

23-25

sRs GeneralTroubleshootingInformation(cont'dl Erasingthe DTGMemory

Troubleshootinglntermittent Failures

Specisl Tool Required SCSserviceconnector07PAz-0010100

lf there was a malfunction,but it doesn't recur.it will be storedin the memory as an intermittentfailure,and the SRS indicatorwill come on.

To erasethe DTC(S)fromthe SRSunit, use a Honda PGMTester{seelhe HondaPGfMTesterSRSVehicle SystemSupplement)or the following procedure. 1. Make sure the ignition switch is OFF. 2. Connectthe SCSserviceconnector{A) to the MES 2P connector(B).Do not use a jumper wire.

After checkingthe DTC,troubleshootas follows: 1. Readthe DTC(see"Readingthe DTC"). "Erasingthe DTC 2. Erasethe DTCmemory (see Memory"). 3. With the shift lever in neutral,startthe engine,and letit idle. 4 . The SRSindicatorwill come on for about 6 seconds

and then go off. Shakethe wire harnessand the connectors.take a test drive (quickacceleration,quick braking, cornering),turn the steeringwheel fully left and '10 seconds.lf the right, and hold it there for 5 to problem recurs,the SRSindicatorwill come on.

07PAZ-0010100

lf you can't duplicatethe intermittentfailure,the system is OK at this time.

3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 4. The SRS indicatorwill come on for about 6 seconds, and then go off. Removethe SCSserviceconnector from the MES connectorwithin 4 secondsafterthe indicatorgoes off. 5. The SRS indicatorwill come on again.Reconnect the SCSserviceconnectorto the MES connector within 4 secondsafter the indicatorcomes on. 6. When the SRSindicatorgoes off, removethe SCS serviceconnectorfrom the MES connectorwithin 4 seconds. 7 . T h e S R Si n d i c a t ow r i l l b l l n kt w o t i m e s i n d i c a t i n g that the memory has beenerased. 8. Turn the ignition switch OFF,and wait for seconds.

'10

. h e S R Sj s 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )a g a i n T OK if the SRSindicatorcomes on for 6 secondsand then goes off.

23-26

\ J

I Initializingthe OPDS{OccupantPositionDetectionSystem}Unit Special Tool Required SCSserviceconnector07PAz-00'1 0100 When a seat-backcover,seat-backcushion,and/or OPDSunit is replaced,initializethe OPDSby following the procedurebelow. NOTE:Make sure the front passenger'sseat is dry. Set the seat-backin the normal position,and make sure there is nothing on the seat. '1.

l\4akesure the ignition switch is OFF. 2. Connectthe HondaPGM Tester(A)to the DLC(16P)(B),andfollowtheTester's prompts jn the ,,SCS,,menu to ground the SCSline (seethe Honda PGM TesterOperator'sManuaD. 3. Connectthe SCSserviceconnector(C)to the MES 2P connector(D).Do not use a iumoer wire.

07PAZ-00r0100

4 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) . 5. The SRS indicatorcomes on for about 6 secondsand goes off. Removethe SCSserviceconnectorfrom the MES connectorwithin 4 secondsafterthe SRSindicatorwent off. 6. The SRSindicatorcomes on again.Reconnectthe SCSserviceconnectorto the MES connectorwithin 4 seconds afterthe SRS indicatorcomes on. 7. The SRSindicatorgoes off. Removethe SCSserviceconnectorfrom the MES connectorwithln 4 seconds. 8. Watch the sRS indicator. 'lftheindicatorblinkstwotimesandthenstayson,theOPDSisinitialized.buttheDTCSneedtobeerased. step 9, then erasethe DTCS. .lftheindicatorblinkstwotimesandthengoesoff,theOPDSunitisinitialized.Gotostep9. ' lf the indicatorstayson without first blinking.theOPDSis not initialized.Readthe DTC.lf DTC 15-'lis indicated, repeatthe initializationprocedure.lf anotherDTCis indicated,go to the appropriatepage in the DTC TroubleshootingIndex. 9. Turn the ignition switch off, and disconnectthe PGM Tester.

SBS indic.ror

MES

I J

DISCONNECTED

23-27

sRs

t .

DTCTroubleshootingIndex DTC t- |

t-5

1-4 t-5

2-1 2-2 2-3 2-4 2-5 3-1 3-2 3-3 3-4 3-5 21-1

2't-4

2't-5 4-'l

4-2 4-3 4-4 4-5

22-3 22-4 22-5 5-1

5-2 5-4

5-8 6-3 6-4

Detection ltem O D e ni n d r i v e r ' sa i r b a qi n f l a t o r Increasedresistancein driver'sairbaq inflator Shon to anotherwire or decreasedresistancein driver's airbag inflator Shortto Dowerin driver'sairbao inflator Shortto qround in driver'sairbaq inflator Open in front Dassenqer's airbaq inflator I n c r e a s e rde s i s t a n cien f r o n tp a s s e n q e r 'asi r b a qi n t l a t o r Short to anotherwire or decreasedresistancein front passenger's airbao inflator Short to oower in front oassenoer'sairbaq inflator Short to qround in front passenqer'sairbaq inflator ODenin driver'sseat belttensioner lncreasedresistancein driver's seat belt tensioner Short to anotherwire or decreasedresistancein driver'sseat belt tensioner Short to oower in driver'sseat belt tensioner Short to oround in driver'sseat belt tensioner ODenor increasedresistancein driver'sseat belt buckletensioner Short to anotherwire or decreasedresistancein driver'sseat belt buckletensioner Short to Dowerin driver'sseat belt buckletensioner Shon to oround in driver'sseat belt buckletensioner ODenin front oassenoer'sseat belt tensioner lncreasedresistancein front oassenqer'sseat belttensioner Short to anotherwire or decreasedresistancein front passenger's seat belt tensioner seat belt tensioner Shon to Dowerin front Dassenqer's Short to qround in front oassenoer'sseat belt tensioner Open or increasedresislancein front passenger'sseat belt buckle tensioner Short to anotherwire or decreasedresistancein front passenger's seat belt buckletensioner Short to oower in front oassenqer'sseat belt buckletensioner Short to oround in front oassenoer'sseatbelt buckletensioner lnternalfailure of SRSunit NOTE: BeforetroubleshootingDTCS5-1 through 8-6,checkbattery/system voltage.lf the voltage is low, repairthe charging system before troubleshootinothe SRS.

Notes (seeDaqe23-36) (seeDaoe23-36 (seepage23-37) (seepaqe23-39 {seepaqe23-40 {seeoaoe23-42 (seeoaqe 23-42 (seepage23-43) (seepaqe23-45 (seepaqe 23-46 (seepage 23-48 (seepaqe 23-48 (seepage 23-49) (seeDaqe23-51 (seeoaoe 23-52 (seepaqe 23-54

(seepage23-55) (seepaqe 23-56) (seeoaqe23'57 {seepage23-58) {seepaqe23-58) {seepage23-60)

t J

lsee oaqe23-61 (seeDaqe23-63 (seepage 23-64) (seepage 23-65) (seepaqe 23-66 (seepaqe 23-68 (seepage23-69)

6-7 6-8 1-)

7-3 8-1

a-2 8-4 8-5 8-6

23-28

\ J

J DTC 9-1

Detection ltem Internalfailure of the SRS unit. lf intermittent,it could mean internal failure of the unit or a faulty indicatorcircuit.Referto TroubleshootingIntermittentFailures(seepage 23-26). NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system voltage.lf the voltage is low, repairthe chargingsystem before t r o u b l e s h o o t i nt gh e S R S . Internalfailure of the SRSunit. lf intermittent,it could mean internal failure of the power supply (VB line).Referto Troubleshooting IntermittentFailures(seepage 23-26). NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system voltage.lf the voltage is low, repairthe chargingsystem or replace the b€tterybeforetroubleshootingthe SRS. Faultydriver'sseat belt buckleswitch

9-2

9-3 9-4 9-6 9-7

FaultLtglt passenger's seatbeltbuckleswitch FaultyIeft front imDactsensor Faultyright front impact sensor Seat belt and seat belt buckletensioners(and airbag(s))deployed D r i v e r ' ss i d ea i r b a gd e p l o y e d Seat belt and seat belt buckletensioners(and airbag(s))and driver's s i d ea i r b a gd e p l o y e d Frontpassenqer'sside airbaodeDloved Seat belt and seat belt buckletensioners(and airbag(s))and front passenqer'sside airbaq deDloved Driver'sand front passenqer'sside al Seat belt and seat belt buckletensioners(and airbag(s))and driver's and front passenger'sside airbagsdeployed Open or increasedresistancein driver's side airbao inflator Short to anotherwire or decreasedresistancein driver'sside airbao inflator Short to power in driver'sside airbaq inflator Short to ground in driver's side airbaq inflator Open or increasedresistancein front passenger'sside airbag inflator Short to anotherwire or decreasedresistancein front passenger's side airbag inflator Short to power in front passenqer'sside airbaq inflator S h o r tt o g r o u n di n f r o n t p a s s e n g e r 'ssi d ea i r b a qi n f l a t o r Internalfailure of the driver's side impactsensor

10-1

10-2

r0-3 '10-4

'10-5 10-6

l r

10-7 11-1

11-4 I t-5

12-4 Iz-5

13-1

N o s i g n a lf r o m t h e d r i v e r ' ss i d ei m p a c ts e n s o r

13-4 7 14-1 i i 14-3 14-4 15-1 15-2 15-3

Notes (seepage23-69)

(seeDaqe23-71) lgqgfage 23-74) {see Daqe23-77) (seepaqe 23-79)

(seepage23-69)

( s e ep a q e2 3 - 8 1 )

(seepage23-82) (seeoaqe 23-83) {seepaqe 23-85) (seepage 23-86) (seepage 23-87) {seeDaqezJ-uu} (seeoaqe 23-90) (seepage 23-70) ( s e ep a q e2 3 - 9 1 )

Faultypowersupplyto the df,rglllug t Opacts9I99L Internalfailureofthe frontpassenger's sideimpactsensor

(seepage23-92) (seepage23-70)

N o s i g n a lf r o m t h e f r o n t p a s s e n g e r 'ssi d ei m p a c ts e n s o r Faultypower supply to the front passenqer'sside impact sensor F a u l t vO P D Su n i to r O P D Sn o t i n i t i a l i z e d Faultyside airbagcutoff indicatorcircuit FaultyOPDSsensor

(seepaqe 23-94) (seepage 23-95) ( s e ep a q e2 3 - 9 6 1 (seeDaqe23-99) (seeoaoe 23-104)

I J 23-29

SRS \

Symptom TroubleshootingIndex Symptom SRSindicatordoesn'tcome on SRSindicatorstayson when in "SCS" menu method

Slde airbagcutoff indicatorstays o n a f t e rb u l bc h e c k( l f t h e indicatorstayson, it does not set a DTC).Side airbagcutoff indicatoris flashing

Diagnosticprocedure S R SI n d i c a t oTr r o u b l e s h o o t i n(gs e e p a o e2 3 - 1 0 5 ) SRSIndicatorTroubleshooting(see step 1 on page 23-107)

. M a k es u r en o t h i n gi s o n t h e f r o n l passenger'sseat. . lf the side airbagcutoff indicator stayson after the ignition switch i s t u r n e dO N ( l l ) ,i n i t i a l i z teh e OPDSunit (see page23-271. - lf the side airbagcutoff i n d i c a t o or p e r a t e sn o r m a l l Yt,h e system is OK. - lf the side airbagcutoff indicatorstayson, replacethe nUl. u F U 5 S e n S O{ rS e eS e C r O Z The sensor is part of the seatback Dad.

Also check for

Inabilityto retrieveDTCswith the PGM Tester.Retrievethe flash codes usingthe SCSmenu method (seepage 23-24). DTC 15-2troubleshooting

t r J

\ J 23-30

SystemDescription SRSComponents Airbags The SRSis a safetydevicewhich, when used with the seat belt, is designedto help protectthe driver and front passengerin a frontal impact exceedinga certainset limit. The system consistsofthe SRS unit, includingsafing sensorand impactsensor(A),the cable reel (B),the driver's airbag(C),the front passenger,sairbag (D).seat belt tensioners(l),seat belt buckletensioners(J), and front impactsensors(K). Sincethe driver'sand front passenger'sairbagsusethe same sensors,both normally inflateat the same ttme. However,it is possiblefor only one airbagto inflate.This can occurwhen the severityof a collision is at the margin,or threshold,that determineswhether or not the airbagswill deploy.In such cases,the seat belt will provide sufficient protection,and the supplementalprotectionofferedby the airbagwould be mininal. Side Airbags The side airbags(E)are in eachfront seat-back.They help protectthe upper torso of the driver or front seat passenger during a moderateto severeside impact.Side impact sensors(F) in each door sill and in the SRS unit detectsuch an impactand instantlyinflatethe driver'sor the passenger'sside airbag.Only one side airbagwill deploy during a side impacl. lf the impact is on the passenger'sside,the passenger'sside airbagwill deploy even if there is no passenger. Seat Belt and Seat Belt Buckle Tensioners The seat belt and seat belt buckletensionersare linkedwith the SRSairbagsto further increasethe effectivenessof the seat belt. ln a front-endcollision,the tensionersinstantlyretractthe belt and bucklefirmly to securethe occupants in their seats.

OPDS The side airbagsystemalso includesan occupantpositiondetectionsystem (OpDS).This systemconsistsof sensors ( G ) a n da n O P D Su n i t( H )i n t h e f r o n t p a s s e n g e r 'sse a t - b a c kT.h e O P D Su n i t s e n d so c c u p a nht e i g h la n d p o s i t i o nd a t at o the SRS unit. lf the OPDSunit determinesthat the front passengeris of small stature(for example,a child) and the front passengeris leaninginto the side airbag deploymentpath,the SRSunit will automaticallydisablethe passenger's side airbag.The SRSunit will also disablethe airbagwhen the OPDSdetectscertainobiectson the seat.When the side airbag is disabled,the side airbagcutoff indicatoron the instrumentpanel alertsthe driver that the passenger's side airbagwill not deploy in a side impact.When the object is removed,or the passengersits upright,the side airbag cutoff indicatorwill go off after a few seconds,alertingthe driver that the passenger'sside airbagwill deploy in a side imDact.

(cont'd)

23-31

sRs SystemDescription(cont'dl

SRSOperation

The main circuit in the SRS unit sensesand judgesthe force of impact and, if necessary.ignitesthe inflatorcharges.lf batteryvoltage is too low or power is disconnecteddue to the impact,the voltage regulatorand the back-uppower circuit,respectively,will keepvoltageat a constantlevel. For the SRS to operate: Seat Belt Tensioners and Seat Belt Buckle Tensioners (1)A front impact sensormust activateand send electricsignalsto the microprocessor. (2)The microprocessormust computethe signalsand send them to the tensioners. (3)The chargesmust ignite and deploy the tensioners. Driver's and Front Passenger'sAirbagls) (1)A front impactsensor musl activate.and send electricsignalsto the microprocessor. (2)The microprocessormust computethe signals.and dependingon the severityof the collisionand whetherthe seat belt buckleswilch is ON or OFF,it sendsthe appropriatesignalsto the airbag inflator(s). (3)The inflatorsthat receivedsignalsmust ignite and deploy the airbags. Side Airbaglsl ( 1)A side impact sensormust activate,and send electricsignalsto the microprocessor. (2)The microprocessormust computethe signalsand send them to the side airbag inflator(s).However,the microprocessorcuts off the signalsto the front passenger'sside airbag if the OPDSunit determinesthat the tront passenger'shead is in the deploymentpath of the side airbag. (3)The inflatorthat receivedthe signal must ignite and deploythe side airbag. lw$ad..n sl

n0m S I P gsfrlctR S oXrVEr 9oEAiA$ SOtlr&G I

J sEctto

f'**)r !

\ J 23-32

Self-diagnosis System A self-diagnosiscircuitis built into the SRS uniUwhen the ignition switch is turned ON (ll),the SRS indicatorcomes on and goes off after about 6 secondsif the SRS is operatingnormally. lf the indicatordoes not come on, or does not go off after 6 seconds.or if il comes on while driving, it indicatesan abnormalityin the SRS.The SRSmust be inspectedand repairedas soon as possible. For betterserviceability,the SRSunit memory storesa DTCthat relatesto the causeof the malfunction,and the unit is connectedto the data link circuit.This informationcan be read with the Honda PGM Testerwhen it is connectedto the data link connector(DLc) (seepage 23-23).

23-33

SRS J

CircuitDiagram

srarsftr rrl$0[n

rrssf c s

r-----Tr-i

i___':--_:"1

\ J 23-34

J tr ozr"* tr ul"ar

NJfl t

|-(tzl

I J 23-35

sRs J

DTCTroubleshooting DTC1-1:Openin Driver'sAirbagInflator Resistance in Driver's DTC1-2:Increased AirbagInflator Special Tools Required . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100

6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC, ls DTC 1-1or DTC 1-2indicated?

1. Erasethe DTCmemory (seepage 23-26).

YES-Go to step 9.

2. Turn the ignition switch ON {ll),and checkthat the SRSindicatorcomes on for aboul 6 secondsand then goes off.

NO Open or increasedresistancein the driver's airbag inflator;replacethe driver'sairbag (seepage 23-113).t 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait ior 3 minutes.

Does the SBS indicator stay on? YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver's airbag4P connector(A) from the cable reel.

07sAz-TB4011A

07xaz-s230100 5. Connectthe SRS inflatorsimulator(2 Q connectors)and the simulatorlead F to the cable reet.

23-36

10. Disconnectthe front passenger'sairbag4P connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 - 2 1 ) . 11. Disconnectboth seat belt tensioners2P connectors from the floor wire harness(seestep 5 on page23-

22t. 1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oA r ( 1 8 P ) f r o mt h e SRSunit (seestep7 on page 23-22).Do not disconnectthe specialtool from the cable reel.

13. Checkresistancebetweenthe No. 7 and the No. t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n d t h e N o . 1 5 r ( 1 8 P )T. h e r e t e r m i n a l so f S R Su n i tc o n n e c t oA s h o u l db e 2 . 0 3 . 0 0 .

'16

SRSUNITCONNECTOR A I18P)

DTC1-3:Shortto AnotherWire or Decreased in Driver'sAirbagInflator Resistance SpecialToolsRequired . SRS inflatorsimulator07SAZ-T8401 1A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes of{. Does the SRS indicator stay on? YES-Go to step 3.

Wiresideof femaleterminals

ls the resistance as specilied? YES-Faulty SRS unit or poor contactat SRSunit connectorA (18P)and the SRSunit, checkthe connectionbetweenthe connectorand the SRS unit. lf the connectionis OK, replacethe SRSunit ( s e ep a g e2 3 - 1 2 2 ) . 1

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes, Disconnectthe driver'sairbag 4P connector(A) from the cable reel.

NO-Open or increasedresistancein dashboard wire harnessB orthe cable reel;replacethe cable reel.lf the problemstill present,replacedashboard w i r e h a r n e s sB .

07sAz-T84011A

07xAz-s230100 ConnecttheSRSinflatorsimulator{2 0 connectors)and the simulatorlead F to the cable reel. Reconnectthe batterynegativecable. 1 . Erasethe DTCmemory.

(cont'd)

23-37

sRs DTCTroubleshooting{cont'd) 8. Readthe DTC. Is DTC 1-3indicated?

14. Checkresistancebetweenthe No. 7 and the No. 16 t e r m i n a l sa n d b e t w e e nt h e N o . 6 a n dt h e N o . 1 5 t e r m i n a l so f S R Su n i tc o n n e c t o r A( 1 8 P )T. h e r e should be an open circuit,or at least 1 M Q .

YES Go to step 9. NO Short in the driver'sairbag;replacethe driver's airbag (seepage 23-'l13).1

SRSUNITCONNECTOR A {18P) GRN/WHT GRN/RED

9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectthe front passenger'sairbag4P connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 - 2 1 ) . 1'1. Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23-

GRN/YEL

GRN/BLK

Wire side of femaleterminals

22t. ls the rcsistance as specified? 1 2 . D i s c o n n e cSt R Su n i tc o n n e c t o r A( 1 8 P ) f r o mt h e SRS unit (seestep 7 on page 23-221.

YES FaultySRS unit; replacethe SRS unit (see page 23-122],.a

13. Disconnectthespecialtool from the cable reel. NO Go to step 15. Disconnectthe cable reelfrom dashboardwire harnessB. Checkresistancebetweenthe No,7 and the No. 16 terminalsand betweenthe No. 6 and the No. 15 terminalsof SRS unit connectorA (18P). Thereshould be an open circuit,or at least 1 M Q . ls the resistance as specified? YES Replacethe cable reel.I N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l

IJ 23-38

DTC1-4:Shortto Powerin Driver'sAirbag Inflator

Readthe DTC. ls DTC 1-4indicated?

SpecialToolsBequired . sRS inflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e SRS indicatorcomes on for about 6 secondsand then goes off.

YES-Go to step 9. NO-Short to power in the driver's airbag;replace t h e d r i v e r ' sa i r b a g( s e ep a g e2 3 - 11 3 ) . 1 te 9 . T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h batterynegativecable,and wait for 3 minutes.

1 0 .Disconnectthe front passenger'sairbag4P connectorfrom dashboardwire harnessB (seestep 3 o n p a g e2 3 ' 2 1 ) .

Does the SRS indicator stay on? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

1 1 .Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23221. 1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oA r ( 1 8 P ) f r o mt h e (see page 23-22). step 7 on SRSunit Disconnectthe specialtool from the cable reel.

4. Disconnectthe driver'sairbag4P connector(A) f r o m t h e c a b l er e e l .

't4. Reconnectthe batterynegativecable.

07sAz-T84011A

C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 connectors)and the simulatorlead F to the cable reel. 6 . Reconnectthe batterynegativecable. 1 . Erasethe DTCmemory.

(cont'd)

23-39

SRS

DTCTroubleshooting(cont'd) Turn the ignition switch ON {ll). 1 6 . Checkfor voltage betweenthe No. 7 terminal of ) n d b o d y g r o u n d ,t h e S R Su n i tc o n n e c t oA r ( 1 8 Pa N o . 1 6t e r m i n a a l n d b o d y g r o u n d ,t h e N o . 6 t e r m i n a la n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l and body ground.Thereshould be 0.5 V or less.

DTC1-5:Shortto Groundin Driver's Airbag lnflator Special Tools Required . SRS inflatorsimulator07SM-TB4011A . SRSsimulatorlead F 07XM-S230100 1. Erasethe DTCmemory (seepage 23-26).

SRSUNITCONNECTOR A {18P)

2. Turn the ignition switch ON (ll),and checkthatthe SRS indicatorcomes on for about 6 secondsand then goes oIf. Does the SBS indicator stay on? YES Go to step 3.

Wiresideol lemaleterminals

NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

Is the voltage as specilied?

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

YES-Faulty SRS uniUreplacethe SRS unit (see page 23-122).a

4. Disconnectthe driver'sairbag 4P connector(A) from the cable reel.

NO Go to step 17. 1 1 . Turn the ignition switch OFF. 1 8 . Disconnectthe cable reel from dashboardwire harnessB. 1 9 . Turn the ignition switch ON (ll).

07sAz-T84011A

20. Checkfor voltage betweenthe No. 7 terminal of ) n d b o d y g r o u n d ,t h e r ( 1 8 Pa S R Su n i tc o n n e c t oA N o . 1 6t e r m i n a la n d b o d y g r o u n d ,t h e N o . 6 t e r m i n a la n d b o d y g r o u n d ,a n d t h e N o . 1 5t e r m i n a l and body ground.Thereshould be 0.5 V or less. ls the voltage as specitied?

07xaz-s230100 C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 connectors)and the simulatorlead F to the cable reet.

YES Replace t h e c a b l er e e l . l Reconnectthe batterynegativecable. N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l 1 . Erasethe DTCmemory.

23-40

8. Readthe DTC. ls DTC 1-5 indicated? YES-Go to step 9. NO Short to ground in the driver's airbaginflator; replacethe driver's airbag(seepage 23-113).I 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

14. Checkresistancebetweenthe No.7 terminal of SRS unit connectorA {18P)and body ground,the N o . 1 6t e r m i n a la n d b o d y g r o u n d ,t h e N o . 6 t e r m i n a la n d b o d y g r o u n d .a n d t h e N o . 1 5t e r m i n a l and body ground.There should be an open circuit, o r a t l e a s t1 M Q . A I18PI SRSUNITCONNECTOR GRN/WHT

GRN/RED

'10. Disconnectthefront passenger'sairbag 4P connectorfrom dashboardwire harnessB (seestep 2 on page 23-21). 11. Disconnectboth seat belt tensioner2P connectors from the floor wire harness (seestep 5 on page 23-

22t. 12. DisconnectSRSunit connectorA (18P)fromthe SRS unit (see step 7 on page 23-22],. 1 3 . D i s c o n n e c t t hsep e c i a l t o o l f r o mt h e c a b l er e e l .

Wiresideof femaleterminals ls the resistance as specified? YES-Faulty SRS unit; replacethe SRS unit {see page 23-1221.f N O - G o t o s t e p1 5 . Disconnectthe cable reel from dashboardwire h a r n e s sB . 1 6 . Checkresistancebetweenthe No.7 terminal of S R Su n i tc o n n e c t oA r ( 1 8 P )a n d b o d y g r o u n d ,t h e N o . 1 6t e r m i n a a l n d b o d y g r o u n d .t h e N o , 6 terminaa l n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l a n d b o d y g r o u n d .T h e r es h o u l db e a n o p e nc i r c u i t , or at least 1 fvlQ . ls the resistanceas specified? t h e c a b l er e e l . I YES Replace NO Replacedashboardwire harnessB.l

23-41

sRs DTCTroubleshooting(cont'dl DTC2-1:Openin FrontPassenger's Airbag Inflator DfC 2-2:Increased Resistance in Front Passenger's AirbagInflator

{

Readthe DTC. ls DTC 2-1 or DTC 2-2 indicated? YES Go to step 9.

Special Tools Bequired . S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 '1.

NO-Open or increasedresistancein the front passenger'sairbag inflator;replacethe front p a s s e n g e r 'asi r b a g{ s e ep a g e2 3 - 1 1 4 ) . I

Erasethe DTCmemory {seepage 23-26).

9 . Turn the ignitionswitch OFF.Disconnectthe 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e SRS indicatorcomes on for about 6 secondsand then goes off.

batterynegativecable,and wait for 3 minutes.

1 0 .Disconnectthe driver'sairbag 4Pconnectorfrom the cable reel (seestep 2 on page 23-21],.

Does the SRS indicator stay on? 1 1 .Disconnectboth seatbelt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322).

YES Go to step 3. NO Intermittentfailure,system is OK at this time, Go to TroubleshootingIntermittentFailures(see page 23-261. 3. Turn lhe ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

DisconnectSRS unit connectorA (18P)from the SRSunit (seestep 7 on page23-22).Do not disconnectthe specialtool from dashboardwire h a r n e s sB . !.

4. Disconnectthe front passenger'sairbag 4P connector(A) from dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100 5 . Connectthe SRS inflatorsimulator(2 0 connectors)and the simulatorlead F to dashboard w i r e h a r n e s sB . 6 . Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

! J 23-42

13. Checkresistancebetweenthe No. 4 and No. 13 t e r m i n a l sa n d b e t w e e nt h e N o . 5 a n d N o . 1 4 t e r m i n a l so f S R Su n i tc o n n e c t oA r ( 1 8 P )T. h e r e s h o u l db e 2 . 0 3 . 0 Q . A {18P) SRSUNITCONNECTOR

DTC2-3:Shortto AnotherWire or Decreased Airbag Resistance in FrontPassenger's lnJlator SpecialToolsRequired . S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-T8401'1A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-261. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?

Wiresideof femaleterminals

ls the resistance as specified?

YES FaultySRSunit or poor contactat SRS unit connectorA (18P).Checkthe connection;if the connectionis OK, replacethe SRSunit (seepage 23-1221.a NO Open or increasedresistancein dashboard wire harnessB; replacedashboardwire h a r n e s sB . I

YES-Go to step 3. NO Intermittentfailure, system is OK at this time. Go to TroubleshootingIntermittentFailures{see page23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe front passenger'sairbag 4P connector(A) from dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100 C o n n e ctth e S R Sl n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r sa)n d t h e s i m u l a t o rl e a dF t o d a s h b o a r d w i r e h a r n e s sB . 6 . Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

T J (cont'd)

23-43

sRs qJ

DTGTroubleshooting(cont'd) Readthe DTC.

'12.

DisconnectSRS unit connectorA (18P)from the SRS u nit (see step 7 on page 23-22l..

ls DTC 2-3 indicated? YES Go to step9. NO-Short in the front passenger'sairbag inflator; replacethe front passenger'sairbag (seepage 231 1 4 )t . 9 . Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

1 0 .Disconnectthe driver'sairbag 4P connectorfrom

13. Disconnectthespecialtool from dashboardwire h a r n e s sB . 14. Checkresistancebetweenthe No. 4 and No. 13 t e r m i n a l sa n d b e t w e e nt h e N o . 5 a n d N o . 1 4 t e r m i n a l so f S R Su n i tc o n n e c t oA r ( 1 8 P )T. h e r e s h o u l db e a n o p e nc i r c u i t o , r a t l e a s t1 M Q . SRSUNIT CONNECTOR A I18P) BLU/RED

the cable reel {seestep 2 on page 23-21). 1 1 .Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 23221. BLU/BLK Wiresideof femaleterminals

ls the resistance as specitied? YES FaultySRSunit; replacethe SRS unit (see page 23-122)'.a N O - S h o n i n d a s h b o a r dw i r e h a r n e s sB ; r e p l a c e d a s h b o a r dw i r e h a r n e s sB . l

T J 23-44

DTC2-4:Shortto Powerin FrontPassenger's AirbagInflator

8. Readthe DTC. ls DTC 2-4 indicated?

Special Tools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off, Does the SRS indicatot stay on?

YES-Go to step 9. NO-Short to power in the front passenger'sairbag inflator;replacethe front passenger'sairbag (see p a g e2 3 - 1 1 4 ) . I 9. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectthe driver's airbag4P connectorfrom the cable reel (seestep 2 on page 23-21).

YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootinglntermittentFailures(see page23-26).

11. Disconnectboth seatbelttensioner2P connectors from the floor wire harness(seestep 5 on page 2322).

3. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

4. Disconnectthe front passenger'sairbag 4P connector(A) from dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100 Connectthe SRSinflatorsimulator(2 Q connectors)and the simulatorlead F to dashboard w i r e h a r n e s sB . 6 . Reconnectthe batterynegativecable. 7 . Erasethe DTc memory.

{cont'd)

23-45

sRs DTCTroubleshooting(cont'd) DisconnectSRSunit connectorA (18P)from the SRSunit (seestep 7 on page23-221.

1 3 .Disconnectthe specialtool from dashboardwire harnessB.

{

DTC2-5:Shortto Groundin FrontPassenger's AirbagInflator SpecialToolsRequired . SRSinflator simulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100

1 4 . Reconnectthe batterynegativecable. 1. Erasethe DTCmemory (seepage 23-26). 1 5 . Turn the ignition switch ON (ll). t o . Checkfor voltage betweenthe No. 4 terminal of SRSunit connectorA (18P)and body ground,the N o . 1 3t e r m i n a a l n d b o d y g r o u n d ,t h e N o . 5 terminal and body ground,and the No. 14 terminal and body ground.Thereshould be 0.5 V or less.

2. Turn the ignition switchON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3.

SRS UNIT CONNECTOBA {18PI

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures{see page 23-261. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4, Disconnectthe front passenger'sairbag4P connector(A) from dashboardwire harnessB.

Wire side o{ {emaleterminals

ls the voltageas specified? YES FaultySRSuniureplace the SRSunit(see page23-1221 .a NO-Short to powerin dashboard wire harnessB; replacedashboard wire harnessB.!

07saz-T84011A

07xAz-s230100 5 . Connectthe SRSinflatorsimulator(2 Q connectors)and the simulatorlead F to dashboard wire harnessB.

\ J 23-46

I Reconnectthe batterynegativecable.

12. DisconnectSRS unit connectorA (18P)from the SRS unit (seestep7 on page 23-221.

7 . Erasethe DTCmemory.

1 3 .Disconnectthespecialtool from dashboardwire Readthe DTC. ls DTC 2-5 indicated? YES-Go to step 9. NO-Shon to ground in the front passenger's airbaginflator;replacethe front passenger'sairbag ( s e ep a g e2 3 - 11 4 ) . 1 9 . Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

h a r n e s sB .

't4. Checkresistancebetweenthe No. 4 terminal of SRS unit connectorA (18P)and body ground,the No. 13 terminal and body ground.the No. 5 terminaa l n d b o d y g r o u n d ,a n d t h e N o . 1 4t e r m i n a l and body ground.Thereshould be an open circuit, o r a t l e a s tl M Q . A {18P} SRSUNITCONNECTOR

BLU/RED

BLU/YEL

1 0 .Disconnectthe driver's airbag4P connectorfrom the cable reel {seestep 2 on page 23-21). 1 1 .Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322).

Wire side ol temaleterminals

ls the tesistanceas specitied? YES FaultySRSuniureplacethe SRSunit(see page23-122), .l wire harnessB; NO Shortto groundin dashboard r e p l a cdea s h b o a rwdi r eh a r n e sBs . l

I 23-47

sRs DTCTroubleshooting(cont'dl DTC3-1:Openin Driver'sSeatBeltTensioner DTC3-2:Increased Resistance in Driver's SeatBeltTensioner

6. Reconnectthe batterynegativecable.

Special Tools Required . sRS inflatorsimulator07sAz-TB4011A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100

8. Readthe DTC.

7. Erasethe DTCmemory.

ls DTC 3-1ot DTC 3-2 indicated? YES Go to step 9.

1. Erasethe DTCmemory (seepage 23-26). NO-Open or increasedresistancein the driver's seat belt tensioner;replacethe driver'sseat belt (seepage23-4).I

2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait Ior 3 minutes.

Does the SRS indicator stay on? YES Go to step 3.

10. Disconnectthe floor wire harness4P connector C403{A)from dashboardwire harnessB.

NO Intermittentfailure,system is OK at this time. Go to TroubleshootinglntermittentFailures(see page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver's seat belt tensioner2P connector{A) trom the floor wire harness.

07sAz-T84011A

07sAz-T8401'lA

1 1 .Connectthe SRSinflatorsimulator(2 Q connectors)and simulatorlead F to dashboardwire harnessB.

1 2 . Reconnectthe batterynegativecable. Erasethe DTCmemory.

07TAZ-52501'lA

1 4 .Readthe DTC. 5. ConnecttheSRSinflatorsimulator(2 0 connector) and simulatorlead C to the floor wire harness.

ls DTC 3-1 or DTC 3-2 indicated? YES Go to step 15. NO-Open or increased r e s i s t a n c ien t h e f l o o rw i r e harness;replacethe floor wire harness.l t5.

23-48

Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes.

\ J

I t o . Oisconnect the driver's airbagconnector(seestep

2 on page 23-21),f ront passenger'sairbag connector(seestep 3 on page 23-21),andfront passenger'sseat belt tensionerconnector(seestep 5 on page 23-22).

1 7 . DisconnectSRSunit connectorA (18P)from the SRSunit (seestep 7 on page 23-22).Do not disconnectthe specialtool from dashboardwire harnessB. 1 8 . Checkresistancebetweenthe No.8 terminal and r (18P). t h e N o . 1 7t e r m i n a o l f S R Su n i tc o n n e c t oA 2 . 0 3 . 0 T h e r es h o u l db e Q.

DTC3-3:Shortto AnotherWire or Decreased in Driver'sSeatBeltTensioner Resistance SpecialToolsRequired . SRS inflatorsimulator07SAZ-T8401'1A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthatthe SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?

A (18P) SRSUNITCONNECTOR RED/WHT 2

10 1 l 1Z t 3

t 5 16

i-4

\lel a;

E a

RED/BLU

I ]

Wiresideof femaleterminals

YES Go to step 3. NO-lntermittent failure,system is OK at this time, Go to TroubleshootingIntermittentFailures{see page 23-26). Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. Disconnectthe driver'sseat belt tensioner2P connector(A) from the floor wire harness.

ls the resistance as specitied? YES FaultySRS unit or poor contactat SRSunit connectorA (18P)and the SRSunit. Checkthe connection;if the connectionis OK, replacethe SRSunit (seepage 23-'1221.a -T84011A

NO Open or increasedresistancein dashboard wire harness w i r e h a r n e s sB ; r e p l a c ed a s h b o a r d B,t 07TAZ-S25011A

5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r ) a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .

I (cont'd)

23-49

sRs DTCTroubleshooting(cont'd) 6. Reconnectthebatterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC. ls DTC 3-3 indicated?

16. Disconnectthe driver'sairbagconnector(seestep 2 on page23-211,lrontpassenger'sairbag connector(seestep 3 on page 23-21),and front passenger'sseat belt tensionerconnector(seestep 5 on page 23-22). 1 7 . D i s c o n n e cSt R Su n i t c o n n e c t oA r ( 1 8 P f)r o m t h e SRSunit (seestep 7 on page 23-22:,.

YES-Go to step L NO-Shon in the driver'sseat belt tensioner; replacethe driver's seat belt (seepage 23-4).1 L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectfloor wire harness4P connectorC403 (A)from dashboardwire harnessB.

18. Disconnectthe specialtool from dashboardwire harnessB. 1 9 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 8 t e r m i n a a l nd t h e N o . 1 7t e r m i n a o l f S R Su n i tc o n n e c t oA r ('l8P). Thereshould be an open circuit,or at least 1 l\4Q . SRSUNIT CONNECTOR A I18P)

RED/WHT

RED/BLU

07sAz-TB4or 1A

W i r es i d eo f f e m a l e terminals

ls the resistanceas specified?

1 1 .ConnecttheSRSinflatorsimulator(2 Q connectors)and simulatorlead F to dashboardwire harnessB.

YES FaultySRS unit; replacethe SRSunit (see page 23-1221.a N O - S h o r ti n d a s h b o a r dw i r e h a r n e s sB ; r e p l a c e d a s h b o a r dw i r e h a r n e s sB . l

Reconnectthe batterynegativecable.

1 3 .Erasethe DTCmemory. 1 4 .Readthe DTC. ls DTC 3-3 indicated? YES-Go to step 15. NO Short in the floor wire harness;replacethe floor wire harness.l Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

t J 23-50

J DTC3-4:Shortto Powerin Driver'sSeatBelt Tensioner

6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory.

SpecialToolsBequired . SRSlnflatorsimulator07SAZ-TB4011A . S R Ss i m u l a t o lre a dC 0 7 T M - S 2 5 0 1 1 A . SRSsimulatorlead F 07XAZ-S230100

8. Readthe DTC. Is DTC 3-4 indicated?

1. Erasethe DTCmemory (seepage 23-261.

YES- Go to step 9.

2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

NO-Short to power in the driver'sseat belt tensioner;replacethe driver'sseat belt ( s e ep a g e2 3 - 4 ) . 1 L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

Does the SRS indicatot stay on? YES- Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261.

L ]

10. Disconnectfloor wire harness4P connectorC403 (A) from dashboardwire harnessB.

Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. Disconnectthe driver'sseat belt tensioner2P connector(A)from the floorwire harness. TB4O11A

07sAz-T84011A

1 1 .C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 connectors)and simlator lead F to dashboardwire h a r n e s sB .

' t 2 .Reconnectthe batterynegativecable. Erasethe DTCmemory. 5. Connectthe SRSinflatorsimulator(2 !J connector) and simulatorlead C to the floor wire harness.

1 4 . Readthe DTC. ls DTC 3-4 indicated? YES-- Go to step 15. N O - S h o n t o p o w e ri n t h e f l o o rw i r e h a r n e s s ; r e p l a c et h e f l o o rw i r e h a r n e s s . I

te T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h batterynegativecable,and wait for 3 minutes.

(cont'd)

23-51

sRs DTCTroubleshooting(cont'dl 16. Disconneclthe driver'sairbagconnector(seestep 2 on page23-21l,Irontpassenger'sairbag connector(seestep 3 on page 23-2'l),and front passenger'sseat belt tensionerconnector(seestep 5 on page 23-221. 17. DisconnectSRSunit connectorA (l8P)from the SRS unit (see step 7 on page 23-22).

DTC3-5:Shortto Groundin Driver'sSeatBelt Tensioner Special Tools Required . sRS inflalor simularor07sAz-TB4011A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory {seepage23-26).

18. Disconnectthe specialtoolfrom dashboardwire h a r n e s sB . 19. Reconnectthe batterynegativecable.

2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off.

20. Turn the ignition switch ON (ll),

Does the SRS indicator stay on?

21. Checkfor voltage betweenthe No. 8 terminal of SRSunit connectorA (18P)and body ground,and t h e N o . 1 7t e r m i n a la n d b o d yg r o u n d .T h e r es h o u l d be 0.5 V or less.

YES Go to step 3.

SRS UNIT CONNECTORA {18PI

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). 3. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4, Disconnectthe driver'sseat belt tensioner2P connector(A) from the floor wire harness,

ls the voltageas specified?

-T84011A

YES-FaultySRSunit;replace the SRSunit{see page23-122], .a wire harnessB; NO Shorttopowerin dashboard replacedashboard wire harnessB.l

07TAZ-S25011A

5. Connectthe SRSinflatorsimulator(2 Q conneclor) and simulatorlead C to the floor wire harness.

L J 23-52

t 6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC.

16. Disconnectthedriver'sairbagconnector(seestep 2 on page23-211,lrontpassenger'sairbag connector(seestep 3 on page 23-21),and front passenger'sseat belt tensionerconnector(seestep 5 on page 23-22). 17, DisconnectSRS unit connectorA ('l8P)from the SRS unit (seestep 7 on page 23-221.

ls DTC 3-5 indicated? YES-Go to step 9, NO Shortto ground in the driver'sseat belt tensioner;replacethe driver'sseat belt (seepage 23-4).I 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectfloor wire harness4P connectorC403 (A)from dashboardwire harnessB.

18. Disconnectthe specialtoolfrom dashboardwire harnessB. 19. Checkresistancebetweenthe No. 8 terminal of SRS unit connectorA (18P)and body ground, and t h e N o . 1 7t e r m i n a a l n d b o d y g r o u n d .T h e r es h o u l d be an open circuit,or at least 1 M Q . A (18P) SRSUNIT CONNECTOR

) 07sAz-T84011A

ls the resistance as specified? '11. C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q connectors)and simulatorlead F to dashboardwire h a r n e s sB .

Y E S - F a u l t yS R Su n i u r e p l a c et h e S R Su n i t{ s e e page 23-122l,.a NO Short to ground in dashboardwire harnessB; r e p l a c ed a s h b o a r dw i r e h a r n e s sB . l

Reconnectthe batterynegativecable. Erasethe DTCmemory. 1 4 . Readthe DTC. ls DTC 3-5 indicated? YES Go to step 15. NO-Short to ground in the floor wire harness; replacethe floor wire harness.l

Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

23-53

sRs DTCTroubleshooting{cont'd) DTC21-1:Openor Increased Resistance in Driver'sSeatBeltBuckleTensioner

8. Readthe DTC. l s D T C 2 1 - 1i n d i c a t e d ?

SpecialTools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-261. 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicatot stay on? YES Go to step 3. NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver's seat belt buckletensioner 4P connector(A) from the floor wire harness.

YES Go to step 9. NO Open or increasedresistancein the driver's seat belt buckletensioner;replacethe driver'sseat b e l tb u c k l e . I 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes. 10. Disconnectboth side airbag2P connectors(see step 4 on page 23-2lland the front passenger's seatbelt buckletensioner4P connector(seestep 6 on page 23-22). 1 1 . D i s c o n n e cSt R Su n i tc o n n e c t o B r ( 1 8 P ) f r o mt h e SRSunit (seestep 7 on page 23'22).Do not disconnectthe specialtool from the floor wire narness. 12. Checkresistancebetweenthe No. 1 and No. 10 t e r m i n a l so f S R Su n i tc o n n e c t oB r ( 1 8 P )T. h e r e s h o u l db e 2 . 0- 3 . 0 O .

SRSUNITCONNECTOR B Il8PI GRN/YEL

l t ' ' A\ I' ? 3 Y l r 0t l

]

1 5 t 6 17 t6

GRN/BLK W i r es i d eo f f e m a l tee r m i n a l s

5. ConnecttheSRSin{latorsimulator(2 Q connectors) and simulatorlead F to the Iloor wire harness. 6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory.

ls the resistanceas specified? Y E S * F a u l t yS R Su n i to r p o o rc o n t a c a t t S R Su n i t ) n d t h e S R Su n i t .C h e c kt h e c o n n e c t oB r ( 1 8 Pa connection;if the connectionis OK, replacethe SRS unit (seepage 23-122).a NO Open or increasedresistancein the floor wire h a r n e s sr;e p l a c et h e f l o o rw i r e h a r n e s s . l

L J 23-54

I DTC21-3:Shortto AnotherWireor Decreased Resistance in Driver'sSeatBelt EuckleTensioner Special Tools Required . SRSinflatorsimulator07SAZ-T840't1A . SRSsimulatorlead F 07XAZ-S230100

8. Readthe DTC. ls DTC 21-3 indicated? YES-Go to step 9. NO- Short in the driver'sseat belt buckle tensioner;replacethe driver's seat belt buckle.l

1. Erasethe DTCmemory (see page23-26). 2. Turn the ignition switch ON (ll),and checkthat the S R Si n d i c a t o cr o m e so n f o r a b o u t6 s e c o n d sa n d then goes off. Does the SRS indicator stay on?

9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes, 10. Disconnectboth side airbag2P connectors(see step 4 on page 23-21)and the front passenger's seat belt buckletensioner4P connector(seeslep 6 on page 23-22).

YES Go to step 3. NO Intermittentfailure.system is OK at this time. Go to TroubleshootingIntermittentFailureslsee page 23-26). Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

D i s c o n n e ct h t e d r i v e r ' ss e a tb e l tb u c k l et e n s i o n e r 4P connector(A) from the floor wire harness.

1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e SRS unit {seestep 7 on page 23-22l . '12.

Disconnectthe specialtoolf rom the floor wire harness.

13. Checkresistancebetweenthe No. 1 and No. 10 t e r m i n a l so f S R Su n i tc o n n e c t o B r ( 1 8 P )T. h e r e s h o u l db e a n o p e nc i r c u i t o , r a t l e a s t1 M Q . SRS UNIT CONNECTORB {18PI

GRN/YEL

GRN/BLK

Wiresideof femaleterminals

ls the resistanceas specified? C o n n e c t t h eS R Si n f l a t o rs i m u l a t o (r 2 i ) c o n n e c t o r sa)n d s i m u l a t o rl e a dF t o t h e f l o o r w t r en a r n e s s . 6 . Reconnectthe batterynegativecable.

YES FaultySRS unit; replacethe SRSunit (see page 23-1221.a NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . l

7 . Erasethe DTCmemory.

23-55

sRs (cont'dl DTCTroubleshootang DTG21-4:Shortto Powerin Driver'sSeatBelt BuckleTensioner

Readthe DTC. ls DTC 21-4 indicated?

SpecialToolsRequired . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XM-S230100 1. Erasethe DTCmemory (seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

YES Go to step 9. NO Shon to power in the driver'sseat belt buckle tensioner;replacethe driver's seatbelt buckle.l L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

1 0 .Disconnectboth side airbag2P connectors(see Does the SRS indicatot stay on? YES-Go to step 3.

step 4 on page 23-21)and the front passenger's seat belt buckletensioner4P connector(seestep 6 on page 23-22).

NO Interminentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23'26). 3. Turn lhe ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver's seat belt buckletensioner 4P connector(A) from the floor wrre narness.

5 . ConnecttheSRSinflatorsimulator{2 0 connectors)and the simulatorlead F to the f loor wireharness. Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

\, .J 23-56

1 1 .DisconnectSRS unit connectorB (18P)from the SRSunit (seestep 7 on page 23-22).

DTC21-5:Shortto Groundin Driver'sSeat BeltBuckleTensioner

1 2 . Disconnectthe specialtool from the floor wire harness.

Special Tools Required . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulatorlead F 07XAZ-S230100

Reconnectthe batterynegativecable. 1 4 . Turn the ignitionswitch ON (ll). Checkfor voltage betweenthe No. 1 lerminal of SRSunit connectorB {18P)and body ground, and t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d be 0.5 V or less. SRSUNITCONNECTOR B I18PI

1. Erasethe DTCmemory {seepage 23-26}. 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

4 . Disconnectthe driver'sseat belt buckletensioner 4P connector{A) from the floor wire harness.

J ls the voltageas specitied? YES FaultySRSunit;replace the SRSunit(see page23-1221 .f NO Shortto powerin thefloorwire harness; replace the floorwire harness.l

C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q connectors)and simulatorlead F to the floor wire n ar n e s s . 6 . Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

(cont'd)

23-57

sRs DTCTroubleshooting(cont'dl DTC4-1:Openin FrontPassenger's SeatBelt renstoner DTC4-2:lncreasedResistance in Front Passenger's SeatBeltTensioner

Readthe DTC. ls DTC 21-5 indicated? YES Go to step9. NO Short to ground in the driver's seat belt buckletensioner;replacethe driver's seat belt buckle.l

9 . Turn the ignitionswitch OFF.Disconnectthe

Special Tools Required . SRS inflatorsimulator07SM-T84011A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 'L

Erasethe DTCmemory (seepage23-26).

batterynegativecable,and wait for 3 minutes.

1 0 .Disconnectboth side airbag2P connectors(see step 4 on page 23-21)andthe front passenger's seat belt buckletensioner4P connector(seestep 6 on page 23-221. 1 1 .DisconnectSRSunit connectorB (18P)from the SRS unit (see step 7 on page 23-22)

1 2 .Disconnectthe specialtool from the floor wire harness. '1

1 3 .Checkresistancebetweenthe No. terminal of SRS unit connectorB (18P)and body ground,and t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d b e a n o p e nc i r c u i t o , r a t l e a s t1 M Q . SRSUNITCONNECTOR B {18PI

ls the tesistanceas specilied? YES FaultySRSuniureplace the SRSunit(see page23-122) .a

Turn the ignition switch ON {ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES-Go to step 3. NO- Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures{see page23-26). Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. Disconnectthe front passenger'sseat belt tensioner2P connector(A) from the floor wire harness.

07TAZ-525011A

5. Connectthe SRS inflatorsimulator(2 0 connector) a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .

N O - S h o r t o g r o u n di n t h ef l o o rw i r eh a r n e s s ; replace thefloorwire harness.l

\ J 23-58

) 6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory.

15. Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes. '16.

8. Readthe DTC. ls DTC 4-1 or DTC 4-2 indicated?

Disconnectthe driver'sairbagconnector{seestep 2 on page23-211, tront passenger'sairbag connector(seestep 3 on page 23-21),and driver's seat belt tensionerconnector(seestep 5 on page 23-221.

YES Go to step 9. NO-Open or increasedresistancein the front passenger'sseat belttensioner;replacethe front passenger'sseat belt (seepage 23-4).t L Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10, Disconnectthe floor wire harness4P connector C403(A)from dashboardwire harnessB.

17. DisconnectSRS unit connectorA (18P)from the SRS unit (seestep 7 on page 23-22).Do not disconnectthe specialtool from dashboardwire harnessB. 18. Checkresistancebetweenthe No. 9 terminal and '18 the No. terminal of SRS unit connectorA (18P). T h e r es h o u l db e 2 . 0 - 3 . 0 Q . SRS UNIT CONNECTORA {18P}

RED/YEL 1

3 4

1 0 11 12

5 15

)

{

l 6\t

1 7 r8l

r l

RED/BLK

07sAz-T840't 1A

Wire side of lemale terminals

ls the resistance as specitied? 1 1 .Connectthe SRSinflatorsimulator(2 i) connectors)and simulatorlead F to dashboardwire harnessB.

YES FaultySRS unit or poor contactat SRS unit connectorA (18P)and the SRS unit. Checkthe connection;if the connectionis OK, replacethe SRS unit (seepage 23-122l,.a

1 2 .Reconnectthe batterynegativecable. Erasethe DTCmemory.

NO-Open or increasedresistancein dashboard wire harnessB; replacedashboardwire harness B.T

1 4 . Readthe DTC. ls DTC 4-l or DTC 4-2 indicated? YES-Go to step

'15.

NO-Open or increasedresistancein the floor wire harness;replacethe floor wire harness.I

I 23-59

sRs DTCTroubleshooting(cont'dl DTC4-3:Shortto AnotherWire or Decreased Resistance in FrontPassenger's SeatBelt Tensioner Special Tools Required . SRSinflatorsimulator07SAZ-TB40l1A . SRSsimulatorlead C 07TM-S25011A . SRSsimulatorlead F 07XAZ-S230100

8. Readthe DTC. ls DTC 4-3 indicated? YES-Go to stepL NO-Short in the front passenger'sseatbelt tensioner;replacethe front passenger'sseat belt ( s e ep a g e2 3 - 4 ) . 1

1. ErasetheDTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. '10.

Disconnectthe floor wire harness4P connector C403{A)from dashboardwire harnessB.

Does the SRS indicator stay on? YES-Go to step 3. NO Intermittentfailure.system is OK at this time. Go to TroubleshootinglntermittentFailures(see page 23-26). 3. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

TB40,I1A

4. Disconnectthe front passenger'sseat belt tensioner2P connector(A)from the floor wire narness. 1 1 .C onnectthe SRSinflatorsimulator(2 0 connectors)and simulatorlead F to dashboardwire harnessB. Reconnectthe batterynegativecable.

1 3 .Erasethe DTCmemory. 1 4 .Readthe DTC. ls DTC 4-3 indicated? 07TAZ-S25011A

Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead C to the floor wire harness. 6 . Reconnectthe batterynegativecable.

Y E S - G o t o s t e p1 5 . NO Short jn the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I 1 5 .Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

7 . Erasethe DTCmemory.

\ J 23-60

16. Disconnectthedriver'sairbagconnector(seestep 2 on page23-211, front passenger'sairbag connector(seestep 3 on page 23-21),and driver,s seat belt tensionerconnector(seestep 5 on page 23-221. 17. DisconnectSRSunit connectorA (18p)from the SRS unit (see step 7 on page 23-22). 18. Disconnectthe specialtool from dashboardwire harnessB. 19. Checkresistancebetweenthe No. 9 terminal and t h e N o . 1 8t e r m i n a o l f S R Su n i tc o n n e c t oA r (18p). T h e r es h o u l db e a n o p e nc i r c u i t o , r a t l e a s t1 M e . SRSUNITCONNECTOR A I18P}

RED/YEL 2 3

10 t l 12 t 3

It 6]

15 16 1 7 r8l

RED/BLK

]

Wire side of femaleterminals

DTC4-4:Shortto Powerin FrontPassenger's SeatBeltTensioner Special Tools Required . SRS inflatorsimulator07SAZ-T84011A . S R Ss i m u l a t o rl e a dC 0 7 T A Z - S 2 5 0 1 1 A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON {ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO- Intermiftentfailure.system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthefront passenger'sseat belt tensioner2P connector(A)from the floor wire harness.

ls the resistanceas specified? YES-FaultySRSunit;replace the SRSunit(see page23-1221 .f NO-Short in dashboard wire harnessB;replace d a s h b o a rwdi r eh a r n e sB s .I

07TAZ-S2501'lA

5. Connectthe SRSinflatorsimulator(2 e connector) and simulatorlead C to the floor wire harness.

{cont'd)

23-61

sRs DTCTroubleshooting(cont'd) 6. Reconnectthe batterynegativecable.

1 5 .Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

7. Erasethe DTCmemory.

t o . Disconnectthe driver's airbagconnector(seestep

tront passenger'sairbag 2 on page23-211, connector(seestep 3 on page 23-21),and drivefs seatbelt tensionerconnector(seestep 5 on page 23-22t.

8. Readthe DTC. ls DTC 4-4 indicated? YES Go to step 9. NO-Short to power in the front passenger'sseat belt tensioner;replacethe front passenger'sseat b e l t( s e ep a g e2 3 - 4 ) . I

1 1 . DisconnectSRS unit connectorA ('l8P)trom the SRS unit (seestep 7 on page 23-22). 1 8 . Disconnectthe specialtool from dashboardwire h a r n e s sB .

9. Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes.

1 9 . Reconnectthe batterynegativecable.

'10.Disconnectfloor wire harness4P connector

20. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

C403(A)from dashboardwire harnessB.

2 1 .Checkfor voltage betweenthe No. 9 terminal of ) n d b o d y g r o u n d ,a n d r ( 1 8 Pa S R Su n i tc o n n e c t oA l n d b o d y g r o u n d .T h e r es h o u l d t h e N o . 1 8t e r m i n a a be 0.5 V or less. A (18PI SRSUNITCONNECTOR

07sAz-TB4o11A

1 1 .Connectthe SRSinflatorsimulator(2 0 connectors)and simulatorlead F to dashboardwire h a r n e s sB .

tJ.

terminals WiresideoJJemale

Reconnectthe batterynegativecable.

Is the voltageas specified?

Erasethe DTCmemory.

YES FaultySRSunit; replacethe SRS unit (see page 23'1221.a

1 4 . Readthe DTC. ls DTC 4-4 indicated?

N O S h o r t t o p o w e ri n d a s h b o a r dw i r e h a r n e s sB ; w i r e h a r n e s sB . l r e p l a c ed a s h b o a r d

Y E S - G o t o s t e p1 5 . NO- Short to power in the floor wire harness; replacethe floor wire harness.l

J 23-62

I DTC4-5:Shortto Groundin FrontPassenger's SeatBeltTensioner

8. Readthe DTC. ls DTC 4-5 indicated?

Special Tools Required . SRSinflatorsimulator07SAZ-TB40'11A . SRSsimulatorlead C 07TAZ-S25011A . SRSsimulatorlead F 07XAZ-S230100 1. ErasetheDTCmemory (seepage 23-26]|. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?

YES-Go to step 9. NO Short to ground in the front passenger'sseat belt tensioner;replacethe front passenger'sseat b e l t( s e ep a g e2 3 - 4 ) . I 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectthe floor wire harness4P connector C403(Alfrom dashboardwire harnessB.

Y E S - G o t o s r e p3 . NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26l,. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

TB40t 1A

4. Disconnectthe front passenger'sseat belt tensioner2P connector(A) from the floor wire harness.

1 1 .Connectlhe SRS inflatorsimulator(2 e connectors)and simulatorlead F to dashboardwire h a r n e s sB . 1 2 . Reconnectthe batterynegativecable. Erasethe DTCmemory. 1 4 . Readthe DTC. 07TAZ-SZ501rA

ls DTC 4-5 indicated? YES Go to step 15.

Connectthe SRS inflatorsimulator(2 e connector) a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .

NO-Short to ground in the floor wire harness; r e p l a c et h e f l o o rw i r e h ar n e s s . l

Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

(cont'd)

23-63

sRs DTCTroubleshooting(cont'dl 16. Disconnectthe driver's airbagconnector(seestep 2 on page 23-21),front passenger'sairbag connector(seestep 3 on page 23-21).and driver's seat belt tensionerconnector(seestep 5 on page 23-22).

in Resistance DTC22-1:Openor Increased FrontPassenger's SeatBeltBuckleTensioner SpecialTools Required . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100

r ( 1 8 P ) f r o mt h e 1 7 . D i s c o n n e cSt R Su n i tc o n n e c t oA SRSunit (seestep 7 on page 23-221.

1. Erasethe DTC memory (see page 23-261.

18. Disconnectthe specialtoolfrom dashboardwire harnessB.

2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes otf.

19. Checkresistancebetweenthe No.9 terminal of ) n d b o d y g r o u n d ,a n d S R Su n i tc o n n e c t oA r ( 1 8 Pa t h e N o . l 8 t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d . r a t l e a s t1 M Q . b e a n o p e nc i r c u i t o A {18P) SRSUNITCONNECTOR

Does the SRS indicator stay on? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page23-26). 3. Turn the ignition switch oFF. Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthefront passenger'sseat belt buckle tensioner4P connector(A)from the floor wire harness.

w i r e s i d eo f l e m a l et e r m i n a l s

ls the rcsistance as specified? Y E S F a u l t yS R Su n i Ur e p l a c et h e S R Su n i t ( s e e page 23-1221.1 NO-Short to ground in dashboardwire harnessB; r e p l a c ed a s h b o a r dw i r e h a r n e s sB . I

5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q connectors)and the simulatorlead F to the floor w t r eh a r n e s s .

23-64

t 6. Reconnectthe bafterynegativecable. 7. Erasethe DTCmemory. 8. Readthe DTC.

SpecialToolsRequired . SRS inflatorsimulator07SAZ-TB4011A . SRSsimulator lead F 07XAZ,S230100

ls DTC 22-1 indicated? YES-Go to step 9.

'1.

NO Open or increasedresistancein the front passenger'sseat belt buckletensioner;replacethe front passenger'sseat belt buckle.l

2. Turn the ignition switch ON fll), and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

9. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectboth side airbag2P connectors(see step 4 on page23-21)and the driver's seat belt buckletensioner4P connector(seestep 6 on page 23-22).

DTC22-3:Shortto AnotherWire or Decreased Resistance in FrontPassenger's SeatBeltBuckleTensioner

1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB r ( 1 8 P ) f r o mt h e SRSunit (seestep 7 on page 23-22).Do not disconnectthe specialtool from the floor wire harness. 1 2 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1 terminalsof SRS unit connectorB ('l8P).There s h o u l db e 2 . 0 3 . 0 0 .

Erasethe DTCmemory (seepage 23-26).

Does the SRS indicator stay on? YES Go to step 3. NO Intermiftentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26),. 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe front passenger'sseat belt buckle tensioner4P connector(A) from the floor wire harness.

SRSUNITCONNECTOR B I,I8PI

)m 3

r5 r6 1T 1 8

W i r es i d eo f f e m a l tee r m i n a l s

ls the resistance as specified? YES FaultySRS unit or poor contactat SRS unit ) n d t h e S R Su n i r .C h e c kt h e c o n n e c t oB r ( 1 8 Pa connection;if the connectionis OK, replacethe SRSunit (seepage 23-122).a

I t

5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 Q connectors)and the simulatorlead F to the floor w t r eh a r n e s s . 6. Reconnectthe batterynegativecable. 7 . E r a s et h e D T Cm e m o r y .

NO Open or increasedresistancein the floor wire harness;replacethe floor wire harness.l {cont'd)

23-65

sRs DTCTroubleshooting(cont'dl 8. Readthe DTC.

DTC22-4:Shortto Powerin FrontPassenger's SeatBeltBuckleTensioner

ls DTC 22-3 indicated? YES Go to slep 9. NO-Short in the front passenger'sseat belt buckle tensioner;replacethe front passenger'sseat belt buckle.l 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectboth side airbag2P connectors(see s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t buckletensioner4P connector(seestep 6 on page 23-22). '11. r { 1 8 P ) f r o mt h e D i s c o n n e cSt R Su n i tc o n n e c t oB SRS unit (seestep 7 on page23-221.

SpecialToolsRequired . S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-TB4011A . S R Ss i m u l a t o rl e a dF 0 7 X A z5 2 3 0 1 0 0 1. Erasethe DTCmemory (seep age23-26). 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l } ,a n d c h e c kt h a tt h e S R Si n d i c a t ocr o m e so n f o r a b o u t6 s e c o n d sa n d then goes off. Does the SHS indicator stay on? YES Go to step 3. N O I n l e r m i t t e n t f a i l u r e , s y s t ei smO K a t t h i s t i m e . Go to TroubleshootingIntermittentFailures(see page 23-261.

12. Disconnectthe specialtool from the floor wire ha r n e s s .

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

1 3 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1 terminalsof SRS unit connectorB ( 18P).There 'l should be an open circuit,or at least M !) .

4. Disconnectthe front passenger'sseat belt buckle tensioner4P connector(A) from the floor wire narness.

B {18P} SRSUNIT CONNECTOR GRN/RED

GRN

WiresideoI femaleterminals

ls the resistanceas specified? YES FaultySRSunit; replacethe SRS unit (see page 23'1221.a

5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 ! J connectors)and simulatorlead F to the floor wire h ar n e s s .

NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I

\ J 23-66

t 6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory.

1 0 .Disconnectboth side airbag2P connectors(see s t e p4 o n p a g e2 3 - 2 1 ) a n dt h e d r i v e r ' ss e a tb e l t buckletensioner4P connector(seestep 6 on page ,1_r'>\

8. Readthe DTC. ls DTC 22-4 indicated?

1 1 .DisconnectSRS unit connectorB (18P)from the SRS unit (seestep 7 on page 23-221.

YES Go to step g.

' t 2 .Disconnect

the specialtool from the floor wire

harness. NO-Short to power in the front passenger,sseat belt buckletensioner;replacethe front passenger,s seat belt buckle.! 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes,

t 5 . Reconnectthe batterynegativecable.

1 4 . Turn the ignition switch ON (ll). Checkfor voltage betweenthe No. 2 terminal of S R Su n i tc o n n e c t oB r { 1 8 P )a n d b o d y g r o u n d ,a n d t h e N o . 1 1t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d b e 0 . 5V o r I e s s . SRSUNITCONNECTOR B I18P)

ls the voltageas specified? Y E S - F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t ( s e e page 23-1221.l NO Short to power in the floor wire harness; replacethe floor wire harness.l

23-67

sRs DTCTroubleshooting(cont'dl DTC22-5:Shortto Groundin Front SeatBeltBuckleTensioner Passenger's

8. Readthe DTC. ls DTC 22-5 indicated?

SpecialTools Required . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead F 07XAZ-S230100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO - Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

YES-Go to step 9. NO Short to ground in the front passenger'sseat belt buckletensioner;replacethe front passenger's s e a tb e l tb u c k l e . l 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectboth side airbag2P connectors(see step 4 on page 23-21)and the driver'sseat belt buckletensioner4P connector(seestep 6 on page 23-22t. r ( 1 8 P l f r o mt h e 1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB (see page 7 23-221. step on SRS unit

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

12. Disconnectthe specialtool from the floor wire harness,

4. Disconnectthefront passenger'sseat belt buckle tensioner4P connector(A)from the floor wire harness,

13. Checkresistancebetweenthe No. 2 terminal of SRSunit connectorB (18P)and body ground, and the No, 11 terminal and body ground.Thereshould be an open circuit,or at least 1 M Q.

b U

g {18PI SRSUNITCONNECTOR

Wire side of femaleterminals

5 . Connectthe SRSinflatorsimulator(2 Q connectors)and simulatorlead F to the floor wire narness. 6 . Reconnectthe batterynegativecable. 1 . Erasethe DTCmemory.

ls the resistance as specified? YES-Faulty SRSunit; replacethe SRS unit (see page 23-1221.a NO Short to ground in the floor wire harness; replacethe floor wire harness.l

!U 23-68

I DTCs-1,5-2,5-4,s-8,6-3,6-4,6-7,6-8,7-1, 7-2,7-3,A-1,4-2,8-3,8-4,8-5,8-6,9-1,9-2: Internal Failureof the SRSUnit

DTC10-1,10-2,10-3,10-4,10-s,10-6,10-7: Airbags,SideAirbags,and/orSeatBeltand Deployed SeatBeltBuckleTensioners

NOTE:Beforetroubleshootingany of these DTCs,check the battery/systemvoltage.lf the voltage is low, repair the chargingsystem or replacethe batterybefore troubleshootingthe SRS.lf the battery/systemvoltage is now OK, ask the customerif the batteryever went oeao,

The SRS unit must be replacedafter any airbagsand/or tensionershave deployed(seepage 23-122).!

1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES Replace t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1 NO Intermittentfailure,system is OK at this time. Go to TroubleshootinglntermittentFailures(see page23-26).

I 23-69

SRS DTCTroubleshooting(cont'd) DTC13-1,13-2:InternalFailureof the Driver's SidelmpactSensor

DTC14-1,14-2:InternalFailureofthe Front Passenger's SidelmpactSensor

1. Erasethe DTCmemory (seepage 23-26).

1. Erasethe DTCmemory (seepage23-26).

2. Turn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

Does the SRS indicatot stay on?

Does the SRS indicator stay on?

YES Replacethe driver's side impact sensor(see page 23-123).a

YES-Replace the front passenger'sside impact sensor (see page 23-123],.1

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261.

NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

I J 23-70

I DTC9-3:Faulty Driver'sSeatBeltBuckle Switch 1. Erasethe DTCmemory (seepage 23 26). 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,t h e n b u c k l ea n d u n b u c k l et h e d r i v e r ' ss e a tb e l ts e v e r atl i m e s . 3. Readthe DTC. ls DTC 9-3 indicated?

6. Bucklethe driver's seat belt. Checkresistancebetweenthe No. 1 and No.3 terminalsofthe driver's seat belt buckleswitch 3P c o n n e c l o rT. h e r es h o u l db e 0 1 ( J . Checkresistancebetweenthe No. 1 and No.2 terminalsof the same connector.Thereshould be a n o p e nc i r c u i t o , r a t l e a s t1 M Q . DRIVER'S SEATBELTBUCKLE SWITCH 3PCONNECTOR

YES Go to step 4. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261. 4 . Turn the ignition switch OFF.

BLU/RED

T e r m i n asl i d eo f m a l et e r m i n a l s

5 . Disconnectthe driver's seat belt buckleswitch 3P

connector(A)from the floor wire harness.

t T e r m i n as li d eo f m a l et e r m i n a l s Ate the resistancereadings as specified? YES- Go to step 7. NO Replacethe driver'sseat belt buckleassembly, t h e n c l e a rt h e D T C . I

I (cont'd)

23-71

sRs (cont'dl DTCTroubleshooting 7, Unbucklethe driver'sseat belt. Checkresistancebetweenthe No. 1 and No.2 terminalsofthe driver'sseat belt buckleswitch 3P c o n n e c t o rT. h e r es h o u l db e 0 1 Q .

8. Checkresistancebetweenthe No. 1 terminal ofthe floor wire harness3P connectorand bodv oround. '1 T h e r es h o u l db e 0 0. FLOORWIREHARNESS3P CONNECTOR

Checkresistancebetweenthe No. 1 and No. 3 terminalsof the same connector.There should be an open circuit,or at least 1 M Q DRIVER'S SEATBELT BUCKLE SWITCH3PCONNECTOR

Wiresideof femaleterminals T e r m i n asl i d eo f m a l et e r m i n a l s

BLU/RED

T e r m i n as li d eo I m a l et e r m i n a l s

ls the resistanceas specified? YES Go to step 9. N O O p e ni n t h e f l o o rw i r e h a r n e s so r p o o r g r o u n d connection a t G 5 5 1 .l f G 5 5 ' 1i s O K , r e p l a c et h e f l o o r w r r eh a r n e s s . l

ls the rcsistance as specified? 9 . Disconnectthe negativecablefrom the battery. YES Go to step 8. NO-Replace the driver'sseat belt buckleassembly, then clearthe DTC.I

1 0 . DisconnectSRS unit connectorC (8P)from the SRS unit {seestep 7 on page 23-22).

\ J 23-72

I 11. Checkresistancebetweenthe No. 2 terminal of the floor wire harness3P connectorand body ground. Thereshould be an open circuit.or at least 1 fvlQ ,

13. Checkresistancebetweenthe No. 8 terminal of SRS unit connectorC (8P)and the No. 3 terminal of the floor wire harness3P connector.There should be0 1Q.

FLOORWIRE HARNESS3P CONNECTOR

FLOORWIRE HARNESS SRSUNITCONNECTORC I8P} 3PCONNECTOB

Wiresideot temaleterminals

]

Wire side of femaleterminals

ls the resistance as specified?

ls the resistance as specitied?

Y E S - G o t o s t e p1 2 .

YES Go to step 14.

NO Short to ground in the floor wire harnessor multiplexcontrol unit. Replacethe faulty harnessor part.I

NO Open in the floor wire harness;replacethe floor wire harness.l

1 2 .Checkresistancebetweenthe No. 3 terminal of the floor wire harness3P connectorand body ground. T h e r es h o u l db e a n o p e nc i r c u i to, r a t l e a s t1 M Q . FLOORWIREHARNESS3P CONNECTOR

1 4 . Checkresistancebetweenthe No. 4 terminal of l f S R Su n i tc o n n e c t oC r ( 8 P )a n d t h e N o . 2 t e r m i n a o floor wire harness the 3P connector.There should be0-1 0. FLOORWIREHARNESS 3P CONNECTOR

SRSUNITCONNECTOR C IsPI

LT GRN

Wire side of femaleterminals

Wiresideof femaleterminals ls the resistanceas specified? ls the resistance as specified? YES Replace t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1 YES Go to step 13. N O - S h o r t t o g r o u n di n t h e f l o o rw i r e harness; replacethe floor wire harness.I

N O O p e ni n t h e f l o o rw i r e h a r n e s so r m u l t i p l e x control unit, or poor connectionat the floor wire harness,the under-dashfuse/relaybox, and the multiplexcontrol unit. Checkthe connectionat the floor wire harness,the under-dashfuse/relaybox, and the multiplexcontrol unit. lf the connectionis OK, replacethe faulty harnessor part.l

23-73

SRS

DTCTroubleshooting(cont'dl DTC9-4:FaultyFrontPassenger's SeatBelt BuckleSwitch 1. Erasethe DTCmemory {seepage 23-26). 2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) ,t h e n b u c k l ea n d unbucklethe front passenger'sseat belt several times. 3. Readthe DTC. ls DTC 9-4 indicated?

6. Bucklethe front passenger'sseat belt. Checkresistancebetweenthe No. 1 and No.3 terminalsof the front passenger'sseat belt buckle switch 3P connector.Thereshould be 0- 1 Q. Checkresistancebetweenthe No. 1 and No.2 terminalsof the same connector.Thereshould be a n o o e nc i r c u i t o , r a t l e a s t1 M Q . FRONT PASSENGER'S SEATBELT BUCKLE SWITCH 3PCONNECTOR BLU/RED

YES-Go to step 4. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermiftentFailures{see page 23-26)'.

T e r m i n asl i d eo f m a l et e r m i n a l s

4. Turn the ignition switch OFF. 5. Disconnectthe front passenger'sseat belt buckle switch 3P connector(A) from the floor wire harness. Terminalsideof maleterminals Is the rcsistanceas specified? YES-Go to step 7. NO Replacethe front passenger'sseat belt buckle assembly,then clearthe DTC.I

23-74

7. Unbucklethe front passenger'sseat belt. Checkresistancebetweenthe No. 1 and No. 2 terminalsof the front passenger'sseat belt buckle s w i t c h3 Pc o n n e c t o rT. h e r es h o u l db e 0 1 ! ) .

8. Checkresistancebetweenthe No. 1 terminal ofthe floor wire harness3P connectorand body ground. T h e r es h o u l db e 0 1 Q . FLOORWIRE HARNESS3P CONNECTOR

Checkresistancebetweenthe No. 1 and No. 3 terminalsof the same connector.Thereshould be an oDencircuit,or at least 1 M Q FRONTPASSENGER'S SEATBELT BUCKLE SWITCH3PCONNECTOR

Wiresideof femaleterminals Terminalside of maleterminals

ls the tesistance as specified? YES Go to step 9.

Terminalsideof maleterminals

NO-Open in the floor wire harnessor poor ground connectionat G551.lf G551is OK, replacethe floor wire harness.I

ls the resistanceas specilied? 9 . Disconnectthe negativecablefrom the battery, YES Go to step 8. NO-Replace the front passenger'sseat belt buckle assembly,then clearthe DTC.I

1 0 . DisconnectSRS unit connectorC (8P)from the SRS unit (see step 7 on page 23-22).

(cont'd)

23-75

sRs DTCTroubleshooting(cont'dl 1 1 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 2 t e r m i n a o l fthe floor wire harness3P connectorand body ground. There should be an open circuit,or at least 1 M 0 .

13. Checkresistancebetweenthe No. 7 terminal of S R Su n i tc o n n e c t oC r ( 8 P )a n d t h e N o . 3 t e r m i n a lo f the floor wire harness3P connector. T h e r es h o u l db e 0 - 1 Q .

FLOORWIREHARNESS 3PCONNECTOR FLOORWIRE HARNESS SRSUNITCONNECTOR C (8P) 3PCONNECTOR

Wiresideof femaleterminals

ls the resistance as specified?

Wiresideof femaleterminals

Y E S - G o t o s t e p1 2 .

ls the tesistance as specified?

NO-Short to ground in the floor wire harness; replacethe floor wire harness.I

YES-Go to step 14.

Checkresistancebetweenthe No. 3 terminal of the floor wire harness3P connectorand body ground. There should be an open circuit,or at least 1 l\40 . FLOOR WIREHABNESS 3PCONNECTOR

NO Open in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I

L J

1 4 . Checkresistancebetweenthe No, 3 terminal of SRS unit connectorC (8P)and the No. 2 terminal of t h e f l o o rw i r e h a r n e s s3 Pc o n n e c t o f T h e r es h o u l db e 0 1 Q . FLOORWIREHARNESS 3P CONNECTOR

SRS UNIT CONNECTORC ISPI

Wiresideof temaleterminals

ls the resistance as specified? Wiresideof femaleterminals Y E S - G o t o s t e p1 3 . NO Short to ground in the floor wire harness; replacethe floor wire harness.I

ls the resistance as specified? YES Replace t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1 N O O p e nl n t h e f l o o rw l r e h a r n e s sr;e p l a c e t h e f l o o rw i r e h a r n e s s . l

23-76

\ J

DTC9-6:FaultyLeftFrontlmpactSensor

8. Disconnect the enginecompartment wire harness 2Pconnector {A)fromthe leftfrontimpactsensor.

Special Tools Required . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. Erasethe DTCmemory (seepage 23-26). 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermiftentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page23-26).

9 . DisconnectSRS unit connectorA {18P)from the SRSunit (seestep7 on page23-22J.

3. Turn the ignitionswitch OFF.Checkthe connectionsbetweenSRS unit connectorA (18P) and the SRSunit. betweenthe engine compartmentwire harness2P connectorand the left front impactsensor{seepage23-13),and at connectorC401.

1 0 .Checkresistancebetweenthe No. 10 and No. 11 terminalsof SRSunit connectorA (18P).There should be an oDencircuit.or at least 1 M 0 . A (18PI SRSUNITCONNECTOR

Are the connectionsOK? YES Go to step 4. NO-Repair the poor connectionsand retest.lf DTC 9-6 is still present,go to step 4. Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes.

2 3 5 6 7 8 9 10 t l 1Z t 3 15 16 17 1 8

RED

I T

ILK

Wire side of femaleterminals

Disconnectthe driver'sairbag4P connectorfrom the cable reel (seestep 2 on page23-21). ls the resistance as specitied? Disconnectthe front passenger'sairbag 4P connectorfrom dashboardwire harnessB {seestep 3 on page23-21). 7 . Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page 2322).

YES Go to step 11. N O - S h o r t i n t h e e n g i n ec o m p a n m e n w t ire harnessor dashboardwire harnessB; replacethe f a u l t yh a r n e s s . I 1 1 .Reconnectthe batterynegativecable. 12. Turn the ignition switch ON {ll).

{cont'd}

23-77

sRs DTCTroubleshooting(cont'dl 13. Checkvoltagebetweenthe No. 10terminalof SRS unitconnector A (18P)andbodyground.There 'l shouidbe V or less. SRS UNIT CONNECTORA {,I8P)

16. Checkresistancebetweenthe No. 10 and No. 11 terminalsof SRS unit connectorA (18P).There s h o u l db e 1 0 o r l e s s . SRS UNIT CONNECTORA Il8PI

10 11 12 l 3 t 4 15 1 6 1 1 t6

RED

Wire side oI femaleterminals

ls the voltage as specitied?

ls the rcsistance as specified?

YES-Go to step 14.

YES Faultyleft front impactsensoror SRS unit; replacethe left front impact sensor (seepage 23-125). lf the problem is still present,replacethe SRSunit ( s e ep a g e2 3 - 1 2 2 ) . 1

NO-Short to power in the engine compartment wire harnessor dashboardwire harnessB; replace the faulty harness.l 1 4 . Turn the ignition switch OFF. t5.

Wire side of femaleterminals

Connectthe SRS inflatorsimulator(jumper connector)and simulatorlead H to the engine compartmentwire harness2P connector(A).

NO-Poor connectionat C401,faulty engine compartmentwire harness,or faulty dashboard wire harnessB. InspectC401.lf it is OK, replacethe faulty harness.l

\y,

07YAZ-S3AA100 07SAZ-TB,O11A

\."r1

23-78

)

DTC9-7:FaultyRightFrontlmpactSensor

Disconnectthe enginecompartmentwire harness 2P connector(A) from the right front impactsensor.

Special Tools Bequired . SRSinflatorsimulator07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. Erasethe DTCmemory {seepage23-26). 2 . T u r nl h e i g n i t i o ns w i t c hO N { l l ) ,a n d c h e c k t h a t t h e SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

3. Turn the ignitionswitch OFF.Checkthe connectionsbetweenSRSunit connectorA (18P) and the SRSunit, betweenthe engine compartmentwire harness2P connectorand the right front impactsensor(seepage 23-13),and at connectorC401. Are the connectionsOK? YES-Go to step 4. NO Repairthe poor connectionsand retest.lf DTC 9-7 is still present,go to step 4.

DisconnectSRSunit connectorA (18P)from the SRS unit (see step 7 on page 23-221.

'10.Checkresistancebetween

the No. 1 and No. 12 terminalsof SRSunit connectorA (18P).There should be an open circuit,or at least1 M 0. SRS UNIT CONNECTORA (18PI GRN

F!t 1 t 2 ) l

I r o l r l r13

1 6 1 7 18

SLK

4 . Turn the ignition switch OFF.Disconnectthe

batterynegativecable,and wait for 3 minutes. Wire side ol femaleterminals

5 . Disconnectthe driver'sairbag4P connectorfrom the cable reel {seestep 2 on page 23-21). ls the resistance as specified? Disconnectthe front passenger'sairbag4P connectorfrom the dashboardwire harness(see step 3 on page 23-21). 7 . Disconnectboth seat belt tensioner2P connectors from the floor wire harness(seestep 5 on page2322).

Y E S G o t o s t e p1 1 . N O - S h o r t i n t h e e n g i n ec o m p a n m e nw t ire harnessor dashboardwire harnessB; replacethe f a u l t yh a r n e s s , I 1 1 .Reconnectthe batterynegativecable. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

I (cont'd)

23-79

sRs DTCTroubleshooting(cont'd) 13. Checkvoltagebetweenthe No.1terminalofSRS unitconnector A (18P)andbodyground.There shouldbe 1 V or less. SRSUNIT CONNECTOR A I18P}

16. Checkresistancebetweenthe No. 1 and No. '12 terminalsof SRS unit connectorA (18P).There s h o u l db e 1 O o r l e s s . SRSUNITCONNECTOR A {18P) GRN

J_ l r 1 2 l r tE.]I /A

Wiresideof femaleterminals

t 3 1 1 r5 16 1 1 t6

BLK

Wire side of femaleterminals

ls the voltage as specified?

ls the resistance as specitied?

YES Go to step 14.

YES Faultyright front impactsensoror SRS unit; replacethe rightfront sensor{seepage 23-125).lfthe problem is still present,replacethe SRS unit (see page 23-1221.a

NO-Short to power in the enginecompartment wire harnessor dashboardwire harnessB; replace the faulty harness.l 1 4 . Turn the ignition switch OFF. Connectthe SRS inflatorsimulator(jumper connector)and simulatorlead H to the engine compartmentwire harness2P connector(A).

07YAZ-S3AA100

23-80

NO- Poorconnectionat C401,faulty engine compartmentwire harness,or faulty dashboard wire harnessB. lnspectC401.lf it is OK, replacethe faulty harness,I

L J

I DTC11-1:Openor Increased Resistance in Driver'sSideAirbagInflator

6. Reconnectthe batterynegativecable. 7. Erasethe DTCmemory.

SpecialToolsRequired . S R Si n f l a t o rs i m u l a t o 0 r 7SM-TB4011A . SRSsimulatorlead E 07XM-S140200

8. Readthe DTC. ls DTC 11-1indicated?

1. Erasethe DTCmemory (seepage 23-26), YES Go to step 9. 2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

NO-Open or increasedresistancein the driver's side airbag inflator;replacethe driver's side a i r b a g( s e ep a g e2 3 - 1 ' 1 5 ) . 1

Does the SBS indicatot stay on? 9. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261.

10. Disconnectthe front passenger'sside airbag 2P connector(seestep 4 on page 23-21)and both seat belt buckletensioner4P connectors(seestep 6 on page 23-221.

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

)

4. Disconnectthe floor wire harness2P connector(A) from the driver'sside airbag.

07sAz-T84011A

5. Connectthe SRSinflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness.

I {cont'd)

23-81

sRs DTCTroubleshooting(cont'dl ' It . D i s c o n n e c t

S R Su n i tc o n n e c t oB r ( 1 8 P ) f r o mt h e (see page SRS unit step 7 on 23-22).Do not disconnectthe specialtool from the floor wire harness2P connector.

Checkresistancebetweenthe No.6 and No. 17 t e r m i n a l so f S R Su n i tc o n n e c t oB r ( 1 8 P )T. h e r e s h o u l db e 2 . 0- 3 . 0 Q .

DTC11-3:Shortto AnotherWireor Decreased Resistance in Driver'sSideAirbag lnflator SpecialToolsRequired ' S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seepage 23 26).

SRSUNITCONNECTOR B I18PI WHT/BLU 1

10 t l

rr--r-{

0 l T l s l s l a

15IdFFI \

WHT/BLK Wiresideof femaleterminals

ls the resistance as specified? YES-Faulty SRS unit or poor contactat SRS unit ) n d t h e S R Su n i t .C h e c kt h e c o n n e c t oB r ( 1 8 Pa connection;if the connectionis OK, replacethe SRS unit (seepage 23'1221.a

2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicatot stay on? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. Disconnectthe floor wire harness2P connector(A) f r o m t h e d r i v e r ' ss i d ea i r b a g .

NO Open or increasedresistancein the floor wire harness;replacethe floor wire harness.l

07sAz-T84011A

C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r ) a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s . Reconnectthe batterynegativecable. 1 . Erasethe DTCmemory.

23-82

I DTG11-4:Shortto Powerin Driver'sSide AirbagInflator

8. Readthe DTC. ls DTC 11-3indicated?

Special Tools Required . SRS inflatorsimulator07SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200

YES-Go to step 9. NO*Shon to anotherwire in the driver's side airbag inflator;replacethe driver'sside airbag (see p a g e2 3 - 1 1 5 ) . I 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes. 10. Disconnectthefront passenger'sside airbag2P connector(seestep 4 on page 23-21)and both seat belt buckletensioner4P connectors(seestep 6 on page 23-22l,. 11. Disconnectthe specialtool from the floor wire harness2P connector.

1. Erasethe DTCmemory {seepage 23-261. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e SRS indicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26l,.

1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oB r { 1 8 P ) f r o mt h e SRSunit {seestep 7 on page23-221.

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

13. Checkresistancebetweenthe No.6 and No. 17 t e r m i n a l so f S R Su n i tc o n n e c t oB r ( 1 8 P )T, h e r e s h o u l db e a n o p e nc i r c u i to, r a t l e a s t1 M 0 .

4. Disconnectthe floor wire harness2P connector(A) from the driver'sside airbag.

SRSUNITCONNECTOR B {18PI

WHT/BLU

07sAz-TB4011A WHT/BLK Wiresideof femaleterminals

ls the resistance as specified?

5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 0 c o n n e c t o r ) a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .

YES FaultySRSunit; replacethe SRS unit {see page23-'t221 .a N O S h o n t o a n o t h e rw i r e i n t h e f l o o rw i r e harness;replacethe floor wire harness.I

(cont'd)

23-83

sRs (cont'd) DTCTroubleshooting 6. Reconnect the batterynegative cable. 7. Erasethe DTCmemory,

1 1 .DisconnectSRS unit connectorB (18P)from the SRSunit (seestep 7 on page 23-22l,.

' t 2 .T u r n

t h e i g n l t i o ns w i t c hO N ( l l ) .

8. Readthe DTC. 1 3 .Checkfor voltage betweenthe No. 6 terminal of Is DTC 11-4indicated? YES-Go to step9. NO Shortto powerin the driver'ssideairbag inflator;replacethe driver'ssideairbag(seepage 23-115).t

SRS unit connectorB (18P)and body ground,and betweenthe No. 17 terminal and body ground. Thereshould be 0.5 V or less. SRSUNITCONNECTOR B I18P)

9 . Turn the ignition swilch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. WHT/BLK

' 1 0 Disconnect . the front passenger'sside airbag2P connector(seestep 4 on page 23-21)and both seat belt buckletensioner4P connectors(seesteD6 on page 23-221.

ls the voltage as specitied? YES- FaultySRSuniUreplacethe SRS unit (see page 23-1221.a

U J

NO Short to power in the floor wire harness; r e p l a c et h e f l o o rw i r e h a r n e s s . l

\.J 23-84

I DTC11-5:Shortto Groundin Driver'sSide AirbagInflator

8. Readthe DTC. ls DTC 11-5indicated?

Special Tools Required . S R Si n f l a t o rs i m u l a t o 0 r 7SM-T84011A ' SRSsimulatorlead E o7XAZ-S140200 '1.

Erasethe DTCmemory {seepage 23-26).

2. Turn the ignitionswitch ON {ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261. 3. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

4. Disconnectthe floor wire harness2P connector(A) from the driver'sside airbag.

YES Go to step 9. NO Short to ground in the driver'sside airbag inflator;replacethe driver'sside airbag (seepage 23-115).t 9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 10. Disconnectthe front passenger'sside airbag2P connector(seestep 4 on page 23-21)andboth seat belt buckletensioner4P connectors(seestep 6 on page 23-221. 1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e SRS unit (seestep 7 on page 23-22). '12. Checkresistancebetweenthe No. 17 and No. 15 t e r m i n a l so f S R Su n i tc o n n e c t oB r ( 1 8 P )a. n d '17 b e t w e e nt h e N o . a n d N o . 1 6t e r m i n a l sT. h e n checkresistancebetweenthe No. 17 terminal and body ground.Thereshould be an open circuit,or at l e a s t1 M 0 . SRSUNIT CONNECTOR B I18P)

WHT/BLK

07saz-TB,r011A

Wiresideof femaleterminals Connectthe SRSinflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness. 6 . Reconnectthe batterynegativecable.

ls the resistance as specified? YES FaultySRSunit; replacethe SRS unit (see page 23-122).a

7 . Erasethe DTCmemory. NO-Short to ground in the floor wire harness; r e p l a c et h e f l o o rw i r e h a r n e s s . I

I 23-85

sRs DTCTroubleshooting(cont'd) Resistance in DTG12-1:Openor Increased FrontPassenger's SideAirbagInflator

Reconnectthe batterynegativecable. 7 . Erasethe DTCmemory.

SpecialToolsRequired . S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200

Readthe DTC. ls DTC 12-l indicated?

1. Erasethe DTCmemory (seepage 23-26). YES Go to step L 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e SRSindicatorcomes on for about 6 secondsand then goes off.

NO-Open or increasedresistancein the front passenger'sside airbag inflator;replacethe front p a s s e n g e r 'ssi d ea i r b a g( s e ep a g e2 3 - 11 5 ) . 1

Does the SBS indicator stay on? 9 . Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes.

YES Go to step 3. NO - Intermittentfailure, system is OK at this time. Go to TroubleshootinglntermittentFailures(see page23-26).

'10. Disconnectthe driver'sside airbag2P connector {seestep 4 on page 23-21)andboth seat belt buckle tensioner4P connectors(seestep 6 on page 23-22).

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe floor wire harness2P connector(A) from the front passenger'sside airbag.

07xAz-s1A0200 5. Connectthe SRSinflatorsimulator(2 Q connector) a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .

I J 23-86

I 1't. DisconnectSRS unit connectorB ('l8P)from the SRSunit (seestep 7 on page 23-22).Do not disconnectthe specialtool from the floor wire h a r n e s s2 P c o n n e c t o r .

1 2 .Checkresistancebetweenthe No.7 and No. 18 t e r m i n a l so f S R S u n i t c o n n e c t oBr ( 1 8 P )T. h e r e s h o u l db e 2 . 0 3 . 0 ( J .

DTC12-3:Shortto AnotherWireor Decreased Resistance in FrontPassenger's SideAirbagInflator SpecialToolsRequired . S R Si n f l a t o rs i m u l a t o 0 r 7SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200 1. Erasethe DTCmemory (seep age 23-261.

SRSUNITCONNECTOR B {18P) WHT/RED

2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3.

WHT/GRN Wiresideof femaleterminals

ls the resistanceas specified?

YES FaultySRSunit or poor contactat SRS unit c o n n e c t oB r ( l 8 P )a n dt h e S R Su n i t .C h e c kt h e connection;lf the connectionis OK, replacethe SRSunit (seepage 23-1221.a

NO - Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4 . Disconnectthe floor wire harness2P connector(A)

from the front passenger'sside airbag.

NO Open or increasedresistancein the floor wire h a r n e s sr;e p l a c et h e f l o o rw i r e h a r n e s s . I

07xAz-s1A0200 5. Connectthe SRSinflatorsimulator(2 0 connector) a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .

(cont'd)

23-87

sRs DTCTroubleshooting(cont'dl 6. Reconnectthe batterynegativecable.

DTC12-4:Shortto Powerin FrontPassenger's SideAirbagInflator

7, Erasethe DTCmemory. Special Tools Required . sRS inflatorsimulator07sAz-TB4011A . SRSsimulatorlead E 07XM-S140200

8. Readthe DTC. ls DTC 12-3indicated?

1. Erasethe DTCmemory (seepage 23-26). YES-Go to step I NO Short to anotherwire in the front passenger's side airbag inflator;replacethe front passenger's s i d ea i r b a g( s e ep a g e2 3 - l l 5 ) . 1

2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on?

9. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

YES-Go to step 3.

10. Disconnectthe driver's side airbag2P connector (seestep 4 on page 23-21)and both seat belt buckle tensioner4P connectors(seestep 6 on page 23-22).

NO- Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures{see page 23-26).

'!1.

D i s c o n n e ct h t e s p e c i a l t o o l f r o mt h e f l o o rw i r e harness2P connector.

12. DisconnectSRS unit connectorB ('lSPlfromthe SRS unit {see step 7 on page 23-221.

3. Turn the ignition switch OFF.Disconnectthe banery negativecable,and wait for 3 minutes. 4. Disconnectthe floor wire harness2P connector(A) from the front passenger'sside airbag.

13. Checkresistancebetweenthe No.7 and No. 18 r ( 1 8 P )T. h e r e t e r m i n a l so f s R S u n i tc o n n e c t o B , r a t l e a s t1 M 0 . s h o u l db e a n o p e nc i r c u i t o B I18P) SRSUNITCONNECTOR WHT/RED -r-'r-Jl

2 3 10 l l

' 8lel n

-T

i['tl,Bl S 07xAz-s1A0200

WHT/GRN Wiresideof {emaleterminals

5. Connectthe SRS inflatorsimulator(2 Q connector) a n d s i m ul a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .

ls the resistance as specilied? Y E S F a u l t yS R Su n i t ;r e p l a c et h e S R Su n i t{ s e e page 23-1221.a N O S h o r tt o a n o l h e rw i r e i n t h e f l o o rw i r e harness;replacethe floor wire harness.I

\.J 23-88

\ 6. Reconnectthe batterynegativecable.

1 1 .DisconnectSRS unit connectorB (18P)from the SRS unit (see step 7 on page 23-221.

7. Erasethe DTCmemory. 1?

Turn the ignition switch ON (ll).

8. Readthe DTC.

1 3 .Checkfor voltage betweenthe No. 7 terminal of ls DTC 12-4 indicated ? YES Go to step 9. NO-Short to power in the front passenger'sside airbaginflator;replacethe front passenger'sside a i r b a g( s e ep a g e2 3 - 1 1 5 t) .

SRS unit connectorB ( l8P) and body ground,and betweenthe No. 18terminal and body ground. T h e r es h o u l db e 0 . 5V o r l e s s . SRSUNIT CONNECTOR B I18P)

9. Turn the ignitionswilch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. WHT/GRN

'10. Disconnectthe driver'sside airbag2P connector (seestep 4 on page 23-21)and both seat belt buckle tensioner 4P connectors (see step 6 on page 23-22l,.

ls the voltage as specified? YES FaultySRSunil; replacethe SRSunit (see page 23-1221.a NO Short to power in the floor wire harness; r e p l a c et h e f l o o rw i r e h a r n e s s . l

23-89

sRs DTCTroubleshooting(cont'dl DTC12-5:Shortto Groundin Front Passenger's SideAirbagInflator

.t 6. Reconnectthebatterynegativecable. 7. Erasethe DTCmemory.

SpecialToolsRequired . SRSinflatorsimulator07SAZ-T84011A . SRSsimulatorlead E o7XAZ-S140200

8. Readthe DTC. ls DTC 12-5indicated?

1. Erasethe DTCmemory (seepage23-26). YES Go to step9. 2. Turn the ignitionswitch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off.

NO-Short to ground in the front passenger'sside airbaginflator;replacethe front passenger'sside a i r b a g( s e ep a g e2 3 - 11 5 ) . 1

Does the SRS indicator stay on? YES-Go to step 3.

9. Turn the ignitionswitch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261.

10, Disconnectthedriver'sside airbag2P connector (see step 4 on page 23-211and both seat belt buckle lensioner4P connectors(seestep 6 onpage23-22).

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB r ( 1 8 P ) f r o mt h e SRS unit (see step 7 on page 23-22).

4. Disconnectthe floor wire harness2P connector(A) from the front passenger'sside airbag.

12. Checkresistancebetweenthe No. 15 and No. 18 ) nd r ( 1 8 Pa t e r m i n a l so f S R Su n i tc o n n e c t oB betweenthe No. 16 and No. 18 terminals.Then checkresistancebetweenthe No. 18 terminal and body ground.Thereshould be an open circuit,or at l e a s t1 M Q .

{

B {18PI SRSUNITCONNECTOR 2 1 0 11

t6 1 7 1E

WHT/GRN LTGRN/REDd i 116\l 9 Y 9

07xAz-s1A0200 5. Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead E to the floor wire harness.

GRY/RED

Wire side of femaleterminals

ls the resistanceas specified? YES FaultySRSunit; replacethe SRS unit (see page 23-1221.a N O - S h o r t t o g r o u n di n t h e f l o o rw i r e h a r n e s s ; r e p l a c et h e f l o o rw i r e h a r n e s s . l

23-90

)

DTC13-3:No Signalfrom the Driver'sSide lmpactSensor Special Tools Required . sRs inflatorsimularor07SAZ-TB4011A . SRSsimulatorlead H 07YM-S3AA100 1. ErasetheDTCmemory (seep age 23-261.

5. Disconnectthedriver's side airbagand front passenger'sside airbag2P connectors(seestep 4 on page 23-21).Also disconnectboth seat belt buckletensioner4P connectors(seestep 6 on page 23-22). 6. Disconnectthe floor wire harness2P connector{A} from the driver'sside impact sensor.

2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES- Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootinglntermittentFailures(see page 23-261.

07sAz-TB4011A

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes.

)

4. Checkthe connectionbetweenthe floor wire harness2P connectorand the driver'sside impact sensor.

7. Connectthe SRS inflatorsimulator(2 Q connector) and simulatorlead H to the floor wire harness.

ls the connectionOK? YES Go to step 5. NO-Replace the driver'sside impact sensorand/ or the floor harness,as needed.I

) (cont'd)

23-91

sRs DTCTroubleshooting{cont'd) B (18P)fromthe SRSunitconnector 8. Disconnect (see page 23-221. SRSunit step7 on 9. Checkresistance betweenthe No.8 andNo.15 B ('l8P).There terminalsof sRSunitconnector s h o u l db e0 1 . 0Q . B I18P) SRSUNITCONNECTOR BRN/YEL

3 10 tl

:fr;f;l n \ l r ol r zl r s|

DTC13-4:FaultyPowerSupplyto the Driver's SidelmpactSensor 1. Erasethe DTCmemory {seepage 23-261. 2. Turn the ignition switchON (ll),and checkthat the SRSlndicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES Go to step 3. NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

LT GRN/RED Wire side of temaleterminals

Is the resistance as specitied? YES Faultydriver'sside impact sensoror SRS unit; replacelhe driver'sside impactsensor(see page 23-123).lf the problem is still present,replace the SRSunit (seepage 23-122).1 N O O p e ni n t h e f l o o rw i r e h a r n e s sr;e p l a c et h e floor wire harness.l

23-92

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthe driver'sside airbagand front passenger'sside airbag2P connectors(seestep 4 on page23-21).Also disconnectboth seat belt buckletensioner4P connectors(seestep 6 on page 23-22).

t (A) 5. Disconnect thefloorwire harness2Pconnector fromthedriver'ssideimpactsensor.

8. Checkresistancebetweenlhe No.8 and No. l5 terminalsof SRSunil connectorB (18P).There should be an open circuit,or at least 1 M 0 . SRSUNIT CONNECTOR B {18P'

BRN/YEL 2 3 10 11

flliT;l

1tr6l1tf;l \ LT GRN/RED

Wire side oI femaleterminals

DisconnectSRSunit connectorB (18P)from the SRS unit (see step 7 on page 23-22) 1 . Checkresistancebetweenthe No. 8 terminal of SRS unit connectorB (18P)and body ground.There should be an open circuit,or at least 1 M Q .

SRSUNITCONNECTOR B {18PI BRN/YEL

ls the resistance as specitied? YES-Faulty driver's side impact sensoror SRS unit; replacethe driver'sside impact sensor(see page 23-1251.lfthe problem is still present,replace t h e S R Su n i t( s e ep a g e 2 3 - 1 2 2 1 . a NO- Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . I

Wire side of femalete.minals

ls the resistanceas specitied? YES-Go to step8. NO-Short to groundin thefloorwire harness; replace the floorwire harness.I

23-93

sRs DTCTroubleshooting(cont'dl DTC14-3:No Signalfromthe Front SidelmpactSensor Passenger's SpecialToolsRequired . SRSinflatorsimulator07SAZ-TB401'lA . SRSsimulatorlead H 07YAZ'S3AA100 1. ErasetheDTCmemory (seepage 23-26).

5 . Disconnectthedriver'sside airbagand front passenger'sside airbag2P connectors(seestep 4 on page 23-21).Also disconnectboth seat belt buckletensioner4P connectors(seestep 6 on page 23-22t. Disconnectthe floor wire harness2P connector{A) from the front passenger'sside impact sensor.

2. Tu rn the ignition switch ON (ll),and checkthat the SRSindicatorcomes on for about 6 secondsand then goes off. Does the SBS indicator stay on? YES Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). 3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Checkthe connectionbetweenthe floor wire harness2P connectorand the front passenger's side lmpact sensor. Is the connectionOK? YES-Go to step 5. NO- Poorcontactbetweenthe floor wire harness 2P connectorand the front passenger'sside impact sensor;replacethe front passenger'sside impact sensorand/orthe floor harness,as needed.

23-94

07sAz-TB4o11A

7. Connectthe SRS inflatorsimulator(2 0 connector) and the simulatorlead H to the floor wire harness.

) 8. DisconnectSRSunit connectorB (18P)fromthe SRSunit (seestep 7 on page 23-221. 9. Checkresistancebetweenthe No.9 and No. 16 terminalsof SRSunit connectorB (18P).There s h o u l db e 0 - 1 . 0 S 2 . SRSUNITCONNECTOR B {18PI PNK/BLU 2 1 0 t1

0 t5

l-u5l n

iFf;l \

DTC14-4:FaultyPowerSupplyto the Front Passenger's SidelmpactSensor 1. Erasethe DTCmemory (seepage23-26). 2. Turn the ignition switch ON (ll),and checkthat the SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO-lntermittent failure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-261.

GRY/RED Wiresideol lemaleterminals

ls the resistance as specified?

YES-Faulty front passenger'sside impact sensor or SRSunit; replacethe front passenger'sside impactsensor(seepage 23-125).lf the problem is still present,replacethe SRS unit (seepage23-122). I

3. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 4. Disconnectthedriver's side airbagand front passenger'sside airbag2P connectors(seestep 4 on page 23-21).Also disconnectboth seat belt buckletensioner4P connectors(seestep 6 on page 23-22t. 5. Disconnectthe floor wire harness2P connector{A} from the front passenger'sside impact sensor.

NO-Open in the floor wire harness;replacethe floor wire harness.!

"-;s.\ \

\f r l/

\--)

- F.,=

DisconneclSRS unit connectorB (18P)from the SRS unit (seestep 7 on page 23-22i.

I (cont'd)

23-95

sRs DTGTroubleshooting(cont'd) 7. Checkresistancebetweenthe No. 9 terminal of SRS unit connectorB (18P)and body ground.There should be an ooen circuit,or at least 1 N4Q. B {18PI SRSUNIT CONNECTOR

PNK/BLU

DTC15-1:FaultyOPDSUnit NOTE: . An incorrectOPDSunit can causeDTC 15-1. . A n e w ( u n i n i t i a l i z eO d )P D Su n i t i n s t a l l e d witha faulty O P D Ss e n s o rc a nc a u s eD T C 1 5 - 1 . . lf you installa new OPDSunit and a new SRSunit at t h e s a m et i m e , i n i t i a l i z teh e O P D Sm a n u a l l y( s e e page 23-27),do not usethe HondaPGM Tester. 1. Make sure nothing is on the front passenger'sseat. 2. Initializethe OPDSunit (seepage23-27). 3. Erasethe DTCmemory (seepage 23-26]'.

Wire side of femaleterminals

4. Readthe DTC. Is DTC 15-1indicated? ls the tesistance as specilied? YES Go to step 5. YES Go to step 8. NO-Short to ground in the floor wire harness; replacethe floor wire harness.l Checkresistancebetweenthe No.9 and No. 16 terminalsof SRSunit connectorB (18P).There should be an open circuit,or at least 1 M O .

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page23-26). Checkthe No. 9 (10A)fuse in the under-dashfuse/ relay Dox, ls the tuse OK?

B (18P) SRSUNITCONNECTOR PNK/BLU

2 10 tl

_-r '18 sl

tltlis-l \

YES Go to step 6. NO Go to step 9. DisconnectOPDSunit harness8P connector(A) from the OPDSunit (A) (seepage23-124).

GRY/RED Wiresideot femaleterminals

ls the resistance as specified? YES-Faulty front passenger'sside impactsensor or SRS unit; replacethe front passenger'sside impact sensor{seepage 23-125).lf the problem is s t i l lp r e s e n tr,e p l a c et h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . I NO Short in the floor wire harness;replacethe f l o o rw i r e h a r n e s s . l

23-96

7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .

) 8. Checkfor voltage betweenthe No. 4 terminal of OPDSunit harness8P connectorand body ground. Thereshould be batteryvoltage.

13. DisconnectOPDSunit harness8P connector(A) from the OPDSunit.

OPDS UNIT HARNESS8P CONNECTOR

Wiresideof femaleterminals

1 4 . Turn the ignition switch ON (ll) for 30 seconds,then turn it off. C h e c kt h e N o . 9 ( 1 0 A )f u s e .

ls there battery voltage? ls the f use OK? YES-Go to step 16. NO Open in the floor wire harnessor OPDSunit harness;replacethe faulty harness.I

)

9. Replace t h e N o . 9 ( 1 0 A ) f u s ei n t h e u n d e r - d a s h fuse/relaybox.

1 0 .Turn the ignitionswitch ON (ll) for 30 seconds,then

YES Short to ground in the OPDSunit; replacethe OPDSunit (seepage 23-1241.1 NO-Short to ground in the No. 9 (10A)fuse circuit (floor harness,or OPDSharness);replacethe affectedharness.I t o . Turn the ignition switch OFF.

turn it off. 1 1 .C h e c kt h e N o . 9 ( 1 0 A ) f u s e .

1 1 . Checkresistancebetweenthe No.8 terminal of OPDSunit harness8P connectorand body ground. '1.0 Thereshould be 0 Q.

ls the tuse OK? OPDSUNIT HARNESSsPCONNECTOR

YES lntermittentfailure,system is OK at this time. Go to TroubleshootingIntermiftentFailures(see page 23-26). NO Go to step 12.

l4V-'l^l TVjEl #

BLK

@ I

Replacethe No. 9 ('l0A)fuse.

W i r es i d eo f f e m a l et e r m i n a l s

ls the resistance as specified? YES Go to step 18. NO Open in the floor wire harnessor OPDSunit h a r n e s so, r p o o rg r o u n d( G 5 5 1 )l.f G 5 5 1i s O K , replacethe faulty harness.I

) (cont'd)

23-97

sRs DTCTroubleshooting(cont'dl 1 8 . Turn the ignition switch OFF.Disconnectthe batterynegativecable.and wait for 3 minutes. 1 9 . Disconnectboth side airbagconnectors(seestep 4 o n p a g e2 3 - 2 1 ) a n db o t hs e a tb e l tb u c k l e t e n s i o n e r 4P connectors(seestep 6 on page23-22).

22. Checkresistancebetweenthe No. 3 terminal of SRSunit connectorB (18P)and the No. 7 terminal of OPDSunit harness8P connector.Thereshould be0 1.0Q. SRSUNITCONNECTOR B (18PI GRN/ORN

20. DisconnectSRSunit connectorB (18P)from the SRS unit (see step 7 on page 23-221. Checkresistancebetweenthe No. 3 terminal of SRS unit connectorB (18P)and body ground.There should be an oDencircuit,or at least 1 MQ .

Wire side of femaleterminals OPOSUNIT HARNESS8P CONNECTOR

SRSUNITCONNECTOR B I18PI BLU GRN/ORN

Wire side of femaleterminals

ls the resistanceas specitied? YES Go to step23. NO Openin thefloorwire harnessor in the OPDS unitharness; replace thefaultyharnessl Wiresideot temaleterminals

Reconnect the bafterynegative cable. ls the resistance as specified? YES- Go to step 22. NO Short to ground in the floor wire harnessor OPDSunit harness;replacethe faulty harness.l

23-98

24. Turnthe ignitionswitchON (ll).

25. Checkfor voltagebetweenthe No. 3 terminal of SRS unit connectorB (18P)and body ground.There s h o u l db e 0 . 5V o r l e s s .

DTC15-2:FaultySideAirbagCutoffIndicator Circuit 1. Make sure nothing is on the front passenger'sseat.

B (18P) SRSUNITCONNECTOR

PNK

2. Erasethe DTCmemory (seepage 23-26]-. 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) , a n d c h e c k t h a t t h e SRSindicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Turn the ignition switch OFF,and go to step

Wiresideof temaleterminals

ls the voltageas specilied? YES Go to step 26.

NO Short to power in the floor wire harnessor in the OPDSunit harness;replacethe faulty harness.l

NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26). NOTE:ThisDTCmay have been causedby turning t h e i g n i t i o ns w i t c hO N ( l l ) w i t ht h e g a u g ea s s e m b l y disconnected. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c k t h a t t h e side airbagcutoff indicatorcomes on.

then 26. Replacethe OPDSunit (seepage 23-'124), initializethe system (seepage 23-27).

2 7 . Erasethe DTCmemory,then checkfor DTC15-1.

Does the side airbag cutoft indicator come on? YES Go to step 5.

ls DTC 15-l indicated?

NO Go to step 6.

YES Replace t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1

Make sure the side airbagcutoff indicatorgoes off after 5 seconds.

NO The system is OK.l Does the side airbag cutoff indicator go otf after 5 seconds? YES FaultyOPDSunit or SRS uniu replacethe lf the problem is still OPDSunit (see page23-1241. present,replacethe SRS unit (seepage 23-122).) NO Go to step 32. Turn the ignition switch OFF.

{cont'd)

23-99

sRs DTCTroubleshooting(cont'd) 7. Checkthe No. 10 (7.5A)fusein the under-dash fuse/relaybox. ls the f use OK?

1 1 .Turn the ignltion switch OFF. 12. Disconnectthe dashboardwire harness17P connectorK from the under-dashfuse/relaybox,

YES Go to step 8. NO Replacethe fuse, then turn the ignition switch ON (ll).lf the fuse blows again,checkfor a short in the No. 10 {7.5A)fuse circuit(ECMwire harness. floor harness,or OPDSharness).1 8. Disconnectthe OPDSunit harness8P connector(A) from the OPDSunit (seepage 23-124).

Turn the ignition switch ON (ll). 1 4 . Checkfor voltage betweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less. OPDSUNITHABNESS 8PCONNECTOR

9 . Turn the ignitionswitch ON (ll). 1 0 .Checkfor voltage betweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground. Thereshould be batteryvoltage. OPDSUNtT HARNESS8P CONNECTOR

Wire side of lemale terminals

ls the voltageas specitied?

W i r es i d eo f f e m a l et e r m i n a l s

YES-FaultyOPDSunit;replacethe OPDSunit(see page23-124) .a NO-Go to step15.

ls there battety voltage? Y E S G o t o s t e p1 1 . NO Go to step 23.

23-100

) t 5 . Turn the ignitionswitch OFF.

Removethe gauge assembly(seepage 22-64). Then disconnectgaugeassemblyconnectorA from the gauge assembly.

1 9 . Turn the ignition switch OFF. 20. Disconnectfloor wire harness6P connectorC509 (A)from the dashboardwire harness.

T u r nt h e i g n i t i o ns w i t c hO N ( l l ) . 1 7 . Turn the ignition switch ON (ll).

22. Checkfor voltage betweenthe No. 3 terminal of the

)

1 8 . Checkfor voltagebetweenthe No. 3 terminal of the OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less.

OPDSunit harness8P connectorand body ground. Thereshould be 0.5 V or less. OPDSUNITHARNESS 8PCONNECTOB

OPOSUNITHARNESS 8PCONNECTOR

Wire side o{ femaleterminals

Wiresideof femaleterminals ls the voltage as specified? ls the voltageas specified? YES Short to power in the gaugeassembly; replacethe gaugeassembly.l NO Go to step 19.

YES Short to power in dashboardwire harnessA; replacedashboardwire harnessA.l NO-Short to power in the floor wire harnessor in t h e O P D Su n i t h a r n e s si;f t h e O P D Su n i t h a r n e s si s OK, replacethe floor wire harness.I

\, (cont'd)

23-101

sRs (cont'dl DTCTroubleshooting 23. Turn the ignitionswitch OFF.

2 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i

24. Removethe gaugeassembly(see page22-64l,. With the connectorsstill connectedto the gauge '15 assembly,backprobethe No. terminal of gauge (22P). assemblyconnectorA

3 0 . ' 0 2 m o d e l :C h e c k f o r v o l t a g e b e t w e e nt h e N o . 4 terminal of dashboardwire harnessA 6P connector C509and body ground.Thereshould be battery vorlage. '03 model: Checkfor voltagebetweenthe No. 5 terminal of dashboardwire harnessA 8P connector C509and body ground.Thereshould be battery vollage. '02 Model:

Turn the ignition switch ON {ll).

26. Checkfor voltage betweenthe No. 15 terminal of gauge assemblyconnectorA {22P)and body ground.Thereshould be batteryvoltage.

OASHBOARD WIREHARNESS A 6PCONNECTOF A {22P) GAUGEASSEMBLY CONNECTOR

Terminalsideof male terminals

Wiresideof femaleterminals ls thete battery voltage?

'03 Model: WIREHARNESS A 8PCONNECTOR DASHBOARD

YES-Go to step 27. NO Go to step 31.

2 7 . Turn the ignitionswitch OFF. 28. Dlsconnectfloor wire harness6P connectorC509 {A) from dashboardwire harness. T e r m i n as li d eo f m a l et e r m i n a l s ls there battety voltage? YES Poorcontactat the dashboardwire harness A 6 P o r 8 P c o n n e c t oar n df l o o rw i r e h a r n e s sa, n o p e ni n t h e f l o o rw i r e h a r n e s so, r a n o p e ni n t h e O P D Su n i t h a r n e s sC. h e c kt h e c o n n e c t i o ni f; t h e connectionis OK, replacethe faulty harness.l NO Poor contactat gaugeassemblyconnectorA w i r e h a r n e s sA . { 2 2 P )o r a n o p e n i n d a s h b o a r d Checkgauge assemblyconnectorA {22P);if the connectionsare OK, replacedashboardwire h a r n e s sA . I

23-102

\ J

Checkfor voltagebetweenthe No. 2 terminal of ) ndbody g a u g ea s s e m b l yc o n n e c t o B r ( 2 2 Pa ground.Thereshould be batteryvoltage.

32. Turn the ignitionswitch OFF. 33. Disconnectthe OPDSunit harness8P connector(A) f r o m t h e O P D Su n i t ( s e ep a g e2 3 -1 2 4 ) .

ASSEMBLY GAUGE CONNECTOR B {22P) YEL 1

1t 12

3 4 IJ

,/1,/1,/)1 1

9 10 21 22

Wiresideof femaleterminals

ls there battery voltage? YES Faultyside airbagcutoff indicatorcircuit; r e p l a c et h e g a u g ea s s e m b l y . l

34. Turn the ignitionswitch ON (ll). Does the slde airbag cutotf indicator come on?

NO Open in dashboardwire harnessA; replace dashboard w i r e h a r n e s sA . I

YES Go to step 35. NO FaultyOPDSunit; replacethe OPDSunit.l

3 5 . Turn the ignitionswitch OFF. 36. Removethe gaugeassembly(seepage 22-64). Then disconnectgauge assemblyconnectorA from t h e g a u g ea s s e m b l y .

\, (cont'd)

23-103

sRs

DTGTroubleshooting(cont'dl 37. Checkresistancebetweenthe No. 15 terminal of gauge assemblyconnectorA (22P)and body ground.Thereshould be an open circuit,or at least 1M0. A I22PI GAUGEASSEMBLY CONNECTOR

DTC15-3:FaultyOPDSSensor 1. Erasethe DTCmemory {seepage 23-261. 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e SRS indicatorcomes on for about 6 secondsand then goes off. Does the SRS indicator stay on? YES-Go to step 3. NO Intermittentfailure,system is OK at this time. Go to TroubleshootingIntermittentFailures(see page 23-26).

Wire side of femaleterminals

ls the resistance as specified? YES-Short to ground in the side airbagcutoff indicatorcircuit;replacethe gaugeassembly.l NO Short to ground in the dashboardwire harnessA, floor wire harness,or OPDSunit harness;replacethe faulty harness.l

NOTE:Aftermarketdevices(fluorescentlights, laptop computers,etc.)used near the front passenger'sseat-backcan interferewith the seatbacksensorsand causea false DTC15-3.lf one of these deviceswas used,erasethe DTC,operatethe devicenearthe seat-back,and recheckfor DTCs.lf DTC15-3is reset,eraseit, and do not usethe devicenearthe seat-back. 3 . Checkthe connectionat the OPDSsensorharness connectorand the OPDSunit connector. Are the connectionsOK? YES-Go to step 4. NO Reconnectthe OPDSsensorharness connector,and clearthe DTC.I foam (seepage 4 . Replacethe OPDSsensor/seat-back 20-141,and initializethe OPDS(seepage 23-27). Erasethe DTCmemory,then checkfor DTC15-3. ls DTC 15-3indicated? YES Replacethe OPDSunit (seepage 23-1241.a NO The system is OK.l

23-104

{

SRSIndicatorCircuitTroubleshooting TheSRSIndicatorDoesn'tComeOn 1. Turn the ignition switch ON (ll),and see if the other indicatorscome on {brakesystem,etc). Do the other indicatorscome on?

4. Checkfor voltage betweenthe No. l4terminal of gauge assemblyconnectorA (22P)and body ground within the first 6 secondsafter turning the ignition switch ON (ll).Thereshould be 8.5 V or less. GAUGEASSEMBLY CONNECTOR A I22PI

YES Go to step 2. N O - G o t o s t e p8 . 2. Turn the ignition switch OFF,then removethe gauge assembly{see page22-641. Disconnect gauge assemblyconnectorA and B from the gauge assembly. Wiresideof femaleterminats Is the voltage as specified? Y E S - F a u l t yS R Si n d i c a t o cr l r c u i ti n t h e g a u g e assembly;replacethe gauge assembly.I

N O - G o t o s t e p5 .

Turn the ignition switch OFF.

Checkresistancebetweenthe No. 12 terminal of gauge assemblyconnectorB (22P)and body g r o u n d .T h e r es h o u l db e 0 1 . 0 Q . GAUGE ASSEMBLY CONNECTOR B I22PI

11 12 l 3

/)x

1 1 1B

9 10 21 22

BLK

o. Wiresideof femaleterminals Is the resistance as specified? YES Go to step 4.

l{,

N O O p e ni n t h e B L Kw i r e o f d a s h b o a r d wire h a r n e s sA o r f a u l t yb o d y g r o u n dt e r m i n a l( G 5 0 1 )l.f t h e b o d y g r o u n dt e r m i n a li s O K ,r e p l a c ed a s h b o a r d w i r e h a r n e s sA . I (cont'd)

23-105

sRs

SRSIndicatorCircuitTroubleshooting(cont'dl 6 . DisconnectSRSunit connectorC (8P)from the SRS unit {see step 7 on page 23-22). 7 . DisconnectgaugeassemblyconnectorA (22P). Connecta voltmeter betweenthe No, l4terminal of gauge assemblyconnectorA (22P)and body g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d measurevoltage.There should be 0.5 V or less. A {22P) CONNECTOR GAUGEASSEMBLY

9. Connecta voltmeterbetweenthe No.2 terminal of gauge assemblyconnectorB (22P)and body g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d measurethe voltage.There should be battery voltaqe. B (22P} GAUGEASSEMBLY CONNECTOR YEL 1

,/x

6 11

9 10 21 22

Wire side of femaleterminals

Wiresideof femaleterminals ls the voltageas specitied? YES-Faulty SRSunit; replacethe SRSunit (see page23-'l22l.a NO-Short to power in the PNKwire of dashboard wire harnessA or in the floor wire harness;replace t h e f a u l t yh a r n e s s . l L Turn the ignition switch OFF.Checkthe No. 10 {7.5A)fusein the under-dashfuse/relaybox.

ls therc battery voltage? YES FaultySRSindicatorcircuitin the gauge assemblyor poor contactat gaugeassembly connectorB (22P)and the gaugeassembly;if the connectionis OK, replacethe gaugeassembly.l NO Open in the under-dashfuse/relaybox No. 10 (7.5A)fuse circuit,or open in the YELwire of dashboardwire harnessA. lf the under-dashfuse/ relay box is OK, replacelhe faulty harness.l 1 0 . Replacethe No. 10 (7.5A)fuse,then checkto see if the indicatorscomes on.

ls the tuse blown?

Do the indicators come on?

YES-Go to step 10.

YES The system is OK at thls time.l

NO Go to step 9.

N O R e p a i tr h e s h o r tt o g r o u n di n t h e u n d e r - d a s h f u s e / r e l a yb o x N o . 1 0 ( 7 . 5 A ) f u s ce i r c u i t . l

23-106

I J TheSRSlndicatorStaysOn Whenln "SCS" MenuMethod NOTE: . lf you cannot retrieveDTCSwiththe PGM Tester usingthe SRSmenu method.retrievethe flash codes with the Testerin SCS mode {seepage 23-24|,. . A new SRS unit must sensethe entire system is OK beforecompletingits initialself-test.The most common causeof an incompleteself-testis the failureto replaceall deployedpartsafter a collision, in particular,seat belt tensionersand seat belt buckle tenstoners. . An incompleteself-testpreventsthe PGM Testerfrom retrievingDTCS,althoughflash codesare availablein the Tester'sSCSmode. 1. Erasethe DTCmemory usingthe MES connector (seepage 23-26). Does the SRS indicatorgo off while you are erasing the DTC memory?

6. Replace t h e N o . 1 3 ( 1 0 A )f u s e . 7. Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 8. Disconnectthe driver'sairbag 4P connector(see step 2 on page 23-21). 9. Disconnectthe front passenger'sairbag4P connector(seestep 3 on page 23,21). 10. Disconnectboth seatbelt tensioner2P connectors (seestep 5 on page 23-221. '11. D i s c o n n e c t S RuSn i t c o n n e c t o r A { 1 8 P ) f r o m t h e SRS unit (see step 7 on page 23-22],. '12.

Reconnectthe batterynegativecable.

1 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0 seconds.Then turn the ignition switch OFF. 1 4 . C h e c k t h eN o . 1 3 ( ' 1 0 Af)u s e .

YES-Go to step 42.

ls the f use OK? NO Go to step 2. Checkthe No. '13{ 10A)fuse in the under-dash fuse/relaybox.

Y E S - S h o r t t o g r o u n di n t h e S R Su n i t ;r e p l a c et h e SRS unit (seepage 23-122).a N O G o t o s t e p1 5 .

l s t h e f u s eO K ? 15. Replace t h e N o . 1 3 ( 1 0 A )f u s e . YES--Goto step 19. NO Go to step 3.

3 . R e p l a c e t h eN o . 1 3 ( 1 0 A )f u s e . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0 seconds.Then turn the ignitionswitch OFF. C h e c kr h e N o . 1 3 ( 1 0 A )f u s e . ls the f use OK? Y E S T h e s y s t e mi s O K a t t h i st i m e . I NO Go to step 6.

I {cont'd)

23-107

sRs SRSIndicatorCircuitTroubleshooting(cont'd) '16. Disconnectdashboardwire harnessB connectorS from the under-dashfuse/relavbor.

24. Beconnectthe batterynegativecable. Connecta voltmeterbetweenthe No. 3 terminal of SRS unit connectorA (18P)and body ground.Turn the ignition switch ON (ll),and measurethe voltage. Thereshould be bafteryvoltage. A (18PI SRSUNITCONNECTOR PNK

1 1 . Turn the ignition switch ON {ll),and wait for 30 seconds.Then turn the ignition switch OFF,

Wiresideof femaleterminals

1 8 . C h e c kt h e N o . 1 3 ( 1 0 A )f u s e . ls there battery voltage? ls the f use OK? YES Go to step 29. YES Short to ground in dashboardwire harness B; replacedashboardwire harnessB.I NO-Short to ground in the under-dashfuse/relay box; replacethe under-dashfuse/relaybox.l

NO Go to step 26.

26. Turn the ignition switch OFF. 2 7 . Disconnectdashboardwire harnessB connectorS

1 9 . Turn the ignition switch OFF.Disconnectthe batterynegativecable,and wait for 3 minutes. 20. Disconnectthe driver'sairbag 4P connector(see step 2 on page 23-2'l).

2 1 . Disconnectthe front passenger'sairbag 4P connector(seestep 3 on page 23-21).

22. Disconnectboth seat belttensioner2P connectors (see step 5 on page 23-22). DisconnectSRS unit connectorA (18P)from the SRS unit (see step 7 on page 23-22).

23-108

from the under-dashfuse/relavbox.

I 28. Checkresistancebetweenthe No. 3 terminal of SRSunit connectorA (18P)and the No. 2 terminal of dashboardwire harnessB connectorS. There s h o u l db e 0 1 . 0 0 .

3 1 . C o n n e ctth e N o . 3 t e r m i n a lo f S R S u n i t c o n n e c t o r A (18P)and the No. 5 terminal of SRSunit connector C ( 8 P ) w i t ha j u m p e rw i r e . SRS UNIT CONNECTORC I8P}

DASHBOARD WIREHARNESS B CONNECTOR S l

Wire side of femaletermr n al s

PNK

a,SRSuNrr CONNECTOR A I18P)

PNKT l

PNK Wire side of femaleterminals JUMPER WIRE A I18P) PNK SRSUNITCONNECTOR

1 0 11 12 l 3 1 4 1 5 16 1 1 l 8

Wire side of temaleterminals

Wiresideof femaleterminals 32. Turn the ignition switch ON (llf. ls the rcsistance as specified? 33. Checkthe SRS indicator.

YES-Open in the under-dashfuse/relaybox or poor contactat dashboardwire harnessB connectors;checkthe connection.lf the connection is OK, replacethe under-dashfuse/relaybox.l NO-Open in dashboardwire harnessB; replace dashboardwire harnessB.I

Did the SRS indicator go off? YES FaultySRS unit; replacethe SRS unit (see page 23-122l.a NO-Go to step 34.

29. Turn the ignitionswitch OFF.

34. Turn the ignition switch OFF.

30. DisconnectSRSunit connectorC {8P)from the SRS

35. Disconnectthe jumper wire betweenthe No. 3 terminal of SRSunit connectorA (18P)and the No. 5 terminal of SRSunit connectorC (8P).

unit (see step 7 on page 23-22],.

3 6 . C h e c kt h e N o . 1 3 ( 1 0 A ) f u s ei n t h e u n d e r , d a s h fuse/relaybox. ls the f use OK? YES Go to step 40. NO Go to step 37. 37. Replace t h e N o . 1 3{ 1 0 A ) f u s e .

I (cont'd)

23-109

sRs SRSlndicatorGircuitTroubleshooting(cont'dl 38. Removethe gauge assembly(seepage 22-64),then disconnectgauge assemblyconnectorA from the g a u g ea s s e m D l y ,

40. Removethe gauge assembly(seepage 22-64),then disconnectgauge assemblyconnectorA from the g a u g ea s s e m b l y .

3 9 . Checkresistancebetweenthe No. 5 terminal of

4 1 . Checkresistancebetweenthe No. 14 terminal of ) n dt h e N o . 5 g a u g ea s s e m b l yc o n n e c t oA r ( 2 2 Pa terminal of SRS unit connectorC (8P).Thereshould 'l be 0 or less,

SRS unit connectorC (8P)and body ground.There should be an ooen circuit,or at least 1 fMQ , C {8PI SRSUNITCONNECTOR

SRS UNIT CONNECTORC (8P}

Wire side of lemale terminals A I22P) GAUGEASSEMBLYCONNECTOR

Wiresideof lemaleterminals

ls the resbtance as specitied? ls the resistance as specitied? YES-Faulty SRS indicatorcircuit in the gauge a s s e m b l yr;e p l a c et h e g a u g ea s s e m b l y . I N O S h o r tt o g r o u n di n t h e f l o o rw i r e h a r n e s so r i n dashboardwire harnessA; replacethe faulty harness.l

YES FaultySRS indicatorcircuitin the gauge assemblyor poor contactat gauge assembly connectorA (22P);checkthe connection.lf the connectionis OK, replacethe gauge assembly,I N O O p e ni n t h e f l o o rw i r e h a r n e s so r i n dashboardwire harnessA; replacethe faulty harness.!

23-110

42. Turn the ignition switch OFF. 43. lf necessary,removethe SCSserviceconnector from the l\4ESconnector. 4 4 . T u r nt h e i g n i t i o ns w i t c hO N { l l } . Does the SBS indicator come on for about 6 seconds and then go off?

47. Checkresistance betweenthe No.6 terminalof SRSunitconnector C (8P)andbodyground.There shoulb d e0 - 1 . 0 Q . SRS UNIT CONNECTORC I8P)

YES-The system is OK at this time. t

BRN

n NO Go to step 45. 4 5 . D i s c o n n e cSt R Su n i tc o n n e c t oC r ( 8 P )f r o m t h e S R S unit (see step 7 on page 23-221. 46. Connectthe HondaPGM Tester{A) to the Data Link Connector(B),and follow the Tester'sprompts in the "SCS" menu (seethe Tester'soperating m a n ual ) .

.r9

Wiresideof femaleterminals

ls the resistance as specified? YES FaultySRSunit or poor contactat SRS unit connectorC (8P);checkthe connection.lf the connectionis OK, replacethe SRS unit (seepage 23-1221.. NO Open in the SCS line betweenthe No.6 terminal of SRS unit connectorC (8P)and the No. 9 terminal (BRNwire) ofthe data link connector (DLC),or open betweenthe No. 4 terminal of the D L Ca n d b o d y g r o u n d .R e p a i rt h e o p e nw i r e ( s ) . 1

,l I

IL, 23-111

sRs After Deployment ComponentReplacement/lnspection NOTE:Beforedoing any SRS repairs.use the PGM TesterSRSmenu method to checkfor DTCS;referto the DTCTroubleshootingIndexfor the lessobvious deployedparts (seatbeit tensioners,front sensors,side airbagsensors,etc.) After a collisionwhere the seat belt tensioners deployed,replacethese items: ' Seat belt tensioners . Seat belt buckletensioners . S R Su n i t . Front impactsensors After a collisionwhere the front airbag(s)deployed. replacethese items: . S R Su n i t . Deployedairbag(s) . Seatbelt tensioners . Seat belt buckletensioners . Front impactsensors After a collisionwhere the side airbag{s)deployed, replacethese items: . S R Su n i t . D e p l o y e ds i d ea i r b a g ( s ) . Side impact senso(s)for the side(s)that deployed Duringthe repair process,inspectthese areas: . lnspectallthe SRSwire harnesses.Replace,don't repair,any damagedharnesses. . I n s p e c t t h e c a b l ree e l f o rh e a t d a m a g el.f t h e r ei s a n y damage,replacethe cable reel. Afterthe vehicleis completelyrepaired,turn the ignitionswitch ON (ll).lf the SRSindicatorcomes on for about 6 secondsand then goes off, the SRSairbag system is OK. lf the indicatordoes not function properly, use the PGM TesterSRS Menu Methodto readthe DTC (seepage23-23).lf this doesn't retrieveany codes,use the Tester'sSCSmenu method (seepage23-24).lf you still cannot retrievea code,go to SRS IndicatorCircuit Troubleshooting.

\|J 23-112

Driver's Airbag Replacement Removal

Installation

1. Disconnectthebatterynegativecable,and wait at least3 minutes beforebeginningwork.

1. Connectlhe horn switch connector(1P)to the driver'sairbag.

2. Removethe accesspanel (A)from the steering wheel, then disconnectthe driver's airbag 4p connector(B)from the cable reel.

2. Placethe new driver'sairbag (A) inthesteering wheel, and secureit with new Torx bohs (B),and installthe maintenancecover (C).

a 9.8 N.m {1.0kgf.m,7.2 lbt.ft)

A \'l9

Removethe maintenancecover (A),then remove the two Torx bolts (B) using a Torx T3Obit.

Connectthe cable reelto the driver's airbag4P connector(A),then installthe accesspanel (B)on the steeringwheel.

Disconnectthe horn switch connector(1P)(D). 5 . Removethe driver'sairbag (C).

4. Connectthe batterynegativecable. 5 . After installingthe airbag,confirm proper system operation: . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R Si n d i c a t o r should come on for about 6 secondsand then go off. . Make sure the horn works.

lfc 23-113

sRs AirbagReplacement FrontPassenger's Removal 1. Disconnectthebatterynegativecable,and wait at least3 minutes before beginningwork,

Installation 1. Placethe new front passenger'sairbag(A) into the dashboard.Tightenthe front passenger'sairbag m o u n t i n gn u t s( B ) .

2. Removethe glove box stops,and lower the glove box.

airbag4P thefrontpassenger's 3. Disconnect (A)from dashboard wire harnessB. connector

9.8N m {1.0kgf.m,7.2lbfft} Connectthe front passenger'sairbag4P connector ( A ) t o d a s h b o a r dw i r e h a r n e s sB .

4 . Removethe three mounting nuts (A) from the

bracket.Coverthe lid and dashboardwith a cloth, and pry carefullywith a screwdriverto lift the front p a s s e n g e r 'asi r b a g( B )o u t o f t h e d a s h b o a r d . N O T E : T h ea i r b a gl i d h a sp a w l so n i t s s i d ew h i c h aftachit to the dashboard.

Raisethe glove box, and reinstallthe stops. 4 . Reconnectthe batterynegativecable. After installingthe airbag,confirm proper system o p e r a t i o nT; u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R S indicatorshould come on for about 6 secondsand then go off.

trr 23-114

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SideAirbag Replacement NOTE:Reviewthe seatreplacement pro6edure in the Bodysectionbeforepertormingrepairsor service.

Removal 1. Disconnectthe batterynegative cable,andwait at least3 minutesbeforebeginning work. 2. Disconnect thesideairbagharness2P connector {A).

Installation NOTE: . l f t h e s i d ea i r b a gl i d i s s e c u r e db y a t a p e , r e m o v e l h e rape. . Do not open the lid of the side airbagcover. . Use new mounting nutstightenedto the specified torque. . Make sure that the seat-backcover is installed properly,lmproper installationmay preventproper deployment. . Be sure to installthe harnesswires so that they are not pinchedor interferingwith other parts. 1. Placethe new side airbagon the seat-backframe (A).Tightenthe side airbag mounting nuts (B).

)

3 . Removethe seatassembly(seepage20-71)and seat-backcover (seepage 20-75). Removethe mounting nut (A) and the side a i r b a g( B ) . 2. Installtheseat-backcover {seepage 20-75). 3. Installtheseat assembly(seepage 20-71),then connectthe side airbagharness2P connector. 4. Move the front seat and the seat-backthrough their full rangesof movement,making sure the harness wires are not pinchedor interferingwith other parts. 5. Reconnectthe batterynegativecable. 6. After installingthe side airbag,confirm proper system operation;Turnthe ignition switch ON (ll); t h e S R Si n d i c a t o sr h o u l dc o m e o n f o r a b o u t6 secondsand then go off.

l,o 23-115

sRs Airbag Disposal Special Tool Required Deploymenttool 07HAz-SG00500 Beforescrappingany airbags,side airbags,seat belt tensioners,or seat belt buckletensioners(including those in a whole vehicleto be scrapped),the airbags, side airbags,seat belt tensioners,or seat belt buckle tensionersmust be deployed.lf the vehicleis still within the warranty period,the HondaDistrictService Managermust give approvaland/orspecialinstruction beforedeployingthe airbags,side airbags,seat belt tensioners,or seatbelt buckletensioners.Only afterthe airbags,side airbags,seat belt tensioners,or seat belt buckletensionershave been deployed(asthe resultof vehiclecollision,for example),can they be scrapped.

Driver's Airbag: 4. Removethe accesspanelf rom the steeringwheel, then disconnectthe driver'sairbag4P connector from the cable reel (seestep 2 on page 23-21). Front Passenger'sAirbag: 5. Lowerthe glove box,then disconnectthefront passenger'sairbag 4P connectorfrom dashboard wire harnessB (seestep 3 on page 23-211. Side Airbag: 6. Disconnectthe side airbag2P connectorsfrom the floor wire harness(seestep 4 on page23-211.

lf the airbags,side airbags,seat belt tensioners,and seat belt buckletensionersappearintact(not deployed), treat them with extremecaution.Follow this Drocedure.

Seat belt tensioner:

DeployingAirbagsin the Vehicle

7. Disconnectthe seat belt tensioner2P connectors from the floor wire harness{seestep 5 on page 2322).Pullthe seat belt out all the way, and cut it off.

lf an SRSequippedvehicleis to be entirelyscrapped,its airbags,side airbags.seat belt tensioners.and seat belt buckletensionersshould be deolovedwhile still in the vehicle.The airbags,side airbags,seat belttensioners, and seat belt buckletensionersshould not be consideredas salvageablepartsand should never be installedin anothervehicle.

Seat belt buckle tensioner: 8, Disconnectthe seat belt buckletensioner4P connectorsfrom the floor wire harness(seestep 6 on page 23-221.

1. Turn the ignition switch OFF,then disconnectthe batterynegativecable,and wait at least3 minutes. 2. Confirmthat each airbag,side airbag,or seat belt tensioneris securelymounted. 3. Confirm that the speciaI tool isfunctioning properly by following the checkprocedureon the tool label.

$ J 23-116

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9. Cut off each connector,strip the ends of the wires, and connectthe deploymenttool alligatorclips (A) to the wires. Placethe deploymenttool at least30 feet (10 meters)away from the vehicle. NOTE:The driver'sairbagand the front passenger's airbageach have four wires,two yellow and two red. Twist each Dairof unlikecoloredwires together,and connectan alligatorclip to each pair.

10. Connecta 12 volt batteryto the tool. . lf the green light on the tool comes on, the igniter circuit is defectiveand cannot deDlovthe component.Go to Disposalof Damaged ComDonents. . lf the red light on the tool comes on, the componentis readyto be deployed. 1 1 . P u s ht h e t o o l ' sd e p l o y m e nst w i t c h T . h e a i r b a g sa n d tensionersshould deploy (deploymentis both h i g h l ya u d i b l ea n d v i s i b l e a : l o u d n o i s ea n d r a p i d inflationof the bag,followed by slow deflation). . lf the componentsdeploy and the green light on the tool comes on, continuewith this procedure. . lf a componentdoesn'tdeploy,yet the green light comes on, its igniter is defective.Go to Disposalof Damagedcomponents. . During deployment,the airbagscan becomehot enoughto burn you. Wait 30 minutesafter deploymentbeforetouchingthe airbags.

12. Disposeofthe completeairbag.No pan of it can be reused.Placeit in a sturdy plasticbag (A),and seal rt securery.

/ :

i'..-':

! (cont'd)

23-117

sRs

Airbag Disposal(cont'dl DeployingComponentsOut of the Vehicle

DeploymentTool Check

lf an intactairbagor tensionerhas been removedfrom a scrappedvehicle,or has beenfound defectiveor damagedduring transit,storage,or service,it should be deolovedas follows:

1. Connect the yellowclipsto bothswitchprotector handleson thetool;connectthetoolto a battery. 2. Pushthe operationswitch:greenmeansthetool is OK;redmeansthetool is faulty 3. Disconnectthe batteryandthe yellowclips.

1. Confirmthat the specialtool isfunctioning properly by following the checkprocedureon this page or o n t h et o o ll a b e l . 2. Positionthe airbagface up, outdoors,on flat ground,at least30 feet (10 meters)from any obstaclesor DeoDle. 3. Follow steps9 through 11 of the in-vehicle deploymentprocedure.

Disposalof DamagedComponents 1. lf installedin a vehicle,follow the removal procedurefor the driver'sairbag (seepage23-113), front passenger'sairbag (seepage 23-114),side a i r b a g( s e ep a g e2 3 - 1 1 5 )s.e a tb e l tt e n s i o n e (r s e e page23-4),and seat belt buckletensioner. 2. In all cases.make a short circuit by cutting, stripping,and twisting togetherthe two inflator wires. NOTE;The driver'sand passenger'sairbageach have four wires:twist each pair of like-colored wires together Packagethe componentin the same packagingthat the new reolacementDartcame in. Mark the outsideof the box "DAMAGEDAIRBAG NOT DEPLOYED'"''DAMAGEDSIDEAIRBAGNOT "DAMAGED DEPLOYED", SEATBELTTENSIONER NOT DEPLOYED"or "DAlvlAGEDSEATBELT BUCKLETENSIONERNOT DEPLOYED"so it does not get confusedwith your parts stock. Contactyour HondaDistrictServiceManagerfor how and where to return it for disposal.

23-118

I|J

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CableReelReplacement Removal

6. Removethe dashboardlower cover (Ai.

1 . M a k es u r et h e f r o n tw h e e l sa r e a l i g n e ds t r a i g h t ahead. Disconnectthe batterynegativecable,and wait at least3 minutes.

3 . Removethe driver'sairbag{seepage 23-113). 4 . Disconnectthe connector(Al from the cruise control sevresumeswitch,then removethe s t e e r i n gw h e e lb o l t( B ) .

7 . Removethe column cover screws(A),then remove t h e c o l u m nc o v e r s( 8 , C ) .

) 5 . Align the front wheels straightahead,then remove the steeringwheel with a steeringwheel puller (see '17-6). step 3 on page Do not tap on the steeringwheel or steering c o l u m ns h a f t w h e nr e m o v i n gt h e s t e e r i n gw h e e l .

I, (cont'd)

23-119

sRs

CableReelReplacement(cont'd) Disconnectthe dashboardwire harness4P connector(A)from the cable reel,then disconnect the dashboardwire harness5P connector{B}from the cable reel.

Installation 1. Beforeinstallingthe steeringwheel. align the front wheels straightahead. 2. lf not alreadydone, disconnectthe batterynegative cable,and wait at least3 minutes. 3. Setthe cancelsleeve(A) so the projections(B)are a l i g n e dv e r t i c a l l y .

9 . R e l e a s teh e t a b ( B ) ,t h e n p u l l o f f t h e c a b l er e e l( A ) .

4 . Carefullyinstallthe cable reel (A) on the steering column shaft.Then connectlhe 5P connector{B) and the 4P connector(C).

J 23-120

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Installthe steeringcolumn covers.

8 . l n s t a l l t h ed r i v e r ' sa i r b a g( s e ep a g e2 3 - 1 1 3 ) .

lf necessary,centerthe cable reel.{New replacementcable reelscome centered.)Do this by first rotatingthe cable reel clockwiseuntil it stops, Then rotateit counterclockwiselabout 2 112lurns) untilthe arrow mark on the cable reel label Doints straightup.

9. Reconnectthe batterynegativecable. 10. After installingthe cable reel,confirm proper syslem operalton: . Turn the ignition switch ON (ll);the SRS indicator should come on for about 6 secondsand then go off. . After the SRS indicatorhasturned off, turn the steeringwheel fully left and right to confirm the SRSindicatordoes not come on. . M a k es u r et h e h o r nw o r k s . . Make sure the cruisecontrolworks,

A gn the projectionson the cable reel with the noleson the steeringwheel, and installthe steering Ai\eelwith a new steeringwheel bolt (A).

) c 23-121

sRs SRSUnit Replacement Removal '1.

Disconnectthe batterynegativecable,and wait at least3 minutesbefore beginningwork.

2. Disconnectthe driver'sand front passenger's airbagconnectors(seepage 23-21). 3. Disconnecttheside airbagconnectors(seepage 23-211. 4 . Disconnectboth seat belt tensionerconnectors(see page 23-22)and both seat belt buckletensioner connectors {see page 23-221.

lnstallation 1 , I n s t a l l t h en e w S R Su n i t ( A ) w i t hT o r x b o l t s( B ) ,t h e n connectthe connectors{C)to the SRSuniu push them into positionuntil they clicks. NOTE:When tighteningthe Torx boltsto the specifiedtorque, be carefulto turn them in so that their headsrest squarelyon the brackets. 9.8 N.m (1.0kgf m, 7.2 lbf ft)

Removethe dashboardcenterlower cover (see step 2 on page 20-57). Pull down the consolecarpeton the passenger's side,then removethe Torx bolt (A)from the SRS unit.

Reinstallthe dashboardcenterlower cover (see step 2 on page 20-57). Reconnectthe driver'sand front passenger'sairbag connectors (see page 23-21]'. 4. Reconnectthe side airbagconnectors(seepage23-

211. Reconnectboth seat belt tensionerconnectors(see page 23-221and both seat belt buckle tensioner connectors (see page 23-22). 7. Pull down the consolecarpeton the driver'sside, then disconnectthe connectors.Removethe Torx bolts (A),then pull out the SRSunit.

6 . Reconnectthe batterynegativecable. 7 . I n i t i a l i zteh e O P D Su n i t ( s e ep a g e2 3 ' 2 7 ) .

8 . After installingthe SRS unit,confirm propersystem operation:Turn the ignition switch ON (ll);the SRS i n d i c a t o sr h o u l dc o m eo n f o r a b o u t6 s e c o n d sa n d then go off.

23-122

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Side lmpact SensorReplacement Removal 1. Disconnectthe batterynegativecable,and wait at least3 minutesbefore beginningwork.

lnstallation 1 . I n s t a ltlh e n e w s i d ei m p a c ts e n s o rw i t h a n e w T o r x bolt (A),then connectthe floor wire harness2P connector{B)to the side impact sensor{C).

2. Disconnectthe appropriateside airbag2P connector(seestep 4 on page 23-21). 3. Removethe seat assembly(seepage 20-71J. 4 . R e m o v et h e f r o n t d o o r s i l l t r i m a n d t h e B - p i l l a r lower trim panel (seepage 20-50). 5. Disconnectthe floor wire harness2P connector from the side impact sensor. 6. Removethe Torx bolt (A) using a Torx T30 bit, then removethe side impact sensor(B).

2. Reconnectthe negativebatterycable. 3 . After installingthe side impact sensor,confirm

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proper system operation:Turnthe ignition switch O N ( l l ) ;t h e S R Si n d i c a t o sr h o u l dc o m e o n f o r a b o u t 6 secondsand then go off. Installall removedparts.

)

23-123

sRs OPDSUnit Replacement NOTE:Reviewthe seat replacementproceduresin the body sectionbeforeperformingrepairsor service.

Removal 1. Disconnectthe batterynegativecable.and wait at least3 minutesbefore beginningwork.

Installation 1. Placethe new OPDSunit (A) on the seat-backframe. Tightenthe two screws(B),and connectthe OPDS unit harness8P and sensorconnectors(C)to the OPDSunit. Reinstallthecover (D).

2. Disconnectthe passenger'sside airbag harness2P connector(seestep 4 on page23-2'll. 3. Removethe front passenger'sseat assembly(see page20-71)andseat-backcover (seepage2O-15],. 4. Removethe cover (A),then disconnectthe OPDS unit harness8P and sensorconnectors(B)from the OPDSunit.

2 . Installtheseat-backcover (seepage 20-75). Installthe seatassembly(seepage20-71),then connectthe side airbag harness2P connector, 4. Reconnectthe batterynegativecable.

Set the seat-backin the normal position,and make sure there is nothing on the front passenger'sseat. Initializethe OPDSunit (seepage 23-27). 5. Removethe two screws(C)and the OPDSunit (D). 1 . After installingthe OPDSunit,confirm proper system operation:Turn the ignitionswitch ON (ll); the SRSindicatorshould come on for about 6 secondsand then go off.

23-124

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Front lmpact SensorReplacement Removal 1 . Disconnectthe batterynegativecable.and wait at least3 minutesbefore beginningwork.

2 . Disconnectthe driver'sairbag4P connectorlsee step 2 on page23-21),the front passenger'sairbag 4P connector(seestep 3 on page 23-21),both seat belttensioner2P connectors(seestep 5 on page 23-221,and both seat belt buckle4P connectors(see step 6 on page23-22).

Installation 1. Installthe new front impact sensorwith new Torx bolts (A),then connectthe engine compartmentwire harness2P connector(B)to the front impactsensor

{c). A 9.8N.m

(1.0kgf.m,7.2lbf.ftl

Removethe front inner fender (seepage 2O-1O21. Disconnectthe engine compartmentwire harness 2P connector(A),and removethe two Torx bolts (B) using a Torx T30 bit, then removethe front impact sensor{C).

Reconnectthe batterynegativecable.

)

After installingthe front impact sensor,confirm proper system operation:Turn the ignition switch ON (ll);the SRS indicatorshould come on for about 6 secondsand then go off.

)

23-125

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ServiceManuallndex NOTE:Refertothe lollowing listto look up DTCS, symptoms, fuses,connectors, wire harnesses, specifications, maintenance schedules, andgeneralservice inlormation:

A/C PressureSwitch Circuit Troubleshooting ......... ...-.-....-...-.-.-....-..21-32 B

DTCTroubleshootingIndexes ABS/TCS Components ........................ 19-34 '17-22 EPSComponents ................................. Fueland Emissions 11-i Heating/Ventilation ................................ 21-9

A/F lAir FuelRatiol Sensor Replacement ....................................... 11-113

A/C SignalCircuit Troubleshooting.........................-...... 11-'133

Back-upLightSwitch Test......................................................... 13'3 Back-upLi9ht3 CircuitDiagram

22-75 A-Dillar CornerTrim Replacement ...............-.....-..............-.... 20,96 BallJoint Boots . .8. . . . . . . . . . . . . . . . . . s R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 2 Replacement ...... 1 81 6 ABS IndicatorCircuit SymptomTroubleshootingIndexes Troubleshooting ... 19-52 BallJoints ABS/TCSComponents........................ 1935 R e m o v a 1 . . . . . . . . . . . . . - . . ................ . . . 1 8 - 1 0 CruiseControlSystem..........................4 38 ABSModulator-contml Unit EPSComponents ................................. 17-23 Bemoval/lnstallation ............................ 19-57 Betterv FanControls 10,12 . . . . . . . 2520 Fueland Emissions.............................. 11-10 ABS/TCSComoonents Heating/Ventilation..............................21 10 Component LocationIndex................. 19-30 Beverage Holder . . . . . . .C. .i.r.c. .u.i.t.D i a q r a m . . . . . . . . . . . . . . . . . . . .1. 9. .' .4. 2 S R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .' .3. 0 .

Blower Motor Fuse/Relaylndexes Replacement ..... 2 14 1 AccessoryPoworSocket Front Power0istribution...............................22-46 TesVReplacement .............................. 22'149 Under-dash Fuse/Relay Box ............... 22 45 Blowor Pow€rTransistor Under-hood Fuse/Belay Box ...............22 44 Accessory PowerSockets 21-38 CircuitOiagram.................................. 22-149 Connectorand Wire Harnesslndexes Blower Unit Component Connectors Air Cleaner Removal/lnstallation ............................ 21-39 (to harness) ......2214 Rep1acemen1.....................................11-162

Meintenence section.................... Section3

Air MixControl Motor Replacement ......................................... 21'34 BrakeCelipers Test ......................21-34Overhaul

19-14,23

Gene.allnlormationsection........Section1

) s

Airbag.Driver's Irake Discs Replacement ....................................... 23 1'l3 Inspection .................... ................... 19-13,22 R e p a i.r. . . . . . . . . . - . . . . . . . . . . . . . . . . . . .2. .3. 1. 1 . .6. . . . . . . . . . . . . A BrakeFluidLevelSwitch Airbag.Front Passenger's Test 19.10 Beplacement....................................... 23-114 AIC BrakeLights Locationfndex...................21-3 Altemator Component CircuitDiagram....................................22-7 D e s c r i p t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B- e. .p. .l 2 ' 1m' l e. n. .t. . . . . . .............. . . . . . . . . . . 4. .2. .9. . . . . . a1 ce CircuitDiagram....................................21-14 Overhaul.................................................4-30 BrakeLinesand Hoses 21.57 Inspection............................................. 19-24 AhernatorFRSignalCircuit R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .9. -. .2. 5. A/C Compressol T r o u b l e s h o o t i n. .g. . . . . . . . . . . - . . . . . . .1. 3 . .41 1 Replacement .......-...-............................. BiekeMeder Cylinder 21-41 Antenna Rep1acement......................................... 19-15 Replacement A/C Compr€ssorClulch .........22-103 Inspection............................................. 19-16 Inspecton........ 21-44 2l-49 AudioUnit BrakePads Overhaul.......... Removal/lnstallation ..........................22-100 Inspection/Rep1acement................ 19-11,20 A/C CompressorClutchCircuit Troubleshooting ................................... 21-30 AudioUnitConnector BrakePedal Replacement 22101 Adjustment.............. 19,6 ArfCComoressorReliefValvc Replacement ..........-...-.......................... 21-51 Audio/Entertainment Breke Pedal Posilion Switch Component LocationIndex.................22-9A Test..... ..-.............. 22-84 A/C Compr$sor ThermalProtector CircuitDiagram R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .1. -. 5 . .1. . . . . . . . . . . . . BrakePedalPositionSwitch SignalClrcuit Troubleshooting 11-137 A/C Condenser Replacement,., .....25 12 A/C CondenserFanCircuit Troubleshooting ................... . . . . . .....21-28 (cont'd)

ServiceManualIndex (cont'dl BrakeSystemIndicatorCircuit CircuitDiagram Conventional BrakeComponents..... 19-9 Troubleshooting ABS/TCS Components........... ......19-55

CombinationLight Swilch CylinderHeadAssembly TesVReplacement ..............................22 80 Component LocationIndex..................... 6-3 Inspection................................................. 66 ConnectingRod Bearings Removal.......... &23 R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .-.. . . . 7 - 8 I n s t a 1 1 a l .i .o. n. . . . . . . . . . . . . . . . . . . . . . . . . .6. .3. 9. . . . . . . . . . . . . .

Bulb,Geuge R e p | a c e m e n l . . . . . . . . . . . .......... . . . . . . . 2 2 6 3

ConnectingRod Bolts CylinderHeadCover fnspection....................-.-.-.-.................... 7-24 8emova1 ..............-.-................................. 6-22 Installation ..............................................6-41 Bulb,Headlight ConnectingRods Replacement ......................................... Inspection........,,.,.,...,.,.,.,.,,,,.,,,.,.,.,.,.,.,.,.. 22-A1 75 CylinderHead,Bare Inspecton..,.....,.

Bumper,Front Removal/1nsra11ation ............................ 20 85

Connectors (Seefirstpageof thisIndex)

Bumper,Rear R e m o v a l / l n s t a l l a t i o.n. . . . . . . . . . 2 0 . 8 6

ConventionalBrakeComponent3 D ComponentLocationIndex................... 19'3 Troub1eshootin9 ..................................... 19-4 R e p a i.r. . . . . . . . . . . . . . . . . Dampers.Front 19-8 R e p l a c e m e n t . . . . . . . .................. . . . . . 1 . .8. 2 . .0. . Coolant Inspectio . .n. . . . . . . . . . . . ........ . . .1 0 6 Oampers,Rear R e p l a c e m e n t . . . . . . . . . . . . ....... . . . .1 06 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . .1 . .8. .-.3. .4. . . . . . . . . . . . .

CableReel Replacement....................................... 23-119 DashVents CoolantTemperatureGat|ge T r o u b 1 e s h o o t i n 9 . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . Bemoval/lnstallation ...... .-.......................... 20-64 Camshaft Inspection.......................-...-................... CoolingSyslem 6-29 Dashboard Component LocationIndex................... Bemoval/1nsta11ation ............................ 20-66 10-2 CargoArea Light TesVRep1acement ................................ CountershaftBearings 22-97 OashboardCenterPanel R e p l a c e m e n t . . . . . . . .. . . . . . . . . . . . . . 1 . .3. .-.4. .2 Removal/1nstaf 1ation............................ 20 62 Carpet R e p l a c e m e n t . . . . . - . . ..-. . . . .... . . . . - . 2 0 - 5 5 Cowl Cover DashboardLower Cover R e p l a c e m e n t . . . . . . . . . . . ........ . . . . . 2 0 - 9 5 Removal/lnstallation ...................... 20-59,63 CeilingLight -estrReplacement ................................ 22.96 DashboardUnderCover Crankshaft R e m o v a. l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- .1. 2. . . . . . .Removal/lnstallation ........ ............................ 20 60 ChargingSystem Inspec(on,,,,, ........14 l n s t a l l a t i o n . . . . . . . . . ... . . . . . . . . . . . . . 1 - 2 4 LocationIndex................... 4-20 Component DifferentialCarrierBearings,M/T C i r c u iDt i a g r a m. . . . . . . . . . . . . . . . . . . . . . . .4. .-.2. .1. . . . . . . . . Rep1acement,,......,...,...,.,.,,,.,.,,,........,.,. 13-54 Troubleshooting . . . . . . . 4 - 2 2 CrankshaltMain Bearings R e p l a c e m e n t . . . . . . . . - . - . . . . . . . . . . . . .7. .-.6. . . . . . .Ditferential . . . . . . . . . . . Oil Seals,M/T ChildSeatTetherAnchor 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 5 . .5. . . . . . . . . . . . . R e m o v a l / l n sl at at ;fo n. .. . . . . . . . . . . . . . . .2. .3. .1.1. . . CrankshaftOilSeal,TransmissionEnd 1nstanation .............................................. 7 28 DifferentialPinionGears,M/T CKP(CrankshaftPosition)Sonsor I n s p e c t i o. n, . . . . - , . , , , . , . . , . - , . , . . . . . .1. .3.5, .3, . , , , R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .1. 6. . . . . . Crankshafl ..... Pulley Removal/lnstallation -..................-.......... 6-11 OLCCircuit Clutch Troubleshooting ................................ 11-109 CruiseControlActuator ComponentLocation 1ndex................... 12-3 ...................... R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . . .1. .2. -. 9 . . . . . . .Test .......... 4-43 Door Glass RepIacement.......................4 . .-. 4. .4. . . . . . R . . e. .p. .1. a. .c e m e n t . , . , , , , , , , , , , , . , , , , , , , 2 , ,0, .-,9. , . , . , . , , , , , , . , , ClutchInteYlockSwitch Adjustment. .. .....................20-11 T e s t . . . . . - . . . . . . . . - . . . - .......-.-.-. .. -. . . . . . . . 4 - 6 CruiseControlActuatorCable Adjustment............................................. 4 45 Door GlassWeathelstrips ClutchMasterCylinder R e p l a c e m e. n . .t. . . . . . . . . . -. .. .. . . . . . . . . - . . . 1 . .0. 2 0 Replacement.......................1 . .2. .5. . . . . . . Cruise . . . . . . . .Control . Main Switch TesVRep1acement .................................. 4 42 Door Latches clutch Pedal Replacement ..........-.-.............................. 20-7 Adjustment............................................. 12 4 CruiseControlSet/Resume/Cancel Switch TesVRep1acement .................................. 4 42 Door LockActuators ClutchPedalPositionSwitch Test...................................................... 22-154 T e s t . , . , , , , , . , , , . , . , , , , , , . , . ,.,.,.,.,.,.,4, ,4. 5, , , , , . . CruiseControlSystom Component LocalionInde\................... 4-36 Door LockKnob Switches Clutch Slave Cylindor C i r c u iDt i a g r a m. . . . - . . . . . . . . . . . . . . . . . . .4. .3. 7 . . . . . . . .Test . . . -......... . . . - . . . . . . . . ......22-160 Beplacemeit... 12-1 CruiseControl Unit Door LockSwitches CMP{CamshaftPositionlSenso] I n p u t T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. ., 4 0 T e s t. . . . . . . ........ . . . . . . . . . . . . . ..................2...2 . .-. 1 6 0 R e p l a c e m e n t . . . . - . . . - . . . . . . . . . . . .1.1. .- .1. 2 . .8. . . . . . . . . . . Door Outer Handles CMP(TDC)Sensors Rep1acemen1 ........................................... 20-6 R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . .1.1. .1. 1. .4. . . . . . . . . . . .

) Door Panels Removal/lnstallation -............................. 20-4

)

Front Speakers Rep|acement....................................... 22-102

Door SashTrim EPSIndicatorCircuit Rep1acement......................................... 20 10 Troubleshooting ................................... 17-47

Front Suspension ComponentLocation Index................... 18-3

Door Strikers EPSMotor Adiustment........................................... 20-13 Removal/lnstallation .-.......................... 17-49

FuelandEmissions Description ........................................... 11-12

Door Weatherst ps EVAPCanister Beplacement...........-............................. 20 11 R e p 1 a c e m e n t . . . . . . . . . . . .. . . . . . . . 1 . .1. ., .1 8 9

FuelFill Door Adjustment..........-................................ 20 93

OriveBeh Inspecaron ................ 4-26 R e p | a c e m e n t . . . . . . . . . ................ . . . . . .4. .2.6. . . .

)

EPSConirol Unit Removal/1nsta11ation ..................-......... 17-67

EVAPControlSyst€m FuelFill Door Openet ComponentLocation Index ..............'11-170 B e p l a c e m e n t . . . . . . . . . . . ... . . . . . . . .2. .0. . 1 0 9

EVAPTwo-WeyValve FuelFill Door OpenerCable DriveBelt Auto-tensionel T e s t. . . . . . . . . . - . . . . . . . . . . . . . - . . . . . . . . 1 . .1. .1. 8. .6. . . . . . .Replacement....................................... ...... 20-lO7 lnspection............................................... 4 21 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .....4. .-.2. .8. . . . . . .Evaporetor .. FuelFilter Core R e p 1 a c e m e n t . . . . . . . . . . . . ... . . . . . . . 2 . .1. - 4 2 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2 ......... Driver'sPocket Removal/lnstallation -........................... 20-60 EvaporatorTomperatureSensor FuelGaugeSendingUnit Replacement......................................... T e s t. . . . . . . . . . . . . . . . . . . . . . - . - . . . . . . . . 1 . .1- .' 1 . .5. .6. . . . . . . . . 21-37 Driver'sTray Test..................................... 2137 Removal/lnstallation .........................-.20-65 FuelInjectionSyslem (PGM"FIl EvaporrtoFHeaterUnit Component Location1ndex................. 11-49 DRL{DaytimeRunningLightsl R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. 4. .3. . . . . . . . . . . . . Control Unit FuelIniectors lnputTest .................... ........ . . . ......22-16 ExhaustManifold R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . .1.1. .1.1. l. . . . . . . . . . . Removal/1nsta11ation ................................ I 7 DTCs FuelLinesand Hoses (Seefirstpageolthis Index) ExhaustPipe I n s p e c t i o. n. . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .' .1. 4 . .6. . . . . . . . 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . .9. -. .8. . . . . . .R. .e. .m. .o. .v.a.. l. . . . . . . . . . . . . . ... . . . . . . . . . . .1 1 - 1 4 9 Dust and PollenFiller I n s t a | 1 a t i.o. .n. . . . . . . . . . . . . . . . . . . . . . . 1 . .1. .1. 5. .0. . . . . . . . . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. -. .3.9. . . . . . . . . . . . . FuelPipeProtectol DynamicDamper,Driveshafts R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0.-. 1 . .0. .4. . . . . . . . R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1 . .6. .-.8. . . . . . . . . . . . . . . FuelPressureRegulatot FanControls R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2 ......... C o m p o n e nL to c a t i oInn d e x . . . . . . . . . .1. .0. .' l.1. . C i r c u iDt i a g r a m. . . . . . .. . .. . . . . . . . . . . . .1. .0. 1. .3. FuelPulsationDamper R e p l a c e m e n l . . . . . . . . . . . . . . . . . . . . .1. .1. 1 . .5. .4. . . . . . . FenderFairing,Front ECTSensor R e p l a c e m e n t . . . - . . . . . . . . . . . . . . . . .2. 0 . .-.1. .0. .3. . . . . Fuel . . . . . Pump R e p l a c e m e n t . , . , , , . , . , , , , , , , , , , , ,1,1, .-.11. .4. . . . . . . . . . . . R e p l a c e m e n t , , , , , . , . , . , , , . , , , , , , ,1, ,1, -, 1 , .5, .3, . , , , . . , FinalDrivenGear.M/T El€ctricalPowerSteeringIEPS) R e p l a c e m e n t.... . . . . . . . . . . . . . . . . . . . . 1 . .3. .-.5. .3. . . . . FuelPumpCircuit SignalCircuit T r o u b l e s h o o t i-n. g . . . . . . - . . . . . . . . . . .1. 1 . .-. 1. .4. .1. . . . T r o u b l e s h o o t i n. .g. . . . . . . . . . .1 1 - 1 3 5 Frame R e p a iCr h a n . . . . . . . . . ...... . . . . . . . . . . . .2. .0. 1. .1.4. . FuelSupplySystem Emblems Component Locationlndex .............. 11 140 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. -0.-.1. .0. .0. . . . . Frame . . . . . Stiffenel A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . 1. .1. .- .1. 4. .4. . . . . . . R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .2. 0 . .-J. .' .1. 3. . . . . . T . .e. .s. t . . . . . . . . - . . . - . . . . . ....... . . . . . . . . . . .1. 1. -- 1 4 5 EngineAssembly R e m o v a. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. .2. . . . . . . .Front . . . . . .Console .... FuelTank Installation ............._.................................. 5-9 Removal/lnstallation ............................ 20 5l B e p l a c e m e n l . . . . . . . .. . . . . . . . .1 11 5 5 DisassembJy/Reassemb|y ................... 20 58 EngineBlockAssembly FuelTankVapor ControlValve C o m p o n e nL to c a t i oInn d e r. . . . . . . . . . . . . .7. . 3. . . . . Front Doors T e s t. . . . . . . . . . . . . . . . . . . . . . -. . . . . . . . . 1 1 - 1 8 7 Component LocationIndex................... 20-2 R e p l a c e m e n t , , . , , . . . , . , , , . ,. . , ,.,., .1. .1 1 8 9 EngineBlock,Bare A d i u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .2. .0. . 1. .2. . . . . . . . . . Inspect|on ................7-15 Fuses Repair . . . . . . . . . . . . .1. 1 ..1 Front DriveshaftAssembly {Seefirstpageofthis Index) I n s p e c l i o. .n. . . . . . . . . . . . . . . . . . . . . . 1 6 3 Entry Light ControlSystem R e m o v a 1 . . . . . . . . . . . . . . . ....... - .. .. .. .. .. .1 6 - 3 Component LocationIndex...............-. D i s a s s e m b l. y. . . . . . . . . . . . . . . . . . . . . . . . . .1. 6. .5. 22-89 CircuitDia9ram.................................... 22 90 Resassemb|y ................................-......... 16-9 I n s t a 1 1 a r.i.o. .n. . . . . . . . . . . . . . . .......... . . . l. 6. . .1 7 EPSComponents Component Location1ndex..........-...... 17-!7 Front lmpact Sensors D e s c r i p t i o. n . . . . . . . . . . . . . . ............. . . . . 1 7 - 2 4 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .2. 3. . 1 . .2. .5. C i r c u i tD i a g r a m 1 12 6 (cont'd)

ServiceManualIndex (cont'dl

HeaterValveCable A d j u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .?. .1. -. .4.6.

GenoralInformation (Seeseclion 1)

Hood Latch R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1 20 8

InstrumentPanel Removal/1nsta11ation................. .......20-59

GloveBox Removal/1nsta11ation .......................-.... 20-63

HoodOpenerCable ComponentLocation Index ..............20 105 R e p l a c e m e. n . .t. . . . . . . . . . ...... . . . . . . . . . 2 01 0 6

IntakeAir BypassControlThermalValve T e s r . . . . . . . . . . . . . . . . . . . ........... . .....1. .1. - 1 6 1

lmmobilizerSystem Component LocationIndex .............. 22-162 Description High Mount BrakeLight C i r c u i t D i a g r a.m ..........................22-164 GaugeA3sembly 8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2 . .2. .8. 2. . . . . . . .Troubleshooting ...... ............................ 22,165 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . . . . . . . . Hood InnerFender,Fronl Gaug€s Adjuslment Repfacemenl....................................... 20-102 Component LocationIndex..........-...... 22 54 H o w - t ol n f o r m a t i o n . . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 5Hood 6 lnsulator InsideRearviewMirror CircuitDiagram 22-54 Replacement......................................... 20-89 R e p l a c e m e n t . . . . . . . . . . - . . . . . . . . . . .2. .0. 1. .6. . . . . . . . . . . . . .

Grille IntakeAir System Replacement...........-............................. 20-94 Hood Seal ComponentLocationIndex...-.-........ 11-159 Beplacement.-...........................-........... 20-88 IntakeManitold Horn Removal/1nsta11ation ................................ I 2 H TesVReplacement . . ................ ......22-122 lntermediateShaft Assembly Horn Switch R e m o v a. 1 . . . . . . . . . . . . . . . - . - . . . - . . . . . . .1. 6. .-.1. .9. . . . . . . . . . . . Test ............-........ 22-122 D i s a s s e m b | y . . . . . . . . . . . . . . . . . . . . . - .1. 6. ., 2 0 Adiustment....... R e s a s s e m b. |. y. . . . . . . . . . . . . . . . . . . . . . .1. .6. 2. .2. . . . . . . . . . Horns Installation .........-...-.............................. 16-24 HatchHandle Component LocationIndex. . . . . . . . . . . . . . 2 2 - 1 2 0 Replacement 20-110 Circ!itDiagram 22 121 Hatch Latch Replacement

Replacement

. . . 1. 11 1 3

Hubs KeylessEntry Transmitter R e p l a c e m e n. .t.. . . . . . . . . . . . . . . . . . . . . . 1. .A.2. .6. . . . . . . Repair............... 22-161 T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .6.1. . . . . . . . . . . . . .

Hatch Latch Switch

Test H.tch Lock Actuator Test

H02S.Secondary

20-'110

22-159

KeylessEntry/SecurityAlarm System ComponenlLocationIndex.............. 22 150 C i r c u iDl i a g r a m. . . . . . . . . . . . . . . . . . . . . 2 . .2. .1. 5 1

HatchLockCylinder R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0. ,. 1. .1. .1. . . . . . . . . . IAT {lntakeAir Temperature}Sensor KeylessReceiverUnit '11 HatchSpoiler Replacement.,.........-... 115 lnputTest ............................................ 22-153 Replacement ldle ControlSystem KnockSensor HatchSupport Struts ComponentLocation Index .............. 11-129 R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .1.1. .1. .1. 5 ............ Beplacement..... I n s p e c t i o n , . , . . . . . . . . . - . . . . . . . , . , . ,1,',l,1, 3, .8, , , . , . , . . . . . 20-91 Knuckles HatchWeatherstrio lgnition Coillsl Replacement Replacement.... Bemoval/lnstallation 20-92 ...............-.............. 4 18 F r o nS t u s p e n s r o. .n. . . . . . . . . . . . . . . . .1. 8. .-.1. . . . . . RearSuspension........ .................-... 18-28 HazardWarningSwitch lgnition Key Light test .................... 22_88 T e s t , , . , , , , . , . . . , . . . . . . -....................... . 22-91 H6adlight Adjustment

lgnition Key Switch

..22-78

Test

. . . . . . . . . . . . . . .2. 2 . .-. 9. .1. .

ReQ\ace$ent Hcadlights CircuitDiagram.............................. 22-71,72

lgnition Switch Test .,,,.,.,.,,,,.,.,.

......22-53

License Plate Light R e p l a c e m e n t . . . . . . .-. . . . .- . . .

.....22-83

lgnition System LicenseTrim Component LocationIndex................... R e p l a c e m e n t . . . . . . . . . . . . . . . . . . - . . .2- 0 . .-. 9. .8. . . . . - . . . . . . . 4-15 C i r c u i t D i a 9 r a. m . . . . . . . . . . . . . . . . . . . . . . .4. .' 1 . .6. . . . . . . . 1nspection ............................................... 4-17 Lights,Exterior HeaterControlPanel ComponentLocalionIndex.................22 68 Removal/1nsta11ation ............................ 21-38 lmmobilizerControl Unit-Receiver Lights,Interior 22-161 HeaterControl Powerand GroundCircuits Component LocationIndex................. 22-94 T r o u b f e s h o o t i n g . ................ . . . . . . . . . . . . . . . 2 1 - 2 7 C i r c u i t D i a g r.a. m . . . . . . . . . . . . 2 2 - 9 5

Headliner Removal/lnstallalion ............................ 20-54

)

Oil PressureSwitch MoonroofDrainChannelSlider T e s t. . . . . . . . . . . . . . . . - . - . . . . . . . . - . . . . . . . . .8. -. .4. . . . . . . . . . 20'44 . . . . . . . . 1 1 - 1 5 8 Replacement......................................... R e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . . .8. .-.1. .6. . . . . . . . . . Moonroof Frame LowerArms 18 19 R e p 1 a c e m e n t , , , , , , , , , , . , . , . , . , . , . 2, .0, ,4,2, , , . . . . .Oil . . .Pump, . . . . Engine Removal/1nsta11ation............................ 8-8 Overhau1 .................................................. MoonroolGlass LubricationSystem Oil, Engine 20-37 LocationIndex..................... 8-3 Adiustment........................................... Component . .7. . . . . . . .R. .e. p. .l.a. c e m e n t . . . - . . . . . . . . . . . . . . . . - . - .8. .-.5. . . . . . . . . . Test....................................8 . .4 . . . . . . . .R . .e . .p. .1. a . .c. .e. m . . e n t . . . . . . . . . . . . . . . . . . . . . 2. .0. 3 Low Fuellndicator Test.............

OPDSUnit Moonroot Limit Switch R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .3.-1 . .2. .4. . . . . . . . . . 20 46 Adjustment........................................-.T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .1.3. . . . . . . . . . . . . . M OutsideMirror Holders 20-15 Beplacement......................................... Moonrool Motor R e p l a c e m e n t . . . . - . . . . . . . . . . . . . . . . .2. .D. .-.4. .1. . . . . . . . . . . . M/TAssembly Test . . . . . . . . . . . . . .2. .2. .- .1. 2 .. OutsidePower Mirror Actuators Removal .......... 13-4 22-117 Test...................................................... . . . . .1. 3 - 8 lnstallation....... 22-114 Bepfacement..-.................................... Sunshade D i s a s s e m b.l.y. . . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 1 . .4. . . . . .Moonrool ... R e p 1 a c e m e n t . . . . . . . . . . . ....................2 ....0.4. 0 . .3. .- 4 6 R e s a s s e m b .l y. . . . . . . . . . . . . . . . . 1 OutsidePower Mirror Switch 22-111 Test..-................................................... MoonroofSwitch M/TChangeLever TesVRep1acement .............................. 22-l 12 13-19 lnspection............................................. Outsid€Power Mirrors 13-20 8eassemb1y ................... Disassembly R e p l a c e m e n t . . . . . . . . . . . . . . . . .. .. . .....2. .0. -. .1.5 Mooniool Wind Deflector 22-114 Locationlndex .............. R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. -0. -. 3 . .8. . . . . . Component ....... M/T CountershaftAssembly 22-115 CircuitDiagram.................................. . . . . . . . . . . . . . . . . . . . . . . . .1. 3. .3. 1. .,3. .3. . . . . . I n s p e c t i o. n 22-116 Test-..................................................... . .-. 3. .2. . . . . .Moonroof/Sunroof ... D i s a s s e m b.1. .y. . . . . . . . . . . . . . . . . . . . . . .1. 3 ComponentLocationIndex ...20-35,22-108 ........................................ 13-34 Resassemb|y . .-.4. .8. . . . . . . . . . . . . . . T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 0 ...... C fr c u i tD i a g r a m. . . . . . . . . . . . . . . . . . . . . .2.2. .-1. .0. 9 M/T Differential P Index................. 13-52 ComponentLocation . .6. . . . . .MTF .... A d i u s l m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1. .3. -. 5 I n s p e c t i o n / R e p 1 a c e.m . .e. .n. .t....... . . . .1. 3 . .- 3 Parking Erake M/T Maifthaft Assembly Inspection A d j u s t m e n t. . . . . . . . . . . . . . . . . . 1 . .9. .- 7 MuhiplexControlSystem 13-23, 26 1nspection ...................................... lndex ..............22 168 ComponentLocation 1325 Disassembly ......................................... Parking Brake Cable 22-169 CircuitDiagram.................................. 13 28 Resassembly ........................................ Rep1acement.........................1 . .9. .-.2. .6. . . . . . . . . 22-171 0escription......................................... 13-43 Adjustment........................................... ................................ 22-17 2 Troubleshooting ParkingErakeSwitch M/T ReverseShift Fork . . . .1. 9 - 1 0 Test................. I n s p e c t i o. n. . . . . . . . . . . ................ . . . . . . . .l .3. .1. 9 . . . . Muliiplex ControlUnit, Under-dash InputTest Passenger's TraV 22-92 EntryLightControlSysiem............. M/T Shift Level ............................ 20-65 Removal/lnstallation Alarm Entry/Security R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3. .- .5. 1. . . . . . . . .Keyless .... 22-155 Systern.-....................................... PCVValve 115 MultiplexControl System.............22 MainshaftBearings B e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .'.1. 6 . .9. . . . . . . . . . 22'141 R e p l a c e m e n t . . . . , . . . . . . . . . . . . . . . . .1. .3.4. .1. . . . . . . . . Wiper/Washer................................. ..... T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l. 1. . 1. .6. .9. . . . . . . Mairtenance PistonRings lSeesection3) 8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .7. .- .2. 1. . . . . - . - . . N MIL Pistons ............................. 11.46 How to Informatron R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . - . . .7. .-.1. .8. . . . . . . . . . NoiseReductionCondenser ..........................1 . .-.2. .3. . . . . . . . . . . . . . . . .1. 0 21 2 1 n s t a | 1 a t.i .o. n Test,, MIL Circuit .- . . . . ......... 1197 Troubleshooting .......... PowerR€lay 22-51 Test...............-.-...................................... Mirrors 20'14 Index................. ComponentLocation PowerWindow Motor, Driver's t e s l . . . . . , ,.,,,. , , , . . . . . . . . . . . . Mode ControlMotor . . . . . . . . . 2 1 , 3 5 Oil Filte] Replacement . . . . . . Window Motors, Passenger's T e s t . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 2 1 3 5 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. -. 6. . . . . . . . Power

Oil Filter Feed Pipe MoonroofAuto Stop Switchos R e p l a c e m e n t . . . . . . . . . . . . .....- , . . . , . , , , , , , , , 8 - 7 22'113 Test......................................................

l' ,e

PowerWindow Switch, Master 22-126 lnputTest ..........-.........-....................... T e s r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .2. 4. . . . . . . . . . Oil Pan Moon.oot ControlUnil 22-133 22-110 R e m o v a l. . . . . . . . . . . . . , . , , , , , , , , , , , , . , . , , , .7. .1. .1. . . . - . . .Replacement....................................... .... lnputTest ............................................ ........... l n s t a l l a t i o .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. .- .2. 7

MoonroofDreinChannel B e p l a c e m e n. .t .. . . . . . . . . . . . . . . . . . . . . .2. .0.3. .9. . . .

(cont'd)

ServiceManuallndex (cont'dl PowerWindow Switch, Passenger's lnputTest .............-...... 22-130 22 132 Replacement...,-.-.-...,.. 22-133

RockerArm Assembly Removal 6-26 D;sassembly/Reassembly ..................... 6-27 lnstallation 6-38

sRs

C o m p o n e n t L o c a t i o nI n d e x . . . . . . . . . . . . . . 2122 4 CircuiD t i a 9 r a m. . . . . . . . . . . . ............ . . . . .2. 2 . . .1 2 5

RockerArms Test Inspecton

LocationIndex................. Component 23-13 D e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.3. .1. . . . . . . C i r c uD i t; a g r a m ... .... ...........2334 lnspection/Replacemenl ................... 23 112

Roof Moldings Replacement

o Ouaner Window Glass 8ep1acement ......................................... 20-29

R e p l a c e m e n t. . . . . . . . . . .

10-3 10-10

RadiatorFanAssembly ........................ r0-4 Test RadiatorFanCircuit Troubleshooting RadiatorFanSwhch Replacement Test RadiatorFanSwitch Circuit Troubleshooting RearAir Outlet Replacement

StabilizerBar Replacement FrontSuspension RearSuspension

1A-17 18-30

StabilizerLinks Removal/lnstallation FrontSuspension RearSuspension

1 81 8 18-31

SeatBehs,Rear Replacement

23-1

SeatCover,Front Replacement

20-75

Startel Test Replacement Overhaul

20-84

StarterSolenoid Test

Replacement

Seat,Driver's Removaf/lnstaf lation............................ 20 11 Disassembly/Reassemb1y ................... 20-73

4-7

StartingSystem \' Component LocationIndex...............-..... 4-3 CircuitDia9ram ........................................ 44 Troubleshooting

10-14 10-17 10-17

Sedt,FaontPassenger's Disassembly/Reassemb1y ................... 20-74 Seat,Rear Removal/lnstallation ............................ 20-80

Steering Component LocationIndex................-.. 17-3 Inspectaon ................... 11-4

Seat-backCover,Reer

SteeringColumn Removal/lnstallation

1 01 6

Replacement

Inspection

Seat-back Latch, ReaI Replacement

SteeringGearbox

2Q-104

RearWindow Defogger Index ..............22 104 ComponentLocalion 22-105 CircuilDiagram 22 106 Test RearWindow D€roggerWires Repair

23-9

SeatCushionCover,R6ar 10-3

23 105

SRSUnit Replacement..-.................................... 23-122

s Seat8ehs, Front Replacement rnspec!on

Radiatorand CondenserFans CommonCircuit T r o u b l e s h o o l i n g . . . ........... . . . . . . . . . 2 12 9 RadialorCap Test..-.-...

SRSlndicatorCircuil Troubleshooting

Seat Belts Component LocationIndex................... 23-3

R Radiator Test......

6-7 6-28

Specifications (Seesection2)

Removal Overhaul lnstallation

Seat-backStriker.Rear Replacement

17-9 1 11 1 17-51 1 75 5 17 63

SteeringHangerBeam Seats Component LocationIndex....-............ 20-70

Replacement

20 68

SteeringLinkage 22-106

Shift Forks

Inspefiron

13,21 Disassembly/Reassembly ................... 13-22

Steering Lock

Inspectton

RearWindow Glass Replacement

SecirculationControlMotor Replacement Test.....

20-25

Replacement

Shitt Lever Trim Removal/lnstallation ............................ 20 61 2l-36 21 36 21 25

17-13

SideAirbag,Drivel's Replacement

Recirculation Control Motor Circuit Troubleshooting

SteeringRackGuide Adiustment

.....11-12

23-115

Sidelmpact Sensors

Replacement 23 123 Refrigerant Replacement ..-.-.-...................... 21 53,54,55 Side Marker Light Test........................................................ 21-56 R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .2. .-.A. .3. . . .

RetrigerantOil Spark Plugs R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .2 . .1. .-.6. . . - . . . . . . . . . . .

. .._..4_19

174 Removal 17-6 D i s a s s e m b l y / R e a s s e m b l.y. . . . . . . . . . . . . . . .1. .7. .7 1 n s t a 1 1 a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 7. .-.8. . . . . .

Sublrames Replacement

20 112

{

Suspension A d j u s t m e n t . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . .V. . . . . . . . 1 8 4

ComponentLocationIndex................. 20-17

SynchroRing,Triple-cone WindshieldGless I n s p e c t i o n . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . .V. .a. l.v1e3G 39 uides R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .0. 1. .9- . . . . . . . . . . Inspection............-.-................................ 6 32 SynchroSleeve Beplacement ..........-................................ 6 33 WiperIntermittentControlUnit, Inspectaon/Reassemb1y ....................... 1339 RearWindow ValveSeats InputTest .....22-134 R e p a i .r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. 3 . .5. . . . . . . . . . . . . . . . . WiDerMotor, RearWindow Rep1acement....................................... 22-146 Adjustment.-.-....... 6-9 Removal...-...-......................................-... 6-31 WiDerMotor,windshield Taillight Inspec!on .....6-32 Test.......-..........-.....-.........................

Thermostai Test ........................ 10 4 R e p l a c e m e n t . . . . . - . . . .- . . . . . . . . . . . . . 1. .0. I. . . . .

Vehicle Speed Signal Circuit Wiper/WasheI Troubleshooting .....-... ..........................22-65 Component LocationIndex ..............22-134 CircuitDiagram.......................... 22-136, 131

vss

Throttle Body Replacement -.............. ............ .............22 61 Test.................. 11-160 Removal/lnstallation .. . . . . . .. ... 11-'165 VTCActuator Disassembly/Feassemb|y................-11-166 Inspection .................68

Wiper/Washor Switch TesVReplacement .............................. 22-140 WireHarnesses

R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . .2.4. . . . . . . . .( .S e e f i r s t p a g e o f t h i s l n d e x )

ThrottleCable A d j u s t m e n t. . . . . . . . . - . . . . . . . . . . . .1. .1. 1 . .6. .3. V T CO i lC o n l r o l S o l e n oVi d alve R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . .R. .e. m . 1o1v1a6l4. . . . - . . . - .| .1.- 1 2 7

t s

Tie-rodBallJoint Boots VTCSystem B e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . .1. .7. .6.7. . . . . . . C . . o. .m . .p . o n e n t L o c a t i o n l n d e x . . . . 1. .1. .-.1. 1 . .7. . Timing/CamChain ...612 lnstallation

Wi.ing System H o w t o I n { o r m a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 BelayandControlUnit Locations .-....-.............. -.-.-....22-7,4, 11, 12

VTECSolenoidValve Femoval/lnspection....-......................11-128

...........6 . . .1. 5 .

Timing/Cam Chain Auto-tensionel R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -W 19

Timing/CamChainCaseOilSeal Installation......................-......................6,21 WasherFluidLevelSwitch TesVReplacement .............................. 22 144 TrailingArms Removal/lnstallation .............. . . . . .....1833 WasherFluidReservoir Replacement ....................................... 22-146 tnm Component Locationlndex................20 49 WasherMotor,Windshield R e m o v a l / l n s t a l l a. t. i-o. .n. . . . .5200, 5 1 , 5 2 , 5 3 T e s t- . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .1. .4. 4. . 2 2 Troubleshooting {Seefirstpageot thisIndex) Turn SignalLight Replacement Turn Signal/HazardRelay InputTest........

WasherTube,Windshield Replacement......-...-............................ 22 147 .........22 A4

Weter Passage 22-87

Turn Signal/HazardWarningLights Component LocationIndex.................22 85 Circuit Diagram................-................... 22-86

],s

W.ter Outlet '10-9 Installation ..................-...........................

UndeFdashFuse/R€layBox Removal/lnstaf lation............................ 22-49

lnstallation

Water Pump Inspection........................... .. . . . .......10 5 Replacement .-......................................... 10 5 WheelBearings I n s p e c | i o n. . . . . . . . . . . . . . . . . . . . . . . . . . ............1...8. 8. . . . Wheel Speed Sensors I n s p e c t i o n . . - . . , . , . , , . , , , , , . , . , , , . . . . . . . . . . . .1. .9.-. 5 . .9. . . . R e p l a c € m e n. t. . . . . . . - . . . ..... . . . . . - . . . 1 . 9-59

WheelsandTires UpperArms R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1. .8. -. .3. 2.

. . . . . . . . . . .1. 0 . .I. .

Inspect|on