Civic Manual EP3 Tyre r Manual

8/6/2019 Civic Manual EP3 Tyre r Manual

http://slidepdf.com/reader/full/civic-manual-ep3-tyre-r-manual 1/1136

ServiceManualndex

sNOTE:Referto he ollowing istto lookup A/C Pressure witch CircuitDTCS,ymptoms,uses, onnectors,ire Troubleshooting... . . . . .. .-.-. . . .-. . .-.-.-. . . .-. .21-32harnesses,pecif icat ions,aintenanceschedules,ndgeneral erviceinlormation:

DTCTroubleshootingndexes

A/C SignalCircuitTroubleshooting... . . . . . . . . . . . . . . . . . . . . . .-. . . . . .

1- '133 Back-up ightSwitchTest . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . .3'A/F lAir FuelRatiolSensor

ABS/TCS omponents.. . . . . . . . . . . . . . . . . . . . . .9-34 Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-113 Back-up i9ht3EP SComponents.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-22

Circuit iagramFue land miss ions 11-i A-Dil lar orner r im

ABS ndicatorCircuit

Heating/Ventilat ion... . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9 Replacement.. . . . . . . . . . . . .-. . . . .-. . . . . . . . . . . . . .-. . . .0,96 Ball ointBootssRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -28 Replacement.. . . .

... 19-52 BallJoints

22-7

1 81

Remova1. . . . . . . . . . . . . - . . . . . . . . . .. . . . . . . . . . .18-SymptomTroubleshootingndexes TroubleshootingABS/TCSComponents.. . . . . . . . . . . . . . . . . . . . . . .935Cruise ontrol ystem .. . . . . . . . . . . . . . . . . .. . . . . .48 AB SModulator-contmlni tEP SComponents.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23 Bemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .9-57 BettervFa nControls 10,12

AccessoryPoworSocket Front

Blowor Pow€rTransistor

. . . . . . . 22

Blower UnitRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . .1-3

Fuel ndEm ssions... . . . . . . . . . . . . . . . . . . . . . . . . . .1-10 ABS/TCS omoonentsHeating/Ventilat ion... . . . . . . . . . . . . . . . . . . . . . . . . . . .210 Component ocationndex .. . . . . . . . . . . . . . .9-30 Beverage older

SRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 '30 C i rcu i tD iaqram. . . . . . . . . . . . . . . . . . . . . . . . . .9 '42

Blower MotorReplacement.. . . 214

21-3

Power istr ibut ion... . . . . . . . . . . . . . . . . . . . . . . . . . . .22-46esVReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2'149Under-dashuse/Relayox .. . . . . . . . . . . . .2 45Under-hooduse/Belayox .. . . . . . . . . . . . .224 Accessory owerSockets

Fuse/Relayndexes

(t oharness)

Connector nd Wire HarnessndexesComponent onnectors

Circuit iagram... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-149

Air Cleaner. . . . . .2214 Rep1acemen1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-162

Air MixControl MotorMeintenenceection .. . . . . . . . . . . . . . . . . .ect ion Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1'34 Brake elipers

Test .. . . . . . . . . . . . . . . . . . . . .21-34Overhaul 19-14,Gene.al nlormationsection........ ection1

21.57

Airbag.Driver's

AhernatorFRSignalCircuitT roub leshoo t i ng. . . . . . . . . . . . - . . . . . . . . . .1134

AntennaReplacement

Inspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-2Rep|acement . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .9 -

BiekeMeder Cylinder

Irake Discs

A

Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1 l3 Inspection... . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .9-13,Repa i r. . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 1 6

BrakeFluidLevelSwitchAirbag.Front Passenger's TestBeplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 4

AIC BrakeLightsComponentocationndex ... . . . . . . . . . . . . . . .21-3 Altemator CircuitDiagram... . . . . . . . . . . . . . . . . . . . . . . . . .Descr ip t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . .21 '1 ' lep lacem en t. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .29CircuitDiagram... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-14verhaul . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .4-30rake ines ndHoses

1 9 .

A/C CompressolReplacement.. . . . .-. . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 41

A/C Compr€ssor lulchRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

.. . . . . . . .22-103 Inspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1I nspec t on . . . . . . . .Overhaul.. . . . . . . .

A/C CondenserReplacement,. ,

21-442l-49 AudioUnit

Replacement

BrakePadsRemoval/ lnstallat ion. . . . . . . . . . . . . . . . . . .. . . . .22-100nspection/Rep1acement.. . . . . . . . . . . . .9-11,

A/C Compressor lutchCircuitTroubleshooting... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30 AudioUnitConnector Brake edal

22101 Adjustment... . .. . .. . .. . . 19,ArfCComoressorReliefValvcReplacement.. . . . . . . .-. . .-. . . . . . . . . . . . . . . . . . . . . . . . . .1-51 Audio/Entertainment

A/C Compr$sor ThermalProtector CircuitDiagramReplacement . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -51

Component ocationnde x ... . .. . .. . .. . . ..22-9A Test .. . . . .-. . .. . .. . . .. . ..2-8Breke Pedal Posilion Switch

BrakePedalPositionSwitch SignalClrcui11-13

. . . . .21 2

A/C Condenser anCircuitTroubleshooting... . . . . . . . . . . . . . . .. . . . . . . . .21-28

sTroubleshooting

(cont 'd



Manual ndex

(cont'dl

BrakeSystem ndicatorCircuitCircuit iagram

Conventionalrake omponents.. . . .9- 9Troubleshooting

ABS/TCS omponents . . . . . . . . .. . . . . 9-55

Bulb,GeugeRep | acem en l . . . . . . . . . . . . . . . .. . . . . . . . . . . . .22 63

Bulb,HeadlightReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-A1

Bumper,FrontRemoval/1nsra11ation... . . . . . . . . . . . . . . . . . . . . . . . .0 85

Bumper,RearRem ova l / l ns t a l l a t i on . . .. . . . . . . .20 .86

Combination ightSwilchTesVReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .220

ConnectingRodBearingsRep|acement . . . . . . . . . . . . . . . . . . . . . .. . . . . . - . . . .7 -8

ConnectingRodBoltsfnspection... . . . . . . . . . . . . . . . .-.-.-.-. . . . . . . . . . . . . . . . . . . .24

ConnectingRodsInspection... . . . . , , . , . , . . . , . , . , . , . , , , , . , , , . , . , . , . , . , . , . , . .5

Connectors(Seeirstpage f his ndex)

ConventionalBrakeComponent3Component ocationndex .. . . . . . . . . . . . . . . . .9' 3Troub1eshootin9... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9- 4

CylinderHeadAssemblyComponentocationndex .. . . . . . . . . . . . . . . .. . .-3Inspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6Removal.. . . . . . . . &23I ns t a11a l i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

CylinderHeadCover8emova1... . . . . . . . . . .-.-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-2 2Installat ion... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-41

CylinderHead,BareI n s p e c t o n . . , . . . . . , .

D

c

CableReelReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1 9

CamshaftInspection... . . . . . . . . . . . . . . . . . . .-. . .-. . . . . . . . . . . . . . . . . . .-2 9

CargoAreaLightTesVRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-97

CarpetReplacement . . . . . - . . . - . . . . .. . . . . . . . - .20-55

CeilingLight-estrReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.96

ChargingSystemComponentocationndex... . . . . . . . . . . . . . . . .-2 0

C i r cu i t i ag ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-21

19-8

CoolantI n s p e c t i o n. . . . . . . . . . . . . . . . .. . . . . .1 0 6

Replacement . . . . . . . . . . . . . . . . .. . . . .106

CoolantTemperatureGat|geTroub1eshoot in9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

CoolingSyslemComponent ocationndex... . . . . . . . . . . . . . . . .0- 2

CountershaftBearingsReplacement . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .3 -42

Cowl CoverReplacement . . . . . . . . . . . . . . .. . . . . . . . . .20-95

CrankshaftRem ova l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Repa i r. . . . . . . . . . . . . . . . .

I n s p e c ( o n , , , , , . . . . . . . . 1 4

Dampers. rontReplacement . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .820

Oampers,Rear

Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -34

DashVentsBemoval/ lnstallat ion-.. . . . . . . . . . . . . . . . . . . . . . . . .0-64

DashboardBemoval/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . .0-66

Oashboard enterPanelRemoval/1nstafat ion... . . . . . . . . . . . . . . . . . . . . . . . .0 62

Dashboard ower CoverRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . .0-59, 3

DashboardUnderCoverRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .0 60

Diff rentialCarrierBearings,M/T

Rep1acement,, . . . . . . , . . . , . . . , . , . , , , . , . , , , . . . . . . . . , . , .3-54

DitferentialOil Seals,M/T8ep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -55

DifferentialPinionGears,M/TI nspec t i on, . . . . - , . , , , . , . . , . - , . , . . . . . . . . . , . , . , , ,353

OLCCircuitTroubleshooting... . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-109

DoorGlassRep1acement . , . , , , , , , , , , , , . , , , , , , , , , , . , . , . , . , . , , , , , , . , ,0 -9A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . . . . . 2 0 - 1 1

DoorGlassWeathelstripsRep lacem en t. . . . . . . . . . . . - . .. . . . . . . . . - . . . . . .200

DoorLatchesReplacement.. . . . . . . .-.-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0- 7

DoorLockActuatorsTest . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .2-154

Door LockKnob SwitchesTest . . . . . . . . .. . - . . . . . . . . . . . . . .22-160

Door LockSwitchesTes t . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .2 -160

DoorOuter HandlesRep1acemen1... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0- 6

ChildSeatTetherAnchorRem ova l / l ns t a fa t ; on. . . . . . . . . . . . . . . . . . . . . . . .3 11

CKP Crankshaft osition)SonsorReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- 116

ClutchComponentLocationndex... . . . . . . . . . . . . . . . .2- 3Rep1acemen1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -9

Clutch nteYlock witchT e s t . . . . . - . . . . . . . . - . . . - . . . . . . . . . . . . .. . - - - . - . . . . . . . 4 - 6

ClutchMasterCylinderReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

clutch PedalAdjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

ClutchPedalPositionSwitchT e s t . , . , , , , , . , , , . , . , , , , , , . , . , , , , , , , , , . , , , , , . .. . . . . 4 4 5

lns t a l l a t i on . . . . . . . . . . . . . . . . . .. . . . . . . . . .1 -24

CrankshaltMain BearingsReplacement . . . . . . . . - . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-6

CrankshaftOilSeal,Transmission nd1nstanation... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

CrankshaflPulleyRemoval/ lnstallat ion... . . . . . . . . . . . . . . .-. . . . . . . . . .-1

CruiseControlActuator

Troubleshooting

Clutch Slave CylindorBeplacemeit. . .

. . . . . . . . . . . . . . . . . . . . . .-4 3

. . . . . . . 4 -22

Test

12-1

RepIacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-44

CruiseControlActuatorCableAdjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

CruiseControlMainSwitch

TesVRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

CruiseControlSet/Resume/Cancel witchTesVRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

CruiseControlSystomComponent ocalionnde\.. . . . . . . . . . . . . . . . . .-3 6C i r cu i t i ag ram. . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

CruiseControl UnitInputTes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .4 ,40MP Camshaft ositionlSenso]

Replacement . . . . - . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- 128

CMP TDC) ensorsReplacement . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . .1 4



OriveBehInspecaron ... . . . . . . . . . . . . .-2 6

DoorPanelsRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . . . .0- 4

DoorSashTrimRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 10

Door StrikersAdiustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-13

DoorWeatherst psBeplacement.. . . . . . . . . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 11

EPSConirolUnitRemoval/1nsta11ation... . . . . . . . . . . . . . .-. . . . . . . . .7-67

EPS ndicatorCircuitTroubleshooting... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 47

EPSMotorRemoval/ lnstallat ion-.. . . . . . . . . . . . . . . . . . . . . . . . .7-49

EVAPCanisterRep1acement . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 1 , 189

EVAPControlSyst€mComponentLocationndex .. . . . . . . . . . . . '11-170

EVAPTwo-WeyValveTes t . . . . . . . . . - . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . .1186

EvaporetorCoreRep1acement . . . . . . . . . . . . . . . . . . . . . . . .. . . 21-42

Evaporator omperature ensor

Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 37Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .2137

EvaporrtoFHeaterUnitReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

ExhaustManifoldRemoval/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

ExhaustPipe8ep|acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- 8

FrontSpeakersRep|acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

FrontSuspension

ComponentLocationndex... . . . . . . . . . . . .8Fueland missionsDescript ion... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FuelFillDoorAdjustment.. . . . . . . .-. . . . . . . . . . . . . . . . . . . . . .09

FuelFill DoorOpenetBeplacement . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .0 .

FuelFill DoorOpenerCableReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .0- O

FuelFilterReplacement . . . . . . . . . . . . . . . . . . . . . . . . . .- 1

FuelGaugeSendingUnit

Tes t . . . . . . . . . . . . . . . . . . . . . - . - . . . . . . . . . . - . .1 '1

Fuel njectionSyslem(PGM"FIlComponent ocation ndex... . . . . . . . . . . . .1-

Fuel niectorsRep1acemen1. . . . . . . . . . . . . . . . . . . . . . . . .1

FuelLinesand HosesI nspec t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' 1Rem ova l. . . . . . . . . . . . . . . . . . . . . .. . . . . .. 1 -I ns t a | 1a t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FuelPipeProtectolReplacement . . . . . . . . . . . . . . . . . . . . . . . . . .0 -1

FuelPressureRegulatotReplacement . . . . . . . . . . . . . . . . . . . . . . . . . .- 1

FuelPulsationDamperReplacemenl . . . . . . . . . . . . . . . . . . . . . . . . . .11

FuelPumpReplacement , , , , , . , . , . , , , . , , , , , , , , , , , ,1 -1

FuelPumpCircuitT roub leshoo t i ng. . . . . . . - . . . . . . . . . . . . . . . .1 -1

FuelSupplySystemComponent ocationndex .. . . . . . . . . . . .1 1A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . . . . . .1 -Tes t . . . . . . . . - . . . - . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . -1 -1

FuelTankB e p l a c e m e n l . . . . . . . . . . . . . .. . . . . . .1 11

FuelTankVaporControlValveTes t . . . . . . . . . . . . . . . . . . . . . - . . . . . . .. . . . 11 -1Replacement , , . , , . . . , . , , , . , . , , , , . . .. . . 111

Fuses{Seeirstpage fthis ndex)

Rep|acement . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .26

DriveBelt Auto-tensionellnspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 -28

Driver'sPocketRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .0-60

Driver'sTrayRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . .-.-0-65

DRL DaytimeRunningLightslControl Unit

lnputTest . . . . . . . . . . . . . . . . . ... . . . . . .. . . . . . . .22-16

DTCs(Seeirstpage lthis ndex)

Dust and PollenFillerReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 -39

DynamicDamper,DriveshaftsReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 -8

ECTSensorReplacement . , . , , , . , . , , , , , , , , , , , , , , . . . . . . . . . . . . . . . .-1 4

El€ctrical owerSteering EPS)SignalCircuit

T roub leshoo t i ng. . . . . . . . . . . .11 -135

EmblemsReplacement . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . .0 -100

EngineAssemblyRem ova1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2Installat ion... . . . . . . . . ._.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-9

EngineBlockAssemblyCom ponen toca t i onnder . . . . . . . . . . . . . . . . . . . ..3

EngineBlock,BareInspect|onRepair

FanControls

Com ponen toca t i onndex . . . . . . . . . . . . . . . . .0 ' lC i r cu i t i ag ram. . . . . . . . . . . . . . . . . . . . . . . .013

FenderFairing,FrontReplacement . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -103

FinalDrivenGear.M/TRep lacem en t . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -53

FrameRepa i r han. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .0 11

FrameStiffenelReplacement . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 - ' 13

FrontConsoleRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .05lDisassembJy/Reassemb|y.. . . . . . . . . . . . . . . . .0 58

Front DoorsComponent ocationndex... . . . . . . . . . . . . . . . .0- 2Ad ius t m en t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 . 12

FrontDriveshaftAssemblyI n s p e c l i o n. . . . . . . . . . . . . . . . . . .. . . . . . 1 63R e m o v a 1 . . . . . . . . . . . . . . . . . . . - . . . . . .. . . . . . . 1 6 - 3D isassem b ly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . 165Resassemb|y.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . .6- 9I ns t a11a r ion. . . . . . . . . . . . . . . . . . . . . . .. . . . .. . . . . . . . . . .6 17

Front mpactSensorsRep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 23 125

. . . . . . . . . . . . . . . .7 -15

. . . . . . . . . . . . . . . .11

Entry LightControlSystemComponent ocationndex .. . . . . . . . . . . . .-.2-89Circuit ia9ram .. . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . .2 90

EPSComponentsComponent ocation ndex... . . . . . . .-. . . . . .7-!7Desc r ip t i on. . . . . . . . . . . . . . . . . . . . . . .. . . . . . .17-24Circu i tDiagram 1126 (cont '



Manual ndex

(cont'dl

GaugeA3sembly

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264

Gaug€sComponent ocationndex ... . . . . . .-. . . . . .2 54How- t on f o rm a t ion. . . . . . . . . . . . . . . . . . . . . . .22-56Circuit iagram 22-54

HeaterValveCableAd jus t m en t. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .1 -46

High Mount BrakeLight8ep|acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282

Hood

lmmobilizerSystemComponent ocationndex .. . . . . . . . . . . .2-162

\

GDescript ion

Genoral nformation(See eclion1)

GloveBoxRemoval/1nsta11ation... . . . . . . . . . . . . . . . . . . .-. . . .0-63

GrilleReplacement.. . . . . . . . . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-94

Hood nsulatorReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-89

HoodLatchRep1acement . . . . . . . . . . . . . . . . . . .. . . . . . . . .2008

HoodOpenerCableComponentLocationndex ... . . . . . . . . . .2005Rep lacem en t. . . . . . . . . . . . . . .. . . . . . . . . .. . . . 20 06

HoodSealBeplacement.-. . . . . . . . . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . .0-88

HornTesVReplacement. . . . . . . . . . . . . . . . .. . . . . 2-122

C i r cu i t D iag ram. . . . . . . . . . . . . . . . . . . . . . . . . .22-164Troubleshooting ... . . . . . . . . . . . . . . . . . . . . . . . .2,165

InnerFender, ronlRepf cemenl.. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .0-102

InsideRearviewMirrorReplacement . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 16

InstrumentPanelRemoval/1nsta11ation... . . . . . . . . . . . . . .. . . . . . 0-59

IntakeAir BypassControlThermalValveT e s r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 1 1 - 1 6 1

IntakeAir SystemComponent ocationndex ..-.-. . . . . . . .1-159

IntakeManitold

Removal/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

lntermediateShaftAssemblyRem ova1. . . . . . . . . . . . . . . - . - . . . - . . . . . . . . . . . . . . . . . . . . . . . . .6 -19Disassemb|y . . . . . . . . . . . . . . . . . . .. . . . . . . . - . . . .6 ,20Resassem b | y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622Installat ion... . . . . .-. . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

Keyless ntryTransmitter

Adjuslment

H

Adiustment.. . . . .

HatchHandle

Horn SwitchTest . . . . . . . . . . . . - . . . . . . . .

HornsComponentocationndexCirc! itDiagram

H02S.SecondaryReplacement

. . . . . . . . . . . . . .22-120Replacement

22-122

22 1210-110

20-'110Hatch LatchReplacement

K

Hatch Latch Switch

. . . . 11 1 3

HubsRep lacem en t .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A 6est

Test

Replacement

HatchSupportStrutsBeplacement.. . . .

HatchWeatherstrioReplacement.. . .

HazardWarningSwitchtest

ldle ControlSystemComponentLocationndex ... . . . . . . . . . .1-129Inspec t ion, . , . . . . . . . . . - . . . . . . . , . , . , , , , , , . , , , . , . , . . . . .' l138

lgnitionCoillslBemoval/ lnstallat ion... . . . . . . . . . . .-. . . . . . . . . . . . . .18

22-161Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 161

Keyless ntry/SecurityAlarm System

Componenl ocationndex ... . . . . . . . . . .2 150C i r cu i l i ag ram. . . . . . . . . . . . . . . .. . . . . . . . . . . . .2 151

KeylessReceiverUnitlnputTest .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-153

KnockSensorReplacement . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

KnucklesReplacement

Fron t uspens ron. . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -1Rear uspension... . . . .. . . . . . . . . . . . . . . .-. . .8-28

Repair . . . . . . . . . . . . . .

H.tch Lock Actuator22-159

HatchLockCylinderRep|acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 , 111

HatchSpoilerIAT lntakeAir Temperature} ensorReplacement., . . . . . . . . .-. . . ' 1 1

1 1 5

20-91

20-92

... . . . . . . . . . . . . . . . . .2_88lgnition KeyLightTes t , , . , , , , . , . . . , . . . . . . - .

H6adlight

Adjustmentlgnition Key Switch

. . . . . . . . . . . . . . . . . . . . . . .2-91

. . . . . . . . . . . . . . . . . . . . . . .2 -91. 22 -78 Test

ReQ\ace$entlgnition SwitchTest ,, , . , . , . , , , , . , . , . . . . . . .22-53

License PlateLightReplacement . . . . . . . . . . . - . . .. . . . . . . .22-83

License rimReplacement . . . . . . . . . . . . . . . . . . - . . . - . . . . . . . . . . - . . . . . . .0 -98

Lights,ExteriorComponent ocalionndex... . . . . . . . . . . . . . .228

Lights,InteriorComponentocationndex... . . . . . . . . . . . . . .2-94C i r c u i t D i a g r a m. . . . . . . . . . . . . 2 2 - 9 5

HcadlightsCircuit iagram ... . . . . . . . . . . . . . . . . . . . . . . . . . .2-71, 2

HeadlinerRemoval/ lnstallalion... . . . . . . . . . . . . . . . . . . . . . . . .0-54

HeaterControlPanelRemoval/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . .1-38

HeaterControlPowerand GroundCircuitsTroub f eshoo t i ng . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .21-27

lgnitionSystemComponent ocationndex .. . . . . . . . . . . . . . . . .-1 5C i r cu i t D ia9 ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .' 161nspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-1 7

lmmobilizerControl Unit-Receiver22-161



Low Fuel ndicatorTes t . . . . . . . . . . . . . . . . . . . . .11 -158

MoonroofDrainChannelSliderReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0'44

MoonroofFrameRep1acement , , , , , , , , , , . , . , . , . , . , . , . , , , , , , . . . . . . . . . . . .042

MoonroolGlassAdiustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-37Rep1acement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .037

MoonrootLimit SwitchAdjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-.-0 46Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 113

Moonrool MotorReplacement . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D -41

Oil Pressure witchTes t . . . . . . . . . . . . . . . - . - . . . . . . . . - . . . . . . . . . .Rep lacement . . . . . . . . . - . . . . . . . . . . . . . . . . .-

Oi lPump,EngineOverhau1... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil, EngineReplacement . . . - . . . . . . . . . . . . . . . . - . - . . .

OPDSUnitReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -

OutsideMirror HoldersBeplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-

OutsidePowerMirrorActuatorsTest . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. .2-1Bepf cement..-. . . . . . . . . . . .. . . . . . . . . . . . . . . .2-1

OutsidePowerMirror SwitchTest .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Outsid€PowerMirrorsReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 20 -Componentocationndex .. . . . . . . . . . . .2- 1Circuit iagram .. . . . . . . . . . . . . . . . .. . . . . . . . . . .2-1Test .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . .2-1

LowerArms

Removal/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . . .8 19

LubricationSystemComponentocationndex... . . . . . . . . . . . . . . . . . .-3Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

M

M/TAssemblyRemoval .. .. . .. . ..3-4 Test . . . . . . . . . . . . . . . . . . . . . .2 -1 2l n s t a l l a t i o n . . . . . . . . . . . . .3 -8

. . . . . . . . .21 ,35

D isassem b ly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -14R e s a s s e m b l y. . . . . . . . . . . . . . . . . . . . .3 - 4 6

M/TChangeLever

lnspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19Disassemblyeassemb1y... . . . . . . . . . . . . . . .3-20

M/T Countershaft ssemblyI nspec t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331 , 3D isassem b1y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -32Resassemb|y.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

M/T DifferentialComponentLocationndex... . . . . . . . . . . . . . .3-52Ad ius lm en t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -56

M/T Maifthaft Assembly1nspection.. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .3-23,6Disassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325Resassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328Adjustment.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

M/T Reverse hift ForkI nspec t i on. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .3 1 9

M/T Shift LevelReplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -51

MainshaftBearingsReplacement . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341

MairtenancelSee ection )

MI LHow o Informatron... . . . . . . . . . . . . . . . . . . . . . . . . .1.46

MIL CircuitTroubleshooting... . . . . . .- . . . . . . . . . . . . .197

MirrorsComponentLocationndex... . . . . . . . . . . . . . .0'14

Mode ControlMotorReplacement

Moonrool SunshadeRep1acement . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .040

MoonroofSwitch

TesVRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 12

Mooniool Wind Def ectorReplacement . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . .0 -38

Moonroof/SunroofComponent ocation ndex ...20-35, 2-108Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -48Cf cu i t i ag ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 09

MTFI nspec t i on / Rep1acem en t .. . . . . . . . .. . . . . . . . . .3 -3

MuhiplexControlSystemComponentLocationndex .. . . . . . . . . . . .2268Circuit iagram .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .2-1690escript ion... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17Troubleshooting... . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17

Muliiplex ControlUnit, Under-dashInput est

Entry ightControl ysiem ... . . . . . . . . .2-92Keyless ntry/SecuritylarmSystern-.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-155

Mult iplexControlystem ... . . . . . . . . .2215Wiper/Washer.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2'1 1

NoiseTes t , ,

ReductionCondenser

Parking ErakeI n s p e c t i o n d j u s t m e n t . . . . . . . . . .. . . . . . . . . . . .9

Parking Brake Cable

R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 -

ParkingErakeSwitch

P

Test . . . . . . . . . . . . . . . . . . . . . 9 -

Tes t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 2135

MoonroofAuto Stop SwitchosTest . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .2'113

Moon.oot ControlUnillnputTest . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . .2-110

MoonroofDreinChannelBep lacem en t. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .039

Oi l Filte]R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .- 6

Oi l Filter Feed Pipe

R e p l a c e m e n t . . . . . . . . . . . . . . .. . - , . . . , . , , , , , , , , 8 - 7

Oi l Pan

R e m o v a l . . . . . . . . . . . . , . , , , , , , , , , , , , . , . , , , . . . . . . . . . - . . . . . . .11

l n s t a l l a t i o n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 7

Passenger's raVRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . .0-

PCVValveBeplacement . . . . . . . . . . . . . . . . . . . . . . . . . . . ' 1T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1

PistonRings8ep1acement . . . . . . . . . . . . . . . . . . . . . . . . . .-

PistonsReplacement . . . . . . . . . . . . . . . . . . . - . . . . . .-1ns t a | 1a t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .1 -

PowerR€lay

Test . . . . . . . . . . . . . .-.-. .. . . . . . . . . . . . . . . . . . . .. . .2-

PowerWindow Motor, Driver'st e s l . . . . . , , , ,, . , , , . . . . . . . . . . . .

PowerWindow Motors,Passenger's

PowerWindow Switch,MasterlnputTest .. . . . . . . .-. . . . . . . . .-. . . . . . . . . . . . . .2-1Tes r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

N

. . . . . . . . . . . . . .2201

o

,e(cont '



Manualndex

(cont'dl

PowerWindow Switch, Passenger'slnputTest . . . . . . . . . . . .-. . . . ..

Replacement.. . ,-.-.-. . . , . .

RadialorCap

RockerArm AssemblyRemovalD;sassembly/Reassembly

Specifications6-26 (See ection )2-130

22 13222-133

... . . . . . . . . . . . . . . . . . .-2 7

ComponentLocation ndex .. . . . . . . . . . . . .2224

C i r c u i t i a 9 r a m . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .2 1 2 5

OuanerWindow Glass8ep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-29

lnstallat ion 6-38

RockerArmsTestInspecton 6-28

RoofMoldingsReplacement

Seat BeltsComponent ocationndex .. . . . . . . . . . . . . . . . .3- 3

Seat8ehs, FrontReplacement

rnspec!on

sRsComponentocationndex ... . . . . . . . . . . . . .3-13Desc r ip t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -31C i r c u i t; a g r a m. . . . . . . . . . . . . . . . . 2 3 3 4lnspection/Replacemenl.. . . . . . . . . . . . . . . . .3 112

6-7

SRS ndicatorCircuilTroubleshooting

Startel

StabilizerBarReplacement

Front uspensionRear uspension

StabilizerLinksRemoval/lnstallation

Front uspensionRear uspension

23 10 5oSRSUnitReplacement..-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-122s

R

1A-1718-30

1 81 818-31RadiatorTes t . . . . . . 23-9

23-1Replacement . . . . . . . . . .

Radiator nd Condenser ansCommonCircuit

T roub leshoo l i ng . . . . . . . . .. . . . . . . . . . . . .21 9

10-310-10 SeatBehs,Rear

Replacement

SeatCover,FrontReplacement

SeatCushionCover,R6ar10-3 Replacement

ReplacementTest

Test

20-75

20-84

Overhaul

StarterSolenoidTes t . . - . - . . . 4-7

RadiatorFanAssemblyTest

Seat,Driver'sRemovaf/ lnstafat ion .. . . . . . . . . . . . . . . . . . .. . . . . . .011Disassembly/Reassemb1y... . . . . . . . . . . . . . . .0-73

Sedt,FaontPassenger'sDisassembly/Reassemb1y... . . . . . . . . . . . . . . .0-74

Seat,RearRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .0-80

Seat-back over,Reer

StartingSystemComponent ocationndex... . . . . . . . . . . . .-. . . . .-3CircuitDia9ram... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

\'........................0- 4

RadiatorFanCircuitTroubleshooting

RadiatorFanSwhch

ReplacementTest

RadiatorFanSwitch CircuitTroubleshooting

RearAir OutletReplacement

CircuilDiagramTest

RearWindow D€roggerWiresRepair

RearWindowGlass

Replacement

Troubleshooting10-14

10-1710-17

1016

17 3

11-4

17-9

SteeringComponent ocationndex... . . . . . . . . . . . . .-. .

Inspectaon... . . . . . . . . . . . . . . .

SteeringColumnRemoval/lnstallation

Replacement Inspection 1 1 1

17-51175517 63

20 68

Seat-back Latch, ReaI2Q-104 Replacement

Seat-back triker.RearReplacement

SteeringGearboxRemoval

OverhaulRearWindow DefoggerComponentLocalionndex .. . . . . . . . . . . .2204

lnsta l lat ion

SteeringHangerBeamReplacement

SteeringLinkageInspefiron

Steering Lock

Replacement

SteeringRackGuideAdiustment

22-10522 106

22-106

SeatsComponent ocationndex... .-. . . . . . . . . . . .0-70

Shift ForksInspectton 13,21

20-25

2l-3621 36

21 25

Disassembly/Reassembly.. . . . . . . . . . . . . . . . .3-22

Shitt Lever TrimRemoval/ lnstallat ion... . . . . . . . . . . . . . . . . . . . . . . . .0 61

... . .11-12

SecirculationReplacement

ControlMotor1 7 - 1 3

Tes t . . . . .

Recirculation Control Motor CircuitTroubleshooting

SideAirbag,Drivel'sReplacement

Side mpact SensorsReplacement

SparkPlugs

23-115

23 123

Side Marker Light

Rep1acement . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .2 -A3

1 7 417-6

Disassembly/Reassembly. . . . . . . . . . . . . . . . . . . .7 7

1nsta11ation. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . .7- 8

SublramesReplacement

Removal

RefrigerantReplacement.-.-.-. . . . . . . . . . . . . . . . . . . . . .1 53,54 ,55Test . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .1-56

RetrigerantOi lRep lacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - . . . . . . . . . . .1 -6 . . . _ . . 4 _ 1 9

20 112



SuspensionAdjus tment . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . .184 Component ocationndex... . . . . . . . . . . . . .0-

WindshieldGlessReplacement . . . . . . . . . . . . - . . . . . . . . . . . . . .01

SynchroRing,Triple-coneInspec t ion. . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . .1339a lveGu ides

SynchroSleeveInspectaon/Reassemb1y... . . . . . . . . . . . . . . . . . . .339

Inspection... . . . . . . . .-.-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Beplacement.. . . . . . . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Wiper ntermittent ontrolUnit,RearWindow

InputTest

T

ValveSeatsRepa i r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

. . . . . 22 -

WiDerMotor, RearWindowRep1acement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

Adjustment-.-. . . . . . .Removal..-. . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-. . .-31 WiDerMotor,windshield

6-9

. . . . .6 -32 Test . . . . . . . - . . . . . . . . . . - . . . . . - . . . . . . . . . . . . .aillight

ThermostaiTest . . . . . . . . . . . . . . . . . . .. . . .

Inspec!on

Vehicle Speed Signal Circuit

VTCSystem

Wiper/WasheI

Wi.ing System

10 4 Troubleshooting... .-. . .. . . . . . . . . . . . . . . . . . . . . . . . .22-65omponent ocationndex .. . . . . . . . . . . . .22Replacement . . . . . - . . . - . . . . . . .. . . . . . . . . . . . . . . . . . . . .0

vssThrottleBodyTest . . . . . . . . . . . . . . . . .

Removal/ lnstallat ion. . . . . . . . . . 11-'165 VT CActuatorDisassembly/Feassemb|y.. . . . . . . . . . . . . . .-11-166nspection

Circuit iagram .. . . . . . . . . . . . . . . . . .. . . . . .2-136,3

Replacement.. . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .221 Wiper/WashorwitchTesVReplacement.. . . . . . . . . . . . . . . . . . . . . . . . .2-1

.. . . . . . . . . . . . . . . .68 WireHarnesses

11 -160

R e p l a c e m e n t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 )

ThrottleCableAdjus tment . . . . . . . . - . . . . . . . . . . . . . . . . . . . .1163 VTCOi lCon l ro lSo leno ida l veRemoval /1ns ta11at ion. . . . . . . . . . . . . . . . . . . . . . . . . .11164emova l . . . . - . . . - . . .1 -127 Howt o I n {o rm a t ion. . . . . . . . . . . . . . . . . . . . . .

Belay ndControlUnitLocations-.. . .-. . . . . . . . . . . . . ..-.-. . . .-2-7, , 11, 1

Beplacement . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767 Com ponen t Loca ti on lndex . . . . . . .. . . . . . .1 -117Tie-rodBallJoint Boots

lnsta l lat ion

Replacement

Turn Signal/Hazard elay

s Timing/CamChain VTECSolenoidValve. . . 612 Fem ova l / l nspec t i on . . . . - . . . . .. . . . . . . . .. . . . . . . . 11-128

. . . . . . . . . . . . . . . .1 5

Timing/Cam Chain Auto-tensionelRemoval/1nsta11ation... . . . . . . . . . . . . . . . . . . . . . . . . . . .6-19

Troubleshooting{Seeirstpage t his ndex)

Turn SignalLight

Timing/CamChainCaseOilSealInstallat ion... . . . . . . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . . . .6,21asher luid evel witch

TesVReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 4TrailingArmsRemoval/ lnstallat ion... . . . . . . . . . .. . . . . . . . 833 Washer luidReservoir

Replacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2- 1 6t n mComponent ocationndex .. . . . . . . . . . . . . .-0 49 WasherMotor,WindshieldRem ova l / l ns t a l l a t i on. - . . . . . . .200 , 51 , 52 , 53 Test . . . . . . . . . . . . . . - . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .2244

WasherTube,WindshieldReplacement.. . . . .-. . .-. . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1 7

W.ter Outlet. . . . . . . . .224 Installat ion... . . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . . . . . . . . . . . .10-9

I npu t Tes t . . . . . . . . 22-87 lnsta l lat ion . . . . . . . . . . . . . . . .0 IWeter Passage

WheelsandTires

Turn Signal/HazardWarningLights Water PumpComponent ocationn ex ... . . . . . . . . . . . . .225 Inspection... . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 05Circut Diagram .. . . . . . . . . . . . . .-. . . . . . . . . . . . . . . . .. .2-86 Replacement-.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .05

U

WheelBearingsI n s p e c | i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . 88

Wheel Speed SensorsInspec tion . - . . , . , . , , . , , ,, , . , . , , , . . . . . . . . .. . . . . . . . . . . . .9-59R e p l a c € m e n t. . . . . . . - . . . . . . .. . . . . . . - . . . . 9 - 5 9ndeFdash use/R€lay ox

Removal/ lnstafat ion .. . . . . . . . . . . . . . . . .. . . . . . . . .2-49

UpperArmsRem ova l / | ns t a11a t i on . . . . . . .. . . . . . . . ... . 8 -32

, sInspect|on



INTRODUCTION

Safety

Your safety, nd he satetyof others, s very mportant. o help

yo u make nformed ecisions, e haveprovided afetymessages, nd othersafety nformationhroughout his manual.Of course,t is not practical r possibleo warn yo u aboutall hehazards ssociated ith servicing his vehicle. ou must useyour ow n good udgment.

You wil l f ind impoftant afety nformationn a varietyof formsinc lud ing :. SatetyLabels on the vehicle.. Satetv Messages precededby a salety alert symbol A and

one of threesignalwords,DANGEF,WARNING, r CAUTION.These ignalwords mean:

tmEnEErily;,:H,ll ":5* 5"?;rERousLYH Br r

E$EEEE ys,:f#,ff ,:hl:3,:JjERrousLYURTr

tlGtltT]llilll YoucAN b€ HUBTf voudon't ollow

. lnstructionshow o servicehisvehicle orrectlv ndsafelv.

All information ontainedn this manual s based n the atestproduct nformation vailable t the ime of print ing.We reservethe right o make hanges t any ime without notice.No partofthis Oublicat ion aVbe reDrodLrced,r stored n a retr ievalsystem, r transmitted,n an y or m by any means, lectronic,mechanical,hotocopying,ecording, r otherwise, ithout hepriorwrit tenpermission { he publisher. hi s ncludesext,f igures, nd ables-

As vo u read hi s manual, ou will t ind information hat spreceded y a@ symbol.Th e purpose f this messages

to helppreventdamage o your vehicle, ther property, r theenvironment,

*Body z-tl!^ t

FirstEdit ion /2002 1,168 ages HONDAMOTOR O.. TD.All RightsReserved ServicePublicationOfficeSpecif icat ionspply o U.S.A. ndCanada

As seclion3with *inclode SRS comoonentsispecial precautionsare required when servicing.

How to Use This Manual -

This manual s divided nto 23 sections. he irstpageof eachseclion s markedwith a black ab hat inesup with itscorrespondinghumb ndex ab on this pageand he back over.You canquickly ind he irstpageof eachsectionwithoutlooking hrougha full ableof contents. he symbolsprintedatth e op cornerof eachpagecan also be usedas a quick

re{erence ystem.Each ection ncludes:

1. A tableof contents, r an exploded iew ndexshowingl. Parts isassembly equence.. Bolt orquesan d hreadsizes.. Page eferenceso descript ionsn text.Disassembly/assemblyrocedures nd ools.Inspefiron.Testing/troubleshootin.Repa i r .Adjustments.

2.3 .4.5 .6.

Speci f icat ions 1)ll:

Maintenance

Emissions

*Restraints



Generalnformation

Ghassis nd PaintCodes-2002Model . . . . . . . . . . . . . . . . .-2

Chassis ndPaintCodes-2003Model . . . . . . . . . . . . . . . . .-3

ldentif ication umberLocations ....... -4

Warning/Cautionabel ocations .....1-5

Under-hoodEmissionControlLabel .......... .... 1-7

Li f tandSupport o ints . . . . . . . . , . . . . , . . . . . . . , .-8

Towing ......1-9

PaftsMarking ocations .....................-10



General nformation

Chassis nd PaintCodes 2OO2 odel

Vehicle dentffi ationNumber

S H H E P 3 5 ' 2 U 3 0 0 0 0 1

[ [ t t trtFc d e f g h

a. Manufacturer , Make and Type of Vehicle

SHH; HONDAOFTHE .K.MFG. , TD.U.K.

HONDAPassengereh ic le

b. Line,Body and EngineTypeEP3: CIVIC/K20A3

c. Body Type and Transmission Type

3: 2-doorHatchbacUs-speed anual

d. VehicleGrade Series)

5 :S i {U.S. }5 ;S iR Canada)

6: Si with sideairbagsystem U,S.)

6: SiRwith side airbagsystem Canada)

e. CheckDigit

l. ModelYear

2i 2002g. FactoryCode

U: Honda f U.K.Manufactur ingn Swindon,Eng and

h. SerialNumberU.S, : 00001

1 -

V€hicle ldentif cation Numbo.and FederalMotor VehicleSafety Standard Certif cation/Color Label.

1-2

17000012OA3

a

a. EngineTypeK20A3: 2.0 0 DOHCVTECSequentialMultiport

Fuel-injected ngineb. Serial Number

Engine umber

Transmission umber

PaintCode

Code Color u.s . Canada

B-92P Niqhthawk lack earl

NH-578 TaffetaWhiteNH-623M SatinSilver vletall icR-81 Mi lanoRed

Y-62P EuroYel iowPear l

NBH3

I

a

Transmission ypeNRH3; s-sDeedanual

1000001

0



nformation

ldentificationNumberLocations

Vehicle dentif cationNumber {vlN}

Vehicle dentificalionNumbe.lvlN)

-4

EngineNumber



I O warning/cautionLabelLocations

NOTE: RONT ASSENGERIRBAGWARNING AG(CHILD EAT)s nstalledn heglovebo xon he U.S.mooet .

Passenger's ompartment:

SRS NFORMATIONU.S.mode l

SRSWARNINGINFORMATION

FRONTPASSENGERMODULE DANGER

MONITORNOTICE

SIDEAIRBAGCAUTIONLocatedon driver'sano passen9erdoorjamb no tshown)

SIDEMODULEDANGER

,/FRONTSEATBELTTENSIONERCAUTION

Steering Wheel:

DRIVERMODULEDANGER

CABLEREELCAUTION

(cont'

1



Warning/Caution abelLocations cont'dl

SR SWARNINGLABEL

SERVICE NFORMATIONLABEL(Undor-hood Emission ControlInformation ab€l)and ENGINECOOLANT NFORMATION

RADIATORCAPCAUTION

BATTERYCAUTION

-6

TIRENFORMATION

c



Under-hood mission ontrolLabel

EmissionGroup dentifcation

Example: 002model

THIS EHICLEONFORMSOU.S. PA IER BIN

AND NLEVLEVREGULATIONS PPLICABLE O2002

MODEL EARNEWPASSENGERARS NDCALIFORNIAEGULATIONSPPLICABLEO2OO2

MODEL EAR EWLEV i LEVPASSENGERARS.

Example: 003model

THISVEHICLE ONFORMS OU.S.EPATIER2 BIN 5

ANDNLEVLEVREGULATIONSPPLICABLEO 2O03MODEL EARNEWPASSENGERAR S NDCALIFORNIAEGULATIONSPPLICABLEO2OO3

MODEL EARNEWLEV I LEVPASSENGERARS,

rH/ @

Engine ndEvaporative amilies:

EngineFamily:

ModelYear2:20023:2003Manulacturer ubcodeHNX:HONDAFamily ype

V: LDVDisplacementSequence haractersVBP: 002XKC: 003

EvaporativeFamily:

2 HNX R OO99 AAH

t[-l=[a b c d

ModelYear

2t 2002

3: 2003Manufacturer Subcode

HNX:HONDAFamily Type

R: EVAP/ORVR

CanisterWork Capacity

SequenceCharactets

AAH: 2002AAA: 2003

2 HNX V O2.O VBP

rr-tt--[t t la b c d e

c.

d .

e .

c.

d .

e .

1



Generalnformation

Lift and SupportPoints

NOTE: f you ar e going o removeheavycomponentssuchas suspension r the fuel ank rom the rearof th evehicle, irst supportthe ront ofthe vehiclewith tallsafetystands.When substantialweight s removed

from the rearof the vehicle, he centerof gravitycanchangean d cause he vehicle o tip forward on the hoist.

FrameHoist

1. Position he hoist ift blocks A),or safetystands,under he vehicle's ront supportpoints B)an d rearsupportpoints C) .

2. Raise he hoista few inches, nd rock he vehiclegently o be sure t is f irmly supported.

3. Raise he hoistto full height,and nspectthe iftpoints or solidcontactwith the lift blocks.

Safety Stands

To support he vehicleon safetystands.use he samesuppon points Band C) as or a frame hoist,Alwaysus esatetystandswhen workingon or underan yvehicle hat s supportedonly by a ack.

-8

Floor ack

1. Set he parkingbrake.

2. Block he wheels hat are not being ifted.

3. When lift ing he rearof the vehicle.pu t th egearshift ever n reverse.

4. Position he floor ac k under he front ackingbracket A) or rear ackingbracket B) ,center hejackingbracket n th e ac k if t ptatform C),an d ac kup the vehiclehigh enough o fi t th e safetystandsunder t .

c

Position he safetystandsunderthe supportpointsand adjust he m so he vehiclewill tevet.

Lower he vehicleonto he stands.

0

J



Towing

l f the vehicleneeds o be owed, call a professional

towing service.Never ow the vehiclebehindanother

vehiclewith just a rope or chain. t is very dangerous.

Emergency owingThere re hreepopu larmethods f owinga veh ic le .

Flat-bedEquipment The operator oads he vehicle

on the backof a truck.This s the bestway of

transporting he vehicle.

To accommodatelat-bedequipment. he vehicle s

equippedwith towing hooks A)and ie down hooks B) .

The owing hookcan be usedwith a winch o pull he

vehicleonto he truck,an d he tie down hooksslotsca n

be used o secure he vehicle o truck.

Wheel Lift Equipment The ow truck uses wopivotingarms hat go under he tires (frontor rear)an d

lifts hem off th e ground.The other wo wheels emain

on the ground.This s an acceptable ay of towing he

veh ic le .

Sling-typeEquipment The ow truck usesmetal

cab les i th hooks n he ends. hese ooks o aroun

partsof the frame or suspen sion nd he cables ift ha

endof heveh ic le f f he ground. heveh ic le ' s

suspens ionndbodycanbe ser ious ly amagedf h is

method of towing is attemPted.

lf the vehiclecannotbe ransportedby flat-bed, t

should be owed with the front wheelsoff the ground

due o damage, he vehiclemust be owed with the

front wheelson the ground,do the following:

. Releasehe parkingbrake.

. sh i f t he ransmiss ionn Neut ra l .

It s best o tow the vehicleno farther han 50 miles (8

km), and keep he speedbelow 35 mph (55 km/h).

. lmproper owingprepara t ion i l l damage he

transmission. ollow he aboveprocedure xactly.

you cannotshift he transmission,he vehiclemust

be ransDorted n a flat-bed.. Trying o lift or tow the vehicleby the bumperswill

cause er ious amage, hebumpers renot

designed o support he vehicle'sweight.



nformation

PartsMarking

To detervehicle heft, certainmajorcomponentsare markedwith the vehicle dentif ication umber VlN).Originalpartshaveself-adhesiveabels.Replacement od y parts havegenericself-adhesiveabels.The originalengrneortransmissionVIN plate s ransferredo a replacement ngineor transmission nd attachedwith break-off olts.

NOTE:Be carefulnot o damage he partsmarking abelsduring body repair.Mask he labelsbefore epairing he part.

r



r a

Specifications



l o

a ead

o

nderHItem Measur6ment Oualification Standard or New Service Limit

Head Warpage 0.05mm {0.002n.

Height'103.95

104.05 m

(4.093 4.096n.)

Camshaft En dplay 0.05 0.20mm (0.002 0.008n.) 0.4mm (0.02n.)

Camshaft o holderoi l c learance N o . l o u r n a l 0.030 0.069mm

{0.001 0.003n. )

0 .15mm 0.006n .

N o . 2 , 3 , , 5

journals

0.060 0.099mm

(0.002- .004n. )

0.15mm (0.006n.)

Total unout 0.03mr n 0.001n. )max. 0.04mm {0.002n.

Cam obe height Intake, r imary 33.925 m (1.3356n. )

Intake, 29 .638 m ( l .1668n. )

Exhaust 34.092 m (1.3422n. )

clearancecold) lntake 0.21 0.2smm 10.0080.010n. )

Exhaust 0.28 0.32mm (0.011 0.013n. )

StemO.D- ln laKe 5.475 5.485mm 10.2156 .2159n. ) 5.445mm (0.214n

Exhaust 5.450 5.460mm (0.21460.2150n ) 5 .42mm 0.213n .

Stem-to-gLridelearance lntake 0.030 0.055mm (0.00120.0022in.| 0.08mm (0.003n.

Exhaust 0.055 0.080mm (0.00220.0031n ) 0.11mm(0.004

n.lntake 1.25 1.55mm (0.049 0.061n. ) 2.00mm {0.079n.

Exhaust 1.25 1.55mm (0.049 0.061n. ) 2.00mm {0.079n.

stem nstalled eight lntake 40 .8 - 1 .0mm ( 1 .6061 .614 in . )

Exhaust 54 .6 54 .8mm ( 2 .1502 .157n. )

Valve prings Freeength lntake 47.61mm (1.874n. )

Exhaust 49.64mm (1.954n. )

Valveguides LD. Intake 5.515 5.530mm

|.0.21710.2117 n.1

5.55mm (0.219n.

Exhaust 5 .515 5 .530 m

\0.2111 0.2177n. l

5 .55mm 0.219n

Instal led eight lntaKe 15 .2 16 .2mm ( 0 .5980 .638 in . )

Exhaust 15.5 16.5mm (0.610 0.650n. )

Rocker rms Arm-to-shaft learance lntaKe 0.025 0.052mm(0.00'10 .0020n. )

0.08mm (0.003n.

Exhaust 0.018 0.056mm

(0.00070.0022n. )

0.08mm (0.003n.



nq tneItem Measurement Oualification Standardor New ServiceLimir

Block

Piston

I Warpage f deck 0.07mm (0.003n. )max. foro. . (u lur^^- "1tsore iameter A o r i

B o r l l

(3.38583.3862n. )

85.980 85.990 m (3.38503.3854n. )

l-il?0 €s.980 r"i33846

86.010 86.020 m

(3.3862 3.3866n.)

86.000 86.010 m

86.070 m (3.3886n. )

86.070 m (3.3886n. )

0 . 0 5m m ( 0 . 0 0 2n . J

85.920 m (3.3827n. )

0 . 25mm (00 l i n . )

85.930 m (3.383'ln.)

Reboring rmi t

SkirtO.D. t 11mm (0.4n.) rom

bottom of skirtF"

btt"' ' ALetterB

0.020 0.040mm (00008 0.0016n. ) 0.05mm {0.002n. )Top 1.220 1.230 m (0.04810.0484n. ) 1.25mm 10.049nSecond 1 . 2 2 0 1 . 2 3 0 m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049n. )

Pistoning

lFis,.€-"'",";"*

L-ing ndga p

o.D.

i 2.005 2.025mm (0.07890.0797n. )

fo.o:s o.oto.rno.oora .ooza.'.f

EO3t 0056n. {OJ01rOOO2")

?.09rrl9.091lt0.13mm (0.005n )

0 . 13mm 0. 005n . )SecondFEDEHAL

I\4OGUL)

Top

0.025 0.060mm (0.00100.0024n. ) 0.13mm (0.005n )

0.20 0.35mm (0.008 0.014n. ) 0.60mm (0.024n. )

Second 0.40 0.55mm {0.016 0.022n. ) 0.70mm (0.028n. )Oi I REKEN)

21.961 21.965 m {0.86460.8648n. )

0.25 0.65mm (0.010 0.026n. )

0 20 0.70mm 0.008 0.028n. )

0.75mm (0.030n. )O i I (FEDERAL

I\4OG L)0.80mm 10.031n. )

Piston in21.953mm l0 8643 n

Pin'to-pistonlearance 0.005-*0.002 m 0.000200.00008n. )

0.005mm (0.0002n. )

Connectingod Pin to - rod clearance 0.005 0.015mm (0.00020.0006n. ) 0.02mm lO0OO8n ISmal l en d bore d iameler 21.970 21.976 m (0.86500.8652n. )Large-end or e diameter Normal) 48 . 0mm (1 . 89n . )En dplay nslalled n crankshaft 0.15 0.30mm (0.006 0.012n. ) 0 . 40m m (0 . 016n. )

Crankshaft Main ournal d iameter

Rod ournal d iameter

No . journal

No .2 ournal

No . ou rna lNo .5 ournal

No .3 ournal

s4.e84 s5.008 m (2.1648=16il l l

54 . 97655 . 000 m (2 . 1644 -1654 in )

44.976 45.000mm (1.1707 1.1717 n.lRod/main 0.005mm 10.0002n. )max. 0.010mm (0.0004n. )Rod/mainournal ut of,round 0.005mm (0.0002n. )max. 0.010mm (0.0004n. )End lay 0.10 0.35mm (0.004 0.0'14n. ) 0 . 45m m10. 018n. )Runout. . - ' . : - - ' +

0.03mm (0.0012n. )max. 0.04mm {0.0016n. )

Deaflngs

Marn oear,n9-toJournat tt c tearance No . journal

No .2 ournal

No .4 ournal

N o . 5

No .3 ourna/

0 . 017 0 . 041 m (0 . 0007 . 0016n . )

q0rr034, -r n {O'o010-o01r|"tl

0.050mm (0.0020n.)

0.055mm (0.0022n. )Bo dbearing learance 0.021 0.049

mm(0.0008

0.0019n. ) 0.060mm (0.0024n. )

andServiceLimitsEnqineBlock

_

c


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o i Lubrication

a

a

nqlne|tem Measurement Oualificalion Standerdor New ServiceLimil

Engine i l Capacity 5. 30 (5.6USqt)forengine verhaul

4. 20 (4.4USqt ) or oil change,ncludingilter

4. 00 4. 2USqt)foroi lchange, ithout i lter

O i l pum p lnner-to uter otor learance 0.02 0.16mm {0.001 0.006n.) 0.20mm (0.008n. )

Pumphousingo outer otor

clearance

0-15 0.21mm {0.006-0.008n.) 0.23mm (0.009n. )

Pump ousing-to-rotorxial

clearance

0.02 0.07mm (0.001 0.003n.) 0.12mm (0.005n. )

Balancerhafts,ournal iameter No .1 ournal,ront

shaft

19.938 19.950 m 10.7850 .7854n. ) 19.92 m (0.784n.

No 1 ournal, ea rshaft 23.938 23.950 m (0.94240.9429n.) 23.92mm (0.942n.

No .2 ournal,rontan d

rear haft

32.949 32.961 m 11.2912 .2911n. l 32.93mm (1.296n.

Ealancerhafts,ournalaper 0.005 nm 0.0002n. )max.

Balancerhafts, ndplay Front 0.070 0.135mm (0.00280.0053n.) 0.15mm (0.006n. )

Rear 0.070 0.135mm (0.00280.0053n.) 0.15mm (0.006n. )

Balancer hatts, haft-to'bear;ng

clearance

No .1 ournal,ront

shaft

0.050 0.082mm (0.00200.0032n.) 0 .10mm 0. 004n .

No. 1 Journal, ear shaft 0.050 0.082mm (0.00200.0032n.) 0.10mm (0.004n. iNo. 2 ournal, ront an d

rear shafl

0.060 0.120mm (0.00240.0047n.) 0.15mm (0.006n. )

Balancerhaft earings,D. No.1 ournal,ront

shaft

No .1 ournal,ear haft

20.000 20.020 m (0.18140.7442n. l

Z+.OOO I.OZO - tOSa+e-OSa57r'.)

20.03mm (0.789n.

24.03mm (0.946n.

No .2 ournal,rontand

rearshaft

33.021 33.069 m (1.3000 1.3019n.) 33.09mm {1.303n

Reliefvalve, i l pressurewi th o i l

temperatureat 176'F 80"C)

At id le 70 kP a 0. 7kq?cm , 10 psr)min.

At 3,000pm 300 Pa 3. 1 sf/cm',44 si)min.

Standardor New ServiceLimit

6 .7 7 .1 Soolant apacityincludesngine,heater, oses, nd eservoir)

0.53 (0.56 S

93 123 Pa 0.95 1.25 qtcm 14 18psi)'t69 176'F 76 80'C)hermostat OPeningtemPerature

8. 0mm {0.31n. )min.

TurnsOF F Subtract 15'F 3 8"C)from ctualON



Item Measulement Oualification Standardor New Service imitFuel ressure

regulator

Pressure ith fuel pressure auge

connected

320-370kP a 3.3-'3.8gtcm',47 52psi)

Fue l t ank Capacity 504 13 . 2 Sga l iEnginedl e ldlespeed ith headlightsnd adiator

fan off

Neutral 75 0 50 pm

Fast d le Neutral 1,600150pm

StandardsandServiceLimitsFuelandEmissions

.

r

ClutchItem Mea3urem€nl Oualification Slandardor New ServiceLimit

Clutch edal Heightro m he loor 19 3mm (7.60n. )Stroke 130 140mm15. 15 . 5 in . )

10 16mm (0.39 0.63 n.)Disengagement eight rom the f loor 1 '15 m (4 . 53n . )min .Bunout n clutchmating urface 0.05mm 10.002n. )max. 0.15mm (0.006n. )

Clutch is c Bivet ead epth 1.65 2.25mm (0.065 0.089n. ) 0. 7mm {0.03n. )Ihickness 8. 3 8. 9mm (0.33 0.35 n.) 6. 0mm (0.24n. )

Pressure late Warpage 0.03mm (0.001n.)max. 0 . 15mm 0. 001n. )Heightof d iaphragm spring ingers Measured it h

specialtool ndfeeler auge

0. 6mm (0.02n. )max. 0. 8mm (0-03n. )

\



O E

a

o

nualTransmission nd M/T DifferentialItem M€asurement Oualification Standardor New Se.viceLimit

Transmission

fluid

Capacity For luidchange: .5 (1.6USqt )

Fo r ve rhau l :. 7 11 . 8 Sq t )

Mainshaft En dplav 0 .1l - 0 . 17mm 0. 0040 . 007 in . ) Adiust

Diameter f bushing urface 20.80 20.85mm {0.819 0.821n. ) 20.75mm 10.817n

Diameterof d istance o l la r 31.984-32.000 m (1.2594 1.2598n. ) 3 '1 . 93 m (1 . 257n

Diameter f ballbearing ontact rea(clutch ousing ide)

27 . 97727s90mm 1. 10151 . 1020n . ) 27 .92 m (1 . 099n

Diameter f needle earing ontact

area

38.984 39.000 m (1.5348 1.5354in.) 38.93mm (1.533n

Diameter f ballbearing ontact re a

(transmissionousing ide)

27.987 28.000 m (1.10'19 .1024n.) 27 .93 m 1 . 100n

Runout 0.02mm (0.001n. )max. 0.05mm (0.002n.

Mainshaftrd ,

4th and sth

gears

t.D. 44.009 44.025 m 11.73261.7333n. ) 44.08mm (1.735n

En dplay 0.06 0.16mm {0.002 0.006;n.) 0 . 25m m (0 . 010n.

Thickness 23.92 23.97mm (0.94'10.944n. ) 23.80mm (0.937n

Countershaft Diameter f needlebearing ontact

area clutch ousing ide)

35.000-35.015 m (1.3780 1.3785in.) 34.95mm (1.376n

Diameterf distanceollar ontact

alea

39.937 39 95 0mm (1.5723 1.512ain.| 39.88mm (1.570n

Diameterof bal l bearingcontactarea

(transmission ousingside)

30 . 020 -30 . 033m (1 . 1819 -. 1824n . ) 29 . 97 m (1 . 180n

Runout 0.02mm {0.001n. )max. 0.05mm (0.002n.

35mm shim-to'bearingnner ace

clearance

0.04 0.10mm (0.00160.0039n. ) Adjust

Countershaft LD . 52.010 52.029 m (2.0476-2.0484n.i 52.08mm (2.050n

En d play 0.06 0.16mm (0.002 0.006n. ) 0 . 25mm10. 010n .

Thickness 22.92 22.91 m 10.9020.904in.) 22.87mm (0.900n

Countershaft

2n dgear

t.D. 52.010 52.029 m (2.04762.0484n.) 52.08mm {2.050n

En dplay 0.06 0.16mm (0.002 0.006n.) 0.25mm 10.010n

Thickness 21.92 27.91mt n 1.099 1.101n. ) 27.87mm 11.097n

Countershaft'lst gear

distanceollar

LD . 39.95 39.96mm (1.572a1.5132n.) 39.97mm (1.574n

o.D. 46.989- 7.000 m (1.8499- .8504n.) 46.94mm(l.848

nLength 23.03 23.08mm (0.907-0.909n. i

Countersha{l

2n dgear

distanceoliar

l . D . 39.95 39.96mm {1.5728'- .5732n.l 39.97mm (1.574n

o.o. 46.989 47.000 m (1.8499 1.8504n.) 46.94mm (1.848n

Length 28 . 03 28 . 08 m ( l . 104 1 . 106 in . )



anuat ransm cont'Item Measutemenl Oualification Standardor New ServiccLimit

Nlainshaft th

an d5t hgears

distanceollar

LD. 32.00-32.01 m (1.2598 1.2602n. ) 32 . 02 m (1 . 261n . )o.D. 38.989 39.000 m (1.5350 1.5354n. ) 38.94mm (1.533n. )Length 51.95 52.05mm (2.045 2.049n.)

B 24.03 24.08mm (0.946-0.947n. )

MB Sdistance LD. 28.00 28.01mm 1.102 1.103n. ) 28 . 02 m 1 . 103n . )Len9th 23.95 24.05mm (0.943 0.947n. )

Reversedler

gear

t.D. 20.016 20.043 m (0.78800.7891n.) 20.90mm (0.832n.)Gear o reversegear shafic learance 0.036 0.08amm (0.00140.0033n. ) 0 . 16mm 0. 006n . )

Synchro ing Bing o'gear learance Ringpushed

against ea r

0.70 1.49mm (0.028 0 05 9 n ) 0.4mm (0.016 n. )

Triple one Outer ynchroing-to ynchro one

clearance

Ring ushed

against ea r

0.70 '1.19mm {0.028 0.047n. ) 0. 3mm (0.012n. )

Synchro one-to-gearlearance Ringpushed

against ea r

0.50 1.04mm (0.020 0.041n.) 0.3mm (0.012n. )

Outer ynchro ing-to-gearon eclearance

Ring ushedagainst ea r

0.95 1.68mm (0.037 0.066n. ) 0. 6mm (0.024n. )

Shift ork Fingerhickness 7. 4 7. 6mm 10.29 0.30 n.)Fork o-synchroleeve learance 0.35 0.65mm (0.014 0.026n. i 1. 0mm (0.039n. )

Reverse hift

fork

Fingerhinkness 13.4 13.7mm (0.527 0.539n. )Fork-to-reversedlergear clearance 0.20 0.59mm (0.007 0.024n. ) 1. 3mm (0.051n. )

Shift rm t.D. 13.973 14.000mm (0.55010.5512n. )Shi f t fo rk diameterat conlactarea 16.9 '17.0mm (0.665 0.669n. )Shift arm'to-shif t everclearance 0.2 0.5mm (0.008 0.020n. ) 0 . 62mm (0 . 024n . )

Selectever Finger idth 14.85 '14.95mm (0.585 0.589n. )Shift ever Shaft to-selecteverclearance 0.05 0.25mm (0.002 0.010n. ) 0.50mm (0.020n. )

Groove to select ever) 15.00 15.10 m {0.591 0.594n. )

Shaft o shif tar mclearance 0.013 0.07mm (0.00050.003n. ) 0. 1mm {0.004n. )

Mfidif ferential

carrier

Pinionshaftcontactarea .D. 18.010 18.028 m (0.70910.7098n. )Carrier-to-p in ion haftc learance 0.027 0.057mm (0.00110.0022n. ) 0. 1mm (0.004n. lDriveshaft ontactareaLD. 28.025 28.045 m (1.1033 1.1041n. )

Mfi

differential

pinion ear

Backlash 0.05 0.15mm {0.002 0.006n. )

t.D. 18 . 04218 . 066 m (0 . 7103 . 7113 in . )Piniongearto p in ion shaftc learance 0.059 0.095mm (0.00230.0037n. ) 0.15mm (0.006n. )

80mm shim 80mm shim o-bearinguter ace

clearancen ransmissionousing

0 0.10mm (0 0.0039n. ) Adjust

andServiceLimits

ManualTransmission nd Differential

L



o

o

a

0 10mm (0 0.39n. )otat ionalla vmeasuredt outside

29N (3.0 g f . 6 . 6 lbs )tart ingoa dmeasuredt outside

Angle of rackguide screw oosened

nItem Measurement Oualitication Standardor New ServiceLimit

Whee la l i gnm en tCamber Front 0'00' 45 '

Rear 0'45'- 45

Caster Front 1"3 3'11"

TotalToe lryttRear

0 -3 mm 0: : 0 . 12n . )

lN 2 ' , mm (0.08 ' ,, in.)

Frontwheelurning ngle lns idewheel 37'40'-2'

Outside h ee l 2 9' 50 '( Re fe re nc e)

Aluminumwheel unout Ax ia l 0 0. 7mm (0 0.03n. ) 2. 0mm (0.08n. )

R a d i a l 0 - 0. 7mm (0 0 . 03 in . ) l . 5m m {0 . 06 in .

Wheelbearing En dplay Front 0 0.05mm (0 0.002n. )Rear 0 0.05mm (0 0.002n. )



Item M€asurement Oualification Standardor New ServiceLimitParking rake

lever

Distanceraveled hen ever ulled

with 196N (20kgf,44 bs)ol force

7 8 clicks

Brake edal Pedal eight carpetemoved) 1 8 4m m ( 7 4 / 1 6 n . )

Freeplay 0 . 4 3 . 0mm (0016 0 118in . )Master y l inder P iston- to-pushrodlearance 0 0.4mm (0 0.02 n.)

Erake isc Thickness Front 21 . 0mm (0 . 83n . ) 19 . 00 m (0 . 75n . )Rear 9. 0mm {0.35n. ) 8- 0mm (0.31n. i

Runout Front 0.10mm (0.004n. )

Rear 0.10mm (0.004n. )Paral le l ism Front nd ear 0.015mm (0.0006n. )

Brake ad s Thickness Front 10.0mm (0.39n. ) 1 .6mm (0 . 06n . )

llear 9. 0mm {0.35n. ) 1 .6mm (0 . 06n . )

andServiceLimits

Brakes

e

Air GonditioninItem Moasurement Oualilication Standard or New Service Limit

Refrige.ant Tvpe HFC 34 (B -134)

Capacity f system 50 0 55 0 117.6 19.4 z)Refrigeranti l Type SP1O

(P/N 8897-P13-A01AHr 38899-P13-A01Capacityfcomponents Condenser 25 m0,15/6l ozl

Evaporator 45mA111/2 l oz t

Each ine an d

hose

10m0 1/3 l or)

Compressor 130 150m014 /3 5 f l oz )Compressor Startercoil resistance At 68"F 20"C) 3.05 3.350

Pulley-to-pressurelate learance 0.35 0. 6mm (0.014 0.024n. )Drive elt Auto ensionerneeds o adjustment)



DesignSpecifications

O

o

o

|tem Measurement Oualification Specilication

DIMENSIONS Overal l length 4 , 210 m 165 . 8n . )

Overallwidth 1,695 m 166.7n.)

O v e r a l l h e i g h t 1 , 440 m (56 . 7n . )

2 , 570 m (101 . 2n . )

Track rront 1,470 m (57.9n.)

Rear '1,470mm (57.9n.i

Ground learance 15 2mm (5.98n. )Seating apacity four 4)

wEtGt-iTu.s.A.) GrossVehic leWeight Rating

(GVWR)

3,660bs

WEIGHT(CANADA)

Gross ehicleWeightRating

{GVWR)

1,660 g

ENGINE Tvpe Water ooled. stroke OHC -E Cengin(

Cylinder rrangement Inline 'cylinder,ransverse

Boreand stroke 86x 86mm (3.39 3.39n.)

Displacement 1 , 998m ' (122u n . )

Compressionatio 9. 8

Valve rain Chain r ive.DOHC TEC valves ercylinder

Lubricat ionystem Forced, et sump,with rochoid um P

Oilpumpdisplacement At 6,000 nginerp m

54.3 (57.4 Sqo/minute

Water um pdisplacement At 3,400 ngine 820 (8 7US qt)/minute

F!el required UNLEADEDasoline it h86pumpoctane umber r highe

STARTER Tvpe Gear eduction

Normaloutput

Nominalvoltage 12V

Hour at ing 30seconds

Direction f rotation Clockwiseas viewecl rom gear en d

CLUTCH Clutch vp e Sinq lep la tedry, d iaphragmspring

Clutchrict ionmaterialurface re a 174 m ' {26 . 97q n. )

I\,1ANAL

TRANSMISSION

Tvpe Svnchronized,-speedorward, everse

Primarveduction D i rec t : 1Gear at io ls t 3.062

2nd 1.769

3r d 1 . 212

4th 0.921

5th 0.738

Reverse 3.583

Finalreduction Type Sinole elicalgear

Gear atio 4.164



cont'Item Measuremeni Oualification Specilication

STEERING Type Electric,ower ssistedac k ndpinion

Overallat io 15 . 1Turns,locko-lock

Steering heel iameter 360mm (14 . 2n )SUSPENSION Type Independent rru l with stabi l iTer. o i l spr ing

Rear DoublewishboneShock bsorber Front Telescopic,ydraulic. itrogen as-fr l led

Rear Telescopic,ydraulic,itrogen as,f i l ledWHEEL

ALIGNMENTCamber Front 0"00'

Bear 0.45'

Caster Front 1'33'Totaltoe Front 0 mm (0 n. )

Rear I n 2 m m ( 1 / 1 6 n . )

BRAKES Typeof servicebrake Front Powerassisted elf-adjusl ing enti la ted isc

Bear Power-assistedelf-adjust ingolid iscTypeof parkingbrake Mechanicalctuating,ea rwheelsPad rictionsurface rea Front 45 m ' (7 . 0 q n . )x2

Rear 28cm ' (4 . 3q n . ) 2

TIRES Size ffrontan d eart ires Pl95/60 1588VSizeo{ spare ire T125r0D1 5 5M

AI R

CONDITIONING

Compressor Type Scroll

Number f

cylinders

Capacity 85.7m015.23u n.)/rev.

Maximum peed 12,000pm

Lubricant apacity 13 0m0 41/3 loz)

Lubricanttype SP-10P/ N 8897'P13-A01AHr38899-P1301 )Condenser Type CorrugatedinEvaporator Tvpe Corrugatedin

Blower Type Sirocco an

Motor ype 220 Wl12 V

Speed control 4 SpeeoMaximum capacity 48 0m"116.900u t)/h

Temperature ontro l Airmixtype

Compressorlutch Tvpe Dry, ingle late, oly-V el tdrive

Electr icalpower

cons!mptron t

68"F 20.C)

42W maximum t 12V

Refrigerant Type HF C134aR-134a)

Capacity 50 0 55 0 (17.6 19.4 z)

Specifications

L

..


http://slidepdf.com/reader/full/civic-manual-ep3-tyre-r-manual 32/11362-

o

o

a

Item Measurement Oualilication Specitication

ELECTRICAL

RATINGS

Battery 12V 36AH/ 5 ou rs

Sta ter 12V- .1 .1 W,1 . 2 W

Alternator 12V 95A , 90A

Fuses Under-hooduse 80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A

Under'dashus e 304 , 20a , 15A, 10A,7.5

Light bulbs Headlight igh

beam

'1 2v.' 60w

Headlightow

beam

1 2 V 5 5 W

Frontturn ignal

l iqhts

12V 21W

Front parl inq l ights 1 2 V 5 W

Bear urnsignal

l ights

12V 21W

FronVrearid e

markerights

1 2 V 5 W

Brale/ta i l l ighls 12V 21 / 5W

High moLrnt rake

l igh t1 2 V 5 W

Back p ights 12V 21W

License late ight 1 2 V 5 W

Ceilingight'1 2v'.8 w

Cargoarea ight 1 2 V 5 W

Spotlights 1 2 V 5 W

Gauge ights

Indicator ights LED

Side ur nsignal

l ight

1 2 V 5 W



Specifications

Unit: mm {in.)

1.555 61.6)

1, i14056.71



. 4

Maintenance

Lubricants nd Fluids

Maintenance cheduleor NormalConditionsListedby Distance/Time

Maintenance cheduleor SevereGonditionsListed y Distance/Time

Maintenance cheduleListed y Maintenancetem or NormalConditions ...................-8Listed y Maintenancetem or SevereCondi t ions . . . . . . . . . . . . . . . . . . .3 -9



Fluids

For detailsof lubrication ointsand ype of lubricantso be applied, efer o the il lustrated ndex and variouswork

ures such sAssem overhau l .ns ta l la t ion .t c . ) on ta inedn each ec t ion .

NO . LUBBICATIONOINTS LUBBICANT

1 Eng ne HondaMotor Oil(P/N

08798-9023).he oil containermust disolav he API Cenification eal shown below.

Make ure t saysFor

Gaso l ine ng ines. " AE

Viscositv:Se echartbelow.

2 Transmission HondaMTF*' P/N 8798-9016)

3 Brakesvstem includes BS ine) HondaDO T3 BrakeFluid*' P/ N08798-9008)

4 Clu tch ine

56

Releaseork manua lransmiss ion l

Throftlecableen d (thrott le ink)

SuperHighTempUreaGreaseP/N 8798-9002)

7

I

Shift and select ableends manual

t ransmiss ion)

Throttlecableen d (dashboardower panelhole)

S i l i cone rease

9

1 0

1 11 '

1 4

1 6

1 7

Brakeboosterclevis

CIutchboosterclevis

Shift everpivotPeda l inkage

Battery erminals

Fue l l l door

Hoodh inges ndhood a tch

Hatch inges

Doorh inoes, oDer nd ower

Multi-purposerease

1 8 Caliperpistonboot,caliperpinsand boots HondaCaliDerGrease P/ N08C30-80234lvl)

1 9 A ir c on di ti on in gompressor Compressoro i l :P-10 P/N 8897-P13-A01AHr

38899-P'13-A01)

For e f r iqeran t ; FC '134 (R-134 )

I

Recommond6dEngineOilEng ine i lv iscosi lyor ambenttempera lureanges

-30 -20 -10 0 t0 20

* 1 :

"2 :

Always use HondaManualTransmission luid MTF).Using motor oii can causestiffershift ingbecause t does

not contain he Drooeradditives.

Always use HondaDO T3 BrakeFluid.Usinga non-Honda rake luid can causecorrosionan ddecreasehe life of

the system.



o o o oo

o@@a9

3



Listedby Distance/Timeor NormalConditions

This wo page /lanitenancecheduleutl ineshe minimun equired aintenance.ervice t he ndicated istance r ime,whichever omesfirst. se he vlaintenancecheduleor Severe onditionsf hevehiclemeets nyof hequalifiersn heSevere onditionschedule r f hevehicles normally r i ven n Canada.

Inspectalve learance.cold) see ag e -321rntake: .21-0.25mm (0.008 0.010n. )Exhaust:.28 0.32mm (0.011 0.013n. )Replacepark lugs.Use ZFR6K'11NGK) r SKJ20DR-M11DENSO).

1 .0 1 .1mm

! Do tems n A,B,alqq.,

120,000 i/ 192,000m/6 yearsI Replaceransmissionluid.UseHondaMT F se e ag e13-3).

/ / Y vcdrs

120,000 i l 192,000Beplaceoolant se e age106) .Capacity:.00 (5.3USqt).Us eHonda l l Season ntifreeze/Coolantyp e .

Accordingo state nd ederal egulations,ailureo do hemaintenancetemsmarked ith anasterisk*) wil lnotvoid hecustomer'semissions arranties, owever, onda ecommendsha tal lmaintenanceervices edone t he recommendedntervalo ensureong-termreliabil i ty.

I

-4



Do he tems n partsA, B,C,D,an dE as equiredor mileage/timentervalisted.

AReplacengine i l lseepage -5i. Capacity ithout i l terchange: .0S 4.2USqt ,3.5 mp qt )Rotateires. ollowhe pattern hown n heOwner'sManual Checktirenformation nd ondition.

BReplacengine i l i l ter se epage -6). Capacity ith i l ter hange: .204. 4USqt ,3.7 mpqt )Inspectrontan d ea r rakesse e ag e193i .. Check ad s nddjscsor wear thickness),amage, nd racks.' Check alipersor damage,eaks, nd jght ness t mountbolts.Check arking rake djustment.hould e ullyapplied ithin7 o clicks.Inspectie rodends, teering earbox, ndboots se e ag e175) .. Checkac k rease ndsteeringinkage.. Check oots or damage nd eaking rease. Chackluid ine or damage nd eaks.lnspect uspension omponents.. Chock olts o ightness.. Check ondition f ball ointbootsor deteriorationnddamage.Inspect riveshaft oots.Check oots or cracksand boot bands or t ightness seepage16-3).Insp€ct rake oses nd ines including BS). Checkthe astercylinder,roponioningontrol alve, ndAB Smodulator{or amagean d eakage.Check l l luid evels nd ondition t luids; heckor eaks.f necessary,ddMT F se epage13'3), ngioe oolant, rakeluid,and

Lwindshield asherluid.lnspectexhaustystem*. heck atalyticonverter eatshield,xhaust ip ean dmufflerfordamage,leaks,nd ightnessso e ag e ,8).lnspectuel ines nd onnections*.heckor oose onnections,racks nddeterioration;etightenoose onnoctionsnd eplacedamaged arts s€ e ag e 1 146).

InsDectndadiust r ivebelt.. Look or cracks nddamage, nd nspect uto ensionerneeds oadjustment).Replacehe dustan dpolleni l ter se e ag e 1 39).. Replacetheustand olleni l terwhenever ir f ow rom he heating ndcooling ystems essthan ormal.

Replaceir cleaner lement very 0,000 i les 48,000m) independentf ime).

l

D

Ei I Replacerakeluidevery years independentI mileage).

Accordingo state nd ederal egulations,ailureo do hemaintenancetemsmarked ith asterisk() wil l notvoidcustomer'smissionswarranties. owever, onda ecommendsha tal lmaintsnanceervice edoneat he recommendedntervalo ensureon g er m eliabil i ty.

3



chedule

Listedby Distance/Timeor SevereConditions

Service t he ndicatedistance r ime,whicheveromes irst.Use hisschedulef he vehiclesdrivenMAINLYn Canada r n anyof hetollowing onditions;l onlyOCCASIONALLYrivenn hese onditions,se heNormalConditionschedulese e ag e -4).SevereDrivingConditions. Drivingess han5 miles 8km )pe r rip or, n reezingemperatures,r iving ess han10miles 16 m)pe r ri p. Drivingn extremely ot over 0"F/32"C)onditions

. Extensivedl;ng r on gperiods f stopan dgo driving, uchasa axior a commercialelivery ehicle.. Trailerowing, r ivingwith a car-top arr ier, r driving nmountainousonditions.

. Driving n muddy, usty, r de'icedoads

Replace ransmission luid.Us e Honda MTF {seepage 13 3).

Inspect alve learance.cold) se e ag e 32):ntake: .21 0.25mm (0.008 0.010n. )Exhaust:.28 0.32mm (0.011 0.013n. )Replacepark lugs.UseZFR6K1 NGK) r SKJ20DR'M1 DENSO)

km/ 6 years

Replace ransmission luid. Us e Honda MTF (seepage 13 3).

mil 192,000m/ 10 ears,he nevery 0,000 i/ 96,000 m/5 yearsReplaceoolant se e ag e 0-6). apacity:.0015.3 Sqt )Us eHonda l lSeason ntifreeze/cooan tType2.

-6



A

I

Do he tems n parts , B,C,D, E,F,an dG as equiredor mileage/timentervalisted.

Feplace ngine i l(see ageS5). Capacity ithoutl i l ter hange:4.0(4.2US qt,3.5lmp t)

Replacengjne i l i l ter se e ag e 6). Capacity ith i l ter hange: .2014.4 Sqt ,3. 7 mpqt)Insoectrontand ear rakes,. Check ad s nddiscsforwearlthickness),amage, ndcracks.. Check alipersor damage,eaks, nd ightness f mountbolts.Lubricateoor ocks,atches ndhinges ith Hondawhite ithium rease.Rotateires, f hevehicle asbeen riven hedistanceisted. ollowhe pattern hown n heOwner'sManual-Checkir e nflaron oocondition,Inspecttieodends, teering earbox, ndboots se e ag e 7,5).. Check ack rease nd teeringinkage.. Check oots or damage nd eaking rease.. Checklluidinefordamage nd eaks.Inspectuspensronomponents. Check olts or ightness.. Check ondition f ball ointboots or deteriorationnddamage.Inspect r iveshaftoots. heck oots or cracks ndbootbands or ightnessse e ag e16-3).

Check arking rake djustment.hould e ullyapplied ithin7 o 9 clicks.Insp€ct rake oses nd ioes. including BS). Checkhe master ylinder, roportioningontrol alve, ndAB Smodulatoror damagand eakagese e ag e 9-24).Check l l luid evels ndcondition t luids; heckor eaks.f necessary,dd MTF se e ag e133) ,engine oolant, rakeluid, ndwindshield asher uid.Inspect xhaust ystem*. heck atalyticonverter eat hield, xhaust ip ean dmuffler or damage,eaks, nd ightnessse e ag e 8) .Inspectuel ines ndconnections*.heckor oose onnections,racks nddeterioration;etightenoose onnectionsnd eplacedamaged an s se o ag e11'146).Check l l l ights. heckfunctiontall interior ndexteriorights, ndtheposition ftheheadlightsse e ag e 2-68).Inspecthev€hicle nderbody. heckhe paint or damage, cratches,tone hippin0, nddents.

L

D

E

F

H

InsDect nd adiustdrive belt.. Look or cracks nddamage, nd nspect uto ensionerneeds oadjustment).Reolaceus tan doollenilter.

Replaceircleaner lement very 5,000 i les 24,000m) n dustv onditionindependentl imeiotherwise seNormalConditionsscredulese e ag e 1-162).

lR ep lac ea i r c l eane r e lementev e r y 30 ,000mi les ( 48 ,000k m) (i ndependen to { t ime i ( s eepage l l - 162) .

Replacerakeluidevery years independentJmileagei.

Replacetheus tan dpolleni l terevery 5,000 i les fvehiclesdrivenmostlywhere irha shighconcentrationlsootfrom ndustryandiesel owered ehiclesj ls o eplacehe dustan dpollen ilter nyti me arflows ess hanussal se e ag s21-39).

According o statean d ederal egulations, ai lure o do the maintenance tems markedwith asterisk *) wi l l not void customer'semissionswarranties.However,Honda ecommends hat al l maintenance ervicesbe done at he recommended nterval o ensure ong-term rel iabi l i ty

3



Service tthe ndicated istancertime,

whicheveromes irst.

miles 1,000 t0 20 30 40 50 70 80 90 100 110 r20

km x 1,000 16 32 48 64 80 96 112 128 144 160 192

months 12 24 3 48 60 12

Replacengine il o o o o a o o a a o O a

Rotate i res

{Check ir e intlat ionand condi t ionat eastonce pe r month)

Replacengine i l i l ter o o a a a a

Inspectrontan d ea r rakes

Checkparkingbrakeadjustment

Visuallynspecthe ollowingtems:. Tie-rod nds, teering earbox ndboots. Suspensionomponents. Driveshaft oots. Brake oses nd ines including BS i. Allf luid evels nd ondition f{ luids. Exhaustystem*. Fuel ines ndconnections*

Inspect ndadjust r ivebelt a a a a

Replaceus tan dpolleni l ter

Reolaceransmissionluid

Servicethe ollowing tems at the recommendedntervals

a

Replace i r c leanerelement Every0,000 i les48,000m)

Replacepark lugs Every 10,000iles176,000m)

Inspect alve learance Inspectvery 10,000iles176,000m), therwisediuslnl yf noisy.

Inspect dle speed* Every 60.000res1256,000m) r8years

Replace nginecoolant At120,000iles192,000m) r10 ears,hen very 0,000iles96,000m) r5

Replacerakeluid Every years

Listedby Maintenancetem for NormalConditions

Followhe NormalSchedulef hesevere r iving onditionspecifiedn he Maintenancecheduleor Severe ond itionsn he nextpage o

no tapply, nd f onlyOCCASIONALLYriven n severe riving onditions.Followhe Severe onditionschedulef hevehiclesdrivenMAINLYn Canada.

* : Accordingo state nd ederal egulations,ailureo do hemaintenancetemsmarked it hasterisk*) wil l notvoidcustomer'smissions

warranties. owever, onda ecommendsha tal lmaintenanceervice edone t he ecommendedntervalo ensureong-termeliabil i ty-

3-8



Listedby Maintenancetem for SevereConditions

Use hisschedulef hevehiclesdrivenMAINLYnCanada r n anvof he ollowina ondit ions.OTE:t onlyOCCASIONALLYriven n heconditions,se he NormalConditionschedute.SovereDrivingConditions. Drivinges s ha n5 miles 8km )pe r ri por, n reezingemperatures,r ivinges s ha n. Drivingn extremely otover90 F

13 2C)conditions.

10miles 16 m)per rip.

. Extensivedling, r on gperiods t stop-and-go-driving,uch sa axior a commercialelivery ehicle.. Trailerowing, r ivingwith a cartopcarrier, r driving n mountainousonditions.

. Driving n muddy, usty, r de ced oads.

Service t he ndicatedistance r ime,whichever omes irst.

miles 1,000 10 20 30 40 50 60 70 80 90 100 110 120

km x 1,000 16 48 64 80 96 112 128 14 4 160 176 192

months 12 24 36 48 60 72

Replacengine i l Replacevery ,000 i ies 8,000m)or months

Rotateires{Checktirentlation ndcondition t eastonce ermonthi

a o a a o a a o a a a o

Replace ngineoi l f iher

Inspectrontand ear rakes

Lubricate l l ocks,hinges,an d latches

Visuallynspecthe ollowingtems:. Tie rodends, teering earbox ndboots. Suspensionomponents' Driveshaft oots

Checlparking raleadjuslment a a O a o aVisuallynspecthe ollowingtems:. Brake oses nd ines including BS i. Allf luid evels nd ondition fl luids. Exhaustystem*. Fuel ines ndconnections*. Lights ndcontrols,ehicle nderbody

Inspect ndadjust r ivebe h o a o aReplace ust an d pol len i l ter"o ' t '

Replaceransmissionluid a aServicehe following tems atthe recommendednteruals

Replaceircleaner lement Every 5,000 iies 24,000m) n dusty onditions,theMise se ormal chedule.

Replacepark lugs Every 10,000iles176,000m)

Inspect alve learance Inspectvery 10,000iles176,000m), theMisediustnl yf noisy.

Inspect dlespeed' Every 60,000iles256,000m)or8 ears

Replacengine oolant At120,000iles192,000m) f 10 ears,lhenvery 0,000 iles96,000m)or

Replacerakeluid Every years

* : According o stateand federal egulations, ai lure o do the maintenance tems marked wi th asterisk *)wi l l not void customer'semissionswarranties.However,Honda recommends hat al l maintenance ervicebe done at he recommended nterval o ensure ong{erm rel iabi l i tv.

NOTE1: Replace he dust and pol len i l ter at 15,000mi les/24,000 m i f the vehicle s driven mostly n urban areas hat have high concentrationof soot n the ai r rom industrvand diesel -Doweredehicles.

3



Electrical

SpecialTools

Number Tool Number Description otvo@

07746-001040007749-0010000

Attachment, 2 x 55 mmDriver

11

\

\



StartingSystem

ComponentLocation ndex

UNDER-DASHFUSE/RELAYBOX

CLUTCH INTERLOCK WITCHTest,page4- 6

STARTERStanerCircuitTroubleshoot,ng,ag e4 5SolenoidTest,page4- 7Performance est,page4- 8Replacement, ag e4- 9Overhaul, ag e4

'1 0

- l - -a r ] ] ] l l- i

I

- .- _ -

r t _ . 1_-- _. /

I t t i :: - l t . i t i t -! t : ! | -

- ! t

STARTER UTRELAYTest, age 2-51

\ r \ ' l\ ' \ l I\ r \ , l ,

, . \ \ /\ \ /'....",r.v

\ : , . . . )

\ /'\t l \

4



StarterCircuitTroubleshooting

NOTE:. Airtemperaturemust be between59'and 100'F 15'

and 38'C)during his procedure.

. After his est,or any subsequent epair, eset heenginecontrolemodule(ECM) o clearany diagnostlc

troublecodes DTCS)seepage11-4).. Th e batterymust be n good conditionan d ully

charged.. lf you disconnect he baftery,do the ECM dle earn

proceduresee age11-139) .

Recommended rocedure:. Us ea startersystem ester.. Connect nd operate he equipment n accordance

with the manufacturer's nstructions.

Alternate Procedure

1. Hookup the following equipment:. Ammeter,0 400A. Voltmeter,0 20 V (accurate ithin 0.1volt). Tachometer,0 1200 pm

2 . Remove he No. 17(15A) use rom the under-dash

fuse/relay ox.

With the clutchpedalpressed,urn the ignit ion

switch o start l l l).

Did thestarter crank the enginenormally?

YES-The starting ystem s OK.I

NO-Go to step4.

3.

4

4. Check he batterycondition.Checkelectrical

connections t the battery, he negativebaftery

cable o body, he enginegroundcablesand he

starter or looseness nd corrosion.Then rystarting he engineagain.

Did the statter crank the engine?

YES Repairing he looseconnection ixed he

problem.The startingsystem s now OK.!

NO l f s ta r te rw i l l o tc ranktheeng ine ta l l ,go to

step5. f it cranks he engineerratically r too

slowly,go to step7. f it won't disengagerom the

flywheel ring gearwhen yo u release he key,chec

for the following until you find the cause.

. Solenoidplungerand switchmalfunction

. Dirty drivegearor damagedoverrunning lutch

5. Makesure he transmission s in neutral, hen

disconnect he startersubharness Pconnector A

from the enginewire harnesslP

connector B) .

Connecta umperwire from the batterypositive

terminal o the startersubharnesslP connector.

Did the starter crank the engine?

YES-Go to step6.

NO Check he BLK,ANHTire between he start

subharness Pconnectorand he starter. f wire is

OK ,remove he starter, nd repairor replace s

necessary.

(con



StarterSolenoidTest

1. DisconnectheS and vlconnectorsrom hestarterso lenoid.

2. Check he hold-incoil or continuitybetween he S

terminaland he armaturehousing ground).There

should be continuity.

. lf there s continuity, ot o step3.

. lf there s no continuity, eplace he solenoid,

3. Check he pull-incoil or continuitybetwee the S

term ina l nd M te rm ina l . here hou ld e

continuity,

. lf there s continuity, he solenoid s OK.

. lf there s no continuity, eplace he solenoid,



System

StarterPerformance est

1 , Disconnecthe wires from the S terminaland he Mtermrna l .

Makea connection s described elow usingasheavya wire as possible preterably quivalent othe wire used or the vehicle). o avoid damagingth e starter,never eave he batteryconnected ormore than 10seconds,

Connect he batteryas shown.Be sure odisconnecthe startermotor wire from the solenoid.lf the starterpinionmovesout, t is workingpropefly.

Disconnecthe battery rom the M terminal. f thepiniondoes not retract, he hold-incoil of th esolenoid s working properly.

L

5. Disconnecthe battery rom the starterbody. fthepinion retracts mmediately, t is working properly.

Clamp he starter irmly in a vise.

Connect he starter o the batteryas described nthe diagrambelow,and confirm hat he motorsta ts and keeps otating.

6.

7 .

lf the eiectric u rentand motor speedmeet hespecifications he n the batteryvoltage s at 11. 5V,the staner s working properly,

Specifications:

1. 1kw90 A or less

Electricurrent),ot more



System

StarterOverhaul

Disassembly/Reassembly

@

@

,--\----_2<-

; , / 1 ( - \

rw.h\:!@a- @-A

q -z\hsc6b-.- ,"

OVERRUNNINGCLUTCHASSEMBLY

GSOLENOIDEVER

o*"lu*.V*rN*

\ # . A *@\ c^)* -#""Jli[X:""

S #o

7:

a<-4t^ fr/ / ffiAv 9\:-/ ffitr,.. D lW

END COVER t/'!4/

STARTERSOLENOID

BRUSHHOLDER

\



Armature Inspection and Test

1. Remove he starter seepage4-9).

2 . D isassemblehestar te r sshownat the beg inn ing

of this procedure.

3. Inspect he armature or wear or damage rom

contactwith the permanentmagnet. f there s wear

or damage, eplace he armature.

Check he commutator A) surface. f the surface s

dirty or burnt, esurface it h emery cloth or a lathe

within the specificationsn step5, or recondition

with # 500 or # 600 sandpaper B).

6 .

5. Check he commutatordiameter. f th e diameter s

below he service imit, replace he armature.

Commutator DiameterStandard Newl:28.0mm (1.10 n. l

ServiceLimit: 27.0mm (1.06 n. )

Measure he commutator A)runout.

. lf the commutator unout s within the service

limit,check he commutator or carbondust or

brasschips between he segments.. lf the commutator unout s not within the serv

limit, reolace he armature.

Commutator Runout

Standard New): 0.02mm 10.001n.) max.

ServiceLimit: 0.05mm (0.002n. )

(con

4



System

StarterOverhaul cont'dl

7. Check he micadepth (A). f the mica s too high {B),undercut he mica with a hacksawblade o theproperdepth.Cu taway allthe mica (C )between

the commutatorsegments. he undercutshouldnot be oo shallow, oo narrow,or V-shaped D) .

Commutator Mica DepthStandard New):0.50-0.80 mm {0.020-0.031 n.)ServiceLimit: 0.20mm (0.008n. )

Check or continuitybetween he segmentsof thecommutator. f an open circuitexistsbetweenan ysegments, eplace he armature.

M

\

9. Place he armature A) on an armature ester B) .

Holda hacksawblade C)on the armaturecore. fthe blade s attracted o the core or vibrateswhile

thecore s u rned, he armaturesshoned.Rep lacethearmature .

Checkwith an ohmmeter hat no continuityexistsbetween he commutator A)and armaturecollcore (B),and between he commutatoran darmatureshaft C). f continuityexists, eplac e hearmature.

1 0 ,



Starter Brush Inspection

11. lvleasurehe brush ength. f it is not within the

service imit, replace he brushholderassembly.

Brush Length

Standard New):14.0-14.5 mm (0.55-0.57 n. )

Service Limit: 9.0 mm {0.35 n.)

Starter Field Winding Test

12. Check or continuitybetween he brushes A). f

there s no continuity. eplace he armature

hous ing B) .

Check or continuitybetweeneachbrush A) an d

the armaturehousing B) . i there s continuity,

replace he armaturehousing.

1 3 .

Starter Brush Holder Test

14, Check hat here s no continuitybetween he (+ )

brushho lder A)and ) brushho lderB} .

f thereis continuity, eplace he br ush holderassembly.

Brush Spring Inspection

15. Insen he brush A) nto he brushholder,and brin

th e brush nto contactwith the commutator, he n

attacha springscale B) o the spring C) .Measur

the spring ensionat the moment he spring ifts o

the brush. f the spring ension s not within

specification,eplace he spring.

SpringTension: 13.7-17.7 N {1.40-1.80 kgf,3.09 3.97 bf)

(con

4



System

StarterOverhaul cont'dl

PlanetaryGear Inspection

16. Checkhe p lanetary ears A)and inggear B) .Replacehem if they

are worn or damaged.

OverrunningCluich nspection

17 . Slide he overrunning lutchalong he shaft.Replace t if it does not slidesmoothly.

18. Rotate he overrunning lutch A)both ways.Does t lock n one directionand rotatesmoothly nreverse? f it does not ock n eitherdirectionor itlocks n both directions, eplace t.

lf the starterdrive gear (B ) sworn or damaged,replace he overrunning lutchassembly; he gearis not available eparately.Check he conditionof the flywheel ring gear.Replace t if the starterdrivegear eeth areoamageo.

1 9 .

i.-

Starter Reassembly

20, Pry backeachbrushspringwith a screwdriver,he n

position he brushabout halfwayout of its holder,and e leasehe spr ing o ho ld t here .

NOTE:To seatthe new brushes. lip a strip of #5OOor # 60 0sandpaper.with th e grit sideout, be&veenthe commutatorand eachbrush,and smoothlyrotate he armature.The contactsurfaceof thebrusheswill be sanded o the samecontouras hecommutator.

21 l ns ta ll th e rmaturen hehous ing , nd ns ta l l t hebrush holder.Next,pr y backeachbrushspringaga in , ndpush he brushdownunt i l t sea tsagainst he commutator, hen releasehe springagainst he end of the brush.

sInstall he starterend cover o retain he brushho lder .



lgnition System


SPARK LUGInspection,age -'19 IGNITION OIL

lgnit ion iming nspection,ag e -17Removal/lnstallation,age -1 8

4-



System

GircuitDiagram

'No.20lOA):USAmo&l

No.A50A) Cmrda odelUNDEB OODUST/8TIAY)(

lG1ioT in 0N{ll)rd SIARI lll)



lgnition Timing Inspection

1 .

4.

5 .

Connect he HondaPGMTester o the data in k

connector DTC), nd check or DTC'S.f a DTC spresent, iagnoseand repair he causebefore

inspect inghe gn i t ionim ing.

Startthe engine.Hold he engineat 3,000 pm withno load (i n Neutral)until he radiator an comes on,

then let t idle.

Checkhe d le peed see age11-138) .

Follow he tester'sprompts n the "SCS" menu

{see he testeroperator'smanual),

Connect he timing light o the service oop.

o

6. Point he ight oward he pointer A)on the cam

cha in ase.Checkhe gn i t ionim ingunderno oa

conditions: eadlights, lower an. rearwindow

defogger, nd air conditioner reno t

operaling.f

the ignit ion iming differs rom the specification

and hereare no enginecontrolmodule ECM)DTrep laceheECM see age11-4)

lgnit ion Timing:

8"+2" BTDC RE Dmark {B))during dling n neutr

A

7. Turn he ignitionswitchOFF.

Disconnect the ondaPGMTester nd he t im ing

l igh t .

4



System

lgnitionCoilRemoval/lnstallation

1. Remove he ignit ioncoil cover(A), hen remove heign i t ion o i l s B) .

6 x 1 . 0 m m

2. Installthe gnitioncoils n the reverseorderofremoval.

9. 8N. m (1.0kgf.m,7.2lbf tl

--



SparkPlug nspection

1 . Inspect he electrodes nd ceramic nsulator.

Burned or worn electrodes may be caused by:

. Advanced gnition iming. Loosesparkplug

. Plugheat ange oo ho t

. Insu f f i c ien tcoo l ing

Fouledplug may be causedby :. Retarded gnition iming. Oi l n combust ion hamber. Incorrect parkplug gap. Plugheat ange oo cold. Excessivedling/lowspeed unning. C logged i rc leaner lement. Deterioratedgnitioncoils

Worn or deformedelectrodes

Do not adjust he ga p of iridium ip plugs A) ;

replace he sparkplug f the ga p s out ofspecification.

Electrode Gap:

Standard New): 1.0 1.1mm

{0.039-0.0€ in.)

ServiceLimit: 1. 3mm {0.051n. l

f . lmproper apI J .O i l - tou l ingr- 1 . Cs6on deposits' I . Cracked enter

\ electrodensulator

3. Replacehe plug at he specified nterval, r if the

centerelectrode s rounded A) .Use onlV he sparplugs istedbelow.

Spark Plugs: lZFR6Kl1 NGK)

SKJ2ODR-M11DENSO)

Apply a smallquantityof anti-seize ompound o

the plug hreads,and screw he plugs nto he

cylinderhead inger-tight. hen orque hem to

18N m (1.8 gf .m, 3 lbf t ) .

4 .

4-



ystem


CHARGING YSTEMNDICATOR(ln he gaugeassembly)

q

DRIVE ELTInspection,ag e 26Replacement,ag e 26

BATTERYTest, ag e 2-50

ALTEBNATORTroubleshooting,ag e -2 2Replacement,ag e -2 9Overhaul,ag e -3 0



CircuitDiagram

' flo.{l0Al :uSA od.l

ilo.20l50Al C.n.d.mod.lUNDTR OODUSI/RILAYX

+--,I fm il*t"t'

T-

+ilt= l

4-



ChargingCircuitTroubleshooting

l f the chargingsystem ndicatordoes not come on ordoesno t go off, or the battery s deador low, est heseitems n the order istedbelow:

Battery seepage22-50)Charging ystem ndicatorAlternatorand regulator ircuitAlternator ontrolsystem

Charging ystem ndicator est

1. Turn he gn i t ion wi tchON { l l ) .

Does the chatging system indicator come on?

YES Go o step2.

NO Go o step3.

2. Start he engine.

Does the charging system indicator go off?

YES-Charging system ndicator ircuit s OK .Goto th e Alternatorand Regulator ircuitTest.

NO-Go to step3.

3. Turn he ignit ionswitch OFF.

4. Troubleshoothe multiplexcontrolsystem see

page22 172).

ls the multiplex control system OK?

YES Go o step5.

NO Check he multiplexcontrolsystemasindicated y the diagnostic roublecode (DTC) se e

step8 on page22-172) .1

5. Disconnecthe enginewire harness6Pconnectorfrom the starter ub harness P connector.

\ "

6. Measure he voltageat the No. 3 terminalof theeng inewi re harness Pconnector i t h he gn i t ion

swi tchON { l ) .

ENGINEWIREHARNESS PCONNECTOR

IBLK/YEL}

Wire ideof emaleerminals

ls therebattery voltage?

YES-Go to step7.

NO-Check or a b lownNo.4 10A)use n heunder-dashuse/relay ox. f the fuse s OK, repair

open n th e wire between he alternator nd heunder-dash use/relay ox.

Turn he ignit ionswitchOFF.

Disconnect nginecontrol module ECM) onnectorB (24P) .

Check ontinuitybetween he ECMconnectorte rm ina l ' 10 ndeng inewi re harness Pconnectorte rm ina lNo.6 .

?

7 .

8 .

9.

ACGL WHT/BLU)

ENGINE IBEHARNESS6P

L (WHT/BLUIWireside f emaletermina

ls therecontinuity?

YES Go o step 10.

NO-Repair open n the wire between hea l te rna tor nd he ECN4. I

ECM CONNECTOB A (24P)



'10.Check ontinuitybetween he ECMconnectorte rm ina l 10andbodyground.

ECMCONNECTOR I24PI

2 3 4 5 6 78 I 10,/1,/ 3 15

1 1 8 ,Nnt,/21 23ACGL WHT/BLUI

t1'

Wire sideol female erminals

ls there continuity?

YES- Repair hort o ground n th e wire betweenthe ECMand he enginewire harness6Pconnector.t

NO-Go to alternator nd regulator est.

Alternatorand RegulatorCircuitTest

1. Besure he battery s sufficiently hargedand ngood condition

se epage22-50),

nd heconnections t the fuse box and alternator recleanand ight.

2. Raise he hoist o full height.

3. Hookup the ammeter,0 400A, to the startersubharness.

Lower he hoist.

Hookup the voltmeter,0 20 V (accurate ithin0 . 1 V ) , t o T 1 0 1 .

(cont

4-



System

Charging ircuitTroubleshootingcont'd)

6. Start he engine.Hold he engineat 3,000 pm with

no load (i n Neutral)until he radiator an comeson ,then let t idle.

7. Raise he enginespeed o 2,000 pm, and hold tthere.

8. Turn he headlights highbeam)on, and measure

voltageat the under-hood use/relay ox erminal.

ls the voltagebetween 13.9and 15.1v?

YES-Go to step9.

NO Repairor replace he alternator omponents(seepage4-30).1

9. Read he amperageat

'13.5

V.

NOTE:Adjust he voltageby turning he blowermotor, rearwindow defogger,brake ights.etc.ON .

ls the amperage604 ot morc?

YES-Alternator/regulator peration s OK.

NO Repairor replace he alternator omponents(seepage4-30).1

\,

AlternatorControl SystemTest

NOTE:After roubleshooting, erform he enginecontrolmodule(ECM) dle earnprocedure seepage

1 1 - 1 3 9 ) .

1 Check or properoperationof the electrical oad

detector ELD) y checking he malfunction

ind ica toramp MlL) (see age1 -3) . f a DTC spresent, iagnoseand repair he causebeforecontinuingwith this est.

2. Disconnecthe enginewire harness P connectorfrom the startersub harness6Pconnector.

3. Start he engine,and urn the headlights high

beam)ON,

4. Measure oltagebetween he enginewire harness

6P connector erminalNo. 2 and he positive

terminalof he battery.

C {WHT/GRN)

ENGINE IRE ARNESSPCONNECTOR

Wire ide f emaleerminals

ls there 1 V or less?

YE S Go o step8.

NO-Go to s tep5.

Turn he head l igh ts nd gn i t ion w i t chOFF.

Disconnect CMconnectorB (24P).

5 .

6 .

BATTERY



7, Check or continuitybetweenECMconnectorte rm ina l 18andbodyground.

ECM CONNECTOR{24PI

1 2 3 4 5 6 1

8 9 10,/1,/ 3 5

1 1 o nt,/21 23

ACGC WHT/GRN}

o

Wire sideot female erminals

9.


YES-Repair short o ground in the wire betweenthe alternator nd he ECM.I

NO-Check that he terminalsar e irmly seatedatthe ECMconnectorB. f OK ,substitute known-good ECM,and recheck se epage11-6).lf prescribed oltage s now available. eplace heor ig ina l CM, I

Turn he headlights nd gnitionswitchOFF.


10. Check or continuitybetweenEC Mconnectorte rm ina l 18andeng inewi re harness Pconnecterm ina lNo.2 .

ACGCWHT/GRN)

ECM CONNECTOR l2,lPI

1 2 3 1 4 l 5 l l l 78 9 10 t . ) 1 5

1 1 o n 21 23

o C(WHT/GRN)

2 3

5 6

ENGINEWIREHARNESS P CONNECTOR

Wire sideoI emale erminals

ls therc continuity?

YES Repairor replace he startersubharness rthe alternator seepage4-30).I

NO Repairopen n the wire between hea l te rna tor nd heECM. I

4-



DriveBelt Inspection

Checkhat heauto-tensionerndicatorA) swithin hestandardange B)asshown.f it sou tof hestandardrange, eplacehedrivebelt see ag e -26).

4-26

DriveBelt Replacement

1, Move he auto-tensionerA) o relieve ension romthe drive belt (B).and remove he drive belt.

2. Installthenew belt n the reverse rder of removal.



DriveBeltAuto-tensionernspection

1 . Checkwhether here s a change n the positionofthe auto-tensionerndicatorbeforestarting heengineand afterstarting he engine. f there s achange n he pos i t ion ,ep laceheauto- tens ioner .

3.

Checkor abnormal o ise rom he ens ioner u l ley .

l f abnormal o ise s heard , ep lacehe ens ionerpu l ley .

Remove he drive belt (seepage4-26).

lMovehe auto-tensioner ithin ts imit with th ebelt ension elease ool in the directionshown.Check hat he ensionermovessmoothlyan dwithout any abnormalnoise. f the tensionerdoesnot move smoothlyor there s abnormalnoise,replace he auto-tensioner.

7 .

8 .

Remove he auto-tensionerse epage4-28).

Ins ta l lhe ens ioner u l ley .

Clamp he auto-tensionerA)by using wo 8 mmbolts (B )an d a vise (C )as shown. Do not clamp heauto-tensionertself

Set he torquewrench (D)on the pulleybolt.

Align he indicator E)on the tensionerbasewithcentermark F)on he ens ioner rm by us ing hetorquewrench,and measure he torque. f thetorquevalue s out of specif ication,eplace heauto-tensioner,

NOTE; f the indicatorexceeds he centermark,recheck he torque.

Auto-tensioner spring torque:26.5-36.3 N.m 12.7-3.7kg.m, 19.5-26.8lbt.ft)

9 .

4-



ystem

DriveBeltAuto-tensionerReplacement

1. Remove he drive belt (seepage4'26).

2. Removehe d le rpu l ley .

6 x l . 0 m m9. 8N. m(1,0 gl.m,7.2 tbf.ft)

d

Ix 1 , 0 m m12 N.m

('1.2 gt.m.8.7 bt. f t)

3. Re move he tensionerpulley.

x 1.25mm22N. m{2.2kgt m, 16 bf ft}

4-28

4. Remove he auto-tensioner,

8 x 1.25mm22 N. m (2.2 gf.m,16lbt. f t)

5. lnstall in the reverse order of removal. \ -



AlternatorReplacement

1. Makesureyo u have he anti-theft od e or the radio,then write down the frequenciesor the radio'spresetbuttons,

2. Disconnecthe negative able rom the battery irst,thendisconnect he positive able.

3. Remove he front bumper (seepage20-85).

4. Remove he right side headlight se epage22-79).

5. Remove he reserve ank rom the bracket.

6. Remove he drive belt (seepage4-26).

7. Remove he three boltssecuring he alternator.

8 x 1 .25mm

22 N.n 12.2 gl.m,

Disconnecthe alternator onnector A) and BLKwire (B) rom the alternator.

8 N.m10.8 gf.m,6lbf. f t)

\6

' I1 .

9 .

1 0 .

13 .

14.

Remove he alternator.

Installthealternator nd drive belt n the reverseorder of removal.

Connect he positive ablean d negative able othe battery.

Enter he anti-theft ode or th e radio, hen enterthe customer's adiostationpresets.

Set he clock.

Perform he enginecontrol module ECM) dle eaproceduresee age11-139) .

t t .

4-2



System

AlternatorOverhaul

ExplodedView

BEARING

PULLEYLOCKNUT

\ -

TERMINALINSULATOR

REARHOUSINGASSEMBLY

INSULATORBUSHING

PULLEY

/

\ /

/@

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

\ ,/ ./ FRoNrB

@b.J.y{=RE+LN'"'IVFko"-% \ /qtr*njlvV (

) ,

"VBRUSH \1 1BRUSH OLOER HOLDER -\\TNSULATOR \ \l

\ \ VOLTAGE }

\- \

REGULATOR (-

@*F,\:v_re*^i\gP^@'*ffilw9

ROTOR



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

NOTE:Refer o the ExplodedView as neededduringthis procedure.

1, Test he alternator nd regulatorbeforeyo uremove them (seepage 4-22l,.

2. Remove he alternator seepage4-29).

3. lf th e front bearingneeds eplacing, emove hepulley ocknutwith a 10 mm wrench (A )and a22 mm wrenc h B). f necessary, sean mpactwrencn.

Remove he harnessbracket A) , nsulator B) . hreeflange nuts(C),and he screw D) , hen remove hep la te ermina l E) .

, ( , t t; r _l L t

5. Removeheendcover A)anddustsea l B) .

Remove he brushholder A) ,voltage egulator B

and he rubber ea l C} .6.

L1i.21---^tqLJ

B-"--|.

(cont'

1!q[-dr,:l

4-



System

AlternatorOverhaul cont'dl

7. Remove he four screws, hen remove he rectif ier(A )and our nsu la torsB) .

Remove he four f lange nuts, hen remove he rear

hous ing A)andwasher B) .

o \

f . r

9. lf yo uar enot replacinghe rontbearing nd/orrearbearing, o o step

16.Removehe rotor romthestator riveen dhousing.

Inspect he rotor shaft or scoring,an d nspect he

bearing ournalsurface n the statorhousing or

se tzure arks .

. l f e i ther the otorors ta torhous ingsdamaged,

replace he alternator,. lf both he rotor and he statorhousingare OK,

go o s tep11.

' l1 . Removehe rearbear ing s ing pu l le r sshown.

10 .

\"



12. Wi tha hammer ndcommerc ia l l yva i lab leoo lsshown, nstalla ne w rear bearingon the rotor shaft.NOTE: nstallthebearingusing he nner race.

13. Remove he front bearing etainerplate.

s qH E

6 eu sf-\\ \r-:1s---'^/

14 . Supportthe stator housing n a vise,and drive outthe front bearingwith a brassdrift and hammer.

15 . Wi tha hammerand hespec ia l too ls ,ns ta l l newfront bearing n the statorhousing.

07749-0010000

07746-0010400

(cont

4-



System

AlternatorOverhaul cont'd)

Rectitier Test

16 . Check or continuity n eachdirection, etween heB erminaland P erminals,and between he E

term ina l ndP ermina ls f each iodepa i r .A l l d iodes hou ldhave ont inu i t yn on lyonedirection.Because he rectif ier iodesare designedto allow current o pass n one direction, nd herectif ier s made up of eightdiodes four pairs). ou

musttest eachdiode n both directions orcontinuitywith an ohmmeter hat has diodechecking apabil ity: total of 16checks.

. lf any diode s faulty. eplace he rectif ier

assembly. Diodes re not available eparately.)' l f all he diodesare OK,go to step 17.

/--:',t- -L . --- -o \-- l'-=

B P "

P,

P.

P,

P.

1 9 .

\ r

Alternator Brush Inspection

17. Measurehe ength f bo thbrushesA)wi thavern ie r a l iper B) .

. l f e i ther rush sshor te r thanthe erv iceim i t ,rep lacehe brushassembly .

. lf brush ength s OK ,go to step18 .

Alternator Brush Length:Standard New):10.5mm (0.41 n. )

ServiceLimit: 1.5mm (0.06 n. )

RotorSlip Bing Test

18 . Check hat here s continuitybetween he slip rings

{A) .

. lf there s continuity, o to step 19.

. lf there s no continuity, eplacethealternator.

Check hat here s no continuitybetweeneachslipring and he rotor (B )and he rotorshaft (C).

. lf there s no continuity, ot o step20.

. lf there s continuity, eplace he alternator.

\"



Stator Test

20. Check thatthere s continuitybetweeneachpairofleads A) .

lf there s continuity, o to step21lf there s nocontinuity, eplace he alternator.

Check or no continuitybetweeneach eadand hecoil core B).

. lf there s no continuity, oto step22 .

. lfthere is continuity, eplace he alternator.

Assemble he alternator n reverseorder of

disassembly, nd note hese tems:

. Be carefulno t o ge t an y greaseor oil on he slip

nngs.. lf yo u removed he pulley, ighten ts ocknutto

111N.m 11.3 gf m,81.7 b f . f t )whenyounsta l l

it .

2 1 .

22.

'--l-- --i

4-



Control


CLUTCH EDAL OSITIONswtTcHTest, ag e -45Clutch edal djustment,page 2- 4

t.- _,- _

CRUISE ONTROLACTUATORTest, ag e '4 3Replacement,ag e -44

CRUISECONTROL NITlnputTest, ag e -40

BRAKE EDAL OSITIONWITCHTest,page22-84Pedal eight djustment,ag e19-6

CRUISECONTROLNDICATOR(Built nto gaug6assembly)

ACTUATORCABLEAdjustment, ag e4-45

- l l

\ -



CircuitDiagram

'No.aloAl USAnod.lNo.20toAl C.md! modrl

UISEF NOODUS'/iILAY IOX

-to ots BU/YIL

lcl H0Tii0llilllmdSTARTlllll

1 Honilsffroi

CTuICII EDALP0sm0 wtrct

2 6 1 1 1 3

cnu6E oNTnoLNtT l0

4



Gontrol

CruiseControl Unit Input Test

SRScomponentsare ocated n this area.ReviewtheSR Scomponent ocations se epage23-'13) nd precautions ndprocedures se epage23-14) n the SRSsectionbeforeperforming epairsor service.

1. Disconnecthe 14Pconnector rom the controlunit.

2. Inspect he connectorand socket erminals o be sure hey are all makinggood contact.

. lf the terminalsare bent, oos e,orcorroded, repairthem as necessary, nd recheckthe ystem.

. lf the terminals ook OK,go to s tep 3.

Wiresideoffemale erminals

3. With the 14Pconnectordisconnected,make hese nDut ests.

Cavity Wire Test condition Test:Desired esult PossiblecausefresuhsnotobtainedBRN/WHT Connectbattery

powerCheck he operationof themagneticclutch:Clutchshou ld l i ck ndoutput ink

should be ocked.

' Faultyactuator. Poorground G301). An open n the wire. Shon to ground (arcswhen

Dower s connected)2 BLU lgnit ionswitch ON

(ll),main swltchONand brakepedalpressed, he nreteaseo

Check or voltage o ground;

Thereshould be 0 V with lh epedalpressed nd batteryvoltagewith the pedal

released.

. Faultybrakepedalposit ion

switch. An open n hewi re. Open n cruisecontrolmain

swrtcn. B lownNo.4 (10A) fuse n he

under/dashuse/relav ox3 BLK Under l l cond i t ions Check or continuity o

grouno:

Thereshouldbe continuitv

. Poorground G501)

. An open n the wire

BLIVORN l gn i t i on w i t chONflr) Check or voltage o ground:Thereshould be batteryvottaqe.

BlownNo.4 (10A) fuse n heunder-dashuse/relay oxAn oDen n th e wire

5 WHT/BLK Brakepedalpressed,

then releasedCheck or voltage o ground:

Thereshould be batteryvoltagewith the pedalpressed, nd 0 V with th epedal eleased.

BlownNo.7 {15A) use n heunder-hood use/relay oxFaultybrakepedalposit ion

SWIICN

An oDen n hewi re



Cavity Wire Test condition Test:Desiredesult Possibleausel resultsnotobtained

6 GRYiRED Se tbutton ushed Check or voltage o ground:

Thereshould be battery

voltage,When est ingermina lNo.6 ,

thereshould be no voltageon

term ina lNo.7 .

B lownNo.7 (15A) fuse n he

under-hood use/relay ox

Faultyhorn relayFaultysevresume/cancel

swrtchFaultycable ee l

An open n th e wire

Shon to ground (hornsounds

when button s pressed)

7 LT GRN/BLK

Resume uttonpusneo

Check or voltage o ground:


voltage.When est ing erm ina lNo.7 ,

there should be no voltageon

term ina lNo.6 .

BRN Connectbatterypower o the BRN

termina l ndground

to the BRNIVEL

termrna l

Check he operationof th e

actuatormotor:You should

be able o hear he motor.

. Faultyactuator

. An open n the wire1 BRNI/EL

1 0 BLUIVE lgnit ionswitchON

0r)Attach o groundi

Cru isend ica torigh t n hegauge ssembly hou ld ome

on.

Blown No. 10 7. 5A) fuse n

the under-dashuse/relay ox

Blown cruise ndicatorbulflFau l t y auge ssemblyAn open n the wire

12 BLU/VVHT lgnit ionswitch ON(ll)and main switchON; raise he front of

the vehicle,an drotateone wheels lowlywh i leho ld ingthe otherwheel

Check or voltagebetween

thE BLU/VVHT+) AN dBLK( ) te rm ina ls :T h e r e s h o u l d b e 05 V o rmore repeatedly.

Faulty SSAn open n hewireShort o ground

1 3 LTGRN lgnition witch N

{ l l ) ndmain wi tchON

Checkor voltageo ground:

There hould ebatteryvoltage.

BlownNo.4 (10A) fuse n he

under-dashuse/relay oxFaultymain switch

An oDen n th e wire

1 4 LT BLU Clu tch eda l

reteaseoCheck or continuity ogrouno:

There hou ld econt inu i t y .

NOTE:Therehou ld e no

continuitywhen the clutch

oedal s Dressed.

Faultyclutchpedalposit ion

swtlcnPoorground G501)

Incorrect lutchswitch

adjustment

An open n the wire

lf any est ndicates problem, ind and correct he cause, hen recheck he system. f all the input estsproveOK

th e cruisecontrolunit may be faulty.Substitute known-good ruisecontrolunit and retest. f th e systemworks

properly, eplace he cruisecontrolunit.

4



CruiseControlActuatorTest

1. Disconnecthe 4P connector A) rom the cruise

controlactuator B) .

Remove he cover (A),and check he output inkage(B ) or smoothmovement.

2.

,t o

5 .

Connectbatterypower o the No, 2 terminalan d

ground o theNo.1 erm ina l .

Checkor a c l i ck ing ound rom he magnet i c lu tch .

The output inkage hould be ocked.

lf the output inkage s not ocked, eplace he

cruisecontrolactuator ssembly,

6. Check he operationof the actuatormotor n each

output inkagepositionaccording o the table.You

should be able o hear he motor.

Battery ower

Dolarit ies

Output inkageposition

FULtCLOSE

MIDDLEPO$TION

FUtLOPEN

N o , 4Terminal

No. 3Terminal

Th emotorruns.

Th emotorruns.

Th emotorstoDs,

N o . 3Terminal

No.Terminal

Th emotorsIoos.

Th emotorruns.

Th emotorruns.

1. l f the actuatormotor doesnot operateas specifie

replace he cruisecontrolactuatorassembly,

OUTPUTLINKAGE

FULLCLOSE

4



Control

CruiseControlActuator/CableReplacement

1 . Fullyopen he cruisecontrol ink by hand, he nremove he cruisecontrolcable A) rom link.Loosen he locknut B) ,and remove he cable rom

the bracket.

Disconnecthe 4Pconnector, nd remove he threeboltssecuring he cruisecontrolactuator.

2.

6 x 1 , 0 m m12 N. m (1.2 gf.m,8.7 bf. f t)

\r

3. Remove he actuator over (A), he n remove heactuator able B) rom the cruisecontrolactuator.

Install n the reverseorderof removal,and adjustthe free playat the throttle inkageafterconnectingthe actuator able.

4 .



ActuatorCableAdiustment

1. Check hat he actuator able A) moves smoothly

with no bindingor sticking.

2. Start he engine.

3. Measure he amountof movementof the output

linkage B) until he enginespeedstarts o increase.

At f irst, he output inkage hould be ocatedat the

fully closedposition C) .The ree play (D)shouldbe

3.7510.5mm (0.1510.02n, ) .

4. lf th e free play s not within specs, oosenthe

locknut E).and urn the adjustingnu t (F )untilthe

free play s as specified,he n retighten he ocknut

ClutchPedalPositionSwitchTest

1. Disconnecthe 2P connector rom the clutchpeda

positionswitch(A),

CLUTCH EOAL OSITION WITCHPCONNECTOR

Term ina ls idefm a le e rm ina l s

Remove he clutchpedalposit ionswitch.

Check or continuitybetween he terminals

according o the table.. lf the continuity s not as specified, eplace he

clutchpedalposit ionswitch.. lf OK , nstall heclutch pedalposit ionswitch an

adjust he pedalheight seepage 12-4).

TerminalCl"t"h P"d"l IPositionSwitch

1 2

PRESSED

RELEASED o o

4



ssembly

EngineRemoval

Special Tools RequiredFrontsubframeadapterEOS02C00001

NOTE:. Use endercovers o avoid damagingpainted

surfaces.. To avoiddamage,unplug he wiring connectors

carefullywhile holding he connectorportion.. Markall wiring and hoses o avoid misconnection.

Also,be sure hat hey do not contactotherwiring orhoses,or interferewith otherparts.

1. Secure he hood n the wide open posit ion supportrod n the lower hole).

2. Makesureyo u have he anti-theft ode or the radio,then write down the frequenciesor the radio's

presetbuttons.

3. Disconnecthe negative able rom the battery irst,then disconnecthe posit ive able.

4. Remove he battery.

5. Remove he intakemanifoldcover.

II

\,

6. Disconnectthentakeairtemperature lAT)sensorconnector A) , emove he breatherhose B)an dvacuumhose C) ,hen emove he a i rc leaner

housingcover/intake ir ductassemblv D) .

A C

7 . R emov e he a i r c l eane rhous ing .



8. Remove he intakeair duct.

9. Remove he batterycables A) romthe under-hood

fuse/relay ox. hen remove he harness lamp(B )andground ab le C) .

10. Fullvooen he thrott le ink and cruisecontrol in k

by hand, hen remove h e thrott lecable A)an d

cru ise ont ro l ab le B) f rom he inks . oosenhe

locknuts C) ,and remove he cables rom the

bracket.

11 . Re l ieve fue l ressuresee age11-144) .

1 2 .R e m o v eh e u e l i n e ( s e e p a g e l l - 14 9 ) .

13 . Remove he evaporative mission EVAP) aniste

hose A)and brakeboostervacuum hose B) .

(con

5



Engine ssembly

EngineRemoval cont'dl

14. Removehe c lu tch lave y l inder A)andc lu tch l inebracketmounting bolt (B).

15. Remove he shiftcable A)and select able B).

-4

..416 . Disconnecthe enginecontrolmodule ECM)

connectors A)and main wire harness onnector(B) .

Remove he harness lamps A)and grommet (B),

thenpu l l t heeng inewi reharnesshrough hebu lkhead.

't 7.

\ l,



Assembly

EngineRemoval cont'd)

32. Lower he hoist.

33 . Removehe upper ose A)andheater oses B) .

34. Bemove he radiator se epage 10-10).

35. Attach he chain hoist o the engineas shown.

6

36. Removehe ransmission ountbracket upportboltandnuts.

37. Removehe upper racket ounting oltandnut.

(.g\a



Engine nstallation

Special Tools Required

FrontsubframeadapterEOS02C00001

1. lnstallthe accessory rackets, nd ighten heir boltsand nuts o the specif ied orques.

10x 1 .25m mil 4 N. m {4.5 gf.m,33lbl.ft)

A/C COMPRESSORRACKET

10 x 1 25mm44 N.m {4.5 gf.m,33lbt.ft)

(cont'

ENGINEMOUNTBRACKET

5



Assembly

Engine nstallationcont'd)

Positionhe engineunder he vehicle.Attach he

chain hoist o the engine, he n if t the engine ntopos i t ionn heveh ic le .

Re ins ta l l t he ount ing o l t s / suppor tu ts n

the sequence iven.Failure o follow this

sequencemay causeexcessive oisean dvibration,and reducebushing ife.

3. Install he A,/C ompressor A) ,and connect he

compressor lutchconnector B) .

8 x 1.25mm22 N.m12.2 gf m. 16 bf.ft)

4. Support he subframewith the subframeadapteranda ack.

6r"

6-_-'-

- - -.'.:- --=---=-- .-€..'tt-

--- :--

5. InstallhesubframeA) .Align he eference arks(B )on hesubframe ith hecenter f he boltheads,hen ightenhebol ts .

1 4 x 1 . 5m m1 0 3 N m{ 10 ,5 g f m .76 rbt.ftlReplace.

6. Tighten he rear mount mounting bolts.

l 0 x 1 .25mm59 N.m (6.0kgf.m, 4:] bI.ft)

FI



7. Loosely ighten he front mount bracketmounting

bolt.

Lower he hoist.

Tighten he upper bracketmountingbolt and nut.

8.

9 .

10. Tighten he transmissionmount bracket upport

bolt and nuts.

12 1 .25 m54N m {5.5 gt m, 40 bf.ft}

Raise he hoist o full height.

Tighten he front enginemount bracketmounting

bolt.

' l 1.

' t2 .

12x 1.25 nrn64N. m 6. 5 gf.m,47 bt.ftl

13. Lower he hoist.

14 . Removehecha inho is t rom he eng ine .

'15 .Ins ta l l t head ia to rsee age10-10) .

' 16 .Ra isehe ho is t o fu l l he igh t .

17 . Installa ne w set ringon the end of eachdriveshaf

then install he driveshafts.Makesure each ing"clicks" into place n he differential nd

intermediate haft.

(con t

:l

5 -



Assembly

1 8 .

Engine nstallation cont'dl

10 1.25mm33N. m 3.i1kgf.m,25 bt.ftl

1 9 .

20 .

Connect he suspension ower arm ball oints (see

step6 on page18-19) .

Connect he stabil izerinks seepage18-18).

Install he threeway catalytic onver ter TWC)

assembly A) ;us ene w gaskets B)and new self-

lockingnuts{C).

\D

21.

- d,ry

6\

8 x 1.25mm22N.m|.2.2kglm,16 bt.ft)

Connect he air fuel ratio 4,/F) ensorconnector D)

and secondary eatedoxygensensor secondary

HO2S) onnector E) .

Install he lower radiatorhose.

v

23. Ins ta l l t he p lash h ie ld .

24 .

25 .

26.

Lower he hoist.

Insta l l ther ive e l t .

Installthe ,/ Cin emounting olt.

6 x '!.0mm9. 8N. m (1.0 gf.m,7.2 tbt.ftl

.

- t - --- -- -- r



27. lnstalltheupper adiatorhose A) and heaterhoses(B) .

Pushheengine ontrolmodule ECM) onnectorsthroughhebulkhead,hen nsta l l therommetA).

29. Ins ta l l t he a rness lamps B) .

30. Co nnect he ECI\4 onnectors A) and main wire

harness onnector B) .

Install he thrott lecable seepage11-164),he n

ad jus t the ab le see age11- '163) .

Installthecruisecontrolcable seepage4-44), he

adjust he cable seepage4-45),

Install he brakeboostervacuum hose A)and he

evaporative mission EVAP) anisterhose B).

34 . Ins ta l l t heue l ine see age11-150) .

3 1 .

32.

33 .

(cont'

5-



Assembly

Enginenstallationcont'dl

Install he select able A) and shift cable B)using

th e plasticwashers C) ,washers D) ,and new cotterp ins E) .

6 x 1 . 0 m m9. 8N. m 1. 0 gf.m,7.2 bl.ftl

I ns ta l lhec lu tch lave y l inder A)andc lu tch ine

bracketmounting bolt (B).

6 x 1 . 0 m m9.8 N.m

{1.0gf.m,

7.2 tbt.ft)

"-.----->)"------'6

8 x'1.25

mm

24N. m (2.4 gl.m,

37 . Installthebatterycables A) on the under-hood

fuse/relay ox, hen nstall he harness lamp(B).

Ins ta l l t he round ab le C) .

Ins ta l l t hen take i rduc t .

6 x 1 . 0 m m1 2 N m { 1 . 2 k g f . m ,8.7 tbf.ft)

39.

\"

\-

a

6 x 1 . 0 m m1 2 N m { 1 . 2 k g t . m ,8.7 bf.ft)



40. Ins ta l lhe a i rc leaner ous inq .

6 x 1 . 0 m m12 N m (1.2 gf.m,8.7 bt.ft)

I ns ta l lhe a i rc leaner ous ing over A)andconnect he intakeair emperature lAT)sensorconnector B) ,

42 . Ins ta l l t he rea ther ose C) ndvacuum ose1D) .

41 .

43 . Ins ta l l t hen takeman i fo ld over .

6 x 1 . 0 m m1 2 N m 1 1 . 2 k g f . m8.7 bf.ft)

Installthebattery.Clean he batterypostsan dcab le e rmina ls i th sandpaper ,henassemblethem and applygrease o preventcorrosion.

Check hat he transmission hifts nto gear

smoothly.

Inspect or fuel leaks. urn he ignit ionswitch ON(ll) do not operate he starter) o hat th e fuel pum

runs or about 2 seconds nd pressurizeshe fuel

l ine.Repeat his operation wo or three imes, hencheck or fuel leakage t any point n the fuel l ine.

Ref i l l t he ng inewi theng ine i l (see age -5) .

Ref i l l he ransmiss ion i th lu id see age13-3) .

Refil l he radiatorwith enginecoolant,and bleed

ai r ro m the coolingsystemwith the heater alveopen see age10-6) .

Per fo rmheeng ine ont ro lmodu le ECM)dle eaproceduresee age11-139) .

Inspect he idlespeed seepage11-138).

Inspecthe gn i t ion iming see age4-17) .

Check hewhee la l ignmentsee age18-4) .

Enter he anti-theft ode or th e radio, he n enterthe customer's adiostationpresets.

Set he clock.

Y

44 .

41 .

]t E

46 .

48.

49 .

52 .

53.

54 .

50.

5 1 .

55 .

5-



EngineMechanical

Cylinder eadSpecial oolsComoonentocationndexEngine ompressionnspectionVTEC ocker rmTest . . . . . . . . . . . . . . . . . . . . . . .-7VTCActuatornspection .. . . . . . . . . . . . . . . . . . .-8ValveClearancedjustment .. . . . . . . . . . . .-9Crankshaftul ley emoval nd nstal lat ion.. . . . . . . . . . . .-11

CamChain emova l . . . . . . . . . . . . . . . . . . . . . . . . . . .-12CamChainns ta l l a t i on . . . . . . . . . . . . . . . . . . . . . . .-15Auto-Tensioneremoval/1nsta11ation.. . . . . . . . . . . . . . . . . . . . . . .-19ChainCaseOilSeal nstal lat ion .. . . . . . . -21CyfnderHeadCoverRemoval . . . . . . . . . .-22Cyl inder eadRemoval . . . . . . . . . . . . . . . . . . . . .-23WC Actuator. xhaustCamshaft orocket

Repfcement . . . . . . . . .6-24Cyl inder eadnspectionorWarpage .. . . . . . . . . .. . . . . . . . . .-25Rocker rmAssembly emoval . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . .-26Rocker rmsandShafts

Disassembly/Reassembly .. . . . . . . . . . . . .-27Rocker rmsandShaftsnspection.. . . . . . . . . . . . . . . . . . . . . . . . . .-28Camshaftnspection .. . . . . . . . . . . . . . . . . . . . . . . . .-29Valves, pr ings, ndValve ealsRemoval . . . . . . . . . . .. . . .-31Valve nsoection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-32ValveStem-to-Guidelearancensoection.. . . . . . . . . . . . .-32ValveGuideReolacement .. . . . . . . . . . . . . . . .-33Valve eatRecondit ioning . . . . . . . . . . . . . . . .-35Valves, pr ings, ndValveSealsnstal lat ion.. . . . . . . . . .-37Rocker rmAssemblvnstal lat ion .. . .6-38Cv l inder eadnsta l l a t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-39Cyl inder eadCover nstal lat ion . . . . . . -41

6-26-3b-t'



CylinderHead

SpecialTools

'a- ti--- -- -i

',..)-)--'-

o

..'.,i2.<:'':'v''

5'r' a

/":-- -'''

't'tY-,l

- 1jr- r--- - l -: , .

@ o

, -' '

, ),.-/ r--\

a:-t '" Lq-,

o l?

..#..a:-"

a,/'/'@ @D

Ref. No. Tool Number Description Oty

O OTAAJ.PNAA'IOO.D OTHAH-PJ7O1OB

o Ioz..rae-ootzoa@ 07JAB-0010204o 07NAB-0010404G) 07VAE-001010A

OTZAJ.PNAAlOOE] OTZAJ-PNAA2OOO I 07ZAJ-PNAA300tro 07742-0010100@ 07746-001o4oo(D 07749-0010000

Ai r Pressure egu la tor

Va lveGuideReamer , .5mm

Socket,19 mmHolderHand le

HolderAttachment, 0 mm

ValveSpringCompressor ttachment

VTECAir Adapter

VTECAlr Stopper

Air Joint AdapterVa lveGuideDr iver ,5 .5 m

Attachment, 2 x 55 mm

Dr iver

1111

1121

1

6-2



Component ocationndex

TENSIONERAR M

AUTO.TENSIONERReplacement,ag e6-'l

IGNITION OILCOVER

CYLINDEREADCOVERRemoval,ag e -2 2lnstallation,ag e -4 1

CAM CHAINBemoval, ag e6-'12Installat ion, ag e6-15

frn| ] tJp

CAM CHAINGUIDEB

CAM CHAINGUIDEA

VARIABLEALVETIMINGCONTROLtwc) olL soLENotDVALVE

CRANKSHAFT ULLEYRep lacem en t ,age 11

O-RING

(cont'

6



ComponentLocation ndex cont'd)

CAMSHAFTPOSITIONICMP}SENSOR

TOPDEADCENTER

(TDC) ENSOR

CAMSHAFT

HOLDER

f\frTF]

Fg

YRLI

CA MCHAINGUIDE

/EIg----- -"-oowetew

EXHAUSTCAMSHAFTSPROCKETRemoval, ag e6 24Installat ion, ag e6-25

EXHAUSTCAMSHAFT

ROCKER RMASSEMBLYOverhaul, ag e6 27

Inspection, ag e6-28

-4



SPRINGRETAINER

EXHAUSTVALVESEAL

vALvE / .""or", uo.u,

. \ l l "* I / uo.ur.r","o--€.i

d:l.\aFl

T1l ll lH

,p

2bw9)

\*""'RArNERcovER

\

wcsrRArNER

CYLINDER EA DRemoval, age6'23Inspection, ag e6-25Installat ion, age6-39

EXHAUSTVALVERemoval, ag e6-31Installat ion, ag e6-37

INTAKEVALVERemoval, ag e6 31Installat ion, ag e6 37

CYLINDER EADGASKET

,H v .-- spntruc>il( G\-r_

\ l g| | g -/ TNTAKEALVEI I ^- '-- 9E4LI I U- Replacement,age -3 1

H e ,tl E- _-/ |NTAKE ALVEY I 1.- GUIDE

U Replacement,age -3 3

i

HEATSHIELD

6



CylinderHead

EngineCompressionnspection

1. Warm up heeng ine o normal pera t ing

temperature cooling an comes on).

2. Turn he gnitionswitch OFF.

3. Remove he intakemanifoldcover(seestep 1 onpage6-22).

4, Disconnect l l four injectorconnectors.

5. Start he engine,and et t run until t stalls.

6 . Removehe our gn i t ion o i l s see age4-18) .

7. Remove he four sparkplugs.

8. A ttach he compression auge o the sparkplug

note .

6

V ,

\

9 .

10 .

Open he throttle ully , hen crank he enginewiththe startermotor and measure he compression.

Compression Pressure

Above 930 kpa (9.5kgf/cm', 135psi)

Measure he compression n the remainingcylinders,

Maximum vadationWithin 200 kPa (2.0kgf/cm', 28 psi)

lf the compression s not within specifications,check hese tems, hen remeasurehecompressron.

. Damagedorworn valvesand seats

.Damaged ylinderheadgasket. Damaged r worn piston ings

. Damagedorworn pistonand cylinderbore

1 1 .

\-



WEC Rocker rmsTest

SpecialTools Required. Air pressure egulator 7AAJ-PNAA100. VTECair adaoter07ZAJ-PNAA100. WEC air stoDoer 7ZAJ-PNAA200. Air joint adapter07ZAJ-PNAA300

1. R emove he cylinderheadcover (seepage6-22).

2. S et he No. 1 pistonat top deadcenter TDC) see

step 1 on page6-12).

3. Verify hat he ntakeprimary rockerar m (A) moves

independently f the ntakesecondary ockerar m(B) .

. lf th e intakeprimaryrockerarm does not move,

remove he primaryand secondary ockerarms

as an assemblyand check hat he pistons n thesecondary nd primaryrockerarms move

smoothly. f any rockerarm needs eplacing,

replace he primaryand secondary ockerarms

asan assemblv, nd est.. lfthe intakeprimaryrockerarm moves reely,go

to step 4.

6 .

Repeat tep3 on the remaining ntakeprimary

rockerarmswith eachpistonat TDC.When all heprimaryrockerarms pass he est,go to step 5.

Check hat he ai r pressure n the shop air

compressor auge ndicates ver 400 kPa(4 kgflcm',57 psi).

Inspect he valveclearance se epage6-9).

Remove he sealingbolt (A)from the reliefhole,

an d nstall he VTECair stopper B) .7 .

OTAAJ.PNAAlOODOTZAJ-PNAA

Remove he No. 2 and No .3 camshaftholderbolt

an d nstalltheVTEC ir adapters C) inger-tight.

Connect he air oint adapter D) ,and air pressure

regulatorwith a 0-100psi gauge E).

(cont

OTZAJ.PNAAlO

6



Head

WEC RockerArmsTest(cont'dl

'10.Loosen he valveon the regulator, nd apply hespecified ir pressure.

Specifiedair pressure:

290 kPa 13.0 gt/cm', 42 psi)

NOTE: f the synchronizing istondoes not moveafterapplyingai r pressure;move he primaryorsecondary ockerar m up and down manuallybyrotating he crankshaft lockwise.

11 .Wi th he spec i f ied i rp ressure pp l ied ,move hein take r imary ocker rm (A) fo r theNo,1cy l inder .Th e primary rockerarm and secondary ockerar m(B) hou ldmove ogether .

lf the intakesecondary ockerarm doesnot move,

remove he primaryand secondary ockerarms asan assembly, nd check hat he pistons n th eprimaryand secondary ockerarms movesmoothly. f any rockerarm needs eplac ing,replace he primaryand secondary ockerarms asan assembly, nd est.

Remove he special ools.

Tighten he camshaftholdermountingbolts o22 N m 12.2 gf.m,16 bf.ft).

T igh tenhesea l ing o l t to20 N.m 2.0 gf .m,14 bf.ft).

I ns ta l l t he y l inder ead over see age6-41) .

12 .

13 .

1 4 .

t 5 .

-8

VTGActuator nspection

'11.Remove he cylinderheadcover se epage6-22lr.

2. Remove he auto-tensionerse epage6-19).

3. Loosen he rockerarm adjusting crews see step2on page6-26).

4. Remove he camshaftholder se estep3 on page6-26t.

5. Remove he intake amshaft.

6, Check hat the variablevalve iming control VTC)actuator s ockedby turning he VTCactuatorclockwiseand counterclockwise.f th e VT Cactuatoris not ocked, eplace he VTCactuator.

7 . Sea l headvance o les A)and etard o les B) nthe No. 1 camshaft ournalwith tape.

Puncha hole hrough he tape overone of theadvanceholes.



9. Apply air o the advancehole o relea se he lock.

Check hat the VT Cactuatormovessmoothly. f the

VT Cactuator oes not move smoothly, eplace heVT Cacluator.

1 0 .

ValveGlearance diustment

NOTE:Adjust he valvesonly when the cylinderhead

temperature s less ha n 100'F 38'C).

1. Re move he cylinderheadcover(seepage6-22).

2. Set he No. 1 pistonat top deadcenter TDC). hepunchmark (A) on the variablevalve iming contr(VTC) ctuatorand he punchmark (B )on the

exhaustcamshaft procket houldbe at the top.

Align the TD Cmarks C)on the VT Cactuatorand

exhaustcamshaftsprocket.

{con

6



Head

alveClearance djustment(cont'd)

3. Selecthecorrecthicknesseeler augeor hevalves ou'regoing o check.

Intake: 0.21 0.25mm (0.008-0.010n. )Exhaust;0.28 0.32mm (0.011 0.013n. )

Adiustingscrew ocations:

No. 1

EXHAUST

No.2 No.3 No.

No. 1 N o . 4

4. Insert he feelergauge A) between he adjustingscrew B)and he endof the va lve tem, nds l ide tbackand orth;you should eela slight amountofd ag .

\.

5. l f you ee l oomuchor too l i t t l edrag, oosenthelocknut A) ,and urn the adjusting crew B)untilthe drag on the feelergauge s correct.

Tighten he locknut, nd recheck he clearance.Repeat he adjustment f necessary

Rotate he crankshaft 80 "clockwise camshaft

pu l ley urns90 ' ) .

7 .

t .\-

8. Checkand, f necessary, djust he valveclearanceon No.3 cy l inder .



1 0 .

9. Rotate he crankshaft 80 "clockwise camshaft

pullev urns 90').

Checkand, f necessary, djust he valve clearanceon No.4 cy l inder .

Rotate he crankshaft 80 "clockwise camshaft

pu l ley urns90" ) .

Checkand, f necessary, djust he valveclearance

on No.2 cy l inder .

Install he cylinderheadcover(seepage6-41).

1 1 .

12.

CrankshaftPulleyRemovalandInstallation

SpecialTools Required. Holderhandle07JAB-001020A. Holderattachment, 0 mm 07NAB-001040A. Socket,19 mm 07JAA-0 01020,4r a commercially

ava i lab le 9mm socket

Removal

1. Remove ront t ires/wheels.

2. Remove he splashshield se estep23 on page5-

3 . Ho ld hepu l leywi th ho lder and le A)andho lde

attachment B) .

B07NAB-00104

el/ Srroo.oo,o

/ (o rcommercial

f available)

/

Remove he boltwith a 19 mm socket C)an dbreakerbar.

(con

6



Head

CrankshaftPulleyRemovalandInstallationcont'dl

Installation

1. Clean he crankshaft ulley A) ,crankshaft B),bolt(C).and washer D) .Lubricate s shown below.

. .: CleanO; Lubricate

Ins ta l l t he rankshaf tu l ley , nd ho ld he pu l leywith holderhandle A)and holderattachment B).

B07NAB-0010iroA

A07JAB-001020A

Tighten he bolt o 245 N.m (25.0 gf.m,181 bf.ft)with a torquewrench and 19mm socket C) .Do notus ean impactwrench.

Ins ta l lhesp lash h ie ld see tep20on page5-12) .

Instal front tires/wh els.

l ll l

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

( - , ,

5U-1JI tt -

5.

\-

CamChainRemoval

NOTE:Keep he cam chainaway rom magnetic ields.

1. Turn he crankshaft ulleyso ils top deadcenter(TDC)mark A) ines p w i th

hepo inrer B) .

Remove he front tires/wheels.

Removehe sp lash h ie ld .

a

2.

3.

- , , - - . = . - - - - - _ _ - - _


5. Remove he cylinderheadcover (seepage6-22).

6 . Removehecrankshaf tu l ley see age6-11) .

\



7. Disconnectthe rankshaft osit ion CKP) ensor

connector A)and variablevalve iming control

{VTC) il controlsolenoid alveconnector B).

Remove he VTCoil controlsolenoid alve(see


Support he enginewith a ac kan d wood block

under he o i l pan.

Remove he groundcable A) .and remove he

upperbracket B) .

9 .

1 0 .

11. Removehes ideeng inemountbracket .

12 . Removehe cha in ase.

(con

6



Head

1 4 .

CamChainRemoval cont'd)

Loosely nstall he crankshaft ulley.

Turn he crankshaft ounterclockw iseo compressthe auto-lensioner,

Align he holeson the oc k(A) an d he auto-tens ionerB) , hen nsena 1.5mm (0.06n. )diameterpi n (C) nt o he holes.Turn he crankshaftclockwise o secure he Din.

t 5 .

\-

\

16. Remove he auto-tensioner.

17 . Removehecamcha ingu ideB.

g f f il l l l

U U



18. Removehecamcha in u ideA (A)and ens ioner

a r m B ) .

g"'-

19 . Rem ove he cam cha in .

,o./6. | \{n$1J;

CamChain nstallation

NOTE:Keep he cam chainaway rom magnetic ields

1. Set he crankshaft o top deadcenter TDC). lign

the TDCmark{A )

on the crankshaft procketwith

the po in ter B)on he cy l inder lock .

Setthe camshafts o TDC.Th e punchmark (A )on

th e variablevalve iming control VTC) ctuatoran

thepunchmark B)on heexhaust amshaf t

sprocket houldbe at the top. Align he TD Cmark(C )on the VTCactuatorand exhaust amshaft

sprocKet.

(con

6



Head

CamChain nstallationcont'dl

3. Installthe amchain n hecrankshaftprocketwith hecolored iece A)aligned ith he punchmark B)on hecrankshaftprocket.

Installthecam chainon the VTCactuatoran dexhaustcamshaft procketwith the punchmarks(A )alignedwith the two coloredpieces B).

B

5. Ins ta l l t he amcha ingu ideA (A)and ens ioner rm(B) .

6 x 1 . 0 m m12N.m{1,2 gf.m,8.7 tbf.ftt

I6

8 x 1 .25 m22N. m12.2kgt.m,16 bf.ft)

6. Install he auto-tensi

6 x 1 , 0 m m1 2 N m(1.2 gt.m,8.7 bf t i)



7, Ins ta l lhecamcha ingu ideB.

H4\ i l tH g

8 x 1.25mm22N. m

(2.2 gf.m, 6lbt.ft)

8. Remove he Din ro m th e auto-tensioner,

Check he chaincaseoi l seal or damage. f the oil

seal s damaged, eplace he chaincaseoil seal(see age -21) .

9.

1 0 .

1 1 .

Removeold l iquidgasket rom the chaincase

matingsurfaces, olts,and bolt holes.

Cleanand dry the chaincasematingsurfaces.

Apply iquidgasket.P/N 08718-0009,venly o the

cylinderblockmatingsurfaceofthe chaincasean

to the nner h reads f heho les .

Apply iquidgasket o the cylinderblockupper

surface ontactareas A)on the chaincase.

Apply l iquidgasket,PiN 08718-0009,venly o theoil pa nmating surfaceof the chaincaseand o the

inner hreadsof the holes.

NOTE:Do not nstalltheparts t 5 minutesor mor

haveelapsed inceapplying iquidgasket. nstea

reapply iquidgasketafter emovingol d residue.

(con

1 4 .

Apply iquidgasketalong he broken ine.


6-



Head

CamChain nstallationcont'd)

'15.Install he ne w O-ring A) on the chaincase.Set heedgeof the chaincase B) o the edge of the oil pa n(C) ,hen nsta l lhecha in ase n hecv l inder lock(D) .

NOTE:When nstall ing he chaincase,do not slidethe bottom surfaceon the oil pa n mountingsurface.

',.9

6 x 1 . 0 m m12N.m(1.2 gt.m.8.7 bf. f t)

6 x 1 . 0 m m1 2 N m(1.2 gf.m,8.7 bf.f t)

\-

16. ns ta l l t he ideeng inemount .b racket .

17. Installtheupperbracket A), hen ighten he bolvnuts n the numberedseouence hown.

6x1 . 0mm12 N. m{1.2 gl m, 8.7 bf ft }

12x1 . 25 m54 N.m(5.5kgt m, 40 lbf.ft)

I

\

18. Ins ta l lheground ab le B) .

rbf.ft)



1 9 .

20 .

lnstall he variable alve iming control VTC) il

con t ro l o leno id a lve see tep1 on page11 '127) .

Connect he crankshaft osit ion CKP) ensorconnector A)and VTCoil controlsolenoidvalve

connector B).

21. Install h e crankshaft ulley se epage6-12).

22 . Ins ta l l t he y l inder ead over see age -41) .

23 . Ins ta l l t he r i vebe l t .

24 . Ins ta l l t he p lash h ie ld .

€D@

Auto-Tensioner emovaUlnstallation

Removal:

1. Removehecha in ase over .

Turn he crankshaft ounterclockwiseo compres

the auto-tensroner.

{con

6



Head

Auto-Tensioner emoval/l stallation

3. Align he holeson the ock(A) an d he auto-tens ionerB) , hen nser t 1 .5mm (0.06n. )diameterpi n (C ) nt o he holes.Turn he crankshaftclockwise o secure he oin.

4. Remove he auto-tensioner.

\-

(cont'dl

Installation:

1. Install he auto-tensioner.

\

6 x 1 . 0 m m12 N.m {1.2 gt.m,8.7 bt. t t)

Remove th e pi n from the auto-tensioner.

\



Removeold l iquidgasket ro m the chaincasecovermatingsurfaces, olts,and bolt holes.

Cleanand dry the chaincasecover matingsurfaces.

Apply l iquidgasket,P/ N08718-0009,venly o thechaincasematingsurfaceof the chaincasecover

and o the inner hreadsof the holes.

NOTE:Do not nstalltheparts f 5 minutesor morehaveelapsed inceapplying iquidgasket. nstead,reapply iquidgasketafter emovingol d residue.

6. Ins ta l l t he ha in ase over .

4.

6 x 1 . 0 m m12N.m

{1.2 gt.m,8.7 tbf.ft)

Apply iquidgasketa long heb rokenine .

ChainCaseOil Seal nstallation

SpecialToolsRequired. Driver07749-0010000. Attachment, 2x 55 mm 07746-0010400

1. Use he spec ia loo ls o dr i vea newol l sea lsquarely nto he chaincase o the specifiedins ta l led e igh t .

07749-0010000

2. Measure he distancebetween he chain case

sur face A)ando i l sea l1B) .

Oil Seal nstalledHeight:

33 .0-33.7mm (1.30-1 .33 n . )

33.0 33.7mm{1.301.33n. l

6-



GylinderHeadRemoval

NOTE:. Use ender overso avoiddamaging ainted

surfaces.To avoiddamage,unplug he wiring connectorscarefullywhlle holding h e connectorportion.

To avoiddamaging he cylinderhead,wait unti l heenginecoolant emperature rops below 100'F 38"C)

betore oosening he cylinderheadbolts.Mark al lwiring and hoses o avoid misconnection.

Also, be sure hat hey do no t contactotherwiring orhoses,or interferewith otherparts.

'1.

2 .

3.

Drain he enginecoolant se epage 10-6).

Remove he drive belt (seepage4-26).

Remove he ntakemanifold seepage9-3).

Remove he air cleanerhousing seestep7 on page

5-2t.

5. Remove he water bypasshose A).

Remove he exhaustmanifold se epage9- 7

Remove he cam chain seepage6-12).

6 .

7.

) .

8. Remove he enginewire harness onnectors ndwire harness lamps rom the cylinderhead.

. Engine oolant emperature ECT) ensorconneclor

. Camshaftposit ion Cl\4P)to pdead center TDC

sensorB connector. Camshaftposil ion CMP) ensorA connector

9. Remove he upper radiatorhose A)and heater

hose B) .

'10.Remove he harnessholder(A)from the bracket,

then remove he connectingpipe mountingbo h {Band brakeboostervacuum ine mountingbolts C

(cont

11. Remove he water bvpasshose D) .

6-



Head

'1 .

2 .

RockerArm AssemblyRemoval

Remove he cam chain seepage6-12).

Loosen he rockerarm adjusting crews A),

A

3. Remove he camshaftholderbolts.To Drevent

damaging he camshafts, nscrew he bolts wo

turns at a t ime, n a crisscross attern.

CAMSHAFTHOLDERBOLTSLOOSENING

SEOUENCE:

6-26

\-

4. Remove he camchainguide B, camshaftholders,

and camshafts.

Insert he bolts A) nt o he rockershaftholder, hen

remove he rockerarm assembly B).5 .



NOTE:

RockerArmsand ShaftsDisassembly/Reassembly

ldentifypartsas hey are removed o ensure ein stallationn original ocation.

Inspect he rockershaftsand rockerarms (seepage6-28).The rockerarms must be nstalled n the sameposit ions f reused.

When removingor install ing he rockerarm assembly, o not remove he camshaftholderbolts.Th e boltswill keethe holders, pringsand rockerarms on the shaft.Prior o reassembling, leanall the parts n solvent,dry them, and apply ubricant o any contactpoints.Bundle he rockerarms with rubberbands o keeDhem tooetheras a set.

EXHAUSTROCKERSHAFT

EXHAUSTROCKER RM

wASHEB Yr rY Y V

\ n l I l t n r l l l nIJI_J;-L,JLI]1_L^|l]rffinffif-

INTAKEROCKERARM ASSEMBLY

INTAKEROCKER HAFT

'rl)

70 )

.; .. . 1

t:l P- l

, , _ t l

o

,q

'lo

6-2



Head

1 .

2 .

RockerArms and Shafts nspection

Remove he rockerarm assembly seepage6-26).

Measure he diameterof the shaftat the first rocker

location.

3. Zero he gauge A) o the shaftdiameter.

\

4. M easure he insidediameterofthe rockerarm, and

check t for an out-of-round ondition.

Rocker Arm-to-Shaflt Clearance:

Standard lNew):lntake: 0.025 0.052 mm

(0.0010 0.0020 n.)

Exhaust: 0.018 0.056mm(0.0007 0.0022n. )

Service Limit: 0.08 mm (0.003 n.)

5. Repeat or all rockerarmsan d both shafts. fthe

clearances over he Ilmit. replace he rockershaft

and all overtoleranceockerarms. f any VTEC

rockerarm needs eplacement,eplace he rocker

arms (primaryand secondary) s a set.

6. Inspect he rockerar m pistons A} .Pusheachp is tonmanua l l y .

lf it doesnot move smoothly, eplace he rocker

ar m set.

NOTE:Apply oil to the pistonswhen reassembling.

,,,@@

\.



Gamshaft nspection

NOTE:Do not rotate he camshaftduring nspection.

1. Remove he rockerarm assembly se epage6-26).

and disassemblet (seepage6-27).

2. Put he rockershaftholders, amshaft, ndcamshaftholderson the cylinderhead, hen ightenthe bolts o the specif ied orque.

Specified orque:

I mm bolis:

22 N.m {2.2kgt m, 16lbf.ft}

6 mm bolts:12 N.m {1.2kgf.m,8.7 bf.ft l

6 mm bolts: @, €0,@

I

I

3. Se at he camshaftby pushing t away rom th ecamshaf t u l ley ndof the cy l inder ead .

4. Zero he dial ndicatoragainst he end of the

camshaft, hen push he camshaftbackand forthand read he end play. f the end play s beyond hservice imit, replace he camshaftheadan drecheck. f it is sti l l beyond he service imit, replacthecy l inder .

CamshaftEnd Play:

Standard New}:0.05 0.20mm(0.002 0.008 n.l

ServiceLimit: 0.4 mm (0.02 n. )

(cont

6-



Head

Camshaftnspection cont'dl

1 .

9 .

Unscrew he camshaftholderbolts wo turns ata

time, n a crisscross attern.Then remove he

camshaftholders rom the cylinderhead.

Lift he camshafts ut of the cylinderhead,wipethem clean. hen nspect he lif t ramps.Replacehe

camshaft f any obesar e pitted,scored,or

excessively orn,

C lean hecamshaf tourna l u r facesn hecy l inder

head, he n set he camshaftsback n place.Placeaplastigage trip acrosseach ournal.

Install he camshaftholders, hen ighten h e bolts

to the specif ied orque as shown n step2.

Remove he camshaftholders.Measure he widestportionof plastigage n each ournal.

. lf the camshaft-to-holderlearances within

l imi t s , o o s tep11.. lf the camshaft-to-holderlearances beyond he

service imit and he camshaftha s been eplaced,

replace he cylinderhead.. lf th e camshaft-to-holderlearances beyond he

service imit and he camshafthas not been

replaced, o to step 10.

Camshaft-to-Holder Oil Clearance:

Standard (New):

No. 1 Journal:

No.2 ,3 ,4 ,5 Journa ls :

ServiceLimit:

0.030 0.069mm

{0.001 0.003n- )0.060*0.099 m{0.002 0.004n. )0.15mm {0.006n. )

\-

10. Check he total runoutwith the camshaft upported

on V-blocks,

. l f t he to ta l runout f he camshaf tsw i th in he

service imit, replace he cylinderhead.. lf the total runout s beyond he service imit,

replace he camshaftand recheck he camshaft-

to-holderoil clearance.f the oil clearances sti l l

beyond he service imit, replace he cylinder

neao.

CamshaftTotal Runout:

Standard New):0.03mm (0.001n.) max.

ServiceLimit: 0.04mm {0.002n. )

11 . Measure am obehe igh t .

Ca m

PRI : r imaryC/C:CamChain

SEC:Secondary

,

Lobe HeiohtStandard NewINTAKE EXHAUST

PRI 33.925mm(1.3356n. )

34.092mm

\1 3422 n.l

SEC 29.638 m( 1 . 1 6 6 8n . )



Valves,Springs,and ValveSealsRemoval

Special Tools Bequired

Valvespringcompressor ttachment 7VAE-001010A

ldentify he valvesand valve springsas hey are

removedso that each tem can be reinstalled n itsoriginalposit ion.

1. Remove he cylinderhead se epage6-23).

2. Usingan appropriate-sizedocket A) an d plastic

mallet B) , ightly ap the valve retainer o loosenth e valve keepers.

Install he springcompressor.Compress he spring,and remove he valve keepers.

4 . Ins ta l l t he a lvegu ide ea l emover .

5. t he va lve ea l .emove

\

6-



ValveGuideReplacement

SpecialToolsRequired. Valve uide river, .5mm 07742-0010100. Valve uide eamer, .5mm 07HAH-PJ7o108

1 . Inspect alve stem-to-guide learance se epage6-32t.

As il lustrated elow,use a commerciallyavailable

air-impact alveguidedriver (A )modified o f it th ediameterof the valveguides. n most cases, hesameprocedure an be done using he special ooland a conventional am mer.

10.8mm{0.,|2 n. )

3. Se lect heproper eplacement uides,and chil l

lhem in the freezer ectionof a refriqerator or

aboutan hour.

4. Usea hot plateor oven o evenlyheat he cylinderhead o 300'F 150"C).Monitor he temperaturewith a cooking hermometer.Do not getthe headhotterthan300'F 150"C); xcessive eatmay

loosen he valve seats.

-_|Jfillr-.-4fi'11., tT

7 .

Working rom the camshaft ide. use he driveran

an aar ammerto drive he guideabout 2 mm (0.1

in.)towards he combustion hamber.This wil lknockoff some of the carbonand make removal

easier.Hold he air hammer directly n l inewith thvalveguide o preventdamaging he driver.

Turn he headover,and drive he guideout towarthe camshaft ide of the head.

lf a valveguidewon't move,dril l i t out with a I mm(5/16nch) i t . hen ry aga in .Dr i l lgu ides n ly n

extremecases;youcould damage he cylinder

head f the guidebreaks.

Remove he new guide(s) rom the freezer, ne at

t ime, as vou need hem.

(cont

6-



Head

ValveGuideReplacementcont'dl

Apply a thin coat of cleanengineoil to the outside

of the new valveguide. nstall he guide rom the

camshaftside of the head;use he special ool to

drive he guide n to the specif ied nstalledheight

(A)o{ the gu ide B) . f you haveal l 16gu idesto o,yo u may have o rehea t he head.

Valve Guide Installed Height:

Intake: 15.2 16.2mm (0.598-0.638 n. )

Exhaust: 15.5 16.5mm (0.610-0.650 n. )

\

10 .Coatboth reamerand valveguidewith cuttingoil.

Rotate he reamerclockwise he full lengthof th e

va lvegu idebore .

O7HAH.PJ7O1OB

Continue o rotate he reamerclockwisewhile

removing t from the bore.

Thoroughlywash he guide n detergent ndwater

to removeany cutting esidue.

Checkhe c learances i tha va lve see age6 32) .

Verify hat a valve slides n the intakeand exhaust

valveguideswithout exeningpressure.

1 1 .

1 4 .

' - \



ValveSeatReconditioning

1. Inspect alve stem-to-guide learance seepage6-32). f the valveguidesare worn, replace hem (see

page6-33)beforecutting he valveseats.

2 . Renew he va lve ea ts n hecy l inder eadus ingavalveseatcutter.

Care fu l l y u ta 45 'sea t , emov ing nlyenoughmaterial o ensurea smooth and concentric eat.

Bevel he upperand oweredgesat the angles

shown n the llustration.

Check he width of the seatand adjustaccordingly.

INTAKE:35"EXHAUST:30'

3 ,

4.

- 45 '

, { 67 .5 '

5. Makeone more very l ight passwith the 45 "cutterto removean y possibleburrscausedby the othercutters.

ValveSeat Width:

Standard New):1.25 1.55mm {0.049 0.061 n.)ServiceLimit: 2.00mm (0.079n. )

6. A fter resurfacinghe seat, nspect or evenvalveseat ing : pp lyPruss ian lue ompound A) o theva lve ace . nser theva lve n tsor ig ina l oca t ionth e head, hen ift it and snap t closedagainst heseatseveral rmes.

1. The actualvalveseatingsurface B),asshown bythe bluecompound,should be centered n the sea

. lf it is too high (closer o the valvestem),youmust makea secondcut with the 67.5' cutter omove it down, hen one more cut with the 45 "

cutter o restore ea twidth.. lf it is too low (close o the valveedge), ou mus

makea secondcut with the 35'cutter (intake

sidelor the 30" cutter exhaust ide) o move t u

then makeone more cut with the 45" cutter orestore eatwidth.

NOTE: he ina lcu tshou ld lways e madewi ththe 45'cutter.

(con t

6-



Head

8.

ValveSeatReconditioningcont'dl

Insen he intakeand exhaust alves n th e head,

and measure alvestem nstalledheight A) .

Intake Valve Stem Installed Height:

Standard New):40.8 41.0mm(1.606 1.614n. )

Exhaust Valve Stem Installed Height:

Standard New):54.6-54.8 mm|'2.1502.157 in.l

lf valve stem nstalledheight s over he standard,

replace he valve and recheck. f it is sti l l over hestandard, eplace he cylinderhead; he valveseatin th e head s too deeD.

L

\-

\

\-



Valves,Springs,and ValveSeals nstallation

SpecialTools Required

Valvespringcompressor ttachment 7VAE-00101A

1. Coat he valve stemswith engineoil. nstall hevalves n the valveguides.

2. Check hat he valvesmove up and down smoothly.

Installthespringseatson the cylinderhead.

Install he new valveseals A)using he valveguide

sea l ns ta l le rB) .

NOTE:The exhaust alve seal C)has a blackspring(D),and he ntake alveseal E)has a white spring(F).They ar e not nterchangeable.

6 .

lns ta l l t he a lvespr ing . lacehe endof the va lve

springwith closelywound coils oward he cylindneao.

Install he valve retainer.

Installthevalve springcompressor,Compress he

spring,and nstall he valve keepers.Remove he

valve springcompressor.

Lightly ap the end of eachvalve stem wo or three

times with a plasticmallet A) o ensureproper

seatingof the valvean d valve keepers. ap he

valvestem only along ts axis so you do not bend

the stem.

7 .

6-



Head

RockerArm Assembly nstallation

:,ean and dry the No. 5 rockershaftholdermating

surfaces.

eeassemblehe rockerarm assembly seepage6-

2 1 .

Apply iquidgasket,P/N08718-0009,venly o th e

:ylinderhead matingsurfaceofthe No. 5 rocker

shaftholder.

\OTE: Do not nstall he parts f 5 minutesor more

ravee lapsed ince pp ly ingiqu id aske t .ns tead,'eapplyliquidgasketafter removingol d residue.

Insert he bolts A) nto he rockershaftholder, he n

install he rockerarm assembly B)on the cylinder

head.


l-

\

5 .

6.

Remove he bolts rom the rockershaftholder.

Make ure he DUnch arks n hevar iab le a lve

timing control VTC) ctuatorand exhaust amshaft

sprocket re acing up. hen set he camshafts A) n

th e holder.

Set he camshaftholders B) an dcam chainguideB(C) n p lace .

Tighten he bolts o the specif ied orque.

Specifiedtorque:

8 mm bolts: 22 N.m (2.2kgf.m, 16 bl.ft)

6 mm bolts: 12 N.m {1.2kgf.m,8.7 bf.f i l

6 mm bolts: @),@.@

lnstall he cam chain seepage6-15). nd adjust he

valveclearance se epage6-9).

I

fl

\-

7 .



CylinderHead nstallation

Install he cylinderhead n the reverse rderof

removat:

1. Clean he cylinderheadand blocksurface.

2. Install he new cylinderheadgasket A)anddowelpins (B )on the cylinderblock.Always usea new

cylinderheadgasket.

Set he crankshafto top deadcenter TDC). lign

th e TD Cmark (A) on the crankshaft procketwith

th e pointer B)on the cylinderblock.

4. Install he cylinderhead on the bloc k.

5. Measure he diameterof eachcylinderhead bolt a

oointA and DointB.

a 50mm (2.0n. l

f.f )>-

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

l f e i ther iameters ess han10.6mm {0.42n. ) ,

replace he cvlinderheadbolt.

(con

6



Head

8.

CylinderHead nstallation cont'd)

7 . App ly engineoil to the bolt hreadsan d under hebo l theads f a l l he cy l inder eadbo l t s .

Tighten he cylinderheadbolts n sequence o39N. m {4.0kgf.m,29 bf.ft).Use a beam- typeorque

wrench.When using a preset-typeorquewrench,be sure o tightenslowly and do not overtighten. fa bolt makesany noisewhile yo u are orquing t,loosen he bolt and retighten t from the first step.

9 . After orquing, ightenall cylinderheadbolts n twosteps 90 "pe r step). f you are usinga newcylinderheadbolt, ighten he bolt an extra90..

FIRSTSTEP

SECONDTE P

v

10 . Installthe ockerarm assembly seepage6-38).

1' t Install he water bypasshose A).

- - - l . - .

B6 x 1 . 0 m m'r 2

N. m(1.2 gl.m,8.7bf.ft l

1 2 .

't3.

c6 x l . 0 m m'1 2N, m 1. 2 gt.m,8.7bf.ft)

Tighten he connecting ip e mountingbolt (B)an dbrakebooster acuum ine mountingbolts C) , he nins ta l l t he arness o lder D)on he bracke t .

Installtheupper radiatorhose A)and heaterhose( B ) .



14. Ins ta l l t he a te rbvpass ose.

15 . ns ta l l t he i rc leaner ous ing see tep37 on page5-15) .

16 . Ins ta l l t hen takeman i fo ld see age9-5) .

17. Ins ta l l t he xhaustman i fo ld see age9-7) .

' 18 .Ins ta l l t he amcha in (see age6-15) .

19 . Ad jus t heva lve learance seepage6-9) .

20. Ins ta l l t he r i vebe l t see age4-26) .

21. Clean he batterypostsand cable erminalswith

sandpaper ,henassemblehem andapp lygreaseto preventcorrosion.

22. Af te r ns ta l la t ion ,hecktha ta l lubes, osesand

connectors re nstalled orrectly.

23 . Inspect fo r fue leaks. u rn he gn i t ion w i t chON

{ll) do not operate he starter) o that he fuel pump

runs or about2 seconds nd pressurizeshe fuel

l ine.Repeat hls operation wo or three imes, hen

check o r ue l eakage t any po in t n he ue l ine .

24. Refil l the adiatorwith enginecoolant,an d bleed

air from the coolingsystemwith the heater alve

open (seepage10-6).

25 . Inspecthe d lespeed see age11- '138) .

26 . Inspecthe gn i t ioniming see age4-17) .

GylinderHeadCover nstallation

1. Thoroughlyclean he headcovergasketand he

groove.

2. Installtheheadcovergasket A) n the grooveof

thecy l inder ead over B) .

Check hat he matingsurfaces recleanan d dry.

Apply l iquidgasket.P/N 08718-0009,n the chain

caseand he No.5 rockershaftholdermating are

NOTE:Do not nstall he parts f 5 minutesor mor

haveelapsed inceapplying iquidgasket. nstea

reapply iquidgasketafter removingol d residue.

(con

6-



Head

CylinderHeadGover nstallation cont'd)

Se t he sparkplug seals A)on the sparkplug ubes.Once hecy l inder ead over B) s on hecy l inderhead,slide he cover slightlybackand orth to seatthe headcovergasket.

Inspect he coverwashers C).Replace ny washerthat s damagedor deteriorated.

7. Tighten he bolts n two or three steps. n he finals tep , igh ten l l bo l t s , n sequence,o 9 .8N.m 1.0

kgf.m,7.2 bf.ft).

8 . I ns ta l lhe d ips t i ckA)andbrea ther ose B) .

\

\



9 .

1 0 .

Install he four ignit ioncoils se epage4-'18).

Check hat all ubes,hoses,and connectors re

installed orrectly.

lnstallthe ntakemanifoldcover.1 .

6 x 1 , 0m m'1 2N. m 1. 2 gf m.8.7 bf.ftl

12. After assemblv,wait at least30 minutesbefore

f i l l i ng heeng inewi th o i l .

6



EngineMechanical

EngineBlockSoec ia loo ls . . . . . . . . . . . . .2

Comoonentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-3

ConnectingodandCrankshaftndPlayInsDection .. . . . . . . . . . . . .-5

CrankshaftainBearing eplacement.. . . . . . . . . . . . . . . . . . . .-6ConnectingodBearing eplacement.. . . . . . . . . . . . . . . . . . . .-8Oi lPanRemova l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-11

CrankshaftndPiston emoval ........ -12

Crankshaftnspection .. . . . . . . . . . . . . . . . . . . . . . .-14B lock ndPistonnsoect ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-15Cyf inderon ing . . . . . . . . . . . . " . . . . . . . . . . . . . . . . . . . .'17

Piston, inandConnectingodReplacement.. . . . . . . .-18Piston ingReplacement .. . . . . . . . . . . . . . . . . .21

Pistonnstal lat ion.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .-23ConnectingodBolt nspection .. . . . . . ' 24

Crankshaftnstal lat ion .. . . . . . . . . . . . . . . . . . . . ' .-24Oi lPan ns ta l l a t i on. . . . . . . . . . . . . . . . . . . . . . . . . . . .27

TransmissionndCrankshafteallnstal lat ion- lnar . . . . . . . . . . . . .. . . . . . . . . . . . . . ' 28



Block

SpecialTools

Ref.No. ToolNumberOTZAD-PNAAlOO07746-0010700

07749,0010000

DescriptionOi l SealDriverAttachment 6Attachment, 4 x 26 mm

Driver

Oty

6@

1

1

1

o




MAINBEARINGSOi lc learance,age -6Selection,ag e -6

CRANKSHAFTEn dplay,page7- 5Runou t , age -14Out-of-Round,ag e7-14Removal, ag e7-12lnstallat ion, ag e7-24

fifr 8

-4E

I

BAFFLEPLATE

LOWERBLOCK

FLYWHEEL

CRANKSHAFTILSEAL.TRANSMISSIONNDInstallation,tep 1onpage -2 6

THRUSTWASHERS

(con

7



lock


/^., \

D->< | _,-ersrorurrucs

Y1 l-"t Benlacement.ag e -21rkrej, If f i l

rG\ AalQ[ = l^oJ

\PISTONRemoval, ag e7-'12Measurement, ag e7-15

PISTONPINRemoval, ag e7-18I nspec t i on ,age -19Installat ion, ag e7,20

f,CONNECTINGRODEn dplay,page7- 5Smallend measurement, ag e7-19

CONNECTINGROD

ENGINE LOCKCylinder ore nspection, ag e7-'15Warpage nspection, age7-15Cy l i nde r o rehon ing , age -11Ridge emovai, tep 13on page7-13

\

CONNECTINGROD BOLTlnspectaon,age7 24

-4



ConnectingRodand CrankshaftEndPlay nspection

1 . Removeheoi lpump see age -9).

Removehe baffle latesse e tep6 on page 12).

3. Measure he connecting od en d playwith a feelergaugebetween he connecting od an d crankshaft.

ConnectingRo dEnd Play

Standard New):0.15 0.30mm(0.006-0.012 n.l

ServiceLimit 0.40mm (0.016n. l

4 . lf the connecting od end play s out-of-tolerance,installa new connecting od,and recheck.f it is

sti l l out-of-tolerance,eplace he crankshaft see

page7-12],.

5. lnstalla dial ndicatoras shown.Push he

crankshaft irmly away rom the dial ndicator, nd

zero he dial against he end of the crankshaft. hepull

he crankshaftirmly back oward he indicatothe dial readingshould not exceed he serv ice im

CrankshaftEnd Plav

Standard New): 0.10-0.35 mm

{0.004-0 .014n. l


lf the end play s out-of-tolerance,eplace he thruwashersand recheck.f it is sti l l out-of-tolerance

replace he crankshaft.

7



Block

CrankshaftMainBearingReplacement

MainBearingClearancenspection

1. To checkmain bea ing-to-jouna oil clearance.remove he lower block

and bearinghalvessee

page 1-12)..

2 , C lean achmain ourna l ndbear ing a l fw i thacleanshop owel.

3. Place ne stripof plastigage crosseachmain

lou na l .

4 . Re ins ta l l t heear ings nd owerb lock,hen orquethe bolts o 29 N. m {3.0kgf.m,22 bf.ft)+ 56'.

NOTE:Do not rotate he crankshaft uringInspeclton.

5 . Removehe owerb lock ndbear ings ga in , ndmeasure he widest partof the plastigage.

Main Bearing-to-Journal il ClearanceNo.1 ,2 ,4 ,5 Journa ls :Standard New):0.017 0.041mm

Service Limit:No.3 Journal:

10.0007 0.0016n. l0.050mm {0.0020n.)

Standard Newl:0.025 0.049mm(0.0010 0.0019n. )

Service imit: 0.055mm (0.0022n. l

-6

\.

6. lf the plastigagemeasuresoo wide or too narrow,remove he crankshaft. nd remove he upper halfofthe bearing. nstalla new,completebearingwith

the samecolor code{s), nd recheckhe clearance.Do not i le, shim, or scrape he bearingsor the capsto adjustclearance.

7. lf the plastigage hows he clearances sti l lincorrect, ry the next argeror smallerbearing th e

color istedaboveor below hat one),an dcheckagain. f th e properclearance annotbe obtainedby us ing he appropr ia tearger r smal le r ear ings,replace he crankshaft nd startover.



MainBearing election

Crankshaft Bore Code Location

1. Numbersor lettersor barshavebeenstampedon

the end of the blockas a code or the sizeof eachof

the five main ournalbores.Write down the crank

borecodes. f yo u can't read he codesbecause f

accumulated irt and dust,do not scrub hem with

a wire brushor scraper.Clean hem only with

solventor detergent.

No. 1 JOURNALIPULLEY ND }

No. 5 JOURNAL{FLYWHEELND )

Main Journal Code Location

2. The main ournalcodesa{ estampedon the

crankshaft.

No. 1 JOURNAL No. 5 JOURNAL

(con

7



Engine lock

CrankshaftMainBearingReplacementcont'd)

3. Use he crankborecodesan dcrank ournalcodesto select he appropriate eplacement earingsfrom the following able.

NOTE:. Colorcode s on the edge of the bearing.. When using bearinghalvesof differentcolors. t

does not matterwhich color s used n the top orbottom.

Mainiournslcooe

Crank ---=->Lalgercrankbore

bore | 1or 2ot 3o r c oi__-lc o d e I A o r l B o r l l C o r l l l D o r t t t tI

-- --> Smaller bearing {Thickerl

(Thicker)

1

2

4

5

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

f111f;,,""no* ,""" $;;fl

cr""n $ffi ero-n

ffi#Tr,.*".,""*reen ;g=jiff;i Brown Black

;;lT]*'---l-'o"*,

Brown Black 6il;

Brack !l;kr ar*

-8

Connecting odBearingReplacement

RodBearingClearancenspection

1. Removehe o i l pump see age8-9) .

2. Bemove he baffleplates seestep6 on page7-12).

3. Remove he connecting od cap and bearinghalf.

4 . C lean hecrankshaf tod ourna l ndbear ingha l fwith a cleanshop owel.

5. Placeplastigage cross he rod ournal.

6 . Re ins ta l l t heear ing a l fandcap,and orque hebo l t s o 20 N.m 2.0 gf .m, 4 lb f . f t ) l 90" .

NOTE:Do not rotate he crankshaft uringinspection.

7 . Removehe rodcapandbear ing a l f , nd measurethe widestpartof the plastigage.

ConnectingRod Bearing-to-Journal ilClearance:Standard Newl: 0.020 0.050mm

(0.0008-0.0020in.lServiceLimit: 0.060mm (0.0024n. )

\

\-



8.

9 .

l f the plastigagemeasures oo wide or too narrow,remove he upperhalf of the bearing, nstalla new,completebearingwith the samecolor code(s), nd

recheck he clearance. o not i le. shim, or sc rapethe bearingsor the caps o adjustclearance.

lf th e plastigage hows he clearance s sti l lincorrect, ry the next argeror smallerbearing th e

color istedaboveor below hat one),and checkclearance galn. f the properclearance annotbeobtainedby using he appropriate argeror smaller

bearing, eplace he crankshaft nd stan over.

RodBearingSelection

1. Inspect ac hconnecting od or cracksan d heat

damage.

Connecting Rod Big End Eore Code Locations

2. Each odhasa to le ranceange rom 0 0 .024mm(0.0009n.), n 0.006mm (0.0002n.) ncrements,

dependingon the sizeof its big end bore. t' s he nstamped i th a number r bar 1,2 ,3 or 4 /1 ,l , l l l ,o

l l l l ) nd ica t inghe range. ou may indanycombinat ion f numbers nd bars n anyeng ine .(Ha l f henumber r bar s s tamped n he bear incap, he other half on the rod.)

lf you can't read he code because f an

accumulation f oil and varnish.do not scrub twith a wire brushor scraper.Clean t only with

solventor detergent.

Normal Bore Size: 48.0mm 11.89n. l

(con

7



lock

ConnectingRod BearingReplacementcont'dl

Connecting Rod Journal Code Location

3. The connecting od ournalcodesare stampedon

the crankshaft.

Connecting Rod Journal Code Location (Letters orBars)

No.l JOURNALNo .4 JOURNAL

\

4. Use he big end borecodesan d rod ournalcodes

to selectappropriate eplacement earin gs rom

the following able.

NOTE:. Colorcode s on the edge of the bearing.. When using bearinghalvesof differentcolors, t

doesnot matterwhich color s used n the top or

bottom.

Bigend ----------> Larger ig endboreborecodo

l o r l 2oJll 3 ol l l l 4 or l l l l

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

Pink Pink/Yellow

Yollow/Grecn

Green

Yellow Yellow/Green

Green/Brown

Brown

Green Green/Brown

Erown/Black

Black

Brown Brown/Black

Black/Blue

Blue

Rod

B

c

D

(Thicker)



1 .

OilPanRemoval

Drain he engineoi l (seepage8-5).

lf the engine s sti l l n the vehicle, emove hesubframe.

-1 Attach he chain hoist o the engine se estep35 on page5-6).

-2 Disconnectthe uspensionower arm balljoints (seestep3 on page18-19).

-3 Remove he rearmounl mountingbolts se e

step39 on page5-7).-4 Remove he front mount mountingbolt (see

step40 on page5-7).-5 Us ea marker o makealignmentmarkson the

reference ines hat alignwith the centersofthe rearsubframemountingbolts.Remove hefront subframe seestep 43on page5-8).

Remove he bolts/nuts ecuring he oil pan.

Drivean oil pa nsealcutterbetween he oi l pa nan dcylinderblock.

5. Cut heoi lpanseal yst r ik ingthes ideof thecto slide hecutter long he oil pan.

6. Removehe o i l pan.

7-



Block

Crankshaft nd PistonRemoval

1. Removehe eng ine ssemblysee age5-2) .

2 . Removehe ransmiss ionsee age13-4) .

3 . Removehe o i l pan see age -1 ) .

4. Remove he oil pump {seepage8-9).

5. Remove he cylinderhead se epage6-23).

6. Remove he baffleplates.

7. Remove he 8 mm bolts.

E

8. Remove he bearingcap bolts.To preventwarpage,

unscrew he bolts n sequence /3 urn at a t ime:

repeat he sequence nti l all boltsar e oosened.

Remove he lower blockand bearings,Keepal lbearings n order.

\L



1 0 .Remove he rod caps/bearings. eepall caps/bear ingsn order .

Liftthe crankshaft ut ofthe engine,beingcarefulno t o damage he ourna ls .

Remove he upper bearinghalves rom theconnecting ods.and set hem asidewith theirrespective aps.

lf you ca n ee la ridge of metalor hardcarbonaround he top of eachcylinder, emove t with ar idge eamer A) .Fo l lowthe eamermanufacturer ' sinstructions.f the ridge s not removed, t maydamage he pistonsas hey are pushedout.

1 1 .

t .J .

14. Use he wooden handleof a hammer (A) o driveout the pistons B).

Reinstallhe lowerblockand bearingson theengine n the properorder,

Re ins ta l l t heonnect ingod bear ings ndcapsafter removingeachpiston/connectingodassembly .

To avoi d mixupon reassembly.mark eachpiston

connecting od assemblywith itscylindernumbe

NOTE:The existingnumber on the connecting oddoes not ndicate ts posit ion n the engine, tindicates he rod bore size.

1 5 .

t o .

1 7 .

7-



1 .

Blockand Piston nspection

Remove he crankshaft nd pistons se pageT 121.

Check he piston or distortionor cracks,

Measurehep is ton iameter t a po in t 1 mm {0.4in.) rom the bottom of the skirt.Thereare wostandard-size istons No Letteror A, and B).Th eletter s stampedon the top of the piston.Lettersare alsostampedon the blockas cylinderborestzes.

Piston Diameter:Standard Newl:

No Letter {or A): 85.980 85.990 mm(3.3850 3.3854 n. )

B: 85.970-85.980mm(3.3846-3.3850n. )

Service Limit:No Lefter or A): 85.930mm (3.3831n. )B: 85.920mm 13.3827n. )

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

4. Measurewear and ape r n directionX and Y atth ree eve ls n each y l inder sshown. fmeasurementsn any cylinderare beyond heoversize or eservice imit. replace he block. f th eblock s to be rebored, efer o step7 after reborin

CylinderBoreSize

Standard New):

A or l: 86.010 86.020mm

13.3862 3.3866 n.)B or l l: 86.000 86.010mm

(3.3858 3.3862 n.)Service Limit: 86.070 mm (3.3886 n.)

Oversize:

O.25t 96.250 86.260 mm (3.3957 3.3961 n.)

Reboring imit: 0.25mm (0.01 n.l max.

Bore Taper:

Limit: (Differencebetween first and thirdmeasurement) .0 5mm (0.002n.)

FirstMeasurement

SecondMeasutement

ThirdMeasurement

(cont'd

7-

6 mm {0.2 n. }

6 mm {0.2 n. }



EngineBlock

BlockandPiston nspection cont'd)

Scoredor scratched ylinderboresmust be honed.

Check he top of the block or warpage.Measure

along he edgesand across he centeras shown.

Engine Block WarpageStandard New): 0.07mm (0.003n. )max.

ServiceLimit: 0.10mm (0.004n. l

PRECISIONTRAIGHT DGE

\

7. Calculatehe difference etween he cylinderborediameterand he plstondiameter. f the clearanceis nearor exceeds he service imit, nspect hepistonand cvlinderblock or excessive ear.

Piston-to-CylinderClearanceStandard New): 0.020 0.040mm

{0.0008 0.0016 n.)ServiceLimit: 0.05mm (0.002n. l

++ PISTON-TO-CYLINDERCLEARANCE

\



CylinderHoning

Only a scoredor scratched ylinderbore should benoneo.

Measurehecy l inder ores see age -15) .

lf the block s o be reused, one he cylindersan dremeasure he bores.

Hone he cy l inder o reswi th hon ing i l anda f ine(400grit)stone n a 60 degree ross-hatch attern(A).Use only a rigid honewith 40 0grit or f inerstonesuch as Sunnen,Ammco, or equivalent.Donot usestones hat areworn or broken.

Whenhon ing scomple te ,horough ly lean heengineblockof all metalparticles.Wash hecylinderboreswith hot soapywater, hen dry and

oil them immediately o prevent usting.Neverus e

solvent, t wil l only redistributehe grit on th ecy l inder a l l s .

lf scoringor scratches re sti l l present n thecylinderboresafterhoning o the service imit,rebore he cylinderblock.Some ight vertical

scoringand scratching s acceptablef it is not deepenough o catchyour fingernailand does no t runthe full lengthof the bore.

'L

3.

7-



Block

Piston,Pin,and ConnectingRodReplacement

Disassembly

1. Remove he piston ro m the cylinderblock see

page7 12).

2 . App lyeng ine i l t o the p is ton insnap ings A) ,

and urn them in the ring groovesuntil he endgapsare inedup with the cutouts n the pistonpin

bores B) .

NOTE;Takecarenot o damage he ring grooves.

Removeboth snap rings(A).Startat the cutout nthep is ton in bore .Removehesnap ings

carefully o they do not go flying or ge t ost.Wear

ev eprotection.

\"

4. Heat he pistonand connecting od assembly o

about 158'F 70"C),hen remove he pistonpin.

\



Inspection

NOTE: nspect he piston,pistonpin,an d connectingrod when they are at room temperature.

1. Measure he diameterof the pistonpin.

Piston Pin DiameterStandard New):21.961 21.965mm

(0.8646-0.8648 n. )ServiceLimit: 21.953mm 10.8643n. l

2. Zerc the dial ndicator o thepistonpi n diameter.

3. Check he difference etween he DistonDind iameter ndp is ton in ho led iametern hep is to

Piston Pin-to-PistonClearance

Standard Newl: -0.005 to +0.002 mm(-0.00020 to +0.00008 n.)


Measure he piston pin-to-connectingod clearan

Piston Pin.to-Connecting Rod ClearanceStandard New):0.005 0.015mm

{0.0002 0.0006 n.}ServiceLimil: 0.02mm (0.0008n. l

4 .

(cont'd

7-



EngineBlock

Piston,Pin,andConnecting odReplacementcont'd)

Reassembly

1. Ins ta l l p i s ton insnap ing A) .

Coat he pistonpi n bore n the piston, he bore n

the connecting od, and he piston pin with engineo i l .

Heat he piston o about 158"F 70'C)..

7-20

\

4. Install he pistonpin (A).Assemble he piston B)

and connecting od (C)with th e arrow(D)and he

embossed ark E) n hesame ide .

Ins ta l lhe remain ing nap ing F) .

Turn hesnap ings n he r inggrooves nt i l t he

en dgapsar e positioned t the bottom of the piston.

5 .

6 .



PistonRingReplacement

1. Remove he piston rom the cylinderblock se epage7-121.

2. Usinga ring expander A) , emove he old piston

r ings B) .

3. Cleanall ringgrooves horoughlywith a squared-off broken ing or ring groovecleanerwith a bladeto fit the pislongrooves.Th e op and 2nd ringgrooves re 1 .2mm (0.05n, )w ide . heo i l r inggroove s 2.0 mm (0.08 n. )wide. Filedown a bladelf necessary. o not use a wire brush o clean hering grooves,or cut h e ring groovesdeeperwiththe c lean ingoo ls .

NOTE: f th e piston s to be separatedrom theconnecting od, do not nstallnew ringsyet.

4. Usinga piston,pusha new ring (A ) nt o hecy l inder o re15-20 mm {0.6-0 .8 n . ) rom hebottom.

15 20 mm (0.6 0.8 n.)

I

Measure he piston in gend-gap B)with a feelergauge:

. l f hegap stoo smal l , heckto ee fyou havetheproper ings or youreng ine .

. l f hegap stoo arge, echeckthecy l inderorediameteragainst he wear l imits (seeslep 4 onpage7-15) .

. l f he bore s over theserv iceim i t , hecy l inderblockmust be rebored.

PistonRing End-Gap

Top FingStandard Newl:0.20 0.35mm

(0.008 0.014 n.lServiceLimit: 0.60mm (0.024n..

SecondRingStandard New):0.40-0.55 mm

{0.016 0.022 n.)ServiceLimit: 0.70mm (0.028n.)

Oil RingREKENmanufactured ingStandard Newl: 0.25 0.65mm

(0.010 0.026 n.l


FEDERAL OGUL manufactured in oStandard New):0.20 0.70mm

{0.008 0.028 n.}ServiceLimit: 0.80mm (0.031n. )

B

(cont'

7-



Block

PistonRing Replacementcont'd)

6. Install he op ring and second in g as shown.The

top r ing A)hasa 1Rmarkor no markand he

second ing B)hasa 2R markor 2NDmark. hemarksmust be acing upward.

o\,"16.

s \ =:-=2

\5V"

12-)VP'ffi+a\aq*-pogd

.ZR,V

Piston ing imensions:

t To PRing Standardl:| | o A:3.1mm 0.12n. l| | J

-B:1 .2mm 0.05n.)Socond ing Standard):A:3 .4mm 0.13n. }-

A- B:'1.2 m(0.05n. i

7, Rotate he rings n their grooves o makesure hey

do notb ind .

\

8. Position he ring en d gapsas shown:

OI LRINGGA P

About 90'

SECOND INGGA P

About 45"

OILRINGGAPOPRINGGA Pand SPACERRINGGA P PISTONPIN

9. After nstall ing new set of rings,measure hering-to-groove learances:

Top RingClearanceStandard {New}:

0.035-0.060 m {0.0014-0.0024n. )


SecondRingClearance

Standard New):REKENmanutactured ring0.030-0.055 m (0.0012-0.0022n. )

FEDERALMOGUL manulactured ring

0.025-0.060mm (0.001 -0.0024 n.)




Block

ConnectingRodBolt Inspection

Measure he diameterof eachconnectinq od bolt

at DointA and ooint B.

35 mm

Calculatehe difference n diameterbetweenpoint

A andpo in tB.

Point A-Point B = Difference n Diameter

Diflerence n Diameter:

Specification:0 0.1 mm (0 0.004 n.)

lf the difference n diameter s out of tolerance,replace he connecting od bolt.

1 .

3 ,

mm

\-

Crankshaftnstallation

SpecialTools Bequired. Driver07749-0010000. Attachment, 4 x 26 mm 07746-0 010700. Oil sealdriver attachment 6 o7ZAD-PNAAl00

1. Ins ta l lhecrankshaf tndbush ing i th he spec ia l

toolswhen replacing he crankshaft. rive n the

crankshaf tndbush ing n t i l hespec ia loo ls

bottom aqainst he crankshaft.

07749-0010000

07746-00'l

Checkhe connect ingodbear ing learance i thplastigage se epage7-8).

Checkhe mainbear ing learance i th p las t igage(see age -6) .

lnspecttheconnecting od bolts se epageT-241.

I\-

4 .



5. Ins ta l l t he ear ing a lves n hecy l inder lock ndconneclrng ods.

6. App lya coato f eng ine i l t o he mainbear ings ndrod bearings.

7 . Ho ld hecrankshaf to rod ourna lNo.2and rodjournalNo. 3 are straightup , an d ower hecrankshaft nto he block.

8 . lns ta l l t hehrustwashers A) n he No.4 ourna l fth e cylinderblock.

Apply engineoil to the hreadsot the connectingrod bolts,

Seat he rod ournals nto connecting od No. 1 andconnecting od No. 4. Line up th e mark (B)on theconnecting od and cap, hen installthecapsandbolts inger-tight.

Rotate he crankshaft lockwise, ndseat hejourna lsn toconnect ingod No.2 andconnect ingrod No. 3. Lineup the markon the connecting odand cap, hen install he capsand bolts inger-tight.

9 .

10 .

'1 1.

\-1

12. Tighten he connecting od bolts o 20 N.m(2.0kgf.m, 14 bf.ft).

13. Tighten he connecting od bolts an additional90"

14. Removeol d liquidgasket ro m the lower blockmatingsurfaces, oltsand bolt holes.

15 . Cleanand dry the lower blockmatingsurfaces.

16. Apply l iquidgasket,P/ N08718-0009,venly o thecylinderblockmatingsurfaceof the lower blockand o the nner th reads f the bo l tho les .

NOTE:Do not nstall he parts f 5 minutesor morehaveelapsed inceapplying iquidgasket. nsteareapply iquidgasketafter emovingold residue.

(cont

. \

,i ,

Apply liquid gasketalong he broken ine.

7-



23. Install he baffleplates.

6 x 1 . 0 m m12N.m(1.2 sf m, 8.7 bf ft)

24 . Ins ta l l t he i l pump see age -14) .

25. Installtheoil pa n (seepage7-27).

26. Installthecylinderhead se epage6-39).

27. Installthe ransmission seepage13-8).

28. Installtheengineassembly seepage5-9).

1 .

OilPan nstallation

Removeold liquidgasket rom the oil pan mating

surfaces, olts,and bolt holes.

Cleanand dry the oil pa n mating surfaces.

Apply l iquidgasket,P/N 08718-0009,venly o th ecylinderblockmating surfaceof the oil pa n an d othe inner hreadsof the bolt holes.

NOTE:Do not nstall he parts f 5 minutesor morhaveelapsed inceapplying iquidgasket. nsteareapply iquidgasketafter emovingold residue.

Ins ta l l t he i l pan.

Tighten he bolts n two or threesteps. n he final

s tep , igh ten l lbo l t s ,n sequence,o 1 2N.m 1.2kgf m, 8. 7 bf.ft).

(cont

2.

3 .

4.

5.


( } @

7-



Engine lock

Oil Pan nstallation cont'dl

6. l f he eng ine ss t i l l n heveh ic le ,ns ta l lhesubframe,

-1 Ins ta l l t he ub f rame. l ign he re ferenceineson the subframewith the bolt headcenter, hentighten h e bolts seestep5 on page5-10).

-2 Tighten he front mountingbolt (seestep6 onpage5-10) .

-3 Tighten he rearmount mountingbolts se e

step7 on page5-11) .-4 Connect he suspensionower arm ball oints

(seestep6 on page 18-19).

7. After assembly,wait at east30 minutesbeforef i l l i ng he eng inewi th o i l .

v

Transmission ndGrankshaft ealInstallation InCar

Special Tools Required. Driver07749-0010000. Oil sealdriver attachment96 07ZAD-PNAA100

'1 .Dry hecrankshaf ti l sea lhous ing .

2. Use he special ools o drive a new oil sealsquarely nto he block o the specified nstalledhe igh t .

07749-0010000

ando i l sea l B) .

Oil Seal nstalledHeight:5.5 6.5mm 10.22-0.26 n. l

5.5 6.5mml0.22- O.26 n l

/$rRfr4Tt r*W(r-]t fl\TZAD.PNAAlOO

Measure he distance etween he crankshaft A)



EngineMechanicalt--lr_:



Engine ubrication

SpecialTools \

Ref. No. Tool Number Descriotion Otvo 07HAA-PJ70100 Oil FilterWrench

\-




OI LPUMPCHAINTENSIONER

DRAINBOLT

OILPANRemova l ,age 11Installataon,ag e -2 7

OI LPUMPOverhaLrl,ag e -8

H L ]

BAFFLEPLATE

OI LFILTER EED IP EReplacement, ag e8-7

OI LFILTERReplacement,ag e8- 6

OI LCONTROLORIFICE

WASHER

OIL PRESSURE WITCHSwitchTest,page8 4Oi l Pressureest,page8' 4Rep lacem en t ,age 16

-&\JrI--t N\ksrarr lN-?cKEr dczt$)

# 1\

OI LPUMPCHAINGUIDE

8



Lubrication

OilPumpOverhaul

ExplodedView

BAFFLE LATE6 x 1 . 0 m m12N.m

{1.2gfm,8.7 bf.ft)

x 1 . 25mm27 N.m

6 x 1 . 0 m m12 N.m11.2 gf.m,8. 7 bt t)

(2.8 st m, 20 bt ft)App ly ng ine i l t oth ebolt hreads.

UPPER ALANCERSHAFTHOLDER

BALANCER HAFTBEARINGS

PtrPU IE U

DOWELPIN

REARBALANCER

SHAFT

\

-/=.---'n

fs/t w

FRONTBALANCERSHAFT

LOWERSHAFT

BALANCERHOLDERSEALINGBOLT

39 N.m{4.0 gf.m,29lbf. f t l

$--."Dowetem

-8

\-



Oi lPumpRemoval

1. Se tthe No. 1pistonattop deadcenter TDC) seestep1 on page -12) .

2 . Removehe o i l pan(seepageT-11) .

3 . Remove ndd iscardhe o i l pumpcha in tens ioner .

4. To hold he rearbalancer haft, nserta 6 mm pi n

driver (A) nto he maintenance ole n the owerbalancer haftholderan d hrough he rearbalancershaft.

5. Loosen he oil pump sprocketmountingbolt.

6. Remove he oi l pump sprocket A), he n remove he

oi l pump B) .

(cont

8



Oil PumpOverhaulcont'dl

Oil Pump nspection

1. Removehe pumphous ing .

Check he inner-to-outerotor radialclearancebetween he nner rotor (A )and outer rotor {B). fth e nner-to-outerotor radialclearance xceedsth e service imit, replace he oil pump.

Inner Rotor-to-Outer Botor Radial ClearanceStandard New):0.02 0.16mm (0.0010.006 in.)ServiceLimit: 0.20mm (0.008n.,

1'[1e-\1.-,-21

'a - :.: ,-'r'

\-

4.

3. Check he housing-to-rotoaxia clearance etweenthe ro tor A)andpumphous ing B) . f hehous ing-to-rotoraxial clearance xceeds he service imit.rep laceheo i l pump.

Housing"to-Rotor Axial ClearanceStandard New):0.02 0.07mm (0.0010.003 in.lServiceLimit: 0.12mm (0.005n.l

Check he housing-to-outerotor radialclearancebetween he outer rotor(A) an d pump housing B) .

lf the housing-to-outerotor radialclearanceexceeds he service imit, replace he oil pump.

Housing-to-Outer Rotor Radial ClearanceStandard Newl: 0.15 0.21mm (0.006-0.008 n. l

ServiceLimit; 0.23mm (0.009n.)

Inspect oth rotorsand he pump housing orscoringor otherdamage.Replace arts fnecessary.

\ ,



1 .

BalancerShaft Inspection

Seat he balancer haft by pushing t away rom th eo i l pumpsprocket ndof the o i l pump.

Zero he dial ndicatoragainst he end of thebalancer haft, he n push he balancer haftbackand orth and read he end olav.

Balancer Shaft End Play:Fronl Balancer Shaft:Standard Newl: 0.070 0.135mm

{0.0028 0.0053 n.}ServiceLimit: 0.15mm (0.006n.)Rear Balancer Shaft:Standard New):0.070-0.135 mm

(0.0028 0.0053 n.l

ServiceLimit: 0.15mm (0.006n.)

2 .

3. Remove he baffleplate A) and upperbalancershaftholder with bearings) B) , hen remove hefront balancer haft C)and rearbalancer haft D

9 H . A''/

.r L=] j/

R

Rf l | ]3 I ]U U

r B e

+-

(con

8



Oil PumpOverhaul cont'dl

4. Measurehe nner iameter f heNo .1bearingorthe rontbalancerhaftholeand he rearbalancershaft ole.

BearingnnerDiameier:Front:StandardNew): 0.000-20.020 m

(0.78740.7882n. )Service imit; 20.03mm (0.789n. )Rear:Standard New):24.000-24.020mm

10.9/t49-0.9457n.)ServiceLimit: 24.03mm (0.946n.)

Front:

Rear:

\

5 . Measure he diametersof th e No. 1 ournalson thefront balancer haftand rearbalancer haft.

NO.1Journal Diameter:Front:

Standard New): 19.938 19.950mm(0.7850 0.7854 n.)

ServiceLimit: 19.92mm {0.784n. )Rear:Standard Newl: 23.938 23.950mm

{0.9424-0.9/129n.)ServiceLimit: 23.92mm (0.942n. )

Front:



8.

9 .

6. Cleanboth balancer haftNo. 2 ournalsan dbearinghalveswith a cleanshop owel.

7. Place ne strip of plastigage crosseachNo.2journa l .

Reinstallhe bearingsand upperbalancer haftholder, hen orque he bolts.

NOTE;Do not rotate he balancer haftdurinqinsDection.

Remove he uooerbalancer haftholderandbearingsagain,and measure he widest partof theplastigage.f the balancer haftNo. 2 ournaloi l

clearances out-of-tolerance.nstall he new

bearings, nd recheck. f it is sti l l out-of-tolerance,

replace he balancer hafts.

No. 2 JournalOil Clearance:Standard Newl; 0.060 0.120mm

ServiceLimit:

(0.00240.0047n. l0.15mm {0.006n. )

10. A l ign hepunchmarkon he rearba lancer ha f twith the centerof the wo punchmarkson the fronbalancer haft, hen install ' the alancer hafts nth e lower balancer haftholder

Apply engine oil to the threads of the 8 mm bolts(A) .

6 x 1 . 0 m m'1 2N. m(1.2 gt.m,8.7 bt f t)

1 1 .

Ins ta l l t he pperba lancer ha f t o lder B)andbafileplate C) .

(cont

1 2 .

8-



Oil PumpOverhaul cont'd)

13. ns ta l l t he umphous ing .

6 x 1 , 0 m m12N. m(1.2 gt.m,8.7 bf. f t)

!

Oil Pump nstallation

1. Makesure he No. 1 piston s at TDC seestep 1 onpage -12) .

2. Align he dowel pin{A} on the rearbalancer haftwith the mark (B )on the oil pump.

To hold he rear balancer haft, nserta 6 mm pin

driver {A) nto he maintenance ole n the owerbalancer haft holderand hrough he rear balancershaft.

\,-

9%ttrc+:.:4.4 / t\ \

o/.-lY\

:aa:'

-rrdvf,o-;



EngineLubrication

Oil PumpOverhaul cont'dl

10. Removehesetc l ip rom heo i l pumpcha in

tensioner.

11 . ns ta l lhe o i l pan see ageT-27) .

\

Oif Pressure witch Replacement

1. Discon ect he oi l pressure witchconnector, hen

remove he oi l pressure witch.

2. A pply l iquidgasket o the oil pressure witch

threads, hen installtheoi l pressure witch.



EngineMechanical

IntakeManifoldand ExhaustSystemlntakeManifold emoval nd nstallation... . . . . . . . . . . . . .-2Exhaust anifold emoval nd nstallation... . . . . . . . . . .-7Exhaust ipe ndMufflerReplacement.. . . . . . . . . . . . . . . . . . .-8

rr-!i!1



ManifoldandExhaustSystem

lntakeManifoldRemoval nd nstallation

Exploded View:

INTAKEMANIFOLDPLATEReplacef cracked rif matingsurface sdamaged .

6 x 1 . 0 m m12N. m{1.2 gf.m,8.7 bf. f t)

\

GASKETReplace.

8 x 1 .252 2 N m12.2 sf

\

\8 x22

ke)

t9

w)

k!

1 6

.2 5mm'm

kgf.m,1

8 x 1 .25 m22N.m(2.2 gf m. 16 bt.ft)

8 x 1 ,25mm22 N.m {2.2 gf.m,16 bf f t}

INTAKEMANIFOLDReplacef cracked ri f matingsurface s

\-




IntakeManifoldRemovaland Installation cont'dl

5. Be prepared o catchand cleanup spil ledcoolant.

Remove he water bypasshoses, hen plug he

water bypasshoses.

6 . Re l ieve fue l ressure see age11- '144) .

7 . Removehe ue l ine (seepage l l -149) .

8. Remove he posit ive rankcase entilation PCV)

hose A),harnessholdermountingbolt (B )and

harness lampmount ing o l t C) .

4

\-

9. Remove he enginewire harness onne ctors nd

wi re harness lamps rom he n takeman i fo ld .

. Four njector onnectors

. ldle air control lAC) alveconnector

. Throttleposit ion TP ) ensorconnector

. fvlanifold bsolutepressure lvlAP) ensor

connector. Evaporative mission EVAP)canister urge

valveconnector

Remove he bolt securing he intakemanifoldan d

bracket.

'10.

1 1 .Removeallthe intakemanifoldmountingbolts/

nuts.

Remove he two stud bolts A) , hen remove he

in takeman i fo ld B) .

1 '>



1. Install he ntakemanifold A)with a new gasket B),

then installand ighten he wo stud bolts C) .

8 x 1.25mm22N. m|.2.2k91.m.16 bt.ft)

8 x 1.25mm22 N.rn(2.2 gf m. 16 bf.ttl

Tightenal l ntakemanifold mountlngbolts/nuts n acrisscross attern n two or three steps,beginningwith th e innerbolt.

Tighten he bolt securing he intakemanifoldan dbracket.

8 x 1.25mm22 N.m (2.2 sf m, 16lbf.ft)

*&

\

2.

?

w

4.

7 .

5 .

6 .

Install he PCVhose A) ,harnessholdermountingbo l t B) , nd harness lampmount ing o l t C) .

e-li*h

6 x 1 . 0 m m12N. m 1. 2 gf.m,8.7bf.ft)

I ns ta l l t heue l ine see age11-150) .

Installthewater bypasshoses.

Ins ta l lhe h o t t le ab le see age11-164) ,hen

ad jus t hecab le see age11-163) .

Install he cruisecontrolcable se epage4-44). he nadjust he cable seepage4-45).

8 .

(cont'd

9



Manifoldand ExhaustSystem

IntakeManifoldRemovaland Installation cont'd)

9. lns ta l l t he i rc leaner ous ing over A) , nd

connect he IA Tsensorconnector B) .

B C

Installthe reather ose C) .

lnstallthe VAP anister ose A) ,brake oostervacuum ose B), nd acuum osesC).

1 0 .

1 1 .

6

\

12. Ins ta l l t hen takeman i fo ld over .

6 x 1 . 0 m m12N.ml.1.2k91.m,

8.7 tbf.ftl

Clean p anysp i l l ed ng ine oo lan t .

After nstallation, heck hat all tubes,hoses,and

connectors re nstalled orrectly.

Inspect or fuel eaks.Turn he gnit ionswitchON(ll) do no t operate he starter) o hat the fuel pump

runs or about 2 seconds nd pressurizeshe fuel

l ine.Repeat his operation wo or three imes, hen

check or fuel eakage t any point n th e fuel l ine.

Refil l he radiatorwith enginecoolant,and bleed

air rom the coolingsystemwith the heater alveopen (seepage 10-6).

t o .

\-



1 .

2 .

3.

ExhaustManifoldRemoval nd nstallation

Remove he VTEC olenoid alve(seepage 11-128).

Remove he driveshaft eatshield se epage 16-19).

Remove he coverand exhaustmanifold bracket,hen remove he exhaustmanifold.

8x 1 .25 m22 N. m(2.2 gf.m,16lbt. f t l

#'-.-

GASKETReplace.

SELF-LOCKINGUT10x 1.25mm44 N.m{4.5ksf.m, 33lbt.ftlBeplace.

10 1 .25 m44 N. m(4.5kgt.m, 33 bl ftlReplace.

WASHEB 8 x 1-25mm22 N.m 2. 2 gI m, 16lbf.ft)Replace.Tightenhebolts n steps,alternatingide o side.0x 1.25mm

14N. m{4.5kgl.rn, 33lbf.ft)

5.

Install he exhaustmanifoldand ighten he bolts/nuts n a crisscross attern n two or three steps,beginningwiththe inner bolt.

Installtheotherparts n th e reverse rder of removal.

9




ExhaustPipeand MufflerReplacement

SELF-LOCKINGUT10 1.25 m33N. m 3. 4 gf.m,25 bf.ft)Bep lace .

8 x 1.25mm22 N.m {2.2 gf m, 16lbf. f t)Replace.Tighten he bolts n steps,alternating ide o-side.

\

NOTE:Use new gaskets nd self-locking ut swhen reassembling.

8 x 1 .25mm22 N. m (2.2 st.m. 16lbf. f t lReplace.Tighten he bolts n steps,alternating ide'to side.

EXHAUST IPE

HEATSHIELD\ ,

6 x 1 . 0 m m9. 8N. m{1.0 gt.m,7.2 bf t}

GASKETReplace.

SECONDARY EATEDOXYGENENSOR{SECONDARYO2SIi l 4 N m(4.5 ksf.m,33 lbf.f t l

AIR FUELRATIO A/F)SENSOR44 N.m (it.skgf.m, 33 lbf ftl

-8

\-.



EngineCooling

CoolingSystemComponentocationndex .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . .. .0-2Radiator apTest . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .0-3RadiatorTest .. . . . . . . . . . . .0-3FanMotorTest .. . . . . . . . .0-4Thermostatest . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .0-4WaterPump nspection ... . . . . . . . . . . . . . . . . . .0-5WaterPumpReplacement .. . . . . . . . . . . . . . . .0-5

Coolant heck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -6Coolant eplacement .. . . . . . . . . . . . . . . . . . . . . . . .0-6Thermostat eplacement .. . . . . . . . . . . . . . . . .0-8WaterPassagenstallation ................0-9WaterOutletnstallation ... . . . . . . . . . . . . . . . . .0-9RadiatorndFanReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0-10

FanControlsComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -11Symptom roubleshootingndex ..............................0-12Circuit iagram ... . . . . . . 0-13

Radiator anCircuitTroubleshooting... . . . . . . . . . . . . . . . . . . . .0-14Radiator anSwitchCircuit roubleshooting(Open) . . . . . . . . . . . . . . . . . . . 0 -16

Radiator anSwitchCircuit roubleshooting(Shor t ) . . . . . . . . . . . . . . . . . . . 0 -16

Radiator anSwitch est ........... ........0-17Radiator anSwitchReolacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .0-17



System


WATER UMPInspection,ag e 0- 5Replacement.ag e 0- 5

RESERVETANK

RADIATORCA P

RAOIATORFAN SWITCHTest,page10-17Replacement,ag e10'17

\

WATER UTLET,Ins ta l la t ion ,age '10-g

\ \

CONNECTINGIP E

WATER ASSAGEInstallation,ag e 0- 9

THERMOSTATTest, ag e 04Replacement,ag e 08

RADIATORReplacement,ag e10-'l0

RADIATORFANASSEMgLYR ep lac emen t ,age10 - 10Fa nMotorTest,page10 4

A/C CONDENSERFA NASSEMBLYReplacement, ag e10 10Fa nMotor Test,page 10-4

\J



RadiatorCapTest

1. Remove he radiator ap {A),we t its sealwith

enginecoolant, he n install t on the pressure ester(B) commerc ia l l yva i lab le ) .

Apply a pressure f 93'123

kP a 0.95 1.25

kgf/cm', 4 18psi).

Check or a drop n pressure.

lf the pressure rops, eplace he cap.

3.

4.

RadiatorTest

Wait untilthe engine s cool, he ncarefully emov

th e radiator ap and il l the radiatorwith engine

coolant o the top of the fi l ler neck.

Attach he pressure ester A) (commercially

ava i lab le )o the rad ia to r .

1 .

3 .

4 .

Apply a pressure t 93'123

kP a 0.95 1 25

kgf/cm',14

18 psi).

Inspector eng ine oo lan teaks nda drop npressu e.

Remove he tester,an d reinstall he radiator ap .

10



System

FanMotor Test

1. Disconnecthe 2P connectors rom the radiator an

motor and condenser an motor.

Test he motor by connectingbatterypower o the

B ermina l ndground o theA termina l .

lf the motor fails o run or doesnot run smoothly,rep taceL

\

ThermostatTest

Replacehe hermostat f it is open at room

remperalure.

To test a closed hermostatl

1. Suspend he hermostat A) n a containerof water.

Do not et he thermometer B) ouch he bottom of

the hotconta iner .

\

2.

3 .

Heat he water,and check he temDerature ith athermometer.Check he temperature t which the

thermostat irst opens,and at which t is fully open.

Measure he lift heightof the hermostatwhen t is

fu l l vooen.

STANDARD HERMOSTATLift height; above8.0 mm (0.31 n.)

Starts opening: 169 176"F(76 80"C)

Fullyopen: 194"F 90'Cl

\.



1 .

2 .

Water Pump nspection

Remove he drive belt (seepage4-26),

Turn he water pump pulleycounterclockwise.

Check hat t turns reely.

Check or signsof seal eaka ge. small amount of"weeping"

from the bleedholes A) s normal.

Water PumpReplacement


2 . Dra in he eng ine oo lan t see age10-6) .

3 . Removehe crankshaf tu l ley see age6-11) .

4. Remove he six bolts securing he water pump,

then remove he water pump (A).

6 x 1 . 0 m m12N m { 1 .2 g t m,8.7 rbf.ft)

Inspectand clean he O-ringgrooveand mating

surfacewith th e water passage.

Ins ta l l t he a te rpumpwi th newO r ings n hereverseorder of removal.

7 . C lean p anysp i l l ed ng ine oo lan t .

8 . Ins ta l l t he rankshaf tu l ley see age6-12) .

L Ref i l l he rad ia to r i t h eng ine oo lan t , ndb leed

air from the coolingsystemwith the heatervalve

open see age10-6} .

10



CoolingSystem

1 Lookat the coolant evel n the reserve ank.Make

sure t is between he MAX mark (A )an d MI N mark(B) ,

GoolantCheck

l f the coolant evel n the reserve ank s at or below

the MIN mark,add coolant o bring t up to the l\4AXmark,and nspect he coolingsystem or leaks.

10-6

\-

CoolantReplacement

1 .

\

Start h e engine.Set he heater emperature ontrol

dial o maximum heat. hen urn off the ignit ion

switch.Makesure he engineand radiatorare cool

to the touch.

Remove he radiator ap.

Remove he splashshield seestep23 on page5-5).

Loosen he drainplug (A),and drain he coolant.

Remove he reserve ank drain cap (A),and drain

the coolant.

\



1 .

After he coolantha sdrained, ighten he radiator

drain plug securely. nd nstallthe eserve ank

drain cap securely.

Fil l he reserve ank o the MAX mark(A) with

HondaAll SeasonAntifreeze/Coolantvpe 2(P/NO1999-9001).

8. PourHondaAll SeasonAntifreeze/Coolantype 2

into he radiatorup to the baseof the fi l ler neck.

NOTE:. Always use HondaAll SeasonAntifreeze/Cool

Type 2 {P/N01999-9001). singa non-Honda

coo lan t an esu l t n cor ros ion ,aus inghe

coolingsystem o malfunctionor fail.. HondaAll SeasonAntifreeze/Coolantype 2 is a

mixtureof 50%antifreeze nd 507owater. Pre-

mix ing s no t equ i red .

EngineCoolantRefil lCapacity including he

reserve ank capacity of 0.53 4 (0.56US gtl :

5. 00 (s.3US qt )

Ins ta l l t he ad ia to r ap oose ly .

Start he engine,an d et t run until t warms up (th

radiator an comeson at least wice).

Turn off the engine.Check he level n th e radiato

and add HondaAll SeasonAntifreeze/Coolantyp

2 if needed.

Put he rad ia to r apon igh t l y , hen un he eng in

aga in ndcheck or eaks.

lnstall he splashshield seestep22 on page5-12

1 0 .

1 1 .

L

t J .

10



System

ThermostatReplacement

1. Dra in heeng ine oo lan t see age10-6) .

2. Remove he splashshield seestep 23 on page5-5).

3. Remove he lower hose, he n remove he thermostat.

6 x 1 . 0m m9. 8N. m(1 .0 g f .m,7 .2 lb ft )

u

i*LOWERHOSE

4. Installthe hermostatwith a ne w O-ring, hen nstallthe ower hose.

5 . Ins ta l l t he p lash h ie ld see tep22on page5-12) .

6. Refil l the adiatorwith enginecoolant,an d bleedair from the coolingsystemwith the heater alve open (seepage10_6) .

THERMOSTAT

\_



Water Passagenstallation

1 .C leanand dry the water passagematingsurfaces.

Apply l iquidgasketP/N08718-0009,venly o the

cy l inder lockmat ing ur face f thewaterpassage

and o the nner hreadsof the bolt holes.

NOTE:Do not nstalltheparts f 5 minutesor more

havee lapsed ince pp ly ingiqu id aske t .ns tead,

reapply iquidgasketafter emovingold residue.

3. Ins ta l l t he a te rpassageA)wi tha newO-r ing B) .

10 1.25 m44N m {4.5 gtm.33 bf.ft}

4. After assembly,wait at least30 minutesbefore

f i l l i ng he eng inewi th o i l .

. t ' : . :

Water Outlet nstallation

Insta l l theater ut le tA)wi th newO-r ingB) ,

12N m ( 1 .2 g t m,8 ,7 lb f t )

10



anControls

SymptomTroubleshootingndex

Beforeperformingan y roubleshooting rocedures heck:. Fuses. Grounds. Cleanliness nd ightnessof all connectors

\

\ ,

SYMPTOM PROCEDURE

Radiator an does not run at all RadiatorFa nCircuilTroubleshootingseepage 1O-14).

Radiator an does not run or enginecooling,but t runswith A,/CON

RadiatorFa nSwitch CircuitTroubleshootingOpen)(see age10-16) .

Radiator an runswith ignit ionswitch ON (ll),Ay'C FF,and engine emperaturebelow 199"F 93"C)

RadiatorFa nSwitchCircuitTroubleshooting Short)(seepage10-'16).

\-



o CircuitDiagram

UIIDEFHOODJSE/NILAYOX

'No.20loA)USA oddNo.20l50A)Cm.de od.l

UNDENASX

FUSE/RELAYOX

lG2H0Ti iACl i l l ,0N{lllrndSTABIlll)

10



FanGontrols

RadiatorFanCircuitTroubleshooting

1. Check he No. 4 (20A) use n the under-hood

fuse/relay ox, and he No. 14(10A) use n th eunder-dashuse/relay ox .

ls the tuse (s ) OK ?

YES-Go to s tep 2.

NO- Replacehe fuse (s )and recheck.l

2. Remove he radiator an relay rom the under-hoodfuse/relay ox,and est t (seepage22-51).

ls the relay OK?

YES Go o step3.

NO Replace he radiator an relay.

3. Measure he voltagebetween he No. 2 terminalofthe radiator an relay4P socketand bodyground.

RADIATOR ANRELAY P SOCKET

Terminal ideof female erminals

ls there attery oltage?

YES Go o step4.

NO Replaceheunder-hooduse/relayox .

\-

4 . C o n n e c th eN o . a n d N o . 2 t e r m i n a l s o f t h eradiator an relay4Psocketwith a umper wire.

RADIATORFAN RELAY4P SOCKET

JUMPERWIRE

Termina lide f emaleermina ls

Does he radiatot fan run?

YES Go o step 5.

NO Go o step 6.

Disconnecthe umper,and urn th e ignit ionswitchON { l} .Check or voltagebetween he No .3terminalof th e radiator an relay4Psocketan d

bodyground.

BADIATOB ANRELAY PSOCKET

Termlnal ide f emaleerminals

ls therebattety voltage?

YES-Go to step9.

NO Check or an open n the wire between heunder-hood use/relay ox and under-dashuse/relaybox.l

\-



7 .

Disconnecthe radiator an motor 2Pconnector.

Check or continuitybetween he No. 1 erminalof

th e radiator an relay4Psocketan d he No. 2

terminalof the radiator an motor 2Pconnector.

RAOIATORANREI-AYPSOCKET

Terminal id e ffemale erminals

RADIATORFAN MOTOR2PCONNECTOR

ls thete continuity?

YES-Go o step8.

NO Repair pen n hewirebetweenhe under-hood use/relayoxand he radiatoran motor2PconnectorerminalNo .2, I

8. Check or continuitybetween he No, 1terminalof

th e radiator an motor 2P connector nd bodv

g ound .

RADIATOR

Wire side of female erminals

ls therecontinuity?

YES Replace he radiator an motor.l

NO Check or an open n the wire betweenradiator an motor 2Pconnector erminal No. 1 and

body ground. f the wire is OK,check or a poor

groundat G301.1

AN MOTOR2P CONNECTOR

rftrT-Y

9.

1 0 .

Reinstallhe radiator an relay.

Disconnecthe radiator an switch2P connector.

Connect he No. 1 and No. 2 terminals,of the

radiator an switch2Pconnectorwith a umper wi

RAOIATOR ANSWITCH2PCONNECTOR

1 1 .

5\-\ I J U MP E R

f-;'fl

I wrRE\r--

Wiresideof emale erminals

Does he radiator fan run?

YES- Replacehe radiator an switch.l

NO-Go to s tep12.

Remove he umper wire, and measure he voltag

between he No, 2 terminalof the radiator an

switchconnectoran d body ground,

RADIATOR ANSWITCH2PCONNECTOR


YES Check or an open n the wire between

radiator an switch2P connector erminalNo. 1 an

body ground. f th ewire is OK,check or a poor

groundat G301.1

NO Repairopen n th e wire between he radiato

fan switch erminalNo. 2 and he under-hood

fuse/relay ox.l

10



anControls

RadiatorFanSwitch CircuitTroubleshootingOpenl

1. Disconnecthe radiator an switch2P connector.

2 . Turn he gn i t ion wi t chON ( l l ) .

3 . Measure o l tage etweenhe No.2 ermina l f theradiator an switch2P connector nd body ground.

RADIATOR ANSWITCH PCONNECTOR

ls there battety voltage?

YES-Go to step4.

NO- Repairopen n the wire between he radiatorfa n switch2P connector erminalNo. 2 and under-hood use/relay ox.l

Turn he gnit ionswitch OFF,an dcheck or

continuitybetween he No.1terminalof the

radiator an switch2P connectorand body ground.

RADIATOB ANSWITCX PCONNECTOR


YES Replacehe radiator an switch.

NO Check or an open n the wire between heradiator an switch 2Pconnector erminalNo. 1 andbody ground. f the wire is OK ,check or a poorground t G301.1

\-

RadiatorFanSwitchCircuitTroubleshootingShort)

NOTE:After roubleshooting, erform he enginecont ro lmodu le ECM) id leearn roceduresee age11 , 1 3 9 ) .

1 . Removehe rad ia to ran re lay rom heunder -hoodfuse/relay ox, and est t (seepage22-51).

ls th e relay OK ?

YES Go o step2.

NO Replacehe radiator an relay.I

2. Remove he radiator an switch,and est t (see

page10-17.

Is the radiatot ta n switch OK?

4.

YES Go o step3.

NO Replacehe radiator an switch.I

Disconnecthe batterynegative able rom thebattery.

Disconnect nginecontrolmodule ECM) onnectorB (24P) nd he underhood use e lay ox 14Pconnector.

Check or continuitybetween he No. 2 terminalofthe radiator an switch2Pconnectorand bodygrouno.

RADIATORFAN SWITCH2P CONNECTOR

lstnere continuity?

YES Repair hort n the wire between he radiatorfanswi t ch Pconnectorermina lNo.2 andunder -hood use/relay ox.l

NO Replacehe under-hood use/relay ox.t

\

\



Fueland Emissions

Fueland Emissions ystemsSpec ia lToo lsGeneral roubleshooting

InformationDTC roubleshootingndex . . .Symptom roubleshooting

1 n d e x . . . . . . . . . . . . . . .System escript ions.. . . . . . . . . . . . . .HowtoSetReadinessodes .

PGM-FlSystemComponentocationndex . . . .DTC roub leshoot ing. . . . . . . . . . . . .MILCircuit roubleshooting..DLCCircuit roubleshooting.Injector eplacement.. . . . . . . . . . . . .A,/F ensor eplacement.. . . . . . .Secondary O2S

ReplacementECT ensor eolacement......CMPSensor {TDC ensor)

ReplacementIATSensor ep lacement. . . . . . . .Knock ensor eplacement.. .CKP ensor eolacement......

VTEC/VTCComoonentocationndex . . . .DTC roub leshoot ing. . . . . . . . . . . . .

VTCOilControl olenoidValveRemoval/Test. . . . . . . . . . . .CMPSensor Replacement..VTEC olenoid alve

Remova l / l nsoect ion. . . . . . . . . . . .

ldleControlSystemComponentocationndexDTC roub leshoo t i ng. . . . . . . . . . . . .A, /C ignalCircui t

T roub leshoo t i nS. . . . . . . . . . . . . . . . . .Al ternator RSignalCircut

T roub leshoo t i nS. . . . . . . . . . . . . . . . . .EPSSignalCircui t

T roub leshoo t i nS. . . . . . . . . . . . . . . . . .Brake edal osi t ionwitch ignal

Circui troubleshoot ing... . . . . . . . . .ldleSpeed nspect ionECM d le earnProcedure . . . . . .

FuelSupplySystemComponent ocat ion ndexFuel ump ircuitroubleshooting

1' t -2

I I - J

11-7

11 - 1 011-1211-46

11-4911-5211-971 1 - 1 0 91 1 - 1 1 11 1 - 1 1 3

1 1 - 1 1 311-114

11-1141 1 - 1 1 51 1 - 1 1 51 1 - 1 1 6

11-11711 - 1 8

11-12711-128

11-128

11-1291 I - 1 3 0

I t - t 5 5

1 1 - 1 3 4

11 - 3 5

11 - 1 3 711 - 1 3 811 - 1 3 9

11 - 1 4 011-14111-144

Fue l ressureTest. . . . . . . . . . . . . . . . . .1 -145Fue l inesnspect ion. . . . . . . . . . . . . .1 -146Fuel ine/Ouick-Connect

Fit t ings recautions.. . . . . . . . . . .1-148Fuel ine/Ouck-Conect

Fi t t ings emoval . . . . . . . . . . . . . . . . .1 -149

Fuel ine/Ouck-ConectFi t t ingsns ta l l a t i on. . . . . . . . . . . . . .1 -150

FuelPressure eguatorRep lacement. . . . . . . . . . . . . . . . . . . . . . . .1 -152

FuelFif ter eplacement..........1-152FuelPump/Fuel auge ending

Uni tReDlacement. . . . . . . . . . . . . . . .1 -153Fue l u l sa t ionamoer

Rep1acement. . . . . . . . . . . . . . . . . . . . . . . .1 -154Fue l ankReo lacement. . . . . . . . . .1 -155Fue l augeSend ingn i tTes t. . . . . . 1 -156Low uelndicatorTest. . . . . . . . . . . . . . . .1-158

IntakeAir SystemComoonen t oca t i onndex . . . .11 -159Throt t le odyTes t . . . . . . . . . . . . . . . . . . .1 -160Intake ir BypassControl

Thermal a lve es t . . . . . . . . . . . . . .1 -161A i r C leaner eo lacement. . . . . . . 1 -162A i r C leaner l emen t

Reo lacement. . . . . . . . . . . . . . . . . . . . . . . .1 -162Throt t leCableAdjustment ... . . .11-163Th ot t leCable

Removal/ lnstal lat ion. . . . . . . . . . .1-164Th ot t leBodyRemoval/

I ns ta l l a t ion . . 11 -165Th ot t leBodyDisassembly/

Reassemblv . . . . . . . . . . . . . . . . . . . . . . . . .1 -166

CatalyticConverterSystemDTC roub leshoot ing. . . . . . . . . . . . .1 -167

PCVSystemDTC roub leshoo t i ng. . . . . . . . . . . . .1 -168PCVValve nsDect ion

andTes t . . . . . . 1 - 69PCV a lveReo lacement. . . . . . . . .1 -169

EVAPSystemComponent ocat ionndex . . . .11 -170DTCTroub leshoo t i ng. . . . . . . . . . . . .1 -171EVAP wo Way ValveTest . . . . . .11-186FuelTankVaoorControl

ValveTest . . . 11-187EVAPCan is te r ep lacement. . 11 -189FuelTankVaoorControl

Va lveReo lacement. . . . . . . . . . . . .1 -189ue lPressue Rel iev ing. . . . . . . . . .



General roubleshootingnformation

IntermittentFailures

The erm "intermittentfailure" meansa svstemma vhavehad a failure.but t checks

OKnow. f

th eMalfunction ndicatorLamp(MlL)on the dashdoes notcome on, check or Doorconnections r loose erminalsat all connectors elated o the circuit hat Vo uar e

troubleshooting.

Opens ndShorts

"Ooen" an d "Short" are common electrical erms.Anopen s a break n a wire or at a connection. short san accidental onnection f a wire to groundor toanotherwire. In simpleelectronics,his usuallymeanssomethingwon't work at all.With complexelectronics(such s ECMs) th is ansomet imesmeansometh ing

works, but not he way it 's supposed o.

How to Use he PGMTesteror a ScanTool

lf the MIL {Malfunction Indicator Lamp} has come on

'1 .Star t he eng ine ndcheck he MIL A) .

NOTE:f he gn i t ion w i t ch s urnedON ( l l ) , ndthe engine s not started, he MIL will stayon fo r15 20secondssee age11-46) .

K->"PN/.-

-::: d V-: !

w:ix&K#

2. lf the MIL stayson, connect he HondaPGMTeste(A) or an OBD l scan ool to the DataLinkConnector DLC) B) ocatedunder he driver'ssid

o f thedashboard .

3.

5.

Turn he gn i t ion w i t chON ( l l ) .

Check he Diagnostic roubleCode DTC) nd notit. Also check he freezedata.Refer o the DT CTroub leshoot ingndex, nd beg in heappropr iatroubleshooting rocedure.

lf you do not ind any DTCS, o to MIL circuitt roub leshoot ingsee age11-97) .

NOTE:

. Freeze ata ndicates he engineconditionswhen thfirst malfunction,misfire,or fuel rim malfunction

was detected.. Th e scan ool and he HondaPGMTester an read h

DTC, reezedata,currentdata,and other Engine

Control \4oduleEClvl) ata.. For specificoperations, efer o the user'smanual

that camewith th e scan ool or HondaPG \4Tester.

lf the MIL did not staylf the MIL did not come on but there s a driveabil ityproblem, efer o the SymptomTroubleshootingnde

in h issect ion .

lf you can't duplicate the DTC

Some of the troubleshootingn this section equiresyou to reset he ECMand ry to duplicate he DTC. f rhproblem s intermittent nd you can'tduplicate he codo notcont inuehrough he procedure .o do so w i l lon ly esu l t n confus ion nd ,poss ib ly , need less lyrep laced CM.

(con

1



How to TroubleshootCircuitsat the ECM

Special Tools Required. DigitalMultimeterKS-AHM-32-0031)or a

commerciallyavailable igitalmultimeter. Backprobe et 07SAZ-00100042)

1. Connect he backprobe dapters A) o the stackingpatchcords(B),and connect he cords o a digitalmu l t imeterC) .

07sAz-001000A

2. Us ing hewi re nsu la t ion s a gu ide or hecontoured ip ofthe backprobe dapter, entlyslithe tip into he connector rom the wire side until touches he end of the wire terminal.

3. lf yo u cannotget o th e wire sideof the connectoor th e wire side s sealed A) ,disconnectheconnectoran d probe he terminals B) rom th eterminalside.Do not orce he Drobe nto heconnector.

Do not puncture he nsulationon a wire.

Punctures an causeDooror intermittentelectrical onnections.

(cont

1 1



FuelandEmissionsSystems

General roubleshootingnformationcont'd)

ECMUpdating nd Substitutionor Testing

SpecialTools BequiredHonda nterfaceModule HlM)EOS05435570

Use his procedurewhen yo u have o substituteaknown-goodECM n a troubleshooting rocedure.

Update he EC Monly if th e ECN4 oes not alreadyhave

the atest oftware oaded,

NOTE;. lMake ure he battery s fully chargedbeforeyo u

update he ECN4.. To preventECMdamageduring he update,do not

turn the ignit ionswitchOFF,and do not usean y ofthe vehicle'selectrical evices light,horn, radio,etc. .

How to Update the ECM

1. Turn he ignit ionswitchON (ll).Do no t startthe

eng ne.

2. Connect he Honda nterfaceModule (HlM) o theDataLinkConnector DLC) A) ocatedunder he

dr iver ' s ideof dashboard .

EOS05A35570

Do he ECM updateprocedure s described n the

HlN4abelan d n the ECMupdatesystem.

1 1 - 6

\-

How to Substitute the ECM

'1 .Remove he ECM rom the vehicle.

2. Installa known-goodECM n the vehicle.

3 . Rewr i tehe mmobi l i zerodewi th heECM

replacement rocedure rom the HondaPG MTester. t allowsyo u to start he engine.

4. Aftercompleting ou r tests, einstall he original

ECMand ewr i tehe mmobi l i zerodewi th heECM ep lacementrocedure n he HondaPGMTester ga in .

L



FuelandEmissions ystems


When he vehicleha son e of thesesymptoms, heck he diagnostic roublecode(DTC)with th e scan ool. f there s no

DTC, o the diagnostic rocedure or the symptom, n the sequence isted,untilyou find the cause.

Svmotom Diaqnostic procedure Also check or

Eng ine i l l no ts ta t(MlLworks OK,no DTCS et)

1. Test he battery seepage22-50).2. Test he starter seepage4-8).3. Troubleshoothe fuel pump circult se epage11

1 4 1 ) .

Low compressronNo gn i t ion parkln take i r eaksLocked p eng ine

Brokenim ingcha in

Contaminatedue l

Eng ine i l l no ts ta r t MlL

comeson and stayson, ornever omes n a t a l l ,no

DTCS et)

Troubleshoot he l\4lL ircuit seepage 11-97).

Enginewill not start(immobilizerndicator tays

on or flashs)

Troubleshoothe immobilizer ystem seepage22-165).

Hard tarting(MlLworksOK,no DTCSet) 1. Testthe batteryseepage

22-50).2 . Checktheue lpressuresee age11-145) .

Lo w compressionIn take i r eaks

Contaminateduel

Cold ast dle oo low(MlLworks OK.no DTCS et)

1 . Do heECM d le earn roceduresee age11-139) .

2 . Checkthed lesDeedsee aqe11-138) .

Cold ast dle oo high(MlLworks OK, no DTCS et)

Do he ECI \4d le earn roceduresee age11- 39) .

Checkthedlespeed see age11-138) .

Inspect/adjusthe throttlecable se epage 11-'163).

Inspect nd est he throttlebody {seepage11-160}.

' ]

2.3.

ldlespeed luctuates(MlLworks OK,no DTCS et )

1 . DotheECM d le earnproceduresee age11- '139) .

2 . Checkhe d lespeed see age11-138) .

3, Inspecvadjusthe throttlecable seepage 11''163).

4. Insoect nd est he hrottle bodv (seepaqe11- 60)

In take i r eaks

Afterwarming up, dl espeed

is belowspecifications ithno oad

{MlLworks OK,no DTCS et )

1 . Do he ECIVId le earn roceduresee age11- 39) .

2. TroubleshootthealternatorFRsignalcircuit se epage11- '134) .

3. InsDect nd est he throttlebodv {seepaqe 11-160).

Vacuum hoseclogged/

cracked/poorconnectron

Afterwarming up, dle speed

is abovespecifications it h

no toao(MlLworks OK.no DTCS et)

1 . Do he ECM dle earnproceduresee age1 ' j -139) .

2 . Troub leshoothe a l te rna tor Rs igna l i rcu i t (seep a g e 1 - 1 3 4 ) .

Lo w power(MlLworks OK,no DTCS et)

1 . Checkhe ue lpressure(seepage l l -145) .

2. Inspect nd est he th oftlebody (seepage11-160).

3 . Inspecvad jus the hro t t le ab le see age11- '163) .

Low compressron

Camshaf tim ingproblem

Engine i l eve lp rootem

Engine ta l l s(MlLworks OK.no DTCS et)

1 . Do heECM dle earnproceduresee age1 ' l ' 139) .

2 . Checkhe ue lpressure{seepage l l -145) .

3 . Checkhe d lespeed see age 1-138) .4. Troubleshootthebrakepedalposit ionswitchsignal

c i rcu i t see aqe11-137) .

ln take i r eaks

Fau l t y arness nd

sensorconnections

\

\-

1 1 - 1 0

\-



Symptom Diagnostic rocedure Alsocheck orDifficult o refuel(MlLworksOK .no DTCS et)

1 . Test the fue l ankvapor on t ro l a lve{seepage ' l -2 . 1471.

Inspecthe ue l ank aporcont ro l i gna l ube3. between he fuel pipeand he fuel an kvapor

controlvalve.4. Inspect he fuel ank vapor vent ube between he

EVAP anister nd he fuel ank vaporcontrolvalve.Check he EVAP anister.

Ma l funct ion ingas

sta t ioni l l i ngnozz le .

Fueloverflowsduringrefueling(No DTCS et)

Replacehe fuel ank vaporcontrolvalve (seepage 11

189) .Malfunctioning as

station il l ing nozzle.

11-




SystemDescriptions

ElectronicControl System

The unctionsof the fuel and emlssioncontrolsystemsar e managedby he enginecontrolmodule(ECM).

Fail-safeFunctionWhen an abnormalityoccurs n he signal rom a sensor, he ECI\4gnores hat signaland assumesa pre-programmed

value or that sensor hat allows he enqine o continue o run.

Back-up FunctionWhen an abnormalityoccurs n the ECM, he njectors re controlledby a back-up ircuit ndependent f the system opermi tm in imal r i v ing .

Self-diagnosisWhen an abnormalityoccurs n the signal rom a sensor, he ECMsuppliesground or th e malfunction ndicator amp

{MlL)and stores he diagnostic roublecode{DTC) n erasablememory.When he ignit ion s first urnedon, he EClvl

suppliesground o the l\4lL or 15 o 20 seconds o check he M L bulb condition.

Two Driving CycleDetection MethodTo prevent alse ndications,he "two driving cycledetectionmethod" s used or some self-diagnosticunctions.

When an abnormalityoccurs, he ECMstores t in its memory.When he sameabnormality ecursafterthe gnition

swi tch s urnedOFFandON ( l l )aga in , heECM urnson he MlL .

\

11-12

\.

\



ECMData

You can retrieve ata ro m the ECI\4 y connecting he OBD l scan ool or the HondaPG MTester o the data inkconnector DLC). he tems isted n the tablebelow conform o SAE ecommended ractice. he HondaPGM Tester

also readsdata beyond hat recommended y SAE o helpyou find the causesof intermittentproblems.

Th e "operatingvalues" istedare approximate nd may vary dependingon the environmentand he individualveh ic le .

Unlessnotedotherwise, at idle speed" means dlingwith the enginecompletelywarmed up in the neutralposit ioand he A,/C nd all

DiagnosticTroubleCode(DTC}

lf the ECMdelectsa problem, t wil l store t as a codeconsisting f on e etterand our numbers.Depending nth e problem,an SAE-defined ode (Poxxx) r a Honda,definedcode P1xxx)will be output o the tester.TheECI\4omputes ngine peedro m hesignals entfrom hecrankshaftositionCKP)ensor. hisdata s

usedor determininghe imean damount f njecteduel.

detected, here s no

ourpul.

l f no prob lem s YES

Near ly he sameas

tachometer ndication

At idlespeed;

The ECMconvertspulsesignals rom the vehiclespeedsensor VSS).

Near ly he sameasspeedometerind ica t ion

Mani fo ld

AbsolutePressure(MAP)

Th e absolutepressure aused n the intakemanifoldbyeng ine oadandspeed.

Withengine topped: YESNearly he same asalmospnencpressure.

At idle speed:about20 4'1 Pa(150 310mmHg,6 - 1 2 n . H q ) . 0 . 7 . 3V

Th e ECT ensorconverts oolant emperature nto voltage

and signals he ECM.The sensor s a thermistorwhose

internal esistance hangeswith coolant empetature.Th eECMuses h e voltagesignals ro m the ECT ensor odetermine he amount of injected uel.

Wi thco ldeng ine :Sameas ambient

temperatureand IATWith enginewarmedup;about116 2 '12"F

100'c) .0 .5-0.8Air FuelRatio The A,/F ensordetects he oxygencontent n the exha st 0.0 1 25V(Ay 'F )ensor . gasandsends o l tage igna lso the Ec lv l , asedonthese 8 .0 11 .0mA(PGM(Sensor1) signals, he ECMcontrols he airlfuel atio.When he I Tester)

oxygencontent s high (that s, when th e ratio s eaner At idlespeed:than he stoichiometric atio), he voltagesignal s Iower. about0.1 0.9VWhen he oxygencontent s low (that s,when th e ralio sricher han he stoichiometric atio). he voltagesignal shigher.The A'lF ensorsignalsare electrical urrent hatar e ndicated s voltaqeon theThe HO2Sdetects he oxygencontent n the exhaustga s

andsends o l tage igna lso the ECM.Based n hesesignals, he ECMcontrols he airlfuel atio.When heoxygencontent s high (that s, when the ratio s eanerthan he stoichiometric atio), he voltagesignal s lower.When he oxygencontent s ow (that s,when the ratio sr i cher han hesto ich iomet r i ca t io ) ,hevo l tage igna l s

Secondary

HeatedOxygenSensor(Secondary

H02S,

Sensor2)

0.0 1.25 NO

At idlespeed:about .1 0 .9V

(cont

1 1



J/-\

-1\_/

BEIAY2

A/C CLUTCHRELAY

RAOIATOR

I)

T

UNDER.HOODFUSE/RELAYOX:

ONo.19BATTERY8oA)ONo.6 ECU ECM)15A1(3)No.20lG40A1

{Canada:50A}ONo. 4 OPTION40A1€)No.9 BACK P (7.5A1lo)No. HORN, TOP 15A}

UNDER.DASHFUSE/RELAYOX:ONo.17FUEL UMP{15A}@No. tACG 10A)ONo.1 GNCOIL1sA)q)No. 0METER7.5A)0)No.14A/C CLUTCHRELAYlOA)@No.2+B LA F A/F)HEATER2OA)

(cont'

1 1 -



FuelandEmissions ystems

SystemDescriptionscont'dl

ECMElectrical onnections

\

No. INJECTOR

No,2 INJECTOR

No.3 INJEC]OB

No./tINJECTOF

MAPSENSON

TPSENSOR

IATSENSOR

ECTSENSOB

\'

CMP SENSORB(TDCSENSOSJ

CKPSENSOR

1 1 - 1 6

F€VERSE OCKSOLENOIDVAIVE

\-



EVAPCANISTE6PURGEVAIVE

EVAPCANISTERVENTSHUTVATVE

sotENotovAtvE

A/FSENSOR

A/FSENSOR(sENSOn 1)

CMP SENSOFA

VIC OIL CONTROLSO!ENOIDVALVE

wEcorlPRESSUSE WTICH

VTECSOLENOID

{cont

11-

No. 1 IGNITIONCOIL

No.2 lGNl l lONCOIL

No. 3 IGNITIONCOIL

No. a IGNITIONCOIL



and EmissionsSystems

SystemDescriptionscont'd)

ECMElectrical onnections

\

ARAKEPEDALPOStTtON WTTCH

IMMOBILPENUN|T

EPSCONTROTUNIT

\

GAUGEASSEMBLY

TERMINALLOCATIONS

\-



ECM nputsandOutputsat Connector (31P)

NOTE:Standardbatteryvoltage s 12V.

1AFS]TC

2]GP2

3IGPl ^:^ I - : , 6

AFS+1

CKPI

KS

'10

SG2t 1 1 2

ACV1 5

TPST 6

AFS_1 8

V S S1 9

IVAP2A

vcc221

vccl22

HTC+

23LG2

25CMPA

26CMPB(rDc)

27tGPts,l

28rcPts3

29tGPts2

30GPLS

Wiresideol female erminals

Terminalnumb€r

Who color forminalname Description Signal

ELKAVHT AFSHTCAI R UE LRATIO(4./F)SENSOREATERCONTROL}

DrivesAy'F ensorheater With gni t'on witchON {l l) : attery oltageWith ullywarmed p engine unnang:V

2 YEUBLK IGP2 POWEBOURCE) Power ourceor heEC Mcircuit

With he gnit ion witchON 1ll): attery oltageWith he onit ion witchOFF: bout V

3 YEUBLK IGPl POWEROURCE) Power ourceor he E CM W it h he g ni ti on w at ch N ll): attery oltageWith he onit ion witchOFF: bout V

4 BLK PG2 POWER ROUND GroundortheEC M i rc ui t L ess ha n1. 0V at all imes5 BLK PG 1 POWER ROUND GroundortheEC M ircuit Lessha n1. 0V at all imes6 RED AF S+ (AIR UE LRATIO

(A,/F}SENSOR,ENSOR+ stDE)

Detects y'F ensor{sensor )signal

1 8LU CKP CRANKSHAFTPOSITIONENSOR)

Detects K P e ns or i gn al W it hengine unning: ulses

9 BED/BLU )KSENSOB) Detects nock ensor i qnal Wit henqine nocking:ulses

1 0 YEL 2 {SENSORROUN D); ROUND) Sensor rounr Lessthan .0 Vat ellt imesG1 SENSOR Sensor roun( Less t han.0V ta l l t im es12 BLIVRED IACV IDLE IRCONTROL

(IAC)VALVE)Drives ACvalve Withengine unningr ut ycontrolled

RED/BLK TP S THROTTLEOSITIONSENSOR)

Detects Psenso r ignal Wi th h rott leullyopen: bout .8VWith hronl e ullvclosed: hout -5V

REDI/EL AFS (AIR UE LRATIO(4,/F)SENSOR,ENSOB

SIDE)

Detectsy'Fsensor( senso r) s igna l

1 8 WHT/GRN VSS (VEHICLE PEED

SENSOR)

Detects SS ignal Wathgnit ion witchON ll iand rontwheelsrotat ing:yclesrom about V to about V or

(cont '

1 1 -



andEmissions ystems


ECM nputsand Outputsat Connector (31P}

L

u

1i M oFP R

2sr-{]zs

3LG3

4SG3

6$1025HTC

1MRLY

8AFSHTCR

I

1 4FTP

1 5ELD

1 6EPSLD

18ACC

20Z/VBS

21VSV

22BKSW

23K-LINE

24SEFMJ

26NEP

21rMoCD

29scs

30WEN

31MIL

Wire sideof female erminals

NOTE:Standardbatteryvoltage s 12V.

Terminalnumber

Wire color ferminal name Description Signal

GRNI/EL IMOFP RIMMOBILIZERFLJELUM PRELAYI

DrivesPGM Fl main relay2 0Vfor2 seconds fter urning gnit ion witchON{ll). hen battervvoltaoe

2 WHT/RED SHO2SSECONDARYHEATED XYGEN ENSOR(SECONDARYO2S),SENSORr

Detects econdaryHO2S{sensor )signal

With hrott le ully penedrom dlewith ullywarmed p engine: bove .6 VWith hrott le uickly losed: elow .4V

3 BRN/YEL LG 3 LOGIC ROUND) cround ortheECM/PCMcontrolcircuit

Lessha n1. 0V at all imes

4 PNK SG 3 S EN SO R B OU ND ) S en so r round Lessha n1. 0V at all imes5 YEUELU VCC3SENSOROLTAGE) Provides ensorvoltage With gnit ion witchON ll): bout V

With onit ion witchOFF: bout V6 BLKATr'HT SO25HTCSECONDARY

HEATED XYGEN ENSOR(SECONDARY02S)HEATER ONTROL)

Drives econdary O2Sheater

With ignitionswitchON (ll):bafteryvoltageWilh ullvwarmed pengine unning: ul ,controlled

1 REDA/EL MRLY PGM.FI AI NRELAY}

Drives GM-Flmainelay1Powersource orthe DTC

With gnit ion witchON ll): bout VWith gnitionswitchOFF: atteryvoltage

I ORN AFSHTCRAI R UE L ATIO(Iy'F)SENSOREATERCONTROL ELAY)

Drives ir uel at io ensorheater elay

With gnit ion wirchON ll): V

I YEUBLK I G l ( I G N I T I O N I G N A L ) Detecrs gnit ionsignal With ignition switch ON (ll): battery voltageWith iqnition switch OFF: about 0 V't 4

LTGRN FIP FUEL AN KPRESSUREFTP) ENSOR)

Detects TP ensor ignal With gnit ion witchON ll )and uel i l l ca popen:about .5V

GRN/RED EL D ELECTRICALOA DDETECTOF)

Detects LD ignal With gnit ion wjtchON tt):aOoutO.t l-gV(deDendinon electr icaload)

LTGRN/8LK EPSLDELECIRICALPOWEB TEEBINGOA DDETECT)

DetectsPowersteering oads rgna l

At dlewithsteering heel n straight headposit ion: bout VAt dlewithsteering heelatfull ock:momentary

'18 RED ACC Ay'CLUTCH ELAY) DrivesP,/C lutch elay Withcompressor N:about VWith comoressorOFF: attervvoltaoe

\-



ECM nputsandOutputsat Connector (31P)

lt M oFPR

2$.c2s

i 6SFIO2SHTC

1

IVRLY

IAFSHTCR

9tGl

1 4FTP

1 5ELD

1 6EPSLD

t 8 202,4/BS

21VSV

22BKSW

23K LINE

24SEFMJ

26NEP

21lvoCD

29scs

30WEN

31MIL


NOTE: tandard attery oltages 12V.

Termina l Wirecolor Terminalname Description Signal

20 BLU/RED 2WBS EVAPORATIVEEMISSIONEVAP)BYPASSSOLENOIDALVE)

Drives VAP ypass With gnit ion witchON ll): aftery oltagesolenoid alve

21 LT GRN/RED VSV EVAPORATIVE

EI\4ISSIONEVAP)CANISTEBENT HUTVALVE)

Drives VAP anisteren tshutvalve

With igni l ion switch ON ( l l ) :batteryvoltage

22 WHT/BLK BKSWBRAKE EDALPOSITIONWITCH)

Detects brake pedal

oosit ionswitch s ional

Withbrake edal eleased:bout VWith hrake nedal nresse.l: batterv voltaoe

23 LT BLU K-LIN E Sends nd eceivescan With gnit ion witchON li)r ulses r battery

YE L SEFMJ Communicateswi thmrlt in leY eontro l unit

With gnit ion witchON ll): bout VWithenoine unnino nder oad:DUlses

26 BLU NEP ENGINEPEEDPULSE)

Outputs ngine peed ulse Withengine unning: ulses

21 RED/BLU \40CD l\4MOBTLTZERCODE)

Detects mrnobil izer ignal

29 BRN SCS SERVICE HECK

SIGNAL)

Oetects erv ice hecksignal With heserviceheck ignal horted ith hePG MTester: bout VWiih heservice heck ional oened: bout V

30 RED,A/VHT WE N WRITE NABLESIGNALi

Detectswrite enablesignal With i gnit ion switch ON ( l l ) :about 0 V

G RN /O RN M IL MALFUNCTION

INDICATORAMP)DrivesN4lL WithMIL urnedON :about V

WithMIL urnedOFF: atterv oltaqe

(con

11





VacuumHoseRouting

!

INTAKEAIRBYPASSCONTROLTHERMALVALVE

\*

FRONTOFVEHICLE

EVAPORATIVE MISSION{EVAP}CANISTERPURGEVALVE

\,





PGM-FISystem

The ProgrammedFuel njection PGM-Fl) ystem s a

sequentialmultiport uel njection ystem.

Air Conditioning {A/C)CompressorGlutch RelayWhen he ECfM eceives demand or cooling rom th eAy'C ystem, t delays he compressor rom beingenergized, nd enriches he mixture o assure moothtransit ion o the AVCmode.

Air Fuel Ratio lA/Fl SensorThe Ay'F ensoroperates ver a wide airlfuel ange.Th eAy'F ensor s installedupstreamof the TWC,and sendssignals o the ECMwhich varies he durationof fuelinjectionaccordingly.

SENSORTERMINALS

HEATERTERMINALS

Barometric Pressure BAROISensorTh e BAROsensor s ns ide he ECM. t convensatmospheric ressure nt o a voltagesignal hat he ECMuses o modify he basicdurationof the fuel injectiondischarge.

ztRcoNtaELEMENT

HEATER

\,

CamshaftPosition CMPISensorB (TopDeadCenter(TDCI ensor)TheCM P ensor (TDC ensor) etectsheposition f

the No.1cylinder sa referenceor sequentialuelinjectiono each y linder.

Crankshaft Position (CKPISensorThe CKPsensordetects rankshaft oeedan ddetermines gnition iming and iming for fuel injectionof eachcylinderas well as detecting nginemisfire.

EngineCoolant Temperature (ECT)SensorTh e ECT ensor s a temperature ependent esistor(thermistor). he resistance f the hermistordecreasesas he enginecoolant emperature ncreases.

MAGNET

TERMINAL



lgnition Timing Control

Th e ECMcontains he memory or basic gnition iming

at variousenginespeedsand manifoldabsolute

pressure.t alsoadjusts he timing according o enginecoolant emperature.

Iniector Timing and Duration

The ECMcontains he memory or basicdischarge

dura t ion t var ious ng ine peeds nd man i fo ldpressures. he basicdischarge uration,after being

readout from the memory, s further modified by

signals ent rom varioussensors o obtain he final

d ischarge ura t ion .

By monitoring ong erm fuel trim, he ECMdetects on g

term malfunctionsn the fuel systemand setsa

Diagnostic roubleCode DTC).

Intake Air Temperature (lAT)SensorThe IAT sensor s a temperature ependent esistor

{thermistor). he resistance f the hermistordecreases

as he intakeair temDeraturencreases.

Knock Sensor

Th e knockcontrolsystemadjusts he ignit ion iming to

minimizeknock.

PIEZOCERAMIC

Malfunction ndicatorLamp MlLl Indication ln relatio

to ReadinessCodes)The vehicleha scertain

readinesscodes" hat are par

of the on-boarddiagnosticsor the emissions ystemslf th e vehicle'sbafteryhas beendisconnected r gone

dead. f the DTCS avebeencleared, r if th e ECMha s

been eset. hesecodesare set o incomplete. n some

states,partof the emissions esting s to makesure

thesecodesare set o comDlete.f all of them are not

set o complete, he vehiclemay fail he test and he

test cannotbe finished.

To check f the readiness odesare set o complete,

turn the gnitionswitchON (ll).but do not start he

e n g i n e . T h e M I L w i l lo m e o n f o r l S 2 0 s e c o n d s .f t

then goesoff, he readiness odesare set o complete

lf it blinksseveralt imes,on e or more readiness odes

ar e not set o comolete.To set eachcode,drive heveh ic le r run he eng ine sdescr ibedn heprocedures o set hem in this section se epage 11-46

Manifold Absolute Pressure MAP)Senso]

The MAP sensorconvertsmanifoldabsolutepressure

in toe lec t r i ca ligna lso the ECM.

SENSOR NIT

(con

11



wEc/wc

The -WEC has a VTC Variable alveTiming Control)mechanismon the ntake amshaft n addition o the usual

VTEC.This mechanism mproves ue l efficiency nd reducesexhaustemissions t all Ievelsof enginespeed, ehiclespee

andeng ine oad.

The VTECmechanism hanges he valve ift and iming by using more han one cam profile.

The VTCchanges he phaseof the intake amshaft ia oil pressure. t changes he intake alve iming continuously

HIGH

i

LOW<- ENGINE PEED

DrivinoCondition VTCControl Descr iDt ion

Qr Light-load BasePos i t ion Camangle s retarded o reduce he entry of exhaustga s nto he ntakeport and o achieve table ue l

consumDt ionur inq eanbu n .

?l Med um/h gh-load AdvanceControl Cam angle s advanced or EGReffectand o reduce

this pumping oss.The ntake alve s closedquickly

to help reduce he entry of airlfuelmixture nto heintakeport and mprove he chargingeffect.

€) High speed Advance-Base osit ion Camphase ng le s cont ro l ledor op t imum a lvet im inqandmaximumenoine ower .

{cont

11



System Diagram

INTAKE

CM PSENSOR

BRN/YEL BLU/WHT

BLU/WHT

BLK/WHT

GRN/YEL

BLU/BLK

From No. il

AC C 10A) us e

VARIOUSSENSORS

CAMSHAFT -:-

BL K

It

Camshaft Position{CMP}

SensorThe CMPsensordetects amshaftangleposition or the VTCsystem.

{con

1 1

:5i.T,""



andEmissions ystems


ldleControl System

When he engine s cold, he Ay'C ompressor s on, he

transmission s in gear, he brakepedal s pressed. hepowersteering oad s high,or the alternator scharging, he ECIM ontrolscurrent o the ldle AirControl lAC) alve o maintain he correct dlespeed.Refer o the SystemDiagram o see he functionallayoutof the system.

Brake Pedal Position SwitchThe brakepedalposit ionswitchsignals he ECMwhenthe brakepedal s oressed.

ElectricalPower Steering (EPS)SenserThe EPS ensorsignals he EC Mwhen the power

s teer ingoad s h igh .

ldle Air Control llACl ValveTo maintain he proper dl espeed, he IACvalvechanges he amountof air bypassing he throttlebodyin response o an electrical ig nal rom the ECM.

From AIR To INTAKECLEANER MANIFOLD

IAC VALVE

FuelSupplySystem

FuelCut-off Control

Duringdeceleration ith the hrottlevalveclosed,current o the injectors s cut off to improve ueleconomyat enginespeedsover 1,030 pm. Fuelcut-offactionalso occurswhen enginespeedexceeds6,900 pm, regardless f the positionof the hrottlevalve, o protect he engine rom over-rewing.Whenth e vehicle s stopped. he EC Mcuts he fuel at enginespeedsover 6,500 pm.

Fuel Pump ControlWhen he gnition s turned on, he ECMgrounds hePGM-Flmain relaywhich eedscurrent o the fuel pump

for 2 seconds o pressurizehe fuel system,With theeng ine unn ing .he ECMgroundshe PGM-F l a in

relayand eedscurrent o the fuelpump.When heengine s not runningand he gnition s on, he ECI\4cutsground o the PGM-Flmain relaywhich cutscurrent o the fuel pump.

PGM-FIMain Relay1 and 2The PGM-Flmain relayconsists f two separate elays.Relay1 s energizedwhenever he gnitionswitch s ON(ll) o supplybatteryvoltage o the ECMpower o theinjectors, nd power or relay,Relay2 is energizedosupplypower o the fuel pump or 2 secondswhen theign i t ion wi tch s u rnedON ( l l ) , ndwhen he eng ine srunnrng.



IntakeAir System

Refer o the SystemDiagram o see he functional

layoutof the system.

Intake Air BypassControl Thermal ValveWhen heeng ine s runn ing ,he n take i r bypasscontrol hermalvalvesendsair to the niectors,

INJECTOR

Throttle BodyThe hrottlebody s a single-barrel idedraft ype. thouses he TP senserand he IACvalve.The ower

portionof the IACvalve s heatedby enginecoolantf rom he cy l inder ead.

IAC VALVE

{cont

11



and Emissions ystems


GatalyticConverterSystem

ThreeWay CatalyticConverter TWC)

TheTW C onverts ydrocarbonsHC), arbonmonoxideCO), ndoxides f nitrogenNOx)n heexhaust as o carbon ioxide C02), initrogenN2),andwater aDor.

THREEWAYCATALYST

FRONTOFVEHICLE

PositiveCrankcase entilation(PCVISystem

Th e PCV alve preventsblow-bygasses rom escaping

into he atmosphere y venting hem into he ntakemanifo d.

:: BLOW-BYAPOR€: FRESHIR

\

BREATHER IPE



Fueland Emissions ystems


ldleControl System Diagram

The dlespeedof the engine s controlledby the dle Air Control lAC) arve:

'Af te r theeng inestar t s ,the IACva lveopensforacer ta inamounto f t ime.Theamounto fa i r i s increasedtora ise the

id lesDeed.. When he enginecoolant emperature s low, he IACvalve s opened o obtain he proper ast dlespeed.Th e

amount of byp assed ir s controlled n relation o enginecoolant emperature.

INTAKEMANIFOLD IACVALVE AKEAIR DUCT

CLEANER

\

BLK/

REO

YEL/BLK ---< FromPGM.FIMAINRELAY

THROTTLE ODY

IntakeAir SystemDiagram

This systemsuppliesair for engineneeds.A resona tor nth e ntakeai rdrawn nto he svstem.

VARIOUSSENSOnS

pipe providesadditional i lencing s air s

THROTTLE ODY VARIOUSSENSORS

BLK

BLK

I



Evaporative missionEVAPI ontrolDiagram

The EVAP ontrolsminimize he amount of fuel vapor escaping o the atmosphere. apor ro m the fuel anK stemporarilystored n the EVAP anisteruntil t can be purged ro m the canister nto he engineand burneo.

. Th e EVAP anister s purgedby drawing resh air hrough t and nto a port on the intakemanifold.Th e purgingvacuum s controlledby the EVAP anisterpurgevalve,which operateswheneverenginecootanttemperature s above 149'F 65"C).

' W h e n v a p o r p r e s s u r e i n t h e f u e l t a n k i s h i g h e r t h a n t h e s e t v a l u e o f t h e E V A P t w o w a y v a l v e , t h e v a l v e o

regulates he flow of fuel vapor o the EVAP anister.'Dur ingre fue l ing , the fue l tankvaporcont ro lva lveopenswi th he pressuren he ue l ank, nd eeds he ue lvaDo

to the EVAP anister.

FUEL ANKVAPORRECIRCULATIONVALVE

FUEL AN KVAPOR

SIGNAL UBE

BLU/RED

FUELFILLCAP

BLK

+VAPCANISTER

FUELTANKVENTSHUTVALVE

BLK/YELFrom

--<No. 4 Acc{10 } fuse

FUELTANKVAPORRECIRCULATIONTUBE

EVAPCANISTER

EVAPTWOWAYVALVE

(cont

11-



andEmissions ystems

ystemDescriptionscont'd)

ECM Circuit Diagram

CONNECTOi

mrrrrn

CMP SENSORB(TDCSENSOn)

I-BRN/YEr-

11-38

\,



andEmissions ystems


ECMCircuitDiagramcont'dl

IGP2

YEI/BLK

VET/BLK

---rF-rl-lF-forl--JliD\l--t-l

MAIN BETAV

t_,",f-"'*'o""tr

:tl-,r'l r,

- , u -I SENSOS

IMMOAIL|zERUNIT



SECONDAFYH02S(s€NsoR l

mtlilTPS€NSOR

'--{=l-{r I

CANISTER EAITSHUTVALVE

t-_]

--lti lVAP EYPASSsolENorD

To€PSCONTROLUNIT

CPU

GAUGEASSEMBTY

(cont'

11-



andEmissionsSystems


ECMCircuitDiagramcont'd)

L

!UNDER.HOODFUSE/RELAY9OX

lalLREllY _l

CONN€CTOF

CONNECTOi

WHI/NED

BLK/YET

11-44



""rr"a*JI

r''lHr/cnN1

CONNECTOR

CONNECTOi

CONNECTOFJ

/GRN

IGNITIONSWITCH

lG2

' I

TESTTACHOMETERCONNECTO8

UNDER.HOOD

UNDER.DASHFUSE/RELAY OX:

UNDER.DASHFUSE/FELAYBOX

Brake pedal pressed:closedBrake pedal releasedropen

POStTtON WTTCH

,or"-9J3{51re*_{F "_.rl

4 ACG 1oAt1 tGNCO|L 15A)2 A/F HEATER 2OA)17 FUELPUMP 15A}1OMETER 7.5AI14 A/C CLUTCH ELAY 1OA}

11-



Fueland EmissionsSystems

How to Set Readiness odes

Malfunctionndicator amp MlL) ndication(ln elation o Readiness odesl

The vehicleha scertainreadinesscodes" hat are part

of the on-boarddiagnosticsor the emissions ystems.l f th e vehicle'sbatteryhas beendisconnected r gone

dead, f the DTCS av ebeencleared, r if th e EC Mha s

been eset, hesecodesare set o incomplete. n some

states, ar tof the emission esting s to makesu e hese

codesar e set o complete. f all of them are not set ocomplete, he vehiclemay fail the emission est,or the

test cannotbe finished.

To check fthe readiness odesare complete, urn the

ignit ionswitch ON (ll),but do not start he engine.Th e

MIL will come on for 15 20 seconds. f it thengoesoff,

the readiness odesare complete. f it blinksseveral

t imes,one or more readiness odesare not complete.To set readlness odes rom incomplete o complete.

do the procedure or the appropriate ode.

L

CatalyticConverterMonitorandReadinessCode

NOTE:

. Do no t urn the ignit ionswitchoff during heprocedure.

. Al l readiness odesar eclearedwhen the battery s

disconnected r when the ECM s clearedwith the

OBD l scan ool or HondaPG vlTester.. Low ambient emperatures r excessive lop-and-go

trafficmay increase he drive ime needed o switchthe readiness ode rom incomplete o complete.

' The readiness odewill not switch o comDleteuntil

a l l he enab le r i t e r ia remet .. lf a fault n the secondaryHO2Ssystemcaused he

MIL o come on. he readiness odecannotbe set o

comDlete nti l vou correct he fault.

EnableCriteria. ECT t 158"F70 'C) r h igher .. In take i r empera turelAT) t20"F -7 'C) or h igher .. Vehicle peed s steady,and vehiclespeedsensor

(VSS) eadsmore hen25mph (13km/h) .

Procedure1. Connecthe scan oo l o theveh ic le ' s a ta ink \

connectorDLCi , ndbr ingup he oo l ' sgener ic \ "

OBD l mode.

Start he engine.

Test-drivehe vehicleunderstop-and-go onditionswith short periodsof steadycruise.After about

5 miles(3 km), he readiness odeshouldswitchfrom incomplete o complete.

lf th e readiness od e s sti l l set o incomplete, heckfo r a temporaryDTC. f there s no DTC,one or

more of the enablecrlteriawere probablynot met;

2 .

3.



EvaporativeEmissions EVAP)ControlSystemMonitorand Readinessode

NOTE:

All readiness odeare clearedwhen the batterV sdisconnected r when the ECM s clearedwith theOBD l scan ool or HondaPG MTester.Th eenablecriteriamust be repeated f the intakeai rtemperature lAT)drops ower han 36'F (20"C)romi tsva lueat eng ine an up.

EnableCriteriaAt enginestart up, ECTand IATare higher han32'F(0"C) but ower han95'F (35"C).

At enginestartup, he ECTand IAT arewithin 12'F(7'C)of eachother.

Procedure1. Connect he scan ool o the vehicle'sdata inkconnector DLC), nd bring up the tool'sgenericOBD l mode.

2. Start he engine.

3. Test-drivehe vehicleunderstop-and-go onditionswith shortperiodsof steadycruise.After about2 .5mi les 1.6 m) , he read inessodeshou ldswitch rom incomplete o complete.

4. lf the readinesscodesstil l setto incomplete, heckfor a temporaryDTC. f there s no DTC,one or

moreof the enablecriteriawere probablynot met;repeat he procedure.

Air FuelRatio A/FlSensorMonitorandReadiness ode

NOTE:

. Do not urn the ignit ionswitch off during heorocedure.

. All readiness odesare clearedwhen the baftery sdisconnected r when the ECM s clearedwith theOBD l scan ool or HondaPGMTester.

EnableCriteriaEC Tat 140'F 60"C) r higher.

Procedure1. Connect he scan o olto the vehicle'sdata in k

connector DLC), nd bring up th e tool'sgeneric

OBD l mode.

2. Start he engine.

3. Test-drivehe vehicleunderstop-and-go onditiowith short periodsof steadycruise.During he

drive,decelerate wirh he throttle ully closed) or5 seconds. fter about3.5 miles (2.2km). hereadiness od eshould switch rom incomDleteocomplete.

4 . l f t heread inesscode iss t i l le t o incomple te ,hefo r a temporaryDTC. fthere is no DTC, he enablcriteriawa s probablynot meU epeat he procedu

Air/FuelRatio A/FlSensorHeaterMonitorReadiness ode

NOTE;All readiness odesare clearedwhen the batteis disconnected r when the ECM s clearedwith th eOBD l scan ool or HondaPGMTester,

Procedure'1 .

Connect he scan ool to the vehicle'sdata inkconnector DLC), nd bring up the tool'sgeneric

OBD l mode.

2. Start h e engine,and et t idle or 1 minute.Th ereadiness odeshouldswitch rom incomplete o

comDle te .

3. lf the readiness od e s stil l set o incomplete, hefo r a temporaryDTC. f there s no DTC, epeat heproceoure.

(cont'

11-




How to SetReadiness odes cont'd)

MisfireMonitorandReadiness ode

. This readiness ode s alwaysset o availablebecausemisfiring s continuouslymonitored.

. l\4onitoring auses, nd he misfirecounter esets, f

the vehicle s drivenover a rough road.. Monitoringalsopauses, nd he misfirecounter

holdsat its currentvalue. f th e hrottleposit ion

changesmore han a predetermined alue,or if

drivingconditions all outside he rangeof anyrelatedenablecriteria,

FuelSystemMonitorandReadiness ode

. This readiness ode s alwayssetto available

because he fuel system s continuouslymonitored

duringclosed oop operation.

. Monitoringpauseswhen the catalytic onverter,EVAP ontrolsystem,and Ay'F ensormonitorsar e

active.. Monitoringalsopauseswhen any relatedenable

criteriaare not being met. Monitoring esumeswhen

lh e enablecriteria s againbeingmet.

ComprehensiveomponentMonitorandReadiness ode

This readiness od e s alwaysset o availablebecausethe comprehensive omponentmonitor s continuously

runn ingwheneverheeng ine scrank ing r runn ing .

11-48

\-

L



System

ComponentLocation ndex cont'd) \

\.,

11-50

v



'}

DATALINKCONNECTORDLCIGeneral roubleshootingnformation, ag e1 3

PGM.FIMAINRELAY

Troubleshooting,ag e 1-97

ENGINECONTROLMODULEGeneral roubleshootin Information,page 13

Troubleshooting, ag e 1-96

1 1



PGM-FISystem

DTCTroubleshooting

DTCP0107: APSensor i rcuit owVoltage

1. Turn he gn i t ion w i t chON ( l l i .

2. Chec k he MA Pwith the scan ool.

ls about 101kP a (760 mmHg,30 n.Hg)or 2.9 Vindicated?

YES Intermittent ailu e,system s OK at his time.Check or poorconnections r loose erminalsatthe MAPsensor ndat he ECM. I

NO-Go to s tep3.

3. Turn he ignit ionswitchOFF.

4. Disconnecthe MA Psensor3P connector.

5 . Turn he gn i t ion wi tchON ( l l l .

6. lvleasure oltagebetweenMA Psensor3Pconnec lorerm ina ls o .1 andNo.3 .

1 .

sGl{GRN/WHTI

Wires de o f female termina is

ls there about5 V?

YES Go o step8.

NO-Go to s tep7.

Measure oltagebetweenEClvl onnectorte rm ina ls 11 and42 '1 .

ECMCONNECTOR 13'IP}

MAP SENSOR3P CONNECTOF

vccr{YEL/BED)

sG r{GRN/WHT}

Wire side o f female ermina ls

\

8.

ls thereabout 5 V?

YES-Repair open n the wire between he Eclvl(A21)andhe MAPsensor . l

NO Update he ECM f it doesnot have he latestsoftware,or substitule known-goodECM, henrecheck se epage l

1-6). f the symptom/indicationgoesaway with a known-goodECfvl,eplace heor ig ina l CM. I

Check he MAP with the scan ool.

ls 2 kPa (15 mmHg,0.6 n.Hg)ot lessor 0 Vind cated?

YES-Go to step9.

NO Replace he lvlAP ensor.l


Disconnect CMconnectorA (31P).

Check or continuitybetweenMA Psensorconnector erminalNo. 2 and body ground.

MAP SENSON3P CONNECTOA


YES-Repair short n the wire between he ECM(A19) nd he MAPsensor . l

NO Update he ECM f it doesnot have he atestsoftware, r substitute known-goodECM, hen

recheck seepage 11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

9.

'10.

1 1 .

\



DTCP0108: APSensorCircuitHighVoltage

'1 .Start he engine.Hold he engineat 3,000 pm with

no load (i n neutral)until he radiator an comeson ,

then et t idle.

2. Check he MA Pwith the scan ool.

le about 101kP a (780 nmHg, 30 in.Hg)ot highet,

or about2.9 V or higher ndicated?

YES Go o step3.

NO-lntermittent failure,system s OK at this ime.

Check or poorconnections r loose erminalsat

the MAP sensoran d at the ECM.I


4. DisconnecttheMAP sensor3P connector.

5, ConnectMA Psensor3Pconnector erminalsNo. 2

and No. 3 with a umper wire.

MAP S€NSOR3P CONNECTOR

MAP{GRN/REO} SG 1 GRN/WHTI

JUMPER IRE


6. Turn he gnitionswitchON (ll).

7. Chec k he MA Pwith the scan ool.

ls about 101kP a (760 mmHg,30 n.Hg)ot higher,

or about2.9 V or higher ndicated?

YES-Go to step8.

NO Replacehe MAP sensor.I

8 . Removehe umperwi re .

1 2 3

9. Measureoltage etweenMA Psensor Pconnectorerminals o.1andNo.3.

MAP SENSOR PCONNECTOF

vccl{ Y E L / R E D ), l o c l

l . l . r lI lsct

d) l{GRN/wHrrY I

i l

l l


ls thereabout5 V?

YES Go o step 10 .

NO Repairopen n the wire between he ECM(A11 and he MAP sensor.I


Connect CM onnectorerm ina ls 11andA19

with a umper wire.

ECMCONNECTOR {31PI

Wire s ide o f fema e te .mina ls


Check he MAP with the scan ool.

ls about 101kP a (760 mmHg,30 in.Hg)or highe

or about2.9 V ot higher ndicated?

YES Update he ECM f it doesnot have he ale

software, r substitute known-goodECM, he n

recheck se epage11-6). f the symptom/indicatigoesaway with a known good ECM, eplace he

or ig ina l CM.I

NO-Repair open n the wire betlveen he ECI\i l(A19) nd he MAPsensor . I

1 0 .

1 1 .

JUMPERWIAE

11



System

DTCTroubleshootingcont'dl

DTCPl128:MAPSensor ignal ower hanExpected


2. Check he MAPwith the scan ool.

ls 54.1kPa(406mmHg, 16.0in.Hg),1.6 V, orhigher indicated?

YES- Intermittent ailure.system s OK at thist ime. I

NO Replace he MAPsensor.l

\

\

DTCPl129:MAPSensor ignalHigher hanExpected

1. Start he engine.Hold he engineat3,000

pmwithno load(i n neutral)until he radiator an comeson ,

then Iet t idle.

2. Check he MAPwith the scan oot.

ls 36.9 kPa (277 mmHg, 10.9 n.Hg),1. 1V or lessindicated?

YES- lntermittent ailure,system s OK at thist ime. l

NO Replacehe MAP sensor.l

\



4 .

DTCP0112:ATSensor i rcuit owVoltage

1. Turn he gn i t ion w i t chON ( l l ) .

2. Check he IATwith the scan ool.

ls 302'F (150'C) or highet (o r H-Limit n Honda

node of PGM Tester),ot 0 V indicated?

VES-Go to step3.

NO Go o step8.

Disconnecthe IATsensor2Pconnector.

Check he IA Twith the scan ool.

ls 302'F(150'C)or higher (o r H-Limit n Hondamode of PGM Testet),ot 0 V indicated?

YES-Go to step5.

NO- Replacehe IAT sensor.I



Check or continuitybetween ATsensor2P

connectorerm ina lNo.2 andbodyground,

IAT SENSOR2PCONNECTOR

,^\,

l r 2 lt - l----Tr---

IAT_t{RED/YELI

II

Wiresideof emale erminais


YES Repair hon in th e wire between he ECM(B'17)nd he AT ensor . l

NO Update he ECM f it doesnot have he latestsoftware,or substitute known-goodECM, henrecheck seepage11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig ina l CM. I

5 .

6 .

7 .

8. Check he temperature eadingon the scan ool.Be aware hat f the engine s warm, the reading

wi l l be h igher hanambient empera ture .I theengine s cold, he IA Tan d ECTwill have he sam

va ue.

ls the correc t ambient emperature ndicated?

YES lntermittent ailure,system s OK at this im

Check or poor connections r loose erminalsatthe ATsensor ndat he ECM. I

NO Replacehe IA Tsensor.l

11



System


DTCP0113:ATSensor i rcuit ighVoltage

1. Turn he gnitio n witchON ll).

2. Checkhe ATwith hescan ool.

ls 4'F (-20'C) or less or L-Limitn Hondamodeot PGM Tester)or 5 V indicated?

3.

4.

YES-Go to step 3.

NO Intermitent ailure,system s OK at this time.Check or poorconnections r loose erminalsatth e IA Tsensorand at the ECM.I


Disconnecthe IA Tsensor2P connector.

Connect ATsensor2P connector erminalsNo. 1and No.2 w i th a umperwi re .

IA TSENSORPCONNECTOR

rJ--:---

l ' l L l'_-l--_----r--_

sG2 I rAT{GRN/YEL)

IIRED/YEL)

L ]

JUMPER IR E


6 . Turn he gn i t ion w i t chON { l l ) .

\

\

7. Check he IATwith the scan ool.

ls - 4" F ( 20'C) or less or L-Limit n Hondamode ot P GM Tester)or 5 V indicated?

YES Go o step8.

NO Replace he IAT sensor.l


9 . Removehe umperwi re .

10 . Connect CMconnectorerm ina ls 10and 817wi tha umperwi re .

ECM CONNECTORS

A (3 1P) B {24P)



Check he IAT with the scan ool.

ls - 4" F ( 20"C) or less or L-Limit n Hondamode of PGM Tester)or 5 V indicated?

YES Update he ECM f it doesnot have he atest

software,or substitute known-goodECI\4he n

recheck seepage11-6).f the symptom/indicationgoesaway with a known-goodECM. eplace heor ig ina l CM.

NO Repairopen n the wire between he ECM(A10, 17)and he ATsensor . I

\"

1 1 .

12 .

JUMPERWIRE



DTCP0116: CTSensorRange/PerformanceProblem

NOTE: f DTCP0117 nd/or P0118 re storedat the

same ime as DT CP0116,roubleshoot hose DTCSirst,

then recheckor DTCP0116,

1. Stanthe engine.Hold he engineat 3,000 pm with

no load{in neutral) nti l he radiator an comeson ,

then let t idle.

2. Check he ECTwith th e scan ool.

l s 176- 212 'F (80 100"C)or0 .5 0 .8V

indicated?

YES Intermittentailure.system s OK at this ime.

Check he hermostatand he coolingsystem.l

NO-Checkthe thermostatand he coolingsystem.

lf they are OK, eplace he ECT ensor.l

11



PGM-FISystem


DTCP0117: CTSensorCircuit owVoltage

1. Turn he gn i t ion wi tchON ( l l ) .

2. Check he ECTwith the scan ool.

ls 150'C (302'F)or higher (o t H-Limit n Hondamodeof PGM Tester)or 0 V indicated?

YES Go o step3.

NO Intermittent ailure,system s OK at this ime.Check or poor connections r loose erminalsatthe ECT ensorand at the ECM.

3. Disconnecthe ECTsensor2Pconnector.

4. Check he EC Twith the scan ool.

ls 150'C (302"F)or higher (ot H-Limit n Hondamode ot PGM Tester) or 0 V indicated?

YES-Go to s tep 5.

NO Replacehe ECT ensor.


6. Disconnect CMconnectorB (24P).

\

7. Check or continuitybetween he ECT ensor2Pconnector erminal No. 1 and bodv oround.

ECTSENSOR PCONNECTOR



YES-Repair short n the wire between he ECM(B8) nd heECT ensor . l

NO-Update the ECM f it doesnot have he latestsoftware,or ubstitute known-goodECM, henrecheck se epage 11-6).f the symptom/indicationgoesaway with a known-goodEClvl, eplace heor ig ina l CM. I



DTCP0118: CT ensor i rcuit ighVoltage


2. Check he ECTwith the scan ool.

ls 20'C ( 4'F)or less or L-Limit n Honda

mode of PGM Tester)or 5 V indicated?

?

5.

YES Go to step3.

NO lntermittent ailure,system s OK at this ime.


the ECT ensorand at he ECM.


Disconnecthe ECT ensor2Pconnector.

Connect he ECT ensor2Pconnector erminalsNo.1 andNo.2 w i th a umperwi re .

ECTSENSOR2P CONNECTOR

\

l t l t lt t . l

Ecr-I-l*,

(RED/WHT) {GRN/YEL)

t l

JUMPER IR E

wire sideoI emaleerminals

6 . Turn he gn i t ion w i t chON ( l l ) .

1 .

8 .

9 .

1 0 .

Check he ECTwith the scan ool.

ls 20"C ( 4"F)or less or L-Limit n Honda

mode ot PGM Tester)or 5 V indicated?

YES-Go to step8.

NO Rep laceheECT ensor . I


Removehe umperwi re .

ConnectECMconnector erminalsA10 and Bgwith

a umperwi re .

ECM CONNECTORS

a {31P} B {24P)



Check he ECTwith the scan ool.

ls 20"C ( 4"F) or less or L-Limit n Honda

mode of PGM Tester) ot 5 V indicated?

YES Update he ECM f it doesnot have he lates

software,or substitute known-goodECI\4,he n

recheck seepage 11-6). f the symptom/indicatiogoesaway with a known-goodECM, eplace he

or ig ina l CM. I

NO Repairopen n the wire between he ECM(A10, 8)and heECT ensor . l

1 1 .

12 .

JUMPERWIRE

11



ystem


DTCP0122: PSensorCircuit owVoltage

1. Turn he gn i t ion wi tch N (111.

2. Check he throttleposit ionwith the scan ool.

ls thereabout 10./. r 0. 5 V when he thrctt le sfully closed and about 90% or 4.5 V when thethrottle is fully opened?

YES Intermittent ailure,system s OK at this t ime.Check or poorconnections r loose erminalsatthe TP sensorand at the ECM.

NO Go o step3.

3. Turn he ignit ionswitchOFF,

4. Disconnecthe TP sensor3P connector.

5 . Turn he gn i t ion wi tchON ( l l ) .

6. Measure oltagebetween he TP sensor3Pconnector erminalsNo. 1 and No. 3.

TP SENSOR3P CONNECTOR


ls there bout V?

YES-Go o step7.

NO Go o step 4.

Turn he gnition witchOFF..

8. At the sensorside,measure esistance etween heTP sensor3Pconnector erminalsNo. 1 and No. 2with the throttle ully closed.

TP SENSOR PCONNECTOR

Termina lide f ma leermina ls

Is thereabout 0.5 0. 9kQ ?

YE S Go o step9.

NO Replacehe throttlebody (theTP sensor s notava i lab leepara te ly ) .

Measure esistance etween he TP sensor3Pconnector erminalsNo. 2 an d No .3 with thethrottle ully closed.

TPSENSORPCONNECTOB

Terminal ide f male erminals

ls thereabout 4.5k{l ?

YES Go o step 10.

NO Replacehe throttlebody (theTP sensor s notava i lab leepara te ly ) .

10 . D isconnectCM onnector (31P) .

9.\



11 .At hewireharnesside, heckor continuitybetween Psensor PconnectorerminalNo ,2andbody round.


11 2 1 3'P S

REO

Wire sideot Iemale erminals

ls thetecontinuity?

YES-Repair hort n hewirebetweenhe ECM

{A15) nd heTP ensor . l l

NO-Go ostep 2.

Connect CM onnectorerminal 15 o bodygroundwith a umperwire.

EC MCONNECTOR 131P)

1 1 2 1 34 5 6 7 91011112 t c 6 8 192021

23124 28129130

,tf$,rr*, ] uueen rne

Wire sideoJ femaleterminals

/BLKI

12 .

13. At hewire harnesside, heckor continuitybetween Psensor PconnectorerminalNo.2andbody round.


(RED/BLX}

Wire s ide of female erminals

ls therecontinuity?

YES-Update the ECM f it doesnot have he late

software, r substitute known-goodECM, hen

recheck se epage11-6). f th e symptom/indicatio

goesawaywith a known-goodECM, eplace he

or ig ina l CM. I

NO- Repairopen n th e wire between he ECM(A15) nd heTPsensor . l

14. lvleasure oltagebetweenEC Mconnector

te rm ina ls 10 andA20.

ECMCONNECTOB 131P}

vcc2(YEL/8LU)


ls thereabout 5 V?

YES Repairopen n the wire betlveen he ECM(A20) nd heTPsensor . I

NO Update he ECM f it doesno r have he lates

software,or substilute known-goodECM, hen

rechecksee age11-6) .f he symplom ndica t igoesawaywith a known-goodECM. eplacehe

or ig ina l CM.I

1 2 3TPS

1 1



DTCPl121: PSensor ignal ower hanExpected



ls 12.9'/.,0.6 V, or higher ndi cated when he

throttle is tully opened?

YES- Intermittent ailure,system s OK at this

t ime. I

NO-Replace the TP sensor th eTP sensor s not

available eparately).

DTCP1122:.fPensor ignalHigher hanExpected



ls 12.9%,0.6 V, or less ndicated when he throt

is f ully closed?

YES Intermittentailure,system s OK at this

t ime. l

NO Replacehe TP sensor th eTP sensor s not

available eparately).

11



DTCP0134: y'F ensor Sensor ) No ActivityDetected

1. Check he attachment tateof the A,/F ensor(Sensor ) .

ls it slacked f rom the exhaust pipe?

YES- Reinstallhe Ay'F ensor Seneor1) se epage

1 1 - 1 1 3 ) . t

NO-Go to step2.

2 . Resethe ECM see age11-4) .

3 . Stan heeng ine . o ld he eng ine peed t

3,000rpmwith no oad (i n neutral)until he radiator

fan comes on, hen let t idle or 2 minute.

ls DTC PO134 ndicated?

YES-Replace he Ay'F ensor Seneor1) (seepage

1 1 - 1 1 3 ) . t

NO Intermittent ailu e,sistem s OK at his t ime.


th e Ay'F ensor Seneor1 and he ECM.I

DTCP0137: econdary O2SSensor )Circuit owVoltage

1. ResetheECM see age 1-4)

2. Start he engine.Hold h e engineat 3,000 pm wilh

no load (in neutral)until he radiator an comeson

3. Check he secondaryHO2S Sensor ) output

voltageat 3,000 pm with the scan ool.

ls the re 0.3 V or less?

YES Go o step4.

NO-lntermittent failure,system s OK at this ime

Check or poor connections r loose erminalsat

the secondaryHO2S Sensor ) and at the ECM.I

Turn he gn i t ion w i t chOFF.

Disconnecthe secondaryHO2S Sensor ) 4P

connector.

Turn he ignit ionswitchON (ll).

Check he secondaryHO2S Sensor ) output

voltagewith the scan ool.

ls there 0.3 V or less?

YES Go o step8.

NO Rep lacehe secondary O2S Sensor ) .1

Turn he gnitionswitch OFF.

Disconnect CM onnector (31P) .

i c on t

4.

5 .

6.

7 .

8.

9 .

11




10. Check or continuitybetween he secondaryHO2S(Sensor ) 4Pconnector erminalNo. 2 and bodyground .

SECONDARY02SISENSOR) 4PCONNECTOR

Terminal ide of male erminals


YES-Repair shon in the wire between he ECM(E2) nd he secondaryHO2S Sensor ).

NO Update he EC M f it does not have he atestsoftware, r substitute known-goodECM, henrecheck seepage 11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I |

DTCP0138: econdary O2SSensor )Circuit ighVoltage

1. Reset the CM see age '11-4) .

2. Starttheengine.Hold he engineat 3,000 pm withno load(in neutral)until he radiator an comeson .

3. Check he secondaryHO2S Sensor ) outputvoltageat 3,000 pm with the scan ool.

ls thete 1.0V or morc?

YES Go o step 4.

NO-lntermittent failure,system s OK at this t ime.Check or poorconnections r loose erminalsat


4. Turn he gnitionswitchOFF.

5. Disconnecthe secondaryHO2S Sensor ) 4Pconnector.

Connect econdaryH02S (Sensor ) 4Pconnectorte rm ina ls o . 1 andNo.2 wi th a umperwi re .

SECONDARY O2S{SENSOR ) 4PCONNECTOR

JUMPERWIRE

SG 3 PNKI SHO25 WHT/RED)

Term ina l i deoJmale e rm ina l s

7 . Tu rn t he i gn i t i onswi tch ON ( l l ) .



8. Check he secondaryH02S (Sensor ) output

voltagewith th e scan ool,

ls there 1.0 V ot mote?

YES-Go to step9.

NO Replacehe secondaryHO2S Sensor ).1


ConnectEC Mconnector erminalsE2 and E4with a

JUmper r re .

ECMCONNECTOR 131PI




voltagewith the scan ool.

ls there 1.0V or more?

YES Update he ECM f it doesnot have he latest

soflware,or substitute known-goodECM, hen

recheck seepage11-6). f the symptom/indicationgoesawaywith a known-goodECM. eplace he

or ig ina l CM.I

NO Repairopen n the wire between he ECM E2,

E4 )an d he secondaryHO2S Sensor2).I

9 .

1 0 .

1 1 .

1 2 .

JUMPERWIRE

3.

DTCP0139: econdary O2S Sensor l SloResponse

1. Reset the CM see age11-4) .

Start he engine.Hold he engineat 3,000 pm with

no load (i n neutral)until he radiator an comeson


voltageat 3,000 pm with the scan ool.

ls thete 0.3- 0.8 V, fot 2 minutes?

YES Replacehe secondaryHO2S Sensor ).!

NO - lntermittent ailure,system s OK at his time

Check or poorconnections r loose erminaisat


11



PGM-FISystem

3.


DTCP0141: econdary O2SSensor lHeater ircuitMalfunct ion

1. R eset he ECM seepage1 -4)

2. Start h e engine.

ls DTC P0141 ndicated?

YES-Go to step 3.

NO-lntermittent failure,system s OK at this ime.Check or poorconnections r loose erminalsatthe secondaryHO2S Sensor ) and at the ECM.I

Turn he ignitionswitchOFF.

Disconnecthe secondaryH02S (Sensor ) 4Pconnecror.

At the secondaryHO2S Sensor ) side,measureresistance etweenH02S 4Pconnector erminalsNo.3 and No.4 .

SECONDARYO2S SENSOR14PCONNECTOR

Wire side ol lemale erminals

ls there bout .3 Q?

YES Go o step6.

NO- Replacehesecondary O2SSensor ).

5.

6. Check or continuitybetweenbody groundan dsecondaryH02S (Sensor ) 4Pconnector erminalsNo.3 and No.4 nd iv idua l l y .

SECONDARYO2S SENSOR14PCONNECTOR


ls there ontinuity?

YES- Replacehesecondary O2SSensor ). 1

NO-Go to step7.

Turn he gnition witchON ll).

Measureoltage etween econdary 02S4Pconnectorerminals o.3 andNo.4,

SECONDARYHO2S(SENSOR l ilP CONNECTOR

t.

8 .

9 .

1 0 .

s02sHTc{BLK/WHTI IG 1 BLK/ORN}

Termina lide fma leermina ls

ls there battery voltage?

YES Go o step9.

NO Go o step 12.

Turn he gnitionswitchOFF.

Disconnect CMconnectorE{31P)



11. Checkor continuity etween CM onnectorterminal 6an dbodyground.

ECM CONNECTOR {31PI

Wire side o{f emale erminals


YES-Repair short n the wire between he ECM(E6) nd he secondary O2S Sensor ) .1

NO-Update the ECM f it doesnot have he latest

soflware,or substitute known-goodECM, henrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

Measure oltagebetweensecondaryHO2S(Sensor ) 4Pconnector erminal No. 4 a nd bodyg ound .

SECONDARYO2S SENSORI 4PCONNECTOR

tFff Il[faJl--ro'14 |

IBLK/OFN)

YI

Terminalid eof male erminals


YES Go o step 13.

NO-ChecktheNo.4 ACG 10A)use n he under -dash use/relay ox. f th e fuse s OK ,repairopen n

the wire between he secondaryHO2S Sensor )

andNo.4 ACG 10A)use. l

1 3 .

1 4 .

t 5 .

t o .

Turn he ignit ionswitch OFF.

Reconnecthe secondaryHO2S Sensor ) 4P

connector.

Disconnect CMconnectorE (31P).


Measure oltagebetweenEC Mconnector ermina

E6andA5.

ECMCONNECTORS

A (3 1P)

E 31P}


Is there 0-1 V or less?

YES-Repair open n the wire betwee n he ECM(E6) nd he secondaryHO2S Sensor2) .

NO Update he ECM f it doesnot have he latestsoftware,or substitute known-goodECM, hen

recheck se epage11-6). f th e symptom/indicatiogoesawaywith a known-goodECM, eplace he

or ig ina l CM.

1 7 .

11-



PGM-FI ystem


DTCP0171:uelSystem ooLean

DTCP0172: uelSystemToo Rich

NOTE: f someof the DTCSistedbelow are storedat

the same ime as DfC PO17'l nd/otPO172,

troubleshoot hose DTCSirst, hen recheck or P0171

andlot P0112.

P0107, 0108. 1 28 .P1 29:Man i fo ld bso lu tepressureMAP) ensor

P1 62.P1166,P1167: ,,/Fensor Sensor1 heater

P0137, 0138: econdary O2S Sensor )

P014'l:SecondaryHO2S Sensor ) heater

P1259: TEC ystem

1. Checkhe ue lpressuresee age11- '145) .

ls luel pressureOK ?

YES Go o step2.

NO Check hese tems:

. lf th e pressure s oo high, replace he fuelp ressureegu la torsee age11-152) .1

. l f he pressurestoo ow.checkthe fue l ump,

the fuel ee d pipe, he fuel i lter,and replace he

fue lpressureegu la torsee age11-152) . I


no load (in neutral)until he radiator an comes on.

11-70


4. With a vacuum pump,applyvacuum o the

evaporative mission EVAP) anisterpurgevalve(A ) rom the evaporative mission EVAP) anisters ide .

' A973AX-041-XXXXX

Does t hold vacuum?

YES-Check he enginevalve clearances nd adjust

if necessary,f th e valveclearances re OK,replace

the n jec torssee age11-1 1) .1

NO-Replace the EVAP anisterpurgevalve.l



DTCP0300: andomMisf ire ndAnyCombinationf heFol lowing:

DTCP0301: o.1Cyl inder isf i re

DTCP0302: o.2 CvlinderMisfire

DTCP0303: o,3 Cvl inder isf i re

DTCP0304: o.4 CvlinderMisfire

NOTE:. lfthe misfiring s frequentenough o trigger detection f increased missionsduring wo consecutive riving cycle

the MIL will co me on, andDT CP0300 an dsome comlrination f P0301hrough P0304) i l l be stored.. lf the misfiring s frequentenough o damage he catalyst, he MIL will blinkwhenever he misfiringoccurs,and OT

P0300 an dsome combinationof P0301 hrough P0304) i l l be stored.When he misfirlngstops, he MIL will rema

on.

1. Troubleshoothe following DTCs irst if any of them were storedalongwith th e random misfire DTC(s):

P0 '107,0108, 1128, 1129r 4an i fo ldbso lu te ressureMAP) ensorP0111. 0'172t uelsvstemP0335. 0336:Crankshaft osit ion CKP) ensorP0505: dlecontrolsystem

P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio Ay'F)ensor

P1259: TE C ystemP1361,P1362: amshaftposit ion CMP) ensorB {Topdeadcenter TDC) ensor)P1519:d leai rcont ro l lAC) a lve

2. Test-drivehe vehicle o verify he symptom.

3. Findthesymptom n thechart below,and dothe relatedproceduresn the order isteduntil yo u find the cause.

Symptom Procedure(sl Also check foi:

Randommisf i re n lyat ow RPMan dunder oad

Check uel pressure se epage11-145). . Lowcompressron.. Lo wqualityuel.

Randommisf i re n lydu ing acceleration

Check uel pressure se epage11-145). Malfunctionn heVTEC ystem se e age1' t-1 23 ).

Randommisfireat

h ighRPM, nderload, r underrandomconditions

Checkue lpressuresee age11-145) . Correctenginevalveclearances se epage6-9 1 .

11



PGM-FI ystem

TCTroubleshootingcont'dl

DTCP0301: o.1 Cyl inder isf i re

DTCP0302: o.2 CylinderMisfire



1. After checking nd recording he freezedata, eset

the ECM seepage11-4). f there s no freezedataof

the misfire, us t clear he DTC.

2. Star t he engine,and isten or a clicking ound

from the injectorat the problemcylinder.

Does the injector click?

YES-Go to step3.

NO-Go to step30 .


4. Exchangehe gnitioncoil rom the problem

cylinderwith on e rom anothercylinder,

5. Test-drivehe vehicle or sev eralminutes n th erangeof the freeze ata or underva ious

conditions f therewas no freezedata.

6. Check or a DTCor a TemporaryDT Cwith the scanroot .

ls DTC or Tempotaty DTC P0301, P0302, P0303

or P0304 ind cated?

YES Go o step7.

NO Intermittentmisfiredue o poor contactat heign i t ion o i lconnectorsnomis f i re t h is ime) .

Makesure he coil connections re secure.l

11-72

8.

9 .

1 .

1 1 .

Determinewhich cylinder(s) ad h e misfire.

Does the misf re occur in the cylinder where the

ignition coil was exchanged?

YES Replace he faulty gnit ioncoil.!

NO-Go to step8.


Exchangehe sparkplug rom the problemcylinder

with one rom anothercylinder.

Test-drivehe vehicle or severalminutes n therangeof the freezedataor undervarious

conditions f therewas no freeze ata.

Check or a DTCor TemporaryDT Cwith the scanTool.

ls DTC ot Tempotary DTC P0301, P0302, P0303

or P0304 nd cated?

YES Go o step 12 .

NO Intermittentmisfiredu e o sparkplug ouling,

e tc . nomis f i re t h is ime) .1

Determ ine h ichcy l inder (s)ad he m is f i re .

Does the misl ire occur in the cylinder where thespark plug was exchanged?

YES Rep lacehe au l t y park lug . l

NO Go o step 13 .


Exchangehe njector rom the problemcylinder

wi th one rom another y l inder .

Le t heeng ine d le o r 2 m inutes .

10 .

1 4 .

t 5 .



16.Test-drivehe vehicle or severalminutes n th erangeof the freeze at aor undervarious

conditions f therewa s no freezedata.

Check or a DT Cor a TemporaryDT Cwith the scanTool.

ls DTC or TemporaryDTC P0301,P0302,P0303

or P0304 ndicated?

YES Go o step 18.

NO lntermittentmisfiredue o bad contactat the

injectorconnector no misfireat this ime). Make

sure h e injector onnection s secure.Check orpoor connections r loose erminalsat th e

injector.l

Determinewhich cylinder(s) ad he misfire.

Does the misf re occur in the cylinder where thei njector was exchanged?

YES- Replace he faulty njector.I

NO-Go to s tep19.


Disconnecthe ignit ioncoil 3Pconnector ro m th eproblemcylinder.


't 7.

1 8 .

1 9 .

20 .

22. Measure oltagebetween gnitioncoil 3P

connector erminalNo .3 and body ground.

IGNITIONCOIL3P CONNECTOR

Wire side ol female erminals


YES-Go to step23.

NO Repairopen n the wire between he No. 1

IGNCOIL 15A) fuse nd he gn i t ion o i l .I


Check or continuitybetween gnitioncoil 3P

connector erminalNo. 2 and body ground.

IGNITIONCOIL3P CONNECTOR

Wire side ot female erminals


YES Go o step25.

NO Repairopen n the wire between he ignit ion

c o i l a n dG 1 0 1 . 1

Disconnect CMconnectorA {31P)

23.

24 .

(cont

11-



PGM-FI ystem


26. Check or continuitybetweenbody ground an dEC Mconnector erminal se e able).

ECMCONNECTOR {31PI

PROB E VICYLINDER DTC ECMTERMINAL WIRECOLORN o .1 P0301 430 YEUGRNN o . 2 P0302 A.29 BLU/REDN o . 3 P0303 428 WHT/BLUN o , 4 P0304 421 BRN


YES Repair hon in the wire between he EClvland he gn i t ion o i l . l

NO-Go to step27 .

27. Connectgn i t ion o i l3Pcon ector e rm na lNo.1 tobody groundwith a umper wire (see able).

IGNITIONCOII 3PCONNECTOR

Wire s de o f female termina ls

PROBLEMCYLINDER

DTC WIRECOLOR

No. 1 P0301 YEUGRNNo.2 P0302 BLU/REDNo.3 P0303 WHT/BLUNo.4 P0304 BRN

11-74

28. Check or continuitybetweenbody groundandEC Mconnector erminal se e able).

EC MCONNECTOR {31P}

PROBLEMCYLINDER DTC ECMTERI\4INAL WIRECOLORNo.1 P0301 A30 YEL/GRNNo.2 P0302 429 BLU/REDNo.3 P0303 A.28 WHT/BLUNo.4 P0304 A.21 BRN


YES-Go to step29 .

NO Repairopen n the wire between he ECMan dthe gn i t ion o i l . l

29. Chec k he enginecompression

ls the compression OK?

YES-Update th e ECM f it doesnot have he atest

software,or substitute known-goodECM, henrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CI \4 . I

NO- Repa i rhe eng ine . l



30.



32. fvleasureoltage etween odyground ndEC Mconnectorerminalseeable).

ECMCONNECTOR(24P)

Wire side of female ermrnals


YES-Go to step33,

NO Go o s tep41.

Turn he ignit ionswitch OFF, nd remove heenginecover.

Disconnecthe njector2P connector rom th eprob lem yl inder .

Measure he resistance etween njector2Pconnectorerm ina ls o . 1 and No.2.

INJECTOB P CONNECTOR

Termina l s ide o f ma le te rmina ls

l s there10Q 13A?

YES-Go to step36 .

NO Rep lacehe n jec tor see age11- 1 ) .

33.

34 .

35,

PROBLEM

CYLINDER

DTC EC \4

TERMINAL

WIRE

COLORNo. 1 P0301 B5 BRNN o . 2 P0302 B4 REDN o . 3 P0303 B3 BLUN o . 4 P0304 YEL

36 . Exchangehe injector rom th e problemcylinderwi thone rom another y l inder .

Le t theeng ine d le o r 2 m inutes .

Test-drivehe vehicle or severalminutes n therange I the reeze a taor under ar iouscondilions f therewas no freezedata.

Check or a DTCor TemporaryDT Cwith the scantoo l .

ls DTC or TemporaryDTC P0301,P0302,P0303or P0304 ndicated?

YES Go o step 40.

NO Intermittentmisfiredue o injectormalfunction, tc .Makesure he injectorconnections resecure.Check or poorconnectioor loose erminalsat he injectorconnector.l

Determ ine h ichcy l inder {s}ad hemis f i re .

Does the mislirc occur in the cylinder whete thei njector was exchanged ?

YES Replacehe faulty njector.l

NO Update he ECM f it does not have he latessoftware,or substitute known-goodECM. hen

recheck seepage 1 l-6).lf the symptom/indicatiogoesawaywith a known-goodEClvl, eplace he

or ig ina l CM. I


Remove he enginecover.

Disconnecthe njector2Pconnector rom theprob lem yl inder .

44 . Turn he gn i t ion wi tchON ( l l )

37.

38.

39 .

4 1 .

42.

43 .

(cont'

11-




45. Measureoltage etweennjector Pconnectorterminal o.1andbody round.

INJECTORPCONNECTOR

tll-z],o, "=rrrr*,

-lt-

oI

Wire id eof emaleerminals


YES-Go to step46 .

NO-Repair open n the wire between he injector

and he PGM-F l a in e lay . l

Turn he ignitionswitch OFF.

Check or continuitybetweenbody groundandECMconnector erminal (see able).

46.

47.

EC MCONNECTOR {24P)

Wi re i deof em a le e rm ina l s


YES-Repair short n the wire between he ECMand he n jec tor . I

NO-Go to s tep48.

PROBLEMCYLINDER

DTC ECMTERMINAL

WIRECOLOR

N o .1 P030'1 B5 B R N

N o . 2 P0302 B4 REDN o . 3 P0303 B3 BLUNo.4 P0304 82 YEL

11-76

48. Connectnjector Pconnectorerm nalNo.2 obodygroundwitha umperwire see able).

INJECTOR P CONNECTOR

Wire sideof {emale erminals

49 . Check or continuitybetweenbodyground an dEC Mconnector erminal see able).

ECM CONNECTOR I24P)

Wire sideoJ emale erminals

ls the rc continuity?

YES Replacehe njector, he n recheck.l

NO Repairopen n th e wire between he ECMan d

th e injector.I

tll-Z-l]_r-l_rNJ

I JUMPER

IwrBE

PROBLEMCYLINDER DTC WIRECOLOR

No.1 P0301 BRNN o . 2 P0302 REDNo.3 P0303 BLUNo.4 P0304 YEL

PROBLEMCYLINDER

DTC ECMTERMINAL

WIRECOLOR

No.1 P0301 B5 BRNNo.2 P0302 B4 REDNo.3 P0303 B3 BLUNo.4 P0304 82 YEL



DTGP0325:Malfunctionn KnockSensorCircut

1. Resethe ECM see age11-4) .


no load(in neutral)until he radiator an comes on,then et t idle.

3. Hold he engineat 3,000-4,000 rpm for at east60 seconds.

ls DTC P0325 indicated?

YES-Go to step4.

NO Intermittent ailure,system s OK at this ime.Check or poorconnections r loose erminalsatth e knocksensorand at the ECM.I


5. Disconnecthe startersubharness P connector.

6. Check or continuitybetweenECMconnectorterminalAg and body ground.

ECMCONNECTOR 131P)

Wire sideof emale erminals

ls therecontinuity?

YES-Repair hort n hewire betweenhe ECM(A9) nd hestarter ubharnessPconnector.l

NO Go o step7.

7. Connect taner ubharnessPconnectorerminaNo. o body round i tha umper i re.

8.

STARTER UAHARNESS6PCONNECTOR

l 1 l 2 1 3 ll , / l 5 l 6 l._

KS IJUMPER| RED/ BLU)

I W| REI

Wiresideof emaleerminals

Checkor continuity etween odyground ndECM onnectorerminal 9.

9.

ECMCONNECTOR {31PI



YES-Go to step9.

NO Repairopen n the wire between he ECM A

and he startersubharness Pconnector.l

Check he startersubharness etween he 6Pconnectoran d he knocksensor or an open orshort. f it 's OK,substitute known-good nock

sensorand recheck.


YE S Update he ECM f it does not have he latessoftware.or substitutea known-goodECM, henrecheck seepage 11-6).

lf the symptomlindicatiogoesaway with a known good ECM, eplace heor ig ina l CM. I

NO Rep lacehe or ig ina l nock ensor nd /orsta te subharness.l

11-



PGM-FI ystem

DTCTroubleshootingcont'd)

DTCP0335: KPSensorNo Signal

DTCP0336: KPSensor ntermittentInterrupt ion

'1 .Reset he EC M seepage11-4).

2. Sta t the engine.

ls DTC P0335 and/or P0336 indicated?

YES Go o step3.

NO Intermittentailure,system s OK at his t ime.


the CKP ensor nd at heECM. I


4. Disconnecthe CKPsensor3Pconnector.

5. Turn he ignit ionswitchON {ll).

6. Measure oltagebetweenCK Psensor3P connector

te rm ina lNo.3 and bodyground.

CKPSENSOR PCONNECTOF

(YEL/BLK}

Wire ade f emaleerminals

Is therebattery voltage?

YES- Go o step .

NO Repair pen n hewirebetween GM-Fl ainre lay and heCKP ensor . !

IGP

1 2 3

11-78

7. Measure oltagebetweenCK Psensor3P connector

te rm ina lNo, 1 andbodyground

CKPSENSOR P CONNECTOR

Wire side o f female te f mina ls

ls there bout V?

YES Go o stepL

NO Go o s tep 0.

8. Measureoltage etween K P ensor Pconnectorterminals o.2andNo. .

CKPSENSOR PCONNECTOR

, l l Y t L

L " l(

Gl{BRN/YELI

Wireside f emale erminals


YES Go o step9.

NO Repairopen n the wire between he CKP

sensor ndG101 I

9. Substitute known-goodCK Psensorand recheck.

ls DTC P0335 and/or P0336 ndicated?

YES Update he ECM f it does not have he atest

software.or substitute known good ECM, hen

recheck se epage 11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

NO Replacehe or ig ina l KP ensor . l



1 1 .

1 3 .

'10.l\4easureoltage etween CM onnectorerminalA7andbodyground,

ECMCONNECTOR 13lPI

Wire ideot emaleerminals

ls there about5 V?

YES-Repair open n the wire between he ECM(A7)an d he CKPsensor.

NO-Go to s tep11.


Disconnect CMconnectorA (31P)

Check or continuitybetweenECMconnectorterminal47 and body ground.

ECMCONNEfiORA (31P)

Wire ideof emale erminals


YES-Repair short n the wire between he ECM(A7)and he CK Psensor.

NO Update he ECM f it doesnot have he latestsoftware.or substitute known-goodECI\4,he nrecheck se epage11-6). f the symptom/indicationgoesawaywith a known-goodECM, e place heor ig ina l CM. t

11-



PGM-Fl ystem

6.

1 .


DTCP0500: SSCircuitMalfunction

1. Test-drivehe vehicle.

2. Check hevehiclespeedwith the scan ool.

ls the correct speed ndicated?

YES-lntermiftent ailure,system s OK at this ime.


theVSSandat heECM. I

NO Go to step3.


4. Block he rearwheels,and set he parkingbrake.

5. Raise he front ofthe vehicle,an d makesure t is

securely upported,

Turn he gnitionswitchON (ll).

Block he right ront wheel,and slowly rotate he

left ront wheel.

8. Measure oltagebetweenECMconnector

te rm ina ls 18andA24.

EC MCONNECTOR {31P)


Does the voltage pulse between 0 V and 5 V or

between0V and battery voltage?

YES-Update the ECM f it doesnot have he latest

software, r substitute known-goodECM. hen

recheck seepage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CN4. l

NO Go o step9.

11-80


10. Disconnect CMconnectorA (3'1P).

11 . Turn he gn i t ion wi tchON { l l } .

12. Blockthe ight ront wheel.and slowly rotate he

left ront wheel.

'!3.lMeasure oltagebetweenECMconnector

te rm ina ls 18andA24.

EC MCONNECTOR I31PI


Does the voltage pulse between 0 V and 5 V ol

between0V and battety voltage?

YES Update he ECM f it doesnot have he atest


recheck seepage11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig lna l CM.I

NO Check hese tems:

. A short or an open n the wire between he ECM(A18) nd heVSS. I

. l f hewi re s OK, tes t theVSSsee age22 71) .1



DTCP0563: CMPowerSourceCircuitUnexpected oltage

1. Resethe ECI \4see age 1-4} .


3. Wait 5 seconds.

4 . Turn he gn i t ion wi tchON { l l l .


YES Go to step 5.

NO-lntermiltent failure,system s OK at this ime.Check or poorconnections r loose erminalsatthe No.6 ECU ECM) 15A) use n he under -hoodfuse/relay ox and at the ECM.I


Disconnect CI\4 onnectorE{31P).

Turn he gn i t ion wi tchON ( l l ) .

lvleasure oltagebetweenECMconnector erminalE7and body ground.

6.

7 .

8.

EC MCONNECTOR {31P}

Wire id eol remaleerminals


YES Go o step 12.

NO Go o step9.

MRLY

9 .

10 .

Remove he glove bo x (seepage20-63).

Remove he PGM-FImain relay 1 (A7.

Check or continuitybetweenEC MconnectorterminalE7and body ground.

EC MCONNECTOR 131P)

MRLY{RED/YEL)


ls therecontinuity?

YES-Repair short n th e wire between he ECM

{E7) nd hePGM-F lmain e lay1 I

NO Rep lacehe PGM-F lmain e lay1.1

Turn he gnitionsuitchOFF.

Reconnect CM onnector (31P) .

1 1 .

t t .

'13.

(con l

1 1 -



PGM-FISystem


14. Measure oltagebetweenEC Mconnector erminalE7and body ground.

ECMCONNECTOR 13lPI

MRLYIBEO/YEL)



YE S Go o step 15.

NO-Update the ECM f it doesnot have he latestsoftware, r substitute known-goodEClvl,he nrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM.I

Disconnect CI\4 onnectorA (31P).


Measure oltagebetweenbodyground an d ECIMconnectorerm ina ls 3 and42 ind iv idua l l y .

ECMCONNECTOR {3.IP)

IGP2 IGP1(YEI./BLX) (YEL/BLKI



YES-Go to step 18 .

NO Update he ECM f it does not have he latestsoftware, r substitute known-goodECM, he nrecheck seepage11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace heoriginalECM/PCl\4.1

1 5 .

t o .

1 7 .

11-82

1 8 .

1 9 .

Remove he glovebo x (seepage20-63).

Remove he PGM-FImain relay1{A).

Measure voltage between body ground and ECM

connector terminals A3 and A2 individually.

EC MCONNECTOR {31PI

IGP2 IGP1(YEL/BLK) (YEL/BLK)



YES Repair hortto power n the wire betweenthe ECI \4A2.A3) nd hePGM-F lmain e lay1 .1

NO Rep lacethe GMFlmain e lay1. !

20 .



DTGPl106:BAROSensorRange/PerfomanceProblem

1. ResetheECM see age11-4) .

2. Start h e engine.Hold he engineat 3,000 pm withno oad (i n neutral)until he radiator an comeson ,then et t idle.

Test-drivewith the ransmission n 4thgear.

Accelerateor 5 secondsusingwide open hr ottle.

Check or a TemporaryDT Cwith the scan ool.

Is TemporaryDTC Pl106 indicated?

YES-Update the ECM f it doesnot have he atestsoftware, r substitute known-goodECM. he nrecheck se epage11-6).f the symptom/indicationgoesaway with a known-goodECM, e place heor ig ina l CM.

NO Intermittent ailure,system s OK at his

t ime. I

DTCPl107: ARO ensor i rcuit owVolta

DTCPl108: ARO ensor ircuit ighVoltage


2. Turn he gnitionswitch ON (ll).

l s DTC P1107or P1108nd ica ted?

YES-Update th e ECM f it does not have he iatessoftware,or substitute known-goodECI\4,he n

recheck seepage11-6).f the symptom/indicatiogoesawaywith a known-goodECM, eplace he

or ig ina l CI \4 . I

NO- Intermittent ailure,system s OK at thist r m e . l

11-



PGM-FISystem

DTGTroubleshootingcont'dl

DTCPl157: y'F ensorSensor )Range/Performanceroblem

1. Reset the CIMsee age11-4) .

2. Start he engine.

l s DTC Pl157 ind ica ted?

YES-Go to step3.

NO Intermittent ailure,system s OK at this ime.Check or poorconnections r loose erminalsatthe Ay'F ensor Sensor1 and at the ECN4.I


Disconnecthe Ay'F ensor Sensor1) 4PconnectorandECM onnector (31P) .

ConnectA,/F ensor Sensor1) 4P connectorte rm ina ls o .1 and No.2 w i tha umperwi re .

A/F SENSORSENSOR)4PCONNECTOR

AFS+{BLU)


3.

JUMPERWIRE

11-84

L

6. Checkor continuity etween CM o nnectorterminals6 andA16.

ECMCONNECTOR{3IP)


ls therecontinuity?

YES Go o step9.

NO Go o step7.

Connect /FsensorSensor )4Pconnecrorterminal o .1 o body round i tha umper i re.

A/ F SENSORSENSOR I 4P CONNECTOR

7 .




8. Checkor continuity etween CM onnectorterminals 6 andbodyground.

ECMCONNECTOR 131P}

Wire sideol lemale erminals

ls ther e continuity?

YES-Repair open n the wire between he Ay'F

sensor Sensor1) and he ECM 416).1

NO-Repair open n the wire between he Ay'F

sensor Sensor1) an d he ECM 46).1

Substitute known-goodAy'F ensor Sensor1) an d

recheck.


YES- Update he ECM f it doesnot have he latest


recheck seepage 11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace he

originalECM.

NO- Replacehe Ay'F ensor Sensor1) .

9 .

DTCPl158: y'F ensorSensor )AFSTerminal owVoltage

1. Reset the CMsee age

11-4) .

2. Start he engine.


YES Go o step3.


Check or poorconnections r loose ermanals t

the Ay'F ensor Sensor1) and at the ECIM


4, DisconnecttheAy'F ensor Sensor1) 4PconnectoandECM onnector (31P) .

5. Check or continuitybetweenECMconnector

te rm ina l 16 and bodyground.

ECMCONNECTOR (31P)


YES-Repair shon in the wire between he A,/F

sensor Sensor )and he ECM A16) .1

NO Go o step6.

' con


11



PGM-FISystem


6. Substitute known-goodAy'F ensor Sensor1)andrecheck.

Is DTC P1158nd cated?

YES Update he EC M f it do es not have he latestsoftware, r substitute known-goodECM, he nrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

NO - Replace he Ay'F ensor Sensor1).

DTCPl159:A,/F ensor Sensor )AFS+Terminal owVoltage

1. Reset the CMsee

age11-4) .


ls DTC P1159 nd cated?

YES-Go to step3.

NO-lntermiftent failure.system s OK at this ime.Check or poor connections r loose erminaisatthe A,/F ensor Sensor1)and at the ECM.I


4. Disconnecthe Ay'F ensor Sensor1) 4PconnectorandEcM connector (31P) .

5. Chec k or continuitybetweenECMconnectorterminal46 and body ground.

EC MCONNECTOR {31PI


ls therecontinuity?

YES-Repair hort n hewirebetweenheAy'FsensorSensor)and heECM AO). I

NO Go o step6.



6. Substitute known-goodAy'F ensor Sensor1i and

recnecK.

ls DTC P1159nd ica ted?

YES-Update the ECM f it does not have he atest


recheck seepage 11-6).f the symptom/indicationgoesawaywith a known-goodECN4,eplace he

or ig ina l CM. I

NO Rep laceheAy 'F ensor Sensor ) .1

11-



PGM-FISystem


DTCPl163:Ay'F ensor Sensor SlowResponse

NOTE: fDT CP1162 s storedat the same ime as DTCP1163.roubleshootDT CP1162 irst, hen recheckfor

DTCP1163.


2. Start h e engine.Hold he engineat 3,000 pm withno load (i n neutral)until he radiator an comeson .

3. Test-drive nder he followingconditions:

. 55 mph (89 km/h)steadyspeed' Transmission n sth gear' Until he Ay'F ensor eadiness ode or

TemporaryDT CPl163comeson

4. Check or a TemporaryDT Cwith the scan ool.

ls TemporaryDTC P 1163 ndicated?

YES Replacehe Ay'F ensor Sensor1).I

NO Intermittent ailu e,system s OK at his time.Check or poor connections r loose erminalsatthe A'lF ensor Sensor1 and at the ECM.

DTCPl164: ,/F ensorSensor )CircuitRange/Performanceroblem

1. Reset the CI \4see age1t -4) .

2 . Star t heeng ine .Ho ld theeng ineat3 ,000pmwi thno load(i n neutral)until he radiator an comeson,

3. Test-driven 3r d gear.Startingat 1,600 pm ,accelerate singwide open hrottle or at least5 seconds. hendecelerateor at least5 secondswith the hrottlecompletely loseduntil he A,/Fsensor eadiness ode s set o completeorTemporaryDT CP116 4comes on.

4. Check or a TemporaryDT Cwith the scan ool.

ls TemporaryDTC P1164 ndicated?

YES- Replace he A,,/Fensor Sensor1) .

NO Intermittentailure,system s OK at this time.Check or poorconnections r loose erminalsatthe Ay'F ensor elay,at the Ay'F ensor Sensor1) ,andat he EcM. l



DTCPl166: y'F ensorSensor )HeaterCircuitMalfunct ion


2. Start he engine.


YES-Go to step3.



the Ay'F ensor elay, he A,/F ensor Sensor1) ,an d

theEcM.

3. Check hefollowing use:

. No . 14OPTION 30A)fuse n under-hood use/

rerayDox.. No . 2*B LAF Ay'F) EATER20A) use n under-

dash use/relay ox.. No. 4 ACG(10A) n underdash use/relay ox.

Are any of the fuses blown?

YES Repair hort n the wire between he Ay'F

sensor elayan d he fuses.I

NO Go o step4.

4. Measure oltagebetweenEC Mconnector

terminalsA1 andA24.30 seconds fter he ignit ion

swi tch s u rnedON ( l l ) .

EC MCONNECTOR I31P)

Wi res rde f em a le e rm ina l s

Is therc battery voltage?

YES-Update the ECM f it doesnot have he lates

soflware,or substitute known-goodECM. hen

recheck seepage 11-6). f the symptom/indicatiogoesawaywith a known-goodECM, eplace he

or ig ina l CM. I

NO-Go to step 5.

5. Measure oltagebetweenEC Mconnector

terminalsA22 and A24.

EC MCONNECTOR {31P}


ls therebatteryvoltage?

YES Go o step6.

NO-Go ostep 0.

6. Turn he gnition witchOFF.

7. DisconnectCM onnector (31P).

8. Turn he gni t ionwi tch N l l ) .

(con

11



System


9. ConnectECMconnector erminal EStobodygroundwith a umper wire, hen measure oltagebetweenEC Mconnector erminalsA1 and 424.

ECMCONNECTORS



YES- Update he ECM f it does not have he latestsoflware,or substitute known-goodECM, he nrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM.

NO Repairopen n the wire between he Ay'Fsensor Sensor )andECM A1) .


Disconneclhe ECfM onnectorA (31P) nd he Ay'Fsensor Sensor1) 4P connector.

Check or continuitybetween he Ay'F ensor(Sensor )4Pconnectorerm ina lNo.3 andbodyground.

A/F SENSORSENSOR)4PCONNECTOR

1 0 .

1 1 .

12.

Wire side ot Iemale erminals

t 5 .

14.


YES Repair hort n the wire between he A|/F

sensor elay,A,/F ensor Sensor1) and ECMlA22J.a

NO Go o step 13.


Measure oltagebetweenEC MconnectorterminalsE8and A24.

ECM CONNECTORS

E{3 1P)

a {3 1P)



YES-Repair open n the wire between he ECM(A22)and he IVFsensor Sensor1) .

NO-Go to s tep15.

Check or continuity n the wires between he Ay'Fsensorand he fuses.


YES-The wires are OK.Replace he A,/F ensorre lay . l

NO Repairopen n the wire between he Ay'Fsensor elayand he fuses.l



DTCPl167: y'F ensorSensor )HeaterCircuitMalfunct ion

NOTE: f DTCP1162s storedat the same ime as DTCP1167,roubleshootDT CP1162 irst, hen roubleshoot

DTCP1167.

1 . Reset the CI \4see age11-4)

2. Start he engine.Wait for at east80 seconds.

ls DTC P01167 nd cated?

YES Go o step3.



the Ay'F ensor elay,at the Ay'F ensor Sensor1) ,andat heECM. I


Disconnecthe A,/F ensor4Pconnectorand ECM

connectorA (31P).

Connect he Ay'F ensor Sensor1) 4Pconnector

te rm ina ls o.2 andNo. 1 w i th a umperwi re .

?

5 .

A/F SENSOR SENSOR )4PCONNECTOR

JUMPERWIRE

Wire sideoff em a le e rm ina l s


te rm ina ls46and416.

ECMCONNECTOR {31P)

AFS- {RED)

trTzTil,ils l t 9

t 8 2C21

l?rlzsIelsAF S IRED/YEL)


ls thete ontinuity?

YES-ReplaceheA/F ensorSensor) .1

NO-Repairopen n hewirebetweenheAy'FsensorSensor and heECM 46orA16) . I

11



System

TCTroubleshootingcont'dl

DTCPl297: LDCircuit owVoltage


2. Start he engine.

3 . Turnon he head l igh ts .


YE S Go o step4.

NO Intermittent ailure,system s OK at this ime.Check or poor connections r loose erminalsattheELD nd a t he ECM. I

4. Turn he ignit ionswitch and he headlightsOFF.

5. DisconnecttheELD3P connector.

6. Turn he ignit ionswitchON {ll).

7. Measure oltagebetweenbody groundand ELD3Pconnector erminal No.3.

ELO3P CONNECTOB

{GRN/REDI


ls there bout V?

YE S ReplaceheELD.

NO-Go o step .

Z 3ELD


9. Disconnect CMconnectorE{31P).

10 . Check or continuitybetweenbody groundandECM onnectorerm ina l 15 .

ECMCONNECTOR131PI

I 2 l 3 4 5 6 1 7 8 It o t d / 12021

,2 2al2/ tA 31

ELD(GRN/RED}

7\'


ls therecontinuity?

YES-Repair short n th e wire between he ECM(E 5) nd he ELD.

NO- Update he ECM f it doesnot have he latestsoftware, r substitute known-goodECM, he nrecheck seepage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I



DTCPl298: LDCircuit ighVoltage

1. Resetthe CM see age11-4)

2. Stan he engine.

3. Turn on the headlights.


YES-Go to step4.

NO- Intermittentailure.system s OK at his t ime.


theELD ndat he ECM. I

4. Turn he ignitionswitchand headlightsOFF.

5. DisconnecttheELD3P connector.

6. Turn he ignit ionswitchON (ll).

7. Measure oltagebetweenbody ground and ELD3P

connector erminalNo. 1.

ELD3P CONNECTOR

IG1 BLK/ORNI

Wire sideot {emale erminals


YES-Go to step8.

NO-ChecktheNo.4 ACG 10A) fusen he under -dash use/relay ox. f the fuse s OK, repairopen n

the wire between he No. 4 ACG(10A) use and he

ELD. I

8.

9 .

1 0 .

1 1 .

Turn he gn i t ion wi tchOFF.

ConnectELD3P connector erminalNo. 3 to bodyground

wi th aumperwi re .


Check or continuitybetweenbody groundan d

ECMconnector erminalE15.

ECMCONNECTOR 131PI

1 2 1 3 4 5 o t / I I

1 4 L C 6l / 18 2C2122123 4 21 / 2Q 30 J

EL D

IGRN/RED)i1'


Is thete ontinuity?

YES-Go o step 2.

NO Repair pen n hewirebetweenhe ECM(E15)nd heELD.

(con

EL D3P CONNECTOR

---F-------l 1 l 2 r lEL D(GRN/RED)

IJUMPERrR E

II

Wire sideof temale erminals

11



System


12, Check or continuitybetweenEL D3P connectorte rm ina lNo.2 and bodyground.

ELD3PCONNECTOR



YE S Go o step 13 .

NO- Repairopen n the wire between he ELDan dG 2 0 1 .

Reconnecthe ELD3Pconnectorand ECMconnectorE (31P).

Start he engineand et t idle.

While measuring oltagebetweenECMconnectorte rm ina ls 24 andE15,urn he head l igh tsn

th gh) .

ECMCONNECTORS

Wi.esideof emale erminals

Does the voltage drop?

YES-Update the ECM f it does not have he latestsoftware,or substitute known-goodECM, henrecheck seepage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

NO Replacehe ELD. I

1 4 .

t 5 _



3.

4 .

5.

6.

DTCPl361:Camshaft ositionCMP) ensorB (TDC ensor)ntermittentnterrupt ion

DTCPl362:Camshaft ositionCMP) ensorB (TDC ensor) oSignal


2. Start he engine.

ls DTC P1361and/or P1362 ndicated?

YES Go o step3.

NO- Intermittentailure.system s OK at this ime.


theCMPsensor (TDC ensor ) ndat he ECM. I


DisconnecttheCM PsensorB (TDC ensor)3P

connector.

Turn he gnitionswitchON (ll).

Measure oltagebetweenCM PsensorB (TDC

sensor) P connector erminal No. 3 and bodygrouno.

CM PSENSOR{TDC ENSOR)PCONNECTOR

{YEL/BLK}

Wire ideol emaleerminals


YES Go o step7.

NO-Repair open n the wire between he PGM-Flmain e lay1 and he CMPsensor (TDC ensor ) . I

IG P

1 2 3

7. l\4easureoltagebetweenCM PsensorB {TDCsensor) P connector erminalNo. 1 and bodyground.

CMP S€NSOR 8 ITDCSENSOR)3P CONNECTOR

Wlres de o l lemale termina ls

ls there bout V?

YES-Go o step8.

NO-Go o s tep 0.

8. Measureoltage etween l\ilP ensor (TDC

sensor)P onnectorerminals o. andNo,3.

CMPSENSON lOC SENSOfi) PCONNECTOF

Wire s d e o l fe ma e te fm in a ls


YES-Go to s tep9.

NO Repairopen n the wire between he CMP

sensorB (TDC ensor ) ndG101.1

9. Substitute known-goodCM PsensorB (TDC

sensor) nd recheck.


YES Update he ECM f it doesnot have he late

software,or substitute known-goodECM, henrecheck se epage 11-6).f the symptom/indicatiogoesaway with a known-goodECM, eplace he

or ig ina l CM. I

NO Rep laceheor ig ina lCMPsensorB(TDCsensor ) .1

(cont

11



System


10. Measure oltage etween CI\4onnectorterminalA2 6andbodyground.

EC MCONNECTOR(31P)

1 2 3 4 5 6 1 7 I0 1 11 2 1 . / 61,/18 I 2C2l

2324 21m 30

TD C GRN}

Wire side oI temale erminals

ls thereabout V?

YES Repair pen n hewirebetweenhe ECM(426) nd CMP ensor (TDC ensor).1

NO-Go o s tep 1.

Turn he gnition witchOFF.

DisconnectCI Monnector (31P)

Checkor continuity etween CM onnectorterminal 26andbodyground.

EC MCONNECTOR {31PI



YES Repair hort n the wire between he ECM(426)and he CMPsensorB (TDC ensor).1

NO Update he ECM f it does not have he atestsoftware, r substitute known-goodECM, henrecheck se epage11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace heor ig ina l CM. I

1 1 .

1 2 .

DTCPl607:Malfunct ionn ECM nternalCircuit

1. ResettheEC|\i lsee page11-4).

2 , Turn he gn i t ion w i t chON ( l l ) , ndwai t o r40 seconds.

ls DTC P 1607 ndic ated?

YES Update he ECM f it does not have he atestsoftware, r substitute known-goodECM, henrecheck seepage11 6) . f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

NO Intermittent ailure,system s OK at this t ime.

A low batterycan cause hi s problem Ask hecustomer f there hasbeenan y recent roubles tar t ingheeng ine . l

\



MILCircuitTroubleshooting

1. Connect n OBD l scan ool/HondaPGMTester(see age11-3) .

2. Turn he gnitionswitchON (ll)an d read he OBD lscan ool/HondaPGMTester.

Does the OBD ll scan tool/Honda PGM Tester

communicatewith the ECM?

YES Go o step3.

NO Go o troubleshooting DLCCircuitT roub leshoot ing"see age11-109) .

3. Check he OBD l scan ool/HondaPGMTesterfor

DTCs.

Are any DTCs nd cated?

YES Go o the DT CTroubleshootingndex.

NO-Go to step4.


5 . Turn he gn i t ion w i t chON ( l l )andwatch helMal funct ionnd ica tor amp MlL) .

Does the MIL come on and stay on for more than

20 secondsaftet turning he gnitionswitch

oN(tr)?

YES lf the MIL alwayscomeson and stayson, go

to step76. But f the lMlL ometimesworks

normally, irst check or theseproblems.

. An intermittent hort n th e wire between he

ECIME29) nd he data inkconnectorDLC) .. An intermittent hort n the wire between he

ECM E31) nd hegauge ssembly .

NO lf the MIL s alwaysoff,go to step6. But f thelvllL ometimesworks normally, irst check ortheseproblems.

. A looseNo.10METER7.5A)use n he under

dash use/relay ox.. A looseNo.20 G (40A) Canada:0A) Iusen he

under-hood use/relay ox.. A iooseNo.6 ECU ECM) 15A)use n he under -

hood use/relay ox .

. A looseNo. 17FUEL UMP 15A) fusen he

under-dashuse/relay ox.. A poorconnect ion t ECM ermina l 31 ..

An intermittent pe n n the GRN/ORNwirebetweenheECM E31) nd hegauge ssemb

. An intermittent hort n the wire between he

ECM A21)and he manifoldabsolutepressure(MAP) ensor .

. An intermittent hort n the wire between he

ECI\4A20)and he throttleposil ion TP isensor. An intermittent hort n th e wire between he

ECM E5 ) nd he fuel ank pressure FTP) enso



ls the ow oilpressure ight on?

YES Go o step 10 .

NO-Go to s tep8.

8 . Inspect the o .10 \4ETER7.5A) fusenthe unde

dash use/relay ox.

ls the us e OK ?

YES Go o stepL

NO Repa i r hon n hewi re between o.10

METER7.5A) fusend hegauge ssembly . l so

rep lacethe o .10METER7.5A)use. l

9. Inspect he No.20 G1(40A) Canada: 0A ) use n

the under-hooduse/relay ox.

ls the use OK?

YES Repairopen n the wire between he No. 20

lG (40A) Canadar0A) fuse nd hegauge

assembly. f the wire is OK, est he gnitionswitc

{seepage22 53).

NO Repai r hor t n hewi re be tween o.20 G(40A)Canada: 0A) fuse nd heunder 'dashuse

re lay ox .A lso ep lacehe No.20 G (40Ai(Canada:0A) use. I

(con

11-



System

MILCircuitTroubleshootingcont'dl

1 1 .

Tr y o start heengine.

Does heengine tart?

YES-Go o step 1.

NO-Go o step 4.


Connect CM onnectorerminal 31o bodygroundwith a umperwire.

1 0 .

12 .

EC MCONNECTOR 13lPI

MI L(GRN/ORN}

Wiresideof female erminals

Turn he ignitionswitch ON (ll).

ls the M L on?

YES Update he ECM f it does not have he atestsoftware, r substitute known-goodECM, he nrecheck se epage11-6). f the symptom/indicationgoesawaywith a known-goodECIM,eplace heor ig ina l CM.I

NO-Check for an open n the wire between heECM E31) nd hegauge ssembly . l socheck ora b lownMILbu lb . f hewi resand he bu lbareOK,replace he gaugeassembly.l

Turn he gnltionswitch OFF,

Inspect he No. 6 ECU ECIM)15A) use n th eunder-hood use/relaybox.

ls th e f use OK?

YES-Go to step22 .

NO-Go to s tep16.

't4.

15.

l l 2 l 3 4 5 6 1 7 l 1 8 I4 1 5161,/ 18 2( 2t

2' 23 24 z7l/ 129 31

JUMPERWIRE

t o . Remove he blown No.6 ECU ECfU)154) us efrom the under-hood use/relay ox .

Remove he glove bo x (seepage20-63) nd hePGM'FImain e lay1 .

Check or continuitybetweenbodygroundan dPGM-F l a in e lay1 4Pconnectorerm ina ls o .2and No.4 nd iv idua l l v .

PGM-FIMAIN RELAY4P CONNECTOR

Wrre rde l l em a le e rm rna ls

ls therecontinuity?

YES-Repa i r hor t n hewi re be tweenhe No.6ECU ECl \4)15A) useand he PGM-F l a in e lay .A lso ep laceheNo.6 ECU ECM) 15A)use. l

NO-Go to s tep19.

1 7 .

1 8 .

f V Bv) (wHr/

IABLK)(



19. Disconnect ac hof the components r theconnectors elow,one at a t ime, and check or

continuitybetweenPGM-FImain relay 1 4P


. PGfvl-Fl ain relay2

. EC MconnectorA (31P)

. Each njector2Pconnector

. ldleair control lAC)valve3P connector

. CamshaftPosition CMP) ensorB (Topdeadcenter TDC) ensor) Pconnector

. Crankshaft osit ion CKP) ensor3P connector

PGM-FIMAIN RELAY14PCONNECTOR


YES Go o step20 .

NO - Replacehe component hat made continuity

to body ground go awaywhen disconnected.f theitem s th e ECM,update he ECM f it does not have

th e atestsoftware. r substitute known-goodECM, hen recheck seepage 11-6). f the symptom/indicationgoesaway with a known'goodECM,

rep lacehe or ig ina l CM.

Also replace he No. 6 ECU ECM) 15A) fuse,

Disconnecthe connectors f all hesecomponents.

. PGM-F lmain e lay

. ECM onnector (31P)

.lnjectors. ld lea i rcont ro l lAC)va lve

. CamshaftPosition CMP) ensorB (Topdead

center TDC) ensor). Crankshaft osit ion CKP) ensor

20.


22.

21. Check or continuitybetweenPGM-FImain relay 14Pconnector ermlnalNo. 1 and body ground.

PGM-FIMAIN RELAY1

4P CONNECTOR

ls therecontinuity?

YES Repairshort n the wire between he PGM-

main relay 1 and each tem.Also replace he No. 6

ECU ECM) 15A)use. l

NO-Rep lace hePGM-F lmain e lay1 .Also ep l

the No 6 ECU ECIM)15A) use.

Inspect the o. 17FUEL UI \4P15A) fusen he

under-dash use/relay ox.

ls the tuse OK ?

YES Go o step 34.

NO Go o step23 .

Removehe b lownNo, 17FUELPUMP 15A)use

from the under-dashuse/relay ox.

Disconnect Cfvl onnectorE (31P).

(con

23.

24.

Wire sideof female erminal s

11



25.

MIL CircuitTroubleshootingcont'dl

Check or continuitybetweenEC MconnectorterminalE9and body ground.

ECMCONNECTOR(31P)

Wiresideo{ {emale erminals


YES-Go to step26 .

N O R e p l a c eh eN o . T F U E L P U M P ( 1 5A ) f u s e ,an d update he ECM f it does not have he atest

software.or substitute known-goodECM, he nrecheck seepage11-6). f the symptom/indicationgoesaway with a known-goodECM. eplace heor ig ina l CM. I

26. Remove he PGM-Flmain relay2 (A).

27 . Checkor continuity etween CIVIonnectorterminal gandbodyground.

EC MCONNECTOR 131P)

Wire sideoI Jemale erminals


YES Repair hort n the wire between he No. 17FUELPUMP 15A) fuse nd he ECM E9) , rbetween he No. 17 FUELPUMP (15A) fuse and hePGM-FI a in e lay .A lso ep lacehe No. 17FUEL

PUMP 15A) fuse. l

NO Go o step28 .

Remove he rearseatcushion se epage20-80).

Remove he accesspanel ro m the floor.

Disconnecthe fuel pump 5Pconnector.

\

28.

29.

30 .



31 . Checkor continuity etweenue lpump5PconnectorerminalNo.5 andbodyground.

FUELPUMP5P CONNECTOR


ls therccontinuity?

YES Repair hort n hewirebetweenhe uelpump nd hePGM-Fl a in e lay .Also eplacethENO. 7FUEL UMP15A)USE.T

NO-Go to step32 .

32. Reinstallthe GM-Fl ain elay (A).

33. Checkor continuity etweenue lpump5PconnectorerminalNo.5 an dbodyground.

FUELPUMP5PCONNECTOR

=

Wire side o l lemal€ rermina ls


YES Replacehe PGM-Flmain relay2. Alsorep lacehe No.17FUELPUMP 15A)use. l

NO Check he uel pump, an d replace l ifnecessary. lso replace he No. 17 FUELPUMP(15A) use. !

34. Disconnect CMconnectorE (31P).

35 . Turn he gn i t ion wi rchON {111.

36. Measure oltagebetweenEC MconnectorterminE9 and body ground.

ECfl CON|{CCIORE (3rPt

Wire side o l female ermina ls


YES Go o step37.

NO Repairopen n th e wire between he No. 17FUELPUMP 15A) fuse nd heECM E9) .1

(cont

11 -1



ystem


37. vleasureoltage etween CM/PCMonnectorterminal 7andbody round.

ECM CONNECTOR {31PI

Wireside of female erminals


YES Go o step 42.

NO Go o step38.


Remove he PGM-FImain relay1

38 .

39. {A}

- A

MRLY

40. lv leasure oltagebetweenPGN4-Fl ain relay 1 4Pconnectorerm ina lNo.4 andbodvqround.

PGM-FIMAIN RELAY1ilP CONNECTOR

4 1 .

ls therebattery

voltage?

YES-Go to s tep41.

NO Repairopen n th e wire between he No. 6ECU ECM) 15A)useand he PGfM-F l a in e lay1 .

I

Check or continuitybetweenPGM-FImain relay 14Pconnector erminal No. 3 and ECMconnectorte rm ina l 7 .

PGM.FIMAIN RELAY14P CONNECTOR

\

EC MCONNECTOR 131PI

ls therecontinuity?

YES-Testthe PGM-Flmain relay1 (seepage22-51 . f the relay s OK,update he ECM f it doesno thave he atestsoftware, r substitute known-good ECM, hen recheck seepage11'6). f th esymptom/indication oe saway with a known-goodECM, ep laceheor ig ina l CM. I

NO*Repair open n the wire between he PGM-FImain e lay1 and heECM E7) .1

Wire sideot emale erminals

MRLYRED/YEL)

MRLYRED/YEL)




42.

43.

44.

45.

46.

Reconnect CI\4onnectorE {31P).


Measure oltagebetweenbody ground and ECMconnector erminals42 an d43 individually.



YES Go o step51 .

NO Go o step45 .


RemovehePGM'F lmain e lay1 {A)

, A


EC MCONNECTOR {31PI

49.

50.

48. Measureoltage etween GM-FI ain elay1 4PconnectorerminalNo.2 andbodyground.

PGM.FIMAIN RELAY14PCONNECTOR


YE S Go to step49 .

NO Repa i r pen n he w i rebetweenhe No.6ECU ECM) 15A} fuse nd he PGM-F l a inre lay1


Check or continuitybetweenPGM-Flmain relay 14Pconnector erminalNo. 1 an d ECMconnectorte rm ina ls 2 and43 ind iv idua l l y .

PGM.FI MAIN RELAYilP CONNECTOR


YES Rep lacehe PGM-F l a in e lay1 .1

NO Repairopen n the wire between he PGM-Fmain e lay 1

and he ECM A2,A3) .1

{cont

Wire side of temale erminals

IGPl (YEL/BLK)

Wi res ide f em a le e rm ina l s

11 -



System


51. Measure oltage etween odyground ndECMconnectorerminals 4,A5,423,an d424indiv idual lv .

EC MCONNECTOR131P)PG 2 BLK) PG1 BLKI

Wires ide f em a lee rm ina l s

ls there morc than 1.0 V ?

YES Go o step52 .

NO-Repa i ropen n hewi re(s)ha thadmore han1. 0V betweenG10'land he ECM A4 ,A5, A23,A24l.a

Measure oltagebetweenbody ground an d ECMconnectorerm ina l 21 .

EC MCONNECTOR 131P)


ls there about5 V?

YES-Go to step60 .

NO-Go to s tep53.

53.

54.


Disconnecthe manifoldabsolutepressure MAP)

sensor3P connector.


Measure oltagebetweenbody groundan d EC M

connectorerm ina l 21 .

EC MCONNECTOR {31P)


ls thereabout5 V?

YES Replace he MAP sensor.l

NO Go o step 57.


DisconnectCM onnector (31P) .

55 .

56 .

\

57.

58.



59. Checkor continuitv etween CIMonnectorterminal21andbody round.

ECM CONNECTOR {3,IPI


ls therecontinuity?

YES*Repair short n th e wire between he ECM(421) nd heMAPsensor . l

NO Update he ECM t it does not have he atest

soflware,or substitute known-goodECM, he nrecheck se epage1'l-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig ina l CM.I

Measure oltagebetweenbodyground and ECM

connector erminal420.

EC MCONNECTOR {3TP}

60.

1 1 2 1 3 5 o t / I

1 011112 5 6 / 1189 2t 212' 231?4 ?q Tln 29

vcc2IYEL/BLU)

Wi re ide t emaleermina ls

ls thereabout5 V?

YES-Go to step68.

NO-Go to s tep61.

t t ,

oz,

63.

64 .


Disconnecthe throttleposit ion TP ) ensor3Pconnector.


Measure oltagebetweenbody ground an d EC M

connector erminal420,

EC MCONNECTOR 131P)


ls ther e about5 V?

YES Replace he hr onle body (theTP sensor s

not available eparately).

NO Go o step 65.

Turn he ignit ionswitchoFF.

Disconnect CMconnectorA (31P).

65.

66.

c o n l

11 -



67.

MIL CircuitTroubleshootingcont'd)

Checkor continuity etween CIMonnectorterminal 20 ndbody round.

EC MCONNECTOR (31P)

r l 2 l 3 1 4 o t / 9

10 t1 121,/ ,/ 1516 ta , 9 2A2122 3 241 12526 n

o



YES Repairshon in the wire between he ECN4

{A20)and he TP sensor,or repairshort n the wirebetween he ECM A8)and he knocksensor.

NO Update he ECM f it does not have he atest

software.or substitute known-goodECM, henrecheck se epage l1-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. t

vcc2{YEL/BLU}

68. Measure oltagebetweenbody groundand ECMconnectorerm ina l 5 .

ECMCONNECTOR(31PI

Is thereabout5 V?

YES Update he ECM f it doesnot have he latest

software,or substitute known-goodECM, henrecheck se epage11-6).f the symptom/indicationgoesaway with a known-goodEClvl, eplace heor ig ina l CM. t

NO-Go to step69 .


Disconnecthe fuel ank pressure FTP) ensor3Pconnector.


69 .

7 0 .

1 1 .




13.

7 4 .

7 5 .

72. Measureoltage etween odyground ndECMconnectorerminal 5.

EC MCONNECTOR 131P}

ls there about5 V?

YES Replacehe FTP ensor.t

NO Go o step73 .


Disconnect CMconnectorE (3'lP).

Check or continuitybetweenECMconnectorte rm ina l 5andbodyground.

ECMCONNECTOR{31PI

Is there continuity?

YES Repairshort n th e wire between he ECM(E5) nd he FTP ensor . l

NO Update he ECM f it does not have he latestsoftware,or substitute known-goodECM, henrecheck seepage 11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I



76.

77 .

78.

79.

80.



Measure oltagebetweenECMconnector erminaE29 nd bodyground.

ECMCONNECTOR(31P)

r l 2 l 3 1 4 6 1 8 9

,/1,/1145 6 2A2122 23241 l,/ 2930

scstBRN)


ls there about5 V (or battery voltage)?

YES-Go to step82 .

NO Go o step79 .



(cont'

11-1



DLCCircuitTroubleshooting

lf th e EC Mdoes not communicatewith the OBD l scantool, HondaPGfM ester,or l/M test equipment,do thistroubleshooting rocedure.

1. Measure oltagebetweenDLC erminal No. 16an dbody ground.

DATALINKCONNECTORDLCI

(WHT/RED)

Terminalid eof emaleerminals

ls therc battery voltage?

YES-Go to step2.

NO-Repair open n th e wire betweenDLC erminalNo.16and heNo.9 BACKUP 7.5 ) use n heunder-hood use/relay ox.

Measure oltagebetweenDL C erminalsNo. 4 an dNo.16.

DATA LINK CONNECTORDLCI

Terminal ide fJemaleerminals

Is there battery voltage?

YES Go to step3.

NO Repairopen n the wire betweenDLC erminalNo.4 and bodyground. l

4 .

5 .

3. Measure oltagebetweenDLC erminalsNo. 5 andNo. 16 .

DATALINKCONNECTORDLC)

Terminalsideof female erminals


YES Go o step 4.

NO - Repairopen n the wire betweenDLC erminNo.5 and he ECM E3) .

Turn he gn i t ion w i t chON { l l ) .

Measure o l tage e tweenDLC ermina ls o .5 anN o . 7 .

DATALINKCONNECTORDLCI

Termina lide f emaleermina ls

ls there 8.5 V or more?

YES Go o step 10.

NO Go o step6.


(cont'

11 -1



System

DLCCircuitTroubleshootingcont'dl

7. Disconnect Clvl onnectorE (31P).Makesure he

OBD lscan oo lor HondaPGMTestersdisconnectedrom the DLC.

8. Check or continuitybetweenDLC erminal No. 7

andbodyground.

DATALINK CONNECTORDLC)

Ierminal sideof female erminals


YES-Repair short o ground n the wire between

DLC erminalNo. 7 and he ECM E23). fterrepa i r inghewi re ,check he DTCwi th he OBD l

scan ool/HondaPG MTester,an dgo to the DTCTroubleshootingndex.

NO Go o step9.

Check or continuitybetweenDLC erminalNo. 7andECM ermina lE23,

EC MCONNECTOR {31PI

Terminal ide of female erminals

9.

K-LINE LTBLU)

DATA LINK CONNECTOR

10 .

1I.

t J .


YES Update he ECM f it does not have he latest

software, r substitute known-goodECM, he nrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CI \4 . I

NO Repairopen n the wire betweenDLC erminalNo.7 and he ECM E23) . f te r epa i r inghewi re ,check he DTCwith the OBD l scan ool/Honda

PG \4Tester,an d go to the DTCTroubleshootingIndex. l


Disconnect CI\4 onnectorE (31P).\4ake ur e he

OBD l scan oo lor HondaPGMTester sdisconnectedrom the DLC.


Measure oltagebetweenDLC erminalsNo .5 an d

N o . 7 .

DATALINKCONNECTORDLC}


Is there 0 V?

YES Update he ECM f it doesnot have he latestsoftware, r substitute known-goodECI\4,he n

recheck seepage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

NO Repair hort o power n the wire between heDLC ermina lNo.7 and he ECM E23) . f terrepairing he wire, check he DTCwith the OBD l

scan ool/HondaPGMTester,an dgo to the DTC

Troub leshoot ingndex.

t



InjectorReplacement

Relieveue lpressuresee age1 -144).

Disconnectheconnectorsro m he njectorsA) , isconnectheground able B) , nd emovehebracketC) .

(2.2kgf.m, l6 lbf.ftl

ffi\t\*\

3. Disconnecthe quick-connectitt ings D).

4 . Removethefue la i lmount ingnuts(E)romthefue l a i l F ) then emovethefue l a i land n jec tors san assembl

5. Remove he njectorclip (G)from th e injector.

6. Remove he njector rom th e fuel rail.

(cont'd

11-1

1 .

2 .

o



ystem

InjectorReplacementcont'd)

7. Coat thenewo-r ings(A)wi thc leaneng ineo l l ,and inser t the in jec tors(B)n to the fue l a i l C) .

8 , lns ta l lhe n jec tor l i p D) .

9. Coat he injectoro-rings E)withcleanengineoil.

10 . Ins ta l l t hen jec torsn to the fue l a i l , hen ns ta l l he ue l a i l n to the in takemani fo ld (G) .

1 1. Install he fuel rail mounting nuts,groundcable.and bracket.

12. Connect he connectors o the njectors.

13. Connect he quick-connectitt ings.

14 .Turn the gn i t ion wi tchON ( l l ) , u tdo no topera te the tar te r . f t e r the fue l ump uns or about seconds,hefuel pressure n the fuel l ine rises.Repeat his wo or three imes. hencheck or fuel eakage.

\



A/F SensorReplacement


O2 sensorwrench,Snap-onYA8875.SPTools93750or equ iva len t ,ommerc ia l l y va i labre

1. Disconnecthe A,/F ensor4P connector A) , he nremove he A,/F ensor B).

\I

ffiB44N.m

Installthe V F sensor n th e reverse rder ofremoval.

SecondaryHO2SReplacement

Special Tools Fequired02 sensorwrench,Snap-onYA8875,SPTools93750or equ iva len t ,ommerc ia l lVva i lab le

1. Disconnecthe secondaryHO2S4Pconnector A) ,

then remove he secondaryH02S (B).

InstallthesecondaryHO2S n the reverseorder ofremoval.

2 .

1 1 - 1



PGM-FlSystem

ECTSensorReplacement

' 1 .Removehe a i rc leanersee age11-162) .

2. Disconnecthe ECT ensor2P connector.

3. Remove he ECT ensor A).

{1.2 gt m.8.7 bt. f t}

reverse order of removalnsta l l t he ensorn hewith a new o-ring B) .

11-114

CMPSensorB (TDCSensorl

' t .

2.

Replacement

Removehe a i rc leanersee age11-162) .

Disconnecthe CN4P ensorB (TDC ensor) Pconneclor.

Remove he CMPsensorB (TDC ensor) A) .

----r, ".- ,',',.,nr...8.7 bf.ftl

lnstallthesensor n th e reverse rderof removalwith a new o-ring B).

4 .



IATSensorReplacement

1, Dlsconnecthe IATsensor2P connector.

2. Remove he clip (A) and he IA Tsensor B) .

3. lnstallthesensor n the reverse rderof removal.

KnockSensorReplacement

1. Remove he ntakemanifold bracket A) .

2.

3.

4 .

2 4 N m(2.4 gt.m,17 bt.ftl

Disconnecthe knocksensor1Pconnector.

Removehe knock ensor B) .

Installthesensor n th e reverseorder of removal.

1 1 -



GKPSensorReplacement

1. DisconnectheCKP ensor Pconnector.

2. RemoveheCKP ensor A).

12 N.m (1.2 gt m.8.7 tbf.ftl

3. lns tall he sensor n the reverse rder of removal

with a new o-ring B) .



VTEC/VTC


VTCOILCONTROLSOLENOIDALVETroubleshooting,ag e 1-118Test,page1-'l27

- g l

: 1

ia i- r-:@'-;';'l--i

-lt ..,,

- t l

€)

, . .

' -t t

/

. -''--'-

CAMSHAFTPOSITIONICMPISENSORTroubleshooting, ag e11-121Replacement, ag e '!-128

VTCSOLENOIDALVETroubleshooting,ag e 1-123Removal/lnspection,ag e 1-128

11-1



DTGTroubleshooting

DTCP0010:WC Oil ControlSolenoid alveMalfunct ion

1. Reset theCM

see age11-4) .

2. Start he engine.Hold he engineat 3,000 pm withno load(i n neutral)until he radiator an comeson,then e t t i d le .

3. Test-drive t a steadyspeedbetween20-40mph(30-60 m/h) or 10 minutes.


YE S Go o step 4.

NO - Intermittent ailure,system s OK at this ime.

Check or poor connections r loose erminalsatthe VTCoil controlsolenoidvalveand at th eE C M . I


5. Disconnecthe ECMconnectorB {24P).

6. Measure esistance etweenECrU onnectorte rm ina ls 1and 823.

ECMCONNECTOR I24P)


ls there 6.75 8.25 Q ?

YES Go o step 11.

NO Go to step7.

7. Disconnecthe VT Coil controlsolenoidvalve2Pconnector.

8. Measure esistance etweenVT Coil controlso leno id a lve2P ermina ls o .1 and No.2 .

VTC OIL CONTAOLSOLENOIDVAI"VE2P CONNECTOB

Terminasid6otmate ermina

ls there6.75 8.25 Q ?

YES-Go to stepL

NO-Replace th e VTCoil controlsolenoid alve(seepage11-1271.a

9. Connect TCoi l cont ro l o leno idva lve2Pconnector erminalsNo. 1 and No. 2 to bodygroundwi th a umperwi re nd iv idua l l y .

wc otl coNTBoLotENotoVALVE 2P CONNECTOR

-4-t 1 t 2 l

wc I lwc*tBr-K/wHT) | liELU/WHT)

JUMPERTREI IJUMPEnW|RE

Wiresideof16male e.minats

10 . Check or continuitybetweenECMconnectorte rm ina ls 1and 823andbodyground nd iv idua l l y .


YES Go o s tep11.

NO- Repairopen n the wire between he ECM B1,B23)an d he VTCoi l controlsolenoid alve.I

\




te rm ina ls 1andB23andbodyground nd iv idua l l y .

VTC(BtK/WHT)


YES Go o step 12.

NO Update he ECM f it doesnot have he latest


recheck seepage11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace he

originalEClvl.

Disconnecthe VT Coil controlsolenoidvalve 2P

connector.

Check or continuitybetweenEC Mconnector

te rm ina ls 1and823andbodyground nd iv idua l l y .

12.

1 3 .

vfc(8LK/WHT)

Wires ideof female ermina

ls therecontinuity?

YES-Repa i r hor t n hewi re be tweenhe ECM B1,

B23)and he VTCoil controlsolenoidvalve.l

NO Replacehe VT Coil controlsolenoidvalve(seepage 11-1211.a

4 .

DTCP0011: TCSystemMalfunction

1. Reset he EClvl se epage 11-4).

2 . Star t heeng ine .Ho ld heeng ine t 3 ,000 pmwi t

no oad inneut ra l ) n t i l he rad ia toran comes n

3. Test- drive t a steadyspeedbetween20 40 mph(3 0 60 km/h) or 10 minutes.

Check or TemporaryDTCP0011with the scan oo

ls Tempotaty DTC P0011 ndicated?

YES-Go to step5.

NO- Intermittentailu e,system s OK at his time

Check or poorconnections r loosewires at th eVTCoi lcont ro l o leno id a lveandat heECM. I

Watch he lo w oi l pressure ight with the engine

runn ng.

ls the ow oil pressute ight on?

YES- Check he oil pressure seepage8-4).I

NO-Go to s tep6.


Remove he auto-tensionerse epage4-28).

6 .

7 .

(con

1 1 -




Remove he VTCstrainer A) .Check he WCst ra ineror c logg ing .

ls the strainet OK ?

YES Go to step g.

NO-Clean the VTCstrainer, hen replace heeng ine i l i l t e r nd he eng ine i l . l

9. Check he VTCoil controlsolenoidvalve seepage11-127.

ls the VTC oilcontrol solenoidvalve OK ?

YES Go to step 10.

NO Clean he portsof the WC oil controlsolenoidvalve,or replace he VTCoil controlsolenoidvalve{seepage 11-127).a

InstalltheVTCoi l controlsolenoid alve.

Start he engine.Hold he engineat 700 1,000 pm.

12. Connect CMconnectorerm ina lB23tobodvgroundwi th a umperwi re .

EC MCONNECTOR {24PI

1 0 .

1 1 .

2 1 3 4 1 5 6 78 e 1a/1,/ 151 181./l l./ 21 23

vTc(BLK/WHT}

JUMPERWIRE


13 . ConnectEC Mconnector erminalsA3 and 81 withajumperwi remomentar i l y .

NOTE:Do not ump for more han 1 minute,

ECM CONNECTORS

Did the engine stall or run rough?

YE S Test-drive t a steadyspeedbetween20 40 mph (3 0 60 km/h) or 10 minutes.lf temporaryDT CP00'l s ndicated, pdate heECIVIf it does not have he latest oftware, rsubstitute known-goodECM, hen recheck seepage11-6).f the symptom/indication oe sawaywith a known-goodECM, eplace he originalECM.

NO Go o step 14.

Check he VTCactuator se epage6,8).

ls the VTC actuatotOK ?

YES Remove he auto-tensionersee page4-281,and cleanor replace he VTCoil strainer.Updatethe ECI\4f it does not have he latest oftware, rsubstitute known-goodECM, hen recheck se epage 11-6).f the symptom/indication oe sawaywith a known-goodECM, eplace he originalECM.T

NO Replacehe VTCactuator.t

\

1 4 .




DTCP0340: MPSensor No Signal

DTGP0344: MPSensor Intermittent

Interruption

1. ResetheECM see age 11-4) .

2. Start he engine.


YES-Go to step3.

NO Intermittentailure,system s OK at this ime.


the CMPsensor andat heECM. I


4. Disconnecthe CMPsensorA 3P connector.

5 . Turn he gn i t ion w i tchON ( l l ) .

6. Measure oltagebetweenCM PsensorA 3P


CM PSENSOR 3P CONNECTOR

(BLK/YEL}



YES Go o step7.

NO Checkhe No.4 ACG 10A)use n he under -dash use/relay ox. f the fuse s OK ,repairopen n

the wire between he CN4P ensorA and No. 4 ACG(10A)use. I

tG1

1 2 3

7. Measureoltage etween MP ensor 3PconnectorerminalNo .1 andbodyground.

CMP SENSORA 3P CONNECTOR

Wires ideo l female ermina

ls thercabout V?

YES-Go o step8.

NO-Go to step10.

8. Measureoltage etween MP ensor 3Pconnectorerminals o.2 andNo. .

CMP SENSORA 3P CONNECTOF

;f-;-1 ,o, r.*,"r.,I l1 J l - t

,-or---T--I{8RN/YEL)ni-


YES Go o step9.

NO-Repair open n the wire between he Cl\4P

s e n s o r a n dG 1 0 1 . 1

9. Substitute known-goodCMPsensorA and

recheck.

ls DTC P0340and/ot P0344 ndicated?

YES Update he ECM f it does not have he late

software,or substitute known-goodECM, hen

recheck se epage11-6).f the symptom/indicatiogoesawaywith a known-goodECM, e place he

or ig ina l CM. I

NO Replacehe or ig ina l MPsensor {see ag

1 1 - 1 2 8 ) . t

(cont

11-1



10 .


Measure oltagebetweenEC Mconnector erminalA25 and body ground.

ECMCONNECTOR 131P)

Wire ideof emalee.minals

ls there about 5 V?

YES-Repair open n the wire between he EC M(A25) ndCMP ensor . I

NO-Go to s tep11.



Check or continuitybetweenEC MconnecrorterminalA25 and body ground.

ECMCONNECTON 131P}

Wiresideof emaleterminals

ls tnere continuity?

YES-Repair short n th e wire between he ECM(A25)and he CMPsensorA.

NO Update he ECt\4f it do es not have he latestsoftware,or substitute known-goodECM, he nrecheck se epage 11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

1 1 .

' t2.

DTCP0341:WC PhaseGap


2. Start he engine.


YES Go o step3.

NO Intermittentailure,system s OK at this time.Check or poorconnections r loose erminalsattheCMPsensor andat he ECM. I

3. Check he VTCoi l controlsolenoid alve(seepage11_127]-.

Isthe VT C oil controlsolenoidvalve OK ?

YES-Go to step 4.

NO-CIean the VTCoil controlsolenoid alve,orrep lacet (see age11- ' l27 l .a

4. Remove he headcover,and check he cam chain{seepage6-12).

ls the camchain OK?

YES Go to slep 5.

NO Rep lacehecamcha in see age6-12) .1

5. Check he VTCactuator seepage6-8).

ls the VTC actuatorOK ?

YES- Update he EC M f it does not have he tatestsoflware,or substitute known-goodECI\4,he nrecheck se epage11-6).f the symptom/indicationgoesawaywith a known-goodECM, eplace heor ig ina l CM.I

NO- Replacehe VTCactuator.l



DTCPl259:WEC SystemMalfunction

SpecialToolsRequired.

Pressure augeadapter07NAJ P07010A. A/ T ow pressure augew/panel07406-0070300. A/ T pressure os e07406-0020201. Av/T ressure ose,2,210mm 07IMAJ-PY4o11A. l"/T pressure dapter07MAJ-PY40120. Oi l pressure os e07ZAJ-S54,4200


2 . Checkheeng ine i l eve l , nd e f i l l f necessary .


no load{in neutral)until he radiator an comeson .

4. Road estthe vehicle:Acceleraten the 1s tgear o an enginespeedover

4.000 pm. Hold he speed or at least2 seconds.f

DT CP1259 s not repeated uring he first road est,

repeat he est wo more imes.


YES Go o step5.

NO-lntermittent failure,system s OK at his t ime

Check he oi l consumption f oil was added n step

2. Check or poorconnections r loose erminalsat

th e VTEC olenoid alve, he VTECoi l pressure

switch,an d at he ECI\4.

5, Turn he gnitjonswitchOFF.

6. Disconnecthe VTECoil pressureswitch P

connector.

7. Checkor

continuitybetweenVTECoi l pressure

switch2P connector erminalsNo . 1 and No. 2

VTECOIL PRESSUREWITCH2PCONNECTOR

Term ina l i deo f m a le e rm ina l s

Is there ontinuity?

YES-Go o step8.

NO ReplaceheVTEC il pressurewitch.l

8 . Turn he gni t ionwi tch N l l ) .

9. Measureoltage etween TE C il pressurewit

2PconnectorerminalNo.1 andbodyground


YES Go o s teP14.

NO-Go to step 10.

(con

VTECOILPRESSUREWITCH2PCONNECTOR

VTPSW/T\ {BLU/BLK}

{.--r -l'--.l\rJ I

I

oI

Wires ide f em a le e rm ina l s

11-




10 . Measure oltagebetweenEC Mconnectorterminal89 and body ground.

ECMCONNECTOR (24P)

2 1 3 4 1 5 o 1

8 I at / t /n3 15

WPSW {BLU/BLK}



YES Repairopen n the wire between he VTECoilpressure witch and he ECM 89).t

NO-Go to s tep11.


Disconnect CMconnectorB {24P).

Check or continuitybetweenEC Mconnectorte rm ina l gand bodyground.

ECMCONNECTOR {24P)

2 3 4 1 5 6 7

I 9 ol./ ./ 13 15

VTPSWBLU/BLK}

Wrre side of female erminals


YES Repairshort n the wire between he VTECoi lpressure witch and he ECM 89).I

NO Update he ECM f it does not have he latestsoftware.or substitute known-goodECM, henrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CN4.

1 1 .

2PCONNECTOR

VTPSW(BLU/BLK)

14. fMeasureoltage etween TEC ilpressurewitch2P onnectorerminals o.1andNo. ,

VTECOILPRESSUREWITCH

(BRN/YELI

Wire sideof Iemale erminals


YES-Go to s tep15.

NO Repairopen n the wire between he VTEC ilp ressure wi tch ndG101.1


Disconnecthe VTEC olenoid alve 2Pconnector.

Check or resistance etweenVTEC olenoid alve2Pconnectorerm ina ls o , 1 and No.2.

VTECSOLENOID ALVE2PCONNECTOR

Termina lide f ma leermina ls

ls there 14- 30 Sl?

YES Go o step 18.

NO Replace he VTEC olenoidvalve(seepage

1 1 - 1 2 8 ) . t

t o .

1 7 .



18 .Remove he VTECoil pressure witch(A )an d

ins ta l l t he pec ia l too lssshown, hen e ins ta l lhe

VTECoi l pressure witch.

07406-0070300

\lslt:={

R

07406-0020201t07MAJ-PY,lo11And07MAJ-PY40120

A22N. ml2.2kgt.m,16 bf.ft)

19 .

20 .

21.

22.

07NAJ-P07010A

Reconnecthe VTEC olenoidvalve 2Pconnector

and VTECoi l pressure witch2P connector.

Connect tachometer r OBD l scan ool/Honda

PG MTester o the DLC.

Start he engine.Hold he engineat 3,000 pm with

no load (in neutral)until he radiator an comeson .

Checktheoil pressure t enginespeedsof 1,000

an d 2.000 pm. Keep he measuring ime as shon

asposs ib lelesshan1 minute) ecauseheeng ine

is runn ing i th no oad.

ls the oil ptessure below 49 kPa (0.5 kgf/cnf,

7 psi)?

YES Go o step23 .

NO Inspect he VTEC olenoid alve (seepage11-'t28l.a

23.

24.

25.

26.


Disconnecthe VTEC olenoidvalve 2Pconnecto

Aftach he batterypositive erminalto VTEC

so leno id a lve2Pconnectorerm ina lNo.2 .

Start he engine, hen connect he batterynegativ

te rm ina l toVTEC oleno id a lve2Pconnector

te rm ina lNo.1 ,andcheck he o i l p ressure t an

enginespeedof 3,000 pm.

ls the oil pressure above 390 kPa (4.0 kgt/crtf ,57 ps i )?

YES Go o step27 .

NO InspecttheVTEC olenoid alve (seepage 112Al.a

27. With the battery erminalssti l lconnectedtothe

VTEC olenoid alve connector,measure oltage

betweenEC Mconnector erminal89 and bodv

oround.

ECMCONNECTOR {24P)

ls therebattery voltageabove4,000 pm ?

YES Go o step28 .

NO-Replace the VTECoil pressure witch(see

page11 '128) .1


Disconnecthe battery erminals rom the VTEC

solenoidvalve erminalconnector.

(con

28.

29 .


11-1



30 .


Disconnect CMconnector B (24P)

Check or continuitybetweenEC Mconnector

te rm ina l 15and bodyground.ECM CONNECTORB {24P)


ls there ontinuity?

YES-Repair hort n hewirebetweenheVTECsolenoidalve nd heECM 815) .1

NO Go o step32 .

32. ConnectVTEC olenoid alve 2PconnectorterminalNo .2 to body groundwith a umper wire.

VTEC SOLENOIDVALVL2P CONNECTOR

r-.'-r.---.1

t 1 t 2 l+

JUMPER VtSWIRE I IGRN/YEL)

I


Check or continuitybetweenEC Mconnectorte rm ina l 15andbodyground.

ECM CONNECTOR {24PI



YES Update he ECM f it does not have he atestsoftware,or substitute known-goodECM, he nrecheck se epage11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

NO Repairopen n the wire between he VTECsoleno id a lveand he ECM 815) . I



WC OilControlSolenoid alveRemoval/Test

1. RemoveheWC oi lcont ro l o leno id a lve A) .

NOTE: nstall he valve n th e reverseorder of

removalwith a new o-ring B) , hen check hesetlems:

Cleanand dry the VTCoil controlsolenoidvalve

matingsurface.

Coat he O-ringwith engineoil.Do not nstall he VTCoilcontrol solenoid alve

while wearing ibrousgloves,

Be carefulnot o contaminate he cylinderhead

openrng.

Check he VTCoil controlsolenoid alve ilter or

clogging. f it is clogged, eplace heVT C

oi lcontrol

solenoid alve.

Check he clearance etween he port (advance

side)an d he valve.The clearance A)should be at

least .8mm (1/8 n. ) .

Connect he batterypositive erminal o VTCoi l

controlsolenoidvalve 2Pconnector erminalNo. 2

VTCOIL CONTROL OLENOIDVALVE PCONNECTOR

Terminal ideoJm a le e rm ina l s

Connect he batterynegative erminal o VTCoi lcont ro l o leno id a lve2Pconnectorerm ina lNo.

thenmake ure heva lve A)opens u l l y .

BATTERY

11-1



1 .

CMPSensorA Replacement

Removehe a i rc leaner see age11-162) .

Disconnecthe CMPsensorA 3P connector.

Remove he CMPsensorA (A).

Installthesensor n th e reverse rder of removalwith a ne w o-ring B) .

B-'-----'-l:,",14*

WEC SolenoidValveRemoval/Inspection

1 . Disconnecthe VTEC olenoid alve 2Pconnector.

Measure esistance etweenVTEC olenoid alveconnectorermina ls o .1 andNo.2 .

Resistance:14-30 Q

3. lf the resistances within specif ications,emove heVTEC olenoid alveassemblv A)from th e

cylinderhead,an dcheck he VTEC olenoidvalvef i l t e r B) fo rc logg ing .f t sc logged,ep lacehesolenoid alve i lter, he engineoilf i l ter, and heeng ine i l .

6 x 1 . 0 m m9. 8N. m (1.0 gf.m,7,2 bf. f t l

L



ldleGontrolSystem


TE'

IDLEAIRCONTROLIAC)VALVETroubleshooting,ag e 1-'131

11-1



ControlSystem

DTCTroubleshooting

DTCP0505:dleControlSystemMalfunction

NOTE: f DTCP1519s storedatthe same ime as DTC

P0505,roubleshootDT CP1519 irst, hen recheck orDT CP0505.

1. Start he engine.Hold he engineat 3,000 pm withno load (in neutral)until he radiator an comeson ,then let t idle,

2. Checktheenginespeedat idlewith no,load

conditions: eadlights, lower an, reardefogger,radiator an, and air condit ioner ff.

Is the engine running at 750t50 rpm?

YES Intermittentailure,system s OKat this

t rme. I

NO lf the idle speed s less han 700 rpm, go tostep3; f it 's800 rpm or higher,go to s tep 4.

3 . D isconnecthe d leai rcon t ro l lAC) a lve3P

connector.

Does the engine speed increase or fluctuate?

YES- Check he idlespeed se epage11-138).f theidlewill not adjustproperly, lean he passage nth e thrott le body,and hen adjust he idle.

NO- Rep lacehe AC a lve . I

4. Turn he gnitionswitch OFF.

5. Remove he intakeair duct rom the hrott lebody.

6. Star t he engine,and et t idle.

7 . Pu t our ingers n he owerpon (A) n the thro t t leoooy.

Does he enginestall?

YES Checkthed lespeed see age11-138) .f i t ' s

out of specif ication,eplace he IACvalve.l

NO With the thrott levalvecompletely losed,

check o r vacuum eaks, nd epa i r s necessary . l



DTCPl519: ACValveCircuitMalfunction


2. Turn he ignit ionswitchON (ll)

ls DTC P 1519 ndicated?

YES Go o step3.



th e IA Cvalve and at the ECM.I

3. Turn he gnit ionswitchOFF.

4. Disconnecthe IA Cvalve 3Pconnector.

5. Turn he ignit ionswitch ON (ll).

6. Measure oltagebetlveen ACvalve 3P connector

terminalNo. 2 and body ground.

IAC VALVE3P CONNECTOR

IG P YEL/BLK)


ls therebatteryvoltage?

YES Go o step7.

NO-Repairopen n hewirebetweenhe AC alveand hePGM-Fl a in e lay .1


1 2 3

7 .

8, Check or continuitybetweenbody groundand IA

va lve3Pconnectorermina lNo. 1 .

IACVALVE PCONNECTOR

1 2 3

PG 1 BLK}

a.

Wire sideof lemale erminals

Is therecontinuity?

YES-Go to s tep9.

NO Repairopen n th e wire between he IACval

a n dG ' 1 0 1 . 1



ECM onnectorermina l 12 .

ECM CONNECTOR 131P)

r 2 l 3 l 4 6 1 7 sr0 1l 12 / / 115 6 ./118192C21

da 25126 l27ln2930

IACV BLK/RED}

1,)

Wire ideoJ emaleerminals


YES-Repair short n the wire between he IA C

va lveand he ECM A12) .1

NO Go o s tep11.

9 .

1 0 .

L C O n

1 1 -



ldleControlSystem


11. ConnectAC alve PconnectorerminalNo.3 obodygroundwitha umperwire.

IACVALVE PCONN€CTOR

IACVBLK/REO}

JUMPERWIRE


Check or continuitybetweenEC Mconnectorte rmina lA l2andbodyground.

ECMCONNECTOR 131P)


ls there ontinuity?

YE S Go o step13.

NO-Repairopen n hewirebetweenhe AC alveand heEcM A12) . r

Reconnecthe AC alve Pconnector.


1 3 .

1 4 .

11-132

15. Measure oltagebetweenbody groundan d ECM

connectorermina l 12 .

ECMCONNECTOR 131P}

r l 2 l 3 1 4 6 1 7 9t 0 1t l12l, /l / t c 6 ,/ 118 2C2122 231?4l|2. zil28 30

IACV BLK/RED)

Wire side ol female erminals

Is there battery voltage?

YES-Update the ECI\4f it does not have he atestsoftware,or substitute known-goodECM, hen

recheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l C I \4 .1

NO-Rep lace he AC a lve . I!



A/G SignalCircuitTroubleshooting


Momentarily onnectECMconnector erminals42 4and E18with a umper wire several imes.

1 .

2 .

5.


ls there a clicking noise I rom the NC compressor

clutch?

YES Go o step3.

NO-Go to step6.

Sta t the engine.

Turn he blower switchON .

Turn he Ay'C witchON .

Does the NC operate?

YES-The a i rcond i t ion ingigna l s OK. I

NO Update he ECM f it does not have he latest

software, r substitute known-goodECM. hen

recheck se epage 11-6).f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig ina l CM. l

6. Momentarilyconnectunder-hood use/relay ox

14 Pconnector erminalNo. 10 o body groundwit

a umper wire several imes.

UNDER.HOODUSE/RELAYOXI4P CONNECTOR

1 2 3 5 6

1 8 9 1011 I J 1 4ACC (RED)

JUMPERWIRE


ls there a clicking noise f rom the NC compresso

clutch?

YES- Repairopen n the wire between he ECM(E'18) nd he Ay'C lutch elay.l

NO - Check he A/C system or othersymptoms.l

11 -1



GontrolSystem

' t .

AlternatorFRSignalCircuitTroubleshooting

Disconnecthe alternator Pconnector ro m th e

alternalor.

Turn he gn i t ion wi t chON { l l ) .

Measure oltagebetweenECMconnector

te rmina ls 24 and813.

ECM CONNECTORS

2.

3.

A 31Pl

1 2 1 3 4 5 611 1. , ' I1011112,/ 5 6 , / r8119l2C1

23124 28129130L (BRN/YEL)

ALTF(WHT

2 1 3 4 t 5 6 1

8 9ltal , / l / 15


ls there about5 V?

YES Go o step 4.

NO-Go to s tep13.


5. Reconnecthe alternator Pconnector.

6. Slan the engine.Hold he engineat 3,000 pm with

no oad (in neutral)until he radiator an comeson ,then e t t idle.

7. lvleasure oltagebetweenECMconnector

te rmina ls 24andB13.

Does the voltage decrease when the headlights

and rear window defogger arc tutned on?

YES Thea l te rna tor R igna l s OK. l

NO-Go to s tep8.


9. Disconnect CMconnectorB (24P).

10. Disconnecthe alternator Pconnector.

/REDI

'11.Connect lternator Pco nnecto term nal No.4 to

body groundwith a umper wire.

ALTERNATOR PCONNECTOR

1 2ALTF

3 4IWHT/RED)

JUMPERWIRE

12 .


Check or continuitybetweenbodygroundan d

EClvl onnector erminal813.

ECMCONNECTOB(24PI


ls therecontinuity?

YES-Testthe alternator seepage4-22).1

NO Repairopen n th e wire between he ECM(B13) nd hea l te rna tor . l



\

1 3 .

't4.



15. Check or continuitybetweenbody groundan d

ECIM onnec tor erminal 813.

ECM CONNECTOR I24P}


ls therecontinuity?

YES Repair hort n the wire between he ECM(813) nd he a l te rna to r . l



recheck se epage11-6). f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig ina l CM. I

ElectricalPowerSteering EPSI

SignalCircuitTroubleshooting

Turn he gn i t ion wi t chON ( l l ) .

l\4easureoltagebetweenECMconnector

te rmina ls 24 and E16.

1 .

2 .

3.

4.

5.



YES Go o step6.

NO Go o step3.

Start he engine.

Turn he steeringwheel o the full lockposit ion.

l\4easureoltagebetweenECMconnector

te rmina ls 24andE16.

ls theremomentatybattery voltage?

YES TheEPS igna l s OK. t

NO Go o s tep10.

6 . Turn he gn i t ion w i t chOFF.

7. Disconnecthe EP S ontrol unit 20Pconnector.


(cont

11 -1



ControlSystem

ElectricalPowerSteering EPSISignalCircuitTroubleshootingcont'd)

9. Measureoltage etween PS ontrol nitterminalNo. l7 ndbody round.

EPSCONTROL NIT2OPCONNECTOR



YES-Substitute a known-goodEPS ontrolunit

and echeck. I

NO- Repairopen n th e wire between he ECM(E 6) nd heEPS ont ro l n i t . l


Disconnecthe EPS ontrolunit 20Pconnector.

Turn he gnit ionswitch ON (ll).

10 .

I I.

12 .

'13.l\4easureoltagebetweenEPS ontrolunitterminalNo. 17and he bodyground.

EPSCONTROL NIT2OPCONNECTOR



YES Substitute known-goodEPS ontrolunit

and echeck. l

NO-Go to s tep14,


Disconnect theCM onnector 31P) .

Check or continuitybetweenbody ground an d

ECI \4onnectorermina l 16 .

EC MCONNECTOR {31PI

14.

t 5 _

1 6 .

1 2 3 4 5 6 1 7 l 1 8 9

5 6 . / 1 8 2A2122 23 zi ./ 2930 o l

EPSLD{L TGRN/BLK)

a,

Wire ideot emaleerminals

lsthere continuity?

YES Repair hort n the wire between he ECN4(E 6) nd heEPS ont ro l n i t . l

NO Update he ECM f it does not have he latestsoftware,or substitute known-goodECM, hen

recheck seepage11-6).f the symptom/indicationgoesawaywith a known-goodECM, eplace he

or ig ina l CM. I



BrakePedalPositionSwitch SignalCircuitTroubleshooting

1. Check he brake ights.

Are the brake lights on without pressing the brakepedal?

YES Inspectthebrakepedalposit ionswitch(see age19-6) . I

NO Go o step2.

2. Press he brakepedal.

Do the brake lights come on?

YES-Go to step3.

NO Go to step4.

3. Measure oltagebetweenECMconnector

terminalsA2 4 an d E2 2with the brakepedal

presseo.


YES-The brakepedalposit ionswitch signal s

oK , I

NO Repairopen n th e wire between he Eclvl(E22) nd he brakepedalposit ionswitch.l


4. Inspecthe No.7 HORN, TOP 15A)use n he

under-hood use/relay ox .

ls the tuse OK ?

YES- Repairopen n th e wire between he brakepedalposit ionswitchand he No.7 HORN,STOP( 5A) fuse, nspect he brakepedalposit ionswitch(see age19-10) .1

NO Repair hort n the wire between he ECM(E22) nd he No.7 HORN, TOP 15A) fuse .

Rep lacehe No.7 HORN, TOP 15A) fuse . t

11-1



ControlSystem

ldleSpeed nspection

NOTE:' Leave he dle air control lAC) alveconnecled.. Before hecking he dle speed, heck hese tems:

- Themal funct ionnd ica to ramp MlL) asnotbeen

reported n.- lgn i t i oniming- Spark lugs- A i r c leaner- PCVsystem

. Pu l l t he ark ing rake everup .Star t he eng ine , ndmakesure he headlights re off.

1. Disconnecthe evaporative mission EVAP)

canisterpurgevalve 2Pconnector.

2. Connect tachometer A)to the test achometer

connector B),or connect he HondaPG MTester C)

or an OBD l scan oolto the data

in kconnector(DLC) D) ocatedunder he driver'ssideof the

dashboard.

4 .

3.

5.

6 .

Start he engine.Hold he engineat 3,000 pm withno oad inneut ra l ) n t i l he rad ia to ran comes n ,then e t t d le .

Check he dlespeedwith no-loadconditions;headlights, lower an, radiator an,and aircondit ioner ff.

ldle speedshouldbe : 750 t 50 rpm

Let he engine dle or 1 minutewith the heater answitchon Hl and air condit ioner n, hen check heid lespeed.

ldlespeedshould be: 750 t 50 rpm

NOTE: f the dlespeed s not wilhin specif ication,go

to the SymptomTroubleshootingndex,

Reconnecthe EVAP anisterpurgevalve 2P

connector.



ECM dleLearnProcedure

The dle earnproceduremust be done so the ECMcanlearn he engine dle characteristics.

Do he idle earnprocedurewheneveryou do any oftheseactions:. Disconnecthe battery.

Replacehe EC Mor disconnectts connector.

Reset he ECM.

NOTE:ErasingDTCS ith the HondaPGMTester

does not require ou to do the dle earnprocedure.

Remove he No.6ECU ECM) 15A) use rom th eunder-hood use/relay ox.

Remove he No.19baftery 80A) use rom the under-

hood use/relay ox.

Remove GM-FI a in e lay1 .

Removeany of the wires rom the under-hood use/

retayDox.

Disconnect ny of the connectors rom the underhood use/relay ox.

Disconnecthe connectorbetween he enginecompartmentwire harnessand ECMwire harness.

Disconnecthe G2 er minal rom the transmission

housrng .

DisconnecttheG'l erminal rom the body.

D isconnect the 101 ermina l rom he cy l inder ead

cover.

Procedure:

To complete he dle earnprocedure, o this:

1. Makesure all electrical tems Ay'C,udio, eardefogger, :ghts,etc.,) re off.

2. Start he engine,and hold t at 3,000 pm with no

load inneut ra l ) n t i l he rad ia to rancomeson,orun t i l heeng ine oo lan t tempera tu reeaches 94"F(90'c) .

3. Let he engine dl e or about5 minuteswith the

thrott le ully closed.

NOTE: f the radiator an comeson, do not nclude ts

runn ing ime n he5 minu tes .

11 -1



SupplySystem

omponentLocation ndex

FUELFEED INEFUELPULSATION AMPERReplacement,ag e 1'154

PGM.FIMAINRELAYTroub leshoot ing ,age ' l ' l -141

FUELTUBE/OUICK.CONNECT ITTINGSPrecautions,age 11-148R emov a l ,age 1 - '149Installation, ag e11-'l50

FUELVAPOR INE

i . . /

PUMPTes t , age11 - 141

FUELFILLCAP

FUEL ANKReplacement ,age ' l -155

PGM.FIMAIN RELAY1

Fleplacement,ag e11' 153FUELFILTER

Replacement, ag e11-1 2FUELGAUGESENDING NITTes t , age 1 - 156Replacement,ag e11-153FUELPRESSUN EGULATORReplacement,age'1 - '152



FuelPumpCircuitTroubleshooting

lf yo u suspecta problemwith th e fuel pump,check hatthe fuel pump actually uns;when it is on,yo u will hear

some noise f you listen o the fuel i l l portwith th e fuel

f i l l cap removed.The uel pump should un or 2

secondswhen th e ignit ionswitch s f irst urnedon . fthe fuel pump doesnot makenoise, heckas ollows:


2. Remove he glovebo x {seepage20-63),hen

remove he PGM-FImain relay2 (A).

Turn he ignit ionswitchON {ll).

Measure oltagebetweenPGM-Flmain relay2 5P

connector erminalNo . 5 and body ground.

PGM.FIMAIN RELAY5P CONNECTOR

IGPl(YEL/BLK}



YES-Go to step 5.

NO Repairopen n the wire between he PGM'Flma in e lay1 and he PGM-F l a in e lay . t

3.

5. N4easureoltagebetweenPGM-Flmain relay2 5P

connector erminal No. 1 and body ground.

PGM.FI MAIN RELAY2

5P CONNECTOR



YES Go o step 6.

NO Repairopen n the wire between he under-

dash use/ re lay oxand PGM-F lma in e lay .1


7. Disconnect CMconnectorE (31P).

8. Check or continuitybetweenPGM-FImainrelay2

5P connector erminalNo .3 and ECMconnectorte rmina l 1 .

PGM-FIMAIN RELAY 5P CONNECTOB


ls there ontinuity?

YES-Go o step9.

NO-Repairopen n hewirebetweenhe PGMFlmain e lay and heECM E1) .1

IMOFPR(GBN/YEL)

(con t '

11-1

Et 2 l

Ftxm7 -z

EC MCONNECTOR 131P}



FuelSupply ystem

L

1 0 .

1' ].

FuelPumpCircuitTroubleshootingcont'dl

Reins ta l l t he GM-F lma in e lay .


Measure oltagebetweenECI\4/PCMonnector

te rmina l 1and bodyground.

ECMCONNECTOB {31P)


YES Go o step 12.

NO-Rep lace he PGM-F l a in e lay .1


Reconnecl CMconnectorE (31P).

Turn he gnit ionswitch ON (ll),and measure

voltagebetweenEC Mconnector erminalE1an dbody groundwithin the first 2 secondsafter he

ign i t i on w i t chwas urnedON ( l l ) .

ECMCONNECTOR(31PI

13 .

14 .



11-142

t 5 .

t o .

1 1 .

1 8 .


YE S Update he ECM f it doesnot have he latest

so{1ware, r substitute known-goodECM. hen

recheck se epage 11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

NO Go o step 15.


Remove he rearseatcushion (seepage20-80).

Remove he access anel rom the floor.

Measure oltagebetween uel pump 5Pconnector

terminalNo. 5 and body groundwithin the first 2seconds fter he gnit ionswitchwa s turnedON (ll).


wire side I emaleerminals


YES Go o step 24.

NO-Go to s tep19.


Removehe PGM-F l a in e lay .

1 9 .

20.



21. ConnectPGM-Flmain relay2 5Pconnector

terminalsNo. 1 and No. 2 with a iumDerwire.

PGM.FIMAIN RELAY2

5P CONNECTOR

FUELPUMP(YEL/GRN)

JUMPERWIRE

22.

23.



Measure oltagebetween uel pump 5PconnectorterminalNo .5 and body ground.

FUELPUMP5PCONNECTOR



YES Rep lace the GM-F l a in e lay2 . t

NO-Repair open n the wire between he PGM-Flmain relay2 and he fuel pump 5Pconnector.l

Turn he ignit ionswitchOFF.4.

FNI Etri dfficr fv

{YEL/BLK)A

25. Che ck or continuitybetween uel pump 5P


FUELPUMP5PCONNECTOR


ls there ontinuity?

YES Replacehe uelpump. l

NO-Repairopen n hewire betweenhe uelpump P onnectorndG551.1

11-1



System

FuelPressureRelieving

Beforedisconnectinguel inesor hoses, elieve

pressure rom the systemby disconnectinghe fuel

tube/quick onnect itt ing n the enginecompartment.

1 . Turn he gn i t ion w i t chOFF,

2 . Removehe PGM-F l a in e lay (A) .

Sta r t the ng ine , nd et t d leun t i l t ss ta l l s .

NOTE:Th e DTCS r TemporaryDTCS 0301. 0302,

P0303, 0304may come on during his procedure.

lf an y DTCS re stored, gnore hem.


Remove he fuel i l l cap,and relieve uel pressurein he ue l tank .

Remove he enginecover.

Disconnecthe negative able r om the battery.

Check he fuel quick-connectitt ing or dirt, and

clean t if necessary.

3.

4.

6.

7 .

8 .

1 1

10 .

9. Placea rag or shop owel over he quick-connect

fitt ing(A).

Disconnecthe quick-connectift ing (A):Hold heconnector B)with on e handand squeezehe

retainer abs (C)with the other hand o release

them from th e lockingpawls D) .Pullthe connector

off.

NOTE:. Preventhe remain ingue l n he ue l eed l ineor

hose rom flowing out with a rag or shop owel.. Be carefulnotto damage he in e (E )or other

pa ts.. Do not use ools.. l f heconnectordoesot move, eep the eta iner

tabs presseddown, and alternately ul l an d push

the connectoruntil t comes off easily.. Do not remove he retainer rom the line;once

removed, he retainermust be replacedwith a

ne w one.

After disconnectinghe quick-connectift ing,check

i t o r d i r to r damage see age11-149) .



FuelPressure est

Special Tools Required. Fuelpressure auge07406-0040004. Fuelpressure augesel 07ZAJ-S5A0100

1. Re l ievehe ue lp ressuresee age1 '1 -144) .

2. Disconnecthe quick-connectitt ing(A).Aftach hefuel pressure augeset and ue l pressure auge.

Start he engineand et t idle.

. lf the enginestarts, ot o step5.

. lf the enginedoes not start,goto step 4.

Check o see f th e fuel pump is running: isten o

the fuel i l l portwith th e fuel i l l ca p removed.Th e

fuel pump should un or 2 secondswhen theignit ionswitch s first urnedon .

. lf th e pump runs,go to step5.

. l f he pumpdoesnot un ,do he ue lpumpci rcu i tt roub leshoot ingsee age11-1 1 .

Read he pressure auge.Th e pressure hould be

320-370 kpa(3.3-3.8 kgf/cm',a7-52 psi)

. lf the pressure s OK, he test s complete.

. lf th e pressure s out of specif ication,eplace hefuel pressure egulatorand he fuel i l ter (see

page11-152) ,hen echeckhe ue lp ressure .

5.

11 -1



SupplySystem

FuelLine nspection

Check he fuel system ines,hoses,and uel i l ter or damage, eaks, nd deterioration. eplace ny damagedparts.

Makesure he connection ssecure nd he quick-connectf i t t ingcover s irm ly ocked ntoplace.

\



Check llclamps nd etightenf necessary.A: Dono tdisconnecthehose rom he ineat hese oints.

Setthebol tf lange

Clamp n he middle.

There houldbe no

W . WClamp n he middle.

Setthispart

the uel { i l l ube,al ign he markson he ube andt h e i n e .

11-1



2 .

FuelLine/Ouick-GonnectittingsRemoval

1. Re l ieveue lp ressuresee age1 ' l -144) .

Check he fuel quick-connectift ings or din, and

clean f necessary.

Hold he connector A) with one hand and squeeze

th e retainertabs B)with he otherhand o release

them from the ockingpaws(C).Pull he connector

off.

NOTE:. Becare fu l o t o damagehe ine D)or o ther

parts.Do not use ools.. lf the connectordoesnot move, keep he retainer

tabs presseddown, and alternately ul l and push

the connectoruntil t comesoff easily.. Do not remove he retainer rom the line;once

removed, he retainermust be replacedwith anew one.

4. Check h e contacta ea (A )of the line(B)for dirt an

damage.

.lf the surface

s dirty,clean t.. if the surface s rustyor damaged, eplace he

fue lpump, ue l f i l t e r ,ue l feed ine .

=kTo preventdamagedan d keep oreignmatterout,

cover he disconnected onnector nd ine endwit

plasticbags A) .

NOTE:. The retainer annotbe reusedonce t ha s been

removedrom he ine .

Replacedhe retainerwhen- rep lac inghe ue l a i l .- rep lac inghe ue l eed ine .- rep lac inghe ue lpumP.

- replacing he fuel i l ter.- rep lac inghe ue lgauge end ing n i t- it has been emoved rom the ine.- i t s damaged.

11 -



FuelSupplySystem

FuelLine/Ouick-Connectittings nstallation

1. Check he contacta ea (A )of the line(B ) or dirt anddamage,and clean f necessary.

Inserta new retainer A) nto he connector B) f theretainer s damaged,or after. rep lac inghe ue l a i l .. replacing he fuelfeed line.. replacing he fuel pump.. replacing he fuel i l ter.. rep lac inghe ue lgauge end ing n i t. removing he retainer rom the ine.

3. Beforeconnecting new ueltube/quick-connect

fitt ingassembly A), emove he old retainer romthe mat ino ine ,



4. Align he quick-connectitt ingswith the line (A).

anda l ign he eta inerB) ock ing awlswi th he

connector C)grooves.Thenpress he quick-

connect itt ingsonto he line until both retainer

pawls ockwi th a c l i ck ing ound.

NOTE;f t s hard o connect , u ta smal lamount f

new eng ine i l on he ineend.

Connectionwith new retainer:

Reconnection o existing retainer:

5. lvlake ure he connection s secureand hat he

pawlsare i rmly ockedntop lace ; heck isua l l y

and by pull ing he connector.

6. Reconnectthe egative able o the battery, nd

tu rn he gn i t ion w i t chON ( l l ) . he ue lpumpwi l

run or about2 seconds, nd ue l pressurewill ris

Repeat or 3 t imes,and check hat hereare no

fuel leaks.

1 1 -



FuelPump/Fuel augeSendingUnitReplacement

SpecialToolsRequired

Fue l ender rench 7XAA-001010A

1 . Re l ievehe ue lp ressuresee age11-144) .

Remove he fuel i l l cap.

Remove he seatcushion se epage20-80).

Remove he access anel A)from th e floor.

5 .

7 .

D isconnecthe ue lpump5PconnectorB) .

Disconnecthe quick-connectitt ing{C) rom the

fue l ankun i t .

Us ing hespec ia loo l , oosenhe ue l ankun i t

locknut A) .

93 N.m19.5 gf.m,69 bf.ftl

11 -

8. Removehe ocknut A)andthe fue l ankun i t .

9 . Removehestopper O) .Re leasehehook P) nd

remove he ue l i l t e r B) , he ue lgauge end ing

un i t C) . hecase D) , hewi re harnessE) , nd hefuel pressure egulator F) .

10 . Whenconnect inghe ue l ankun i t ,make ure he

connect ions secure nd he suct ioni l t e r G) s

f i rmlyconnectedo he ue lpump H) .

11. Ins ta l lhe ue l ankun i t n he reverse rdero f

remova l i t h a new base asket l )andnewo-r in

(J ) , hencheck hese tems:

. Whenconnect inghe w i reharness, ake ure

theconnect ionssecure nd heconnectorK)

f i rmly ockednto he p lace .

. When nsta l l i nghe ue lgauge end ing n i t ,

makesure he connection s secureand he

connectors i rmly ockedntop lace . ecare fu

not o bendor twist the connector xcessively. When ns ta l l i nghe ue l tankun i t , l i gn he mar

(L)on he ue l ank M)and he ue l ankun i t N



FuelSupplySystem

FuelPulsationDamperReplacement

1. Re l ievehe ue lp ressure(seepage l l -144) .

2. Remove he enginecover.

3. Remove he fuel rail mountingnuts rom the fuelra i l .

4 . Removeheground ab le G101.

5 . Ra isehe ue l a i l .

6 . P lace wrench A)onthe fue l a i l B ) .

7 . P lace wrench C) n the fue lpu lsa t ion amper D) .

8. Rem ove he pulsation amper.

9. Installthe uel pulsation amper n he reverseorderof removalwith new washers.

NOTE:. Replace ll washerswheneve the fuel pulsation

damper s loosened r removed,. l f he d ra inho le A)o f the fue lpu lsa t iondamper

coverdoes not facebottom, einstall t as shown.



FuelTank Replacement

Rel ieve the fue l ressuresee age11-144) .

Dra in he ue l ank :Removehe ue lpump see age11-153) . s inga handpump,hose, ndconta iner u i tab leo

gasoline. raw he fuel rom the fuel ank.

Jack up the vehicle,an d suppon t with safetystands.

Remove he fuel pipecover (A).Disconnecthe fuel vapor hosean d quick-connectitt ings.

Disconnecthe hoses.Slideback he clamps B), hen wist the hosesas you pull o avoid damaging hem.

A 38N. m(3.9sf.m,28lbfft)

5. Place ac kor othersupportunder he tank.

6 . Removethe t rap o l t s , nd e t thest rap C)hangf ree .

7 . Removehe ue l ank D) . f t s t i cks to the ndercoatontsmount , a re fu l l y ry to f f the mount

8. Install he parts n the reverse rder of removal.

1 .

2 .

3.

(}

\

11 -



SupplySystem

FuelGaugeSendingUnit Test


Fuelsenderwrench07XAA-001010A

NOTE;For he fuel gaugesystemcircuitdiagram, eferto the GaugesCircuitDiagram se epage22-58||.

1 . ChecktheNo.10 UETER7.5A) fusen he under -dash use/relay ox before esting.

2. Do he gaugedrive circuitcheck se epage22-56|l.

' l f the fuel gaugeneedlesweeps rom minimunito maximum positionan d hen returns o themin imumpos i t ion .hegauge s OK.Go o s tep3.

. lf th e fuel ga uge need e does not sweep rommin imum o max imumpos i t ion os i t i on ndthen return o the minimum position, eplace he

gaugeassemblyand retest.

3 . Turn he gn i t ion w i t chOFF.

4. Remove he rearseatcushion se epage20-80).

5. Remove he accesspanel A)from the floor.

6. Disconnecthe fuel pump 5Pconnector B).

-ztr

7. Measure oltagebetween uel pump 5P connectorterminalsNo. 1 and No. 2 with the ignit ionswitchON (ll).Thereshouldbe batteryvoltage.

. lf the voltage s as specif ied, o to step8.

. l f he vo l tages no tasspec i f ied ,checkfo r :

- an open n heYEUBLK r BLKwi re .- poorground G551) .

FUELPUMP5PCONNECTOR


Turn he ignit ionswitchOFF.Remove he No.9BACKUP(7.5A)fuse rom the under-hood use/relaybox or at least10 seconds,hen reinstall t.

Installa 2 Q resistorbetween uel pump 5Pconnector erminalsNo. 1 and No. 2, hen urn theign i t i on wi t chON ( l l ) .


- V V V -

2 9 RESISTOR,

=-aY

\

//,(elrt \

\ 4 5 /

{YEL/BLK)




10. Checktha t the o in te ro f he fue lgauge nd ica tes"F" .

.lf the pointerdoes not ndicate

F" ,

replace hegauge.. lf the pointer ndicates

F" ,inspect he fuel

gaugesendingunit.

NOTE: he pointerof the fuel gauge etu ns o the

bottom of the gaugedialwhen the ignit ionswitch

is OFF, egardless f the fuel level.-

11. Relieve he fuelpressure se epage11-144\.

12 . Removehe ue l f i l lcap .

13. Disconnecthe quick-connectitt ings rom the fuel

pump.

14 . Us ing hespec ia loo l , oosenhe ue l ankun i t

locknut A).

A9 3 N m{9.5 sf.m,69 bf.ft}

15. Measure es is tanceetweenhe No.1 and No.2

terminalswith the float at E (EN4PTY),l1 2\HALF

FULL) , ndF {FULL) os i t i ons .

lf yo u do not ge t he following readings, eplace hfue lgauge end ing n i t see age1 '1 -163) .

F loa t

Pos i t ion

F'U2 LOW E

Resistance

{ 0 )

1 1

t o 1 3

68,5

to 74.5

114.4

to 126.6

130to 132

NOTE:Remove he No. 9 BACKUP(7.5A) use ro

th e under-hood use/relay ox for at least10

seconds ftercompleting roubleshooting,

otherwise t may ake up to 20 minutes o r the fue

gauge o indicate he correct uel level.

11-1



SupplySystem

1 .

4,

Low Fuel ndicatorTest

Do he fuel gaugesendingunit est (seepage 11 ,rco l .

.lf the system s OK,go to step2.. lf the systemhas any malfunction, epair t.

Turn he ignit ionswitch OFF.Remove he No. 9

BACKUP (10A) use rom the under-hood use/

relaybo x fo r at east30 seconds, hen reinstall t.

Turn he ignit ionswitch ON (ll)with the float at theE (EMPry)posit ion.

. lf the low fuel indicator s on, go to step4.

. lf the low fuel indicator s not on, refer o the lowfuel indicatorCircuitDiagram se epage22-58)

and check he circuit.

Turn he ignit ionswitchOFF.Remove he No. 9

BACKUP (10A) use rom the under-hood use/relaybox or at least30 seconds,he n reinstall t.

Lift he float above he LOWposition.

. l f he owfue l nd ica to rgoesf f , thesys tem s OK.

. lf the low fuel ndicator s sti l l on, refer o the low

fuel ndicatorCircuitDiagram se epage22-58),

and check he circuit.

\,



IntakeAir System


INTAKEAIR BYPASSCONTROLTHERMALVALVETest,page1'1-161

i l .

AI RCLEANERR ep lac emen t ,age 1 '162AI RCLEANER LEMENTR ep lac emen t ,age11 - 162

THROTTLEABLEAdjustment,ag e 1-163Remova l / lns ta l la t ion ,age 1-164THROTTLEBODY

Test,page 'l-160Removal/lnstallation,ag e11-165Disassembly/Reassembly,age 11 166

11 -



Air System

Throttle BodyTest

NOTE:. Do not adjust he thrott lestop screw. t is presetat the

factory..

l f he mal funct ionnd ica to rampMlL)

hasbeenreportedon, check or diagnostic roublecodes(DLCS)see age113) .

1. With the engineoff,check he hrott lecablemovement.Th ecableshould move without bindingor s t i ck ing .

. lf he cablemoves OK,goto step2.

. lf the cablebindsor sticks, heck t and ts routing.

. l f he cab le s fau lt y , e rou teto r rep lacetandad jus t t (see age11-163) ,hengo to s tep2.

2. l\4ovehe thrott le everby hand o see f the throft le

valveand/orshaftare oo looseor too tight.

. lf there s excessive la y n the thrott levalve

shaft,or any binding n the thrott levalve at th efully closedposit ion, eplace he thrott lebody.

. l f he th ro t t leva lve ndshaf t reOK,goto s tep3.

3. Connect he scan oolto the DLC.


Check he thrott leposit ionwith the scan ool. The

readingshould be about 10 %when the thrott le sfully closedand about 90%when the thrott le s fully

openeo.

. lf the thrott leposit ion s correct, he thrott lebodyis OK.

. lf thethrott le posit ion s notcorrect, eplace he

thrott lebody.

5 .

!



IntakeAir BypassGontrolThermalValveest


VacuumPump/Gauge,0 30 n. Hg A973X-041-XXXX X

1. Stan he eng ine . hen e t t d l€ .

NOTE:The enginecoolant emperaturemust be

be low149 'F 65 'C) .

2 . Removehe vacuum ose A) f rom he n take i r

duct,and connecta vacuumpump/gauge o the

nose.

3 . Ra ise nd ower the ng ine peed. nd make ure

the vacuum auge ead ing hanges s heeng ine

speeocnanges.

lf the vacuum readingdoes not change, heck or

theseproblems:

. Misrou ted ,eak ing , roken, r c loggedntake i r

bypass ontrolsystemvacuum ines.. A cracked r damaged ntakeair bypass ontrol

thermal a lve .

4 . Ho ld heeng ine t 3 ,000 pmwi th no oad in

neutral)until he radiator an comes on, hen let t

i d e .

5 . Ra ise nd ower heeng ine peed, nd make ure

the vacuumgauge eadingdoes not changeas h

rpm cnanges.

lf the vacuum readingchanges, heck or theseproorems:

. l\4isrouted,eaking, roken,or clogged ntakeai

bypasscontrolsystemvacuum ines.. A cracked r damaged ntakeair bypasscontro

thermal a lve .

1 1 -



Throttle CableAdjustment

1 .Check able reeplayat the thrott le inkage.Cable

f reepfav (A)shou ld e 10 12mm (3/8 1 /2 n . ) .

lf the free play s not within spec 10 12 mm,

318-112 ln . l , l oosenhe ocknut B) , u rn he

adjustingnu t (C )untilthe free play s as specif ied,

then retighten he locknut.

With the cableproperlyadjusted, heck he thrott le

valve o be sure t opens ully when you push he

accelerator edal o the floor.Also check he

thrott levalve o be sure t returns o the idleposit ionwheneveryou release he acceleratorpeoar.

11 -



Air System

ThrottleCableRemoval/lnstallation

1. Fullyopen he thrott levalve, he n remove he

thrott lecable A) ro m the thrott le in k (B).

Removehecab le ous ing C) f rom he cab lebracket D).

Remove he thrott lecable A)from the acceleratorpeda l B ) .

2 .

3.

SILICONE REASE B(P/N08798-9002)

(P/N08?98-9002)

5 .

Install n the reverse rder of removal.

After nstall ing, tart he engine.Hold he engineat

3,000 pm with no load(in neutral)untilthe radiatorfa n comeson, hen let t idle.

Ho ld hecab le , emov ing l l s lack rom t .

Set he ocknuton the cable bracket A) .Turn he adjustingnu t (B )so that ts ree play s

0 m m .

Thes hou ld eno crearance.

Remove he cable rom the cablebracket A) .Set

the adjustingnut on the other sideof the thrott le

bracket,hen ighten he locknut C} .

With the cableproperlyadjusted, heck he thrott le

valve o be sure t opens ully when you push heaccelerator edal o the floor . Also check hethrott levalve o be sure t returns o the idleposit ionwheneveryo u releasehe accelerator

Deoat .

7 .

!

8.

9.

( '1 .0 gf.m,7.2 tbf.ftl



Throttle BodyRemoval/lnstallation

NOTE:' Do not adjust he hrott lestopscrew.. Af te r reassembly ,ad jus t the th ro t t lecab le {seepage l l -163)nd he cru ise on t ro l ab le see age4-45) .. The hrott leposit ion TP ) ensor s not removable.

THROTTLELEVER

There houldbeno c lea r anc e

THROTTLECABLE

MANIFOLDABSOLUTE RESSURE{MAP}SENSOR

2 2 N m(2.2kgt.m, 16 bf.ft)

EVAPORATIVE MISSION EVAPICANISTERPURGEVALVE

IDLEAIR CONTROL{IACI VALVE

11 -1



IntakeAir System

Throttle Body Disassembly/Reassembly

EVAPORATIVEMISSION

EVAP)CANISTERURGE ALVE

A

V

2 N.m{0.2kgt m, 1 lbf.ft)

3. 5N. m(0.35 gf m.2.5lbf f t )

MAPSENSOR

THROTTLE ODY

L

TPSENSOR

11 -166



CatalyticConverterSystem

DTCTroubleshooting

DTCP0420: atalytic ystemEfficiencyBelow hreshold

NOTE: f some of the DTCSistedbelow are storedatthe same ime as DTCP0420,roubleshoot hose DTCSfirst, hen recheck or DTCP0420.

P0137, 0138: econdary eated xygenSensor(secondaryHO2S) Sensor )

P0141: econdary O2S Sensor )heater

1 . ResetheECM see age1 ' l -4 } ,hencont inueostep 2 through 5 to reset he readiness ode.


no oad inneut ra l ) n t i l the ad ia to rancomeson.

Dr ive o r about 0 minu tes i t hou t topp ing . ourspeeocan vary.

With the transmission n 4th gear,drive at a steady

speedbetween50 62 mph (80-'100 km/h) or

30 seconds.

Repeat tep 4 three imes. Between ach repetit ion,

close he hrott lecompletely or 1 2 seconds. f

the engine s stoppedduring his partof theprocedure, epeat teps3, 4 and 5.

Check or a TemporaryDTCwith the scan oo l.

Does he scan ool ndicate Temporaty DTC

P0420?

YES Check he TWC. f necessary, eplace heTWC.I

NO Checkor read inessode omple t ion .f the

readinesss complete, t was a interminent ailure,and he system s OKat this ime. f th e readiness

code s incomplete, epeat teps2 through 5.1

4 .

11-1



PCVSystem

DTCTroubleshooting

DTCP1505: CVAir Leakage



no oad inneut ra l ) n t i l he rad ia to rancomeson

3. Let he engine dle or al least40 secondswith the

thrott le ully closed.

4. Check or a DT CP1505with the scan oo l


YES-Check heseparts or vacuum eaks

. PCV alve

. PCVhose

. EVAP anisterpurgevalve

. Throttlebody

. Brakeboosterhose

NO Intermittentailure,system s OK at hi s

t ime. l

11-168



PCVValve nspection ndTest

2 .

1. Check he PCV alve(A),hoses B) ,an d

connectionsor leaksor restrictions.

At idle,makesure here s a clickingsound rom th ePCV alvewhen the hose between he PCV alve

and ntakeman i fo lds igh t l y inched A)wi thyour

f ingers r p l ie rs .

lf there s no clicking ound,check he PCV alvegrommet or cracks r damage. f th e grommet s

OK .reDlacehe PCV alvean d recheck.

PCVValveReplacement

'LDisconnecthe PC Vhose.

Remove he PCV alve (A).

3 . Ins ta l l

with a

(4.5 gf.m,33bf.ft)

th e parts n th e reverseorder of removal

newgasket B) .

11 -1



System


EVAPORATIVE MISSION EVAP)CANISTERVENT SHUT VALVETroubleshooting,step23 on page1'l 178,s tep1gon page 1 -182

EVAPORATIVE MISSION EVAPICANISTERPURGEVALVETroubleshooting,step3 on page l1-175,

s tep1on page 1 - 180

FUELTANK VAPORCONTROLVALVETest,page11'187R ep lac emen t ,age 1 189

FUELTANK PRESSUREENSORTroub leshoot ing ,age 1-171

EVAPORATIVE MISSION EVAPICANISTERTroubleshooting, te p28 on page11'183Replacement,ag e11-189

EVAPORATIVE MISSION EVAP}BYPASSSOLENOIDVALVETroubleshooting,s tep12on page 11 '176 ,

s tep 10on page11181

EVAPOBATIVE MISSON EVAP)TWO WAY VALVETest,page l1- '186



DTCTroubleshooting

DTCP0451: TPSensorRange/PerformaceProblem


Vacuum Pump/Gauge, -3 0 in. Hg A973X-041-XXXX X

1. Removehe ue l i l lcap .


3. l\4onitoruel ank pressure FTP) ensorvoltage

with the HondaPG MTester, r medsure oltage

betweenECMconnectorterminals 4 and E14.

EC MCONNECTOR 131P)

Wire ide f emaleermina ls

ls thereabout2.5V?

YES-Go to step4.

NO Replacehe FTP ensor.I


Disconnecthe hosebetween he EVAP wo way

valveand he FT P ensorat he EVAP wo wa y

valve end.

4.

5.

7 .

8 .

6. Connect vacuumpump o the open end of the

hose.

Turn he gnit ionswitchON {ll).

l\4onitor TPsensorvoltagewith the Honds PGM

Tester,or measure oltagebetweenECM

connectorermina ls 4andE14, ndcare fu l l y

squeezehevacuumpumpa i t t l e .

ECMCONNECTOR13lPI

Wire ide f emale erminals

The voltageshould smoothlydrop rom about 2.5

to about1 .5V. Stopapp ly ing acuumwhen he

voltagedrops o about 1. 5V or damage o the FT P

sensormay occur.

Does he voltagedrop to about 1.5 V an d hold?

YE S Check or misrouted, eaking, r brokenFT

sensor acuum ines. f hevacuum ines reOK,

update he ECM f i t doesnot have he latest

software.or substitutea known-goodECM, hen

recheck se epage 11-6). f the symptom/indicatiogoesawaywith a known-goodECM, eplace he

or ig ina l CM. I

NO Replacehe FT P ensor.

9 .

11-1



System


DTCP0452: TPSensorCircuit owVoltage

1. Check he vacuum inesat the FTP ensor or

misrouting, eakage. reakage, r clogging.

Are the vacuum ines OK?

YE S Go o step2.

NO Repairor replace acuum inesas

necessary.

2 . ResetheECM see age11-4) .

3 . Removehe ue l f i l lcap .

4. Turn he ignit ionswitch ON (ll)

5. Monitor FT P ensorvoltagewith th e HondaPGM

Tester, r measure oltagebetweenbody ground

an d EC Mconnector erminalE14.

ECMCONNECTOR 131PI

1 2 t 3 t 4 5 o / 8 9

. / . / 114 t c 61./18 2C2122123241 t 26 271/ 29 31

TP (L TGRN)


ls thete about2.5 V?

YES- Intermittent ailure,system s OK at this ime.


th e FT P ensorand at he ECrM.l

NO Go o step6.

11-172


7 . Re ins ta l l t heue l i l l cap .

8. Disconnecthe FT P ensor3P connector.


10. Measure oltagebetweenFTP ensor3P connector

te rmina ls o .1 andNo.2 .

FUEL ANKPRESSUREENSORPCONNECTOR

VCgl {YEL/BLU}


ls ther e about5 V?

YES Go o step 11.

NO-Repair open n the wire between he FT P

sensor nd he ECM E5) .1



' t2 .

13 .

14.

11. Measure oltagebetweenFTP ensor3P connectorte rmina ls o .2 and No.3 .

FUELTANKPRESSUBE ENSOR P CONNECTOR

FTP LTGBN)

Wireside f emaleterminals

ls thereabout5 V?

YES Replacehe FTP ensor.

NO-Go to s tep12.


Disconnect CMconnectorE (31P),

Check or continuitybetweenFT P ensor3P


FTPSENSOR P CONNECTOB

FTP (LT GRNI

Wireside f emalelerminats


YES Repair ho rt n the wire between he FT P

sensor nd he ECI \4E14) . I

NO-Update the ECM f it doesnot have he atest

software,or substitute known-goodECM, henrecheck se epage11-6). f the symptom/indicationgoesaway with a known-goodEClvl, eplace he

or ig ina l CM. I

DTCP0453: TPSensorCircuitHighVoltage

1. Check he vacuum inesat the FT Psensor or

misrouting, eakage, rea kage, r clogging.

Are the vacuum ines OK ?

YES-Go to s tep2.

NO Repa i r r rep lace acuum ines s

necessary.I

2 . Resethe ECM see age11 '4 ) .

3. Remove he fuel i l l cap.


5. lvlonitorFT Psensorvoltagewith the HondaPG M

Tester,or measure oltagebetweenbody ground

andECM onnectorermina l ' 14 .

ECMCONNECTOR131PI

1 1 2 1 34 5 6 7 I 9

5 6 / t18 2C2124 2il./ 293031

TP {L TGRN}


Is thereabout2.5 V?

YES Intermittent ailure,system s OK at his time


the FTP ensor ndat he ECM. I

NO Go o step6.

{cont'

11-1



System



7 . Re ins ta l lhe ue l i l l cap .

8. Disconnecthe FT P ensor3P connector.


'10.l\4easureoltagebetweenFTP ensor3P connector

te rmina ls o .1 and No.2 .

FTPSENSOR3P CONNECTOR

VCC3YEL/BLU)


ls thereabout5 V?

YES Go o s tep11.

NO-Repair open n the wire between he FTP

sensorand he ECM E4).

11-174

11, Measure oltagebetweenFT P ensor3P connector

t e r m i n a l s o . 2a n dN o . 3 .

FTPSENSOR3P CONNECTOR

FTP LTGRN}


ls there about5 V?

YES Replace he FT Psensor.l

NO Go o step 12 .

l\4easureoltagebetweenEC Mconnector

te rmina ls 4andE14,

ECMCONNECTOR(31P)

Wi re ide f emaleermina ls

ls thereabout 5 V?

YES Repairopen n the wire between he FT P

sensor nd he ECM E14) . I


software,or substitute known-goodECN4.hen

recheck se epage11-6). f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

\



DTCPl456:EVAPControl(Fuel ankSvstem)

SystemLeakage

The uel system s designed o allow specif iedmaximum vacuuman d pressure onditions.Do no tdeviate rom th e vacuuman d pressure estsasindicated n theseprocedures. xcessive ressure/

vacuumwould damage he EVAP omponentsor causeeventual uel ank ailure.

Special Tools RequiredVacuumPump/Gauge, -30 in. HgA973X-041-XXXXX

This s a two-tripcode.Oncecleared, t cannotbereproduced n one rip. Also,cenainspecif icdriving

and ambientconditionsmustoccurbefore he ECMwill

complete he systemchecks.Additional est drives maystil l not meet he specif ic ondit ionsneeded oreproduce he code.

Follow hese roubleshooting rocedures arefully o

ensure he integrityof the systeman d o confirm he

causeof the problemor code.

NOTE:Fresh ue l has a highervolati l i ty hat createsgreaterpressure/vacuum.he optimum condltlon ortesting s fresh uel,and must be ess han a full tank. fpossible,o assist n leakdetection, dd 1gallonof

fresh uel o the tank (a s on g as t wil l not i l l the tank).just beforestarting heseprocedures.

Fuel Fill Cap Check

1. Check he fuel i l l cap (thecap must say"l f

no ttightened3 clickscheckengine ight may come

on" .

ls the proper luel till cap installed and properly

tightened?

YES Go o step2.

NO- Replace r t ighten he cap.I

2. Check he fuel i l l cap seal.

ls the tuel fill cap seal missing or damaged?

YES- Rep lacehe ue l i l l cap . I

NO The ue l f i l lcap s OK.Go o s tep3.

EVAPCanister Purge Valve Test

3. Disconnecthe vacuum hose rom the EVAPcanisterpurgevalve (A),and connecta vacuum

oumo to the hose.

A973X-041-XXX


Apply vacuum o th e hose.

Does he valve hold vacuum?

YES-The EVAP anisterpurgevalve s OK. Go o

s tep11.

NO-Go to step6.


Disconnecthe EVAP anisterpurgevalve 2P

connecror.

5 .

7 .

{cont'd

11-1



EVAPSystem


8. Checkor continuity etween VAP anister urge

valve PconnenctorerminalNo.2 andbodygrou o.

EVAP CANISTERPURGEVALVE2P CONNECTOR


ls there ontinuity?

YES Go o step9.

NO Replacehe EVAP anister urge alve.l

DisconnectCM onnector (24P).

Checkor continuity etween VAP anister urge

valve PconnectorerminalNo.2 andbodyground.

EVAPCANISTER URGEVALVE2P CONNECTOR

PCS{YEL/BLU)


ls therecontinuity?

YES Repair hort n the wire between he EVAP

can is te r urge a lveand he ECI \4821) .1


software,or substitute known-goodECM, he n

recheck se epage11-6). f th e symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

9.

1 0 .

1 2

'.\'

11-176

v

F-973X-041-XXXXX

EVAP Bypass Solenoid Valve Test

11 Disconnect oth vacuum hoses rom the EVAP wo

way valve(A),and connecta vacuum pump o the

canisterport on the EVAP wo way valve.

Turn he EVAPbypasssolenoid alve on with the

HondaPGMTester,or connectECMconnecter

terminalE20 o body groundwith a umper wire.

ECMCONNECTOR 131P)

1 2 3 4 5 6 1 7 l 8 9

4 5 6 / 118 2C212 2 t 2 ?24 z7l./29

JUMPERWIRE

2WBS

(BLU/RED}

1 3 .

14.

Wire id e f emaleerminals

Turn he gnit ionswitchON (ll).

Apply vacuum o the hose.


YES-Go to s tep15,

NO Go o step20 .



1 5 .

t o .


Disconnecthe EVAPbypasssolenoid alve2Pconnecror.

Check or continuitybetweenEVAPbypass

solenoid alve 2Pconnector erminal No. 2 and

bodyground.

1 7 .

EVAP BYPASSSOLENOIDVALVE 2P CONNECTOR

'18.

Wire side oI Iemale erminals


YES Go o step 18.

NO-Repair open n th e wire bet\iveenhe EVAP

bypass olenoid alve and he ECM E20).1


2tG'l

'19.Measure oltagebetweenEVAPbypasssolenoid

valve 2P connector erminal No. 1 and body groun

EVAPBYPASS OLENOIDVALVE PCONNECTOR

{BLK/ORN)



YES Replacehe EVAP wo way/bypass olenoid

va lve A) .1

NO-Repair open n the wire between he EVAP

bypasssolenoidvalve and he No. 4 ACG (10A)

fuse . l

{cont'd

11-1



EVAPSystem


20. P lug he ue l tankpor t A)o f theEVAPtwoway

va lve ,

While monitoringFTP ensorvoltagewith th eHondaPGMTester,or measuring he voltage

between CM onnectorermina ls 4andE14,

slowly pump the vacuumpump until he voitage

droDSo about 1.5volts.

ECMCONNECTOR {31PI


Does he voltagedtop to 1.5 V and hold fot at

Ieast 20 seconds?

YES-The EVAPbypasssolenoid alve/EVAPwo

way valve s OK.Go o step22.

NO Repa i rhe eak rom heEVAP ypass

solenoid alve,EVAP wo way valve.or

FTP ensor . l

11-178

Wir es ideof ema le e r m ina l s

EVAP Canister Vent Shut Valve Test

22. Disconnecthe vacuum hose rom the EVAP

canister ent i lter (A),and connecta vacuumpump

to the hose.

Turn he gn i t lon w i t chON ( l l ) .

Apply vacuum o the hosewith f ive strokesof th epump.


YES Go o step25 .

NO The EVAP anister en t shutvalve s OK .Go

to step30 .


Disconnecthe EVAP anister en t shutvalve 2P

conneclor.

Check or continuitybetweenEVAP anister ent

shu tva lve2Pconnectorermina lNo.2 and bodyground.

EVAPCANISTEB ENTSHUTVALVE PCONNECTOR

{L TGRN/REOI

\

25.

26.

21.



28.

29 .


YES-Go to step28 .

NO-Replace the EVAP anister ent shut valve (A )

ando- r ing B) .1


Check or continuitybetweenEVAP anister ent

so leno id a lve Pconnectorermina lNo.2 and

body ground.

EVAPCANISTER ENTSHUTVALVE PCONNECTOR

Wire sideo{ female erminal s

ls therecontinuity?

YES-Repair short n the wire between he EVAP

can is te r en tshu tva lveand he ECM E21) .1

NO Update he ECM f i t doesnot have he atest

soflware,or substitute known-goodECM, hen

recheck se epage11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace he

or ig ina l CM. I

30.

VacuumHoses nd Connections est

Do he fuel an kvapor controlvalve est (seepage

11 - 1 8 7 ) .

ls the fuel tank vapot control valve OK?

YES-Go to s tep31.

NO Rep lacehe ue l tank aporcont ro l a lve . l

Tighten he fuel cap 3"clicks",

then monitorthe

FT P ensor eadingswith the HondaPGMTester.

Start he engine.and et t idle or 5 minutes.

Check he FT P ensor eadings.

ls the reading above0. 5 kp a (4 mm Hg, 0.16 n.

Hg) pressure, or about 3 V?

YES Update he ECM f it does not have he lates


recheck se epage 11-6). f the symptom/indicatio

goesaway with a k nown-goodECfvl,eplace he

or ig ina l CM. t

NO Check he following parts or leaks:l

. Fue l tank A)

. Fue l i l l cap B)

. Fue l i l l p ipe C)

. Fue l tank aporcont ro l a lve(D)

. Fue l tank apor ec i rcu la t iona lve E)

. Fue l tank apor ec i rcu la t ionube F)

. Fue l tank apors igna l tube G)

. Fue l tank aporcont ro l en t tube(H)

. FT Psensor J)- Repa i r r rep lace ny eak ing ar ts .

5 t .

11-1



9. Measureoltage etw een VAP anister urge

valve PconnectorerminalNo.1an dbodyground.

EVAPCANISTER URGEVALVE2PCONNECTOR

Wire side oI emale erminals

ls thetebattery oltage?

YES-Replacehe EVAP anister urge alve.l

NO Repair pen n hewirebetweenheEVAP

canister urge alve nd heNo.4AC G 10A)

fuse.I

EVAP BypassSolenoid Valve Test

10. Disconnect oth vacuum hoses rom the EVAP wo

way valve{A),and connecta vacuum pump o thecanisterport on the two way valve.




YES The EVAP wo way/bypass olenoid valvei

OK.Go o s tep18.

NO-Go to s tep13.


Disconnecthe EVAPbypasssolenoid alve 2P

connector.

Check or continuitybetweenEVAPbypass

so leno id a lve Pconnectorermina lNo.2 and

bodyground.


1 1 .

'I t

1 4 .

(con

11 -




EVAPSystem

t o .

't7.


ls therecontinuity?

YES Go o step 16.

NO- Replace he EVAP wo waylbypass olenoidvalve(A).1

Disconnect CMconnectorE{31P).

Check or continuitybetweenEVAPbypasssolenoidvalve 2Pconnector erminal No.2 andbody ground.


YES Repair he short n the wire between heEVAPbypasssolenoid alveand he ECM E20).

NO Update he ECI\4f it doesnot have he latestsoftware.or substitute known-goodEClvl,he nrecheck seepage11-6).f the symptom/indlcationgoesaway with a known-goodECM, eplace heor ig ina l CM. I


\ ,l l l 2 lI t - l2WBS

-[BLU/REo)())

IWire side of female erminals

EVAPCanisler Vent Shut Valve Test

18. Disconnecthe vacuumhose rom the EVAP

canister ent i lter (A),an dconnecta vacuumpumpto the hose.

19. Turn he EVAP anister ent shut valveon with th eHondaPG MTester, r connectEC MconnectorterminalE2 1 o body groundwith a umper wire.

ECMCONNECTOR(3TP)

1 1 2 1 3 5 8 9 vsv{LT1 / 1 5tal/la 2A21

z3lz4 zil./ m 31

JUMPERWIRE

Wire ide l emaleerminals

Turn he ignit ionswitchON (ll)



YES-The EVAP anister ent shut valve s OK .Goto step27 .

NO Go o step22 .


Disconnecthe EVAP anister ent shut valve2Pconnector.

GBN/RED)

20 .

21.

22.

23.



System


31. While monitoringFT P ensorvoltagewith theHondaPGMTester,or measuring oltagebetweenEC Mconnector erminalsE4and E14, lowly pumpthe vacuum oumD.

ECMCONNECTOR13lPI


32. Continue o pump vacuum until he voltagedropsto about 1.5V. Makesure he enginecoolanttemperature s sti l l above95'F 135.C) nd yourvacuumpumphasno eak.

33. Monitor he voltage or 20 seconds.

Does the voltage drop 1.5V and hold for at least20 seconds?

YES Inspect he EVAP anister ent shutvalvel ineandconnect ions . l

NO-Go to step34 .


35. Discon ect he quick-con ect itt ing (A ) romtheEVAP anister, nd plug he canisterport {B).

36 . Turn he gn i t ion wi t chON ( l l ) .42 . Turn he gn i t ion wi t chON ( l l ) .

I

38 .

39 .

37. While monitoringFT Psensor oltagewith th eHondaPGMTester, r measuring oltagebetweenECM onnectorermina ls 4andE14, low lypump

thevacuum ump.

ECMCONNECTOR{31PI


Continue o pump vacuum until he voltagedropsto about 1.5V.Makesure he enginecoolanttemperature s sti l l above95"F 35"C) nd your

vacuum pump has no leak.

Monitor he voltage or 20 seconds

Does the voltage hold for at least 20 seconds?

YES Inspecl he fuel ank vaporcontrol ineandconnect ions . I

NO Go o step 40.

Turn he gn i t ion wi t chOFF.

Disconnecthe purge ine hose A) rom thecan is te r t he meta l ineandp lug he hose B) .

40.

4 1 .



43. While monitoringFTP ensorvoltagewith the

HondaPGMTester, r measuring oltagebetween

EC Mconnector erminalsE4an d E14, lowly pump

thevacuumpump.

ECMCONNECTOR{31P)


Continue o pump vacuum until he voltagedrops

to about 1.5V.Makesure he enginecoolant

temperature s sti l l above95'F (35'C)an dyour

vacuumpumphasno eak.

Monitor he voltagecontinuously or 20 seconds.

Does the voltage drop to 1.5 V and hold for at

least 20 seco nds?

YES Inspect he EVAP anisterpurgevalve ine

and connections.f they are OK,perform he EVAP

tw o wa y valve est (seepage11-186) nd he fuel

tank vaporcontrolvalve est (seepage1'l-187)

NO-Replace th e EVAP canister(see age11-189) .1

44.

45.

11 -



System

EVAPTwo Way ValveTest

Special Tools Requ ired. Vacuum ump/Gauge,0-30n.Hg

A973X-041-XXXXX. Vacuum/Pressureauge.0-4

in. Hg 07JAZ-0010008

1. Removehe ue l f i l lcap .

2. Disconnecthe vapor ine ro m the EVAP wo wayvalve(A).Connect t to a T-fitt ing B) ro m th evacuum auge nd hevacuumpumpasshown,

07JAZ-0010008

Apply vacuumslowly and continuouslywhile

watching he gauge.Th evacuumshouldstabil izemomentar i l y t 0 .8 2 .1kPa 6 16mmHg,0 ,2 0 .6 n .Hg) .

lf the vacuum stabil izesvalveopens)below 0.8 kpa(6mmHg,0 .2 n .Hg) r above .1kPa 16mmHg,0.6 n.Hg), nstalla ne w valveand retest.

4. Move he vacuumpump hose rom the vacuumfitt ing o th e pressure itt ing,and move he vacuumgaugehose rom the vacuumside o the pressure

side(A )

as shown.

Slowly pressurizehe vapor inewhile watching hegauge.Th e pressure houldstabil izemomentarilVabove1.0 Pa 8mmHg,0 .3 n .Hg) .

. lfthe pressuremomentarilystabil izesvalve

opens) bove1.0 Pa 8mmHg,0 .3 n .Hg) ,heva lve sOK.

. lf th e pressure tabil izes elow 1.0kPa 8 mmHg,0.3 n.Hg), nstalla new valveand retest.



FuelTankVaporControlValveTest

SpecialToolsRequiredVacuum ump/Gauge,-30 in.HgA973X-041-XXXXX

FloatTest1. Make ure he ue l ank s ess hanha l f u l l .

2. Remove he fuel i l l cap o relieve uel ank

pressure,he n reinstall he cap.

3. Disconnecthe fuel ankvapor recirculationub e

{A) , ndconnect vacuumPumP o i t .

P lug he ine B) .

Apply vacuum o the fuel ankvapor recirculation

tuDe.

lf th e vacuumholds, eplace he fuel ankvapor

cont ro l a lve see age11-189) .

lf the vacuumdoesnot hold, he float s OK.Do

th e valve est.

5 .

A973X-041-XXXXX

ValveTest

1. N4akeure he ue l ank s ess hanha l f u l l

2 . Removehe ue l i l lcap .

3. Disconnecthe fuel ankvapor signal ube (A).

Disconnecthe vacuum hoses A) rom the EVAP

canister B), he n plug he portswith plugs C)4 .

A973X-O41-XXXXX

5. Disconnecthe vacuum hose D) rom the EVAP

canister ent shutvalve(E),and connecta vacuu

pump o the vacuumhose.

6 . Pump hevacuum ump80 imes.

. l f hevacuumholds , oto s teP .

. l f hevacuum oesno1 o ld , o o s tep10.

(con

11-1



EVAPSystem

FuelTankVaporControlValve est cont'd)

7. Connect secondvacuum pump to the fuel an kvapor igna l tube A) .

8. Apply vacuum (1pump) o the fuel ankvaporsignal ub e (A). hen check he vacuumon thepump in step6.

. lf the vacuum holds, eplace he fueltank vaporcont ro l a lve see age11-189) .

. If the vacuum s released, ot o step9.

1 0 .

Fill he fuel ank with fuel, hen check o r fuel in th eEVAP wo way valve(A),and fuel ankvaporrecirculation os e(B).

NOTE:At either ocation, in y dropletsof fuel ar enormal .

. lf fuel runsout of the hosesat either ocation,replace he fuel ankvaporcontrolvalve.

. l f t he fue l doesnot unout o f he hoses,he ue ltankvapor system unction s normal.

Disconnecthe fuel ank vaporquickdisconnectfrom the EVAP anister, he n plug he port on thecanister.Reapply acuum 80 pumps).

. lf the vacuum holds, eplace he fuel ank controlva lve see age11-189) .

. lf the vacuumdoes not hold, nsDecthe EVAPcanister ent shut valveo-ring. f the o-ring s OK,

replace he EVAP anister, nd repeat tep 4.

Check or fuel r irnningout.

Check or fuel runningout.



EVAPCanisterReplacement

l . Remove he vacuum hoses A).

2. Remove he boit (B).

3. Remove he EVAP anister C) .

4. Install n the reverse rder of removal.

FuelTankVaporControlValveReplacement

1. Removehe ue l ank(seepage l l -155) .

2 . Removehe ue l tank aporcont ro l a lve(A) rom

the ue l ank B) .

Install he fuel tankvapor controlvalve.

Install he fuel ank (seepage1l-155).

3.

4,

11 -



Clutch

Special ools ......... 2-2

Comoonentocat ionndex . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . .2 -3

Clutch edal, lutch edal osition witch, ndClutchnterlock witch diustment .. . . . . . . . . . . . . . . . . .2-4

Cf tchMaster ylinder ep|acement.. . . . . . . . . . . . . . . . . . .2-5

SlaveCylinder eplacement . ' . . . . . . . .2-7

Clutch eplacement.. . . . . . . . . . . . . . . . . . . . . .12-9



l .l _ l

'l-r

o

SpecialTools

o

.{\

.tt./'\-'/

o

Ref. No. ToolNumber Description Oty(1,

@

o@

OTJAF-PM7O11A07LAB-PV0010or 07924-PD20003

07zAF-PR8A10007936-3710100

,l

1

11

Clu tch l i gnmentD isc

RingGearHo lder

C lu tch l i gnment ha f tRemover and le




""*--/\,L_.Ei

/i(,'.'

CLUTCHNTERLOCK WITCAdjustment,ag e 2- 4

CLUTCH EDALPOSTTTONWITCHAdjus tment ,age '12-4

RETAININGCLIPReplace.

_,___-,-s\

O-RINGReplace.

UTCHPEDALA d jus tmen t , age 2 4

CLUTCHMASTERCYLINDERReplacement,ag e 2- 5

CLUTCHDISCBemoval, ag e12-9Ins ta l l a t i on ,age '12 - 12

PRESSURELATERemoval,age'12-9lns ta l la t ion ,age 2-12

FLYWHEELInspection,age'12-1Replacement,ag e 2- 1

SLAVECYLINDERReplacement,ag e12-7

RELEASEEARINGBep lacement ,age 2-13

\".rr"*"o*

CLUTCHHOSECLIP

1



ClutchPedal,ClutchAdjustment

NOTE:. To check he clutchpedalposit ionswitch

(seepage4-45).. To check he clutch nterlock witch(seepage4-6).. Remove he driver'sside loor mat beforeadjusting

the clutchpedal.. Th eclutch s self-adjustingo co mpensate or wear.. lf there s no clearance etweenthemastercylinder

pistonan d push rod, he release earingwill be heldagainst he diaphragmspring.which can result nclutchslippageor other clutchproblems.

1. Loosen he clutchpedalposit ionswitch ocknut A),

an d backoff the clutchpedalposit ionswitch B)

until t no longer ouches he clutchpedal C).

J9.8 N.m(1.0kgf.m,7.2 bf. f t)

A9. 8N. m11.0 gf.m,7.2 bf.ft)

o18 N.m{1.8 gf.m,13 tbf.ftl

Loosen he clutchpush-rod ocknut D) .and urnth e push ro d (E ) n or out to ge t he specif iedheight(F), troke G) . ree play (H )and disengagementhe igh t l )a t thec lu tch eda l .

ClutchPedalStroke: 130 140mm(5.12 5.51 n . l

ClutchPedalFreePlay: 0 16 mm (0.39-0.63 n. )Clutch PedalHeight: 193mm (7.60 n.)Disengagement

Height: 11 5mm (4.53 n.)Between Floor And

Carpet Height(ApproximateValuel: 38 mm {1.50 n. l

PedalPositionSwitch,andClutch nterlockSwitch

3. Tighten he clutchpush-rod ocknut D) .

4. With the clutchpedal eleased.ur n the clutchpedalposit ionswitch(B ) n until t contacts heclutchpedal C) .

5. Turn he clutchpedalposit ionswitch B) n anadditional3/4 o 1 urn.

6. Tighten he clutchpedalposit ionswitch ocknut A).

7. Loosen ocknut J)and he clutch nterlock witch(K) .

8. Press he clutchpedal o the floor.

9 . Re leasehec lu tch eda l 0 ' l6mm(0,39 0.63 in . )from the fully pressedposit ion, nd hold t there.Adjust he posit ionof the clutch nterlock witch K)

so hat he enginewill startwith the clutchpedal nthls posit ion.

10 . Tighten he clutch nterlock witch ocknut J).



ClutchMasterCylinderReplacement

NOTE:Do not spil l brake luid on th e vehicle; t may

damage he paint; f brake luid doescontact he paint,

wash t of f immediatelV ith water.

1 . Pryout he ockpin (A) , ndpu l l t hepeda l in (B)

out of the yoke.Remove he mastercylinder

mountingnuts(C).

Removehe a i rc leaner ous ing overand he a i r

cleanerhousing (seestep 6 on page5-2).

Remove he brake luid from the clutchmaster

cylinder eservoirwith a syringe.

Remove he clutch ine bracket rom the frame rail,

and remove he clutch in eclip.

Remove he clutchmastercylinder A) ,an d pull t

toward he middleof the enginecompartment.Remove he retaining li p (B).Disconnecthe clutch

line(C).Plug he end of th e clutch ine with a shop

towelto preventbrake luid from coming out.

g-E

3.

6. Disconnecthe reservoirhose D) romtheclutch

mastercylinder eservoir.Plug he end of the

reservoirhosewith a shop owel to preventbrake

fluid from coming out.

7. Remove he O-ring E)and he clutchmaster

cylinderseal F) rom the mastercylinder.

8. Installtheclutchmastercylinder n the reverse

order of removal. nstalla new O-ring.

9. Makesure he hoseclamps A) ar e posit ionedon

the mastercylinder B)an d reservoir C)asshown

(cont

UP

i

12



Clutch

ClutchMasterCylinderReplacementcont'd)

10. To prevent he retaining lip (A ) rom com ing off,pry open he tip of the retaining lip (B )with a

screwdriver,

Tighten he mastercylindermounting nuts o 13 N

m (1.3 g f m, 9 .4 b f . f t ) .

Bleed he clutchmasterhydraulic ystem se estep

11 on page12-8) .

NOTE: he eservo i ri l l i ng scoveredn he

bleedingprocedure.

lns ta l l t he i rc leaner ous ing see tep37on page

5-15) .

1 1 .

12-6

I



SlaveCylinderReplacement

NOTE:. Use ender overs o avo iddamaging a in ted

surfaces.. Donotsp i l lb rake lu idon heveh ic le ;t maydamage

th e paint; f brake luid doescontact he paint,wash it

off immediatelywith water.

1. Write down the frequenciesor th e radio'spreset

buttons.Disconnecthe negative ) cable irst,then he posit ive +)cable from the battery.

Remove he battery.

2. Remove he battery ray.

a

Removehe a i rc leaner ous ing overand he a i r

c leaner ous ing see tep6 on page5-2) .

Remove he intakeair duct (seestep8 on page5-3)

Remove he clutch ine bracket A).

4.

5 .

6. Remove he mountingbolts (A )andtheslave

cy l inder B) .

Remove he roll pins (C).Disconnecthe clutch in(D) , nd emove he O-r ing E) .P lug he endof he

clutch ine with a shop owel o preventbrake luid

f rom coming out.

Installtheslavecylinder n th e reverseorder ofremoval. nstalla new O-ring A).

7 .

,,6NJ'=--

#.q!4sEn(P/N 8798-900

9.

(Brak6 ssemblyube

Pu l l t heboot B)back, ndapp lybrake ssembly

lube o the bootands lave y l inder od C) .Re ins

the boot.

Apply superhigh em p ureagrease P/ N08798-

9002)o thepush odof hes lave y l inder . i gh tethe s lave y l indermount ing o l t s o 22N m (2 .2

kg f m, 16 lb f . f t ) .

(cont

12

1 0 .



SlaveCylinderReplacementcont'd)

11. Bleed he clutchhydraulic ystem.

. Aftacha hose o the bleeder crew(A),an d

suspend he hose n a container f brake luid.. Make ure here s an adequate upp ly f f l u id n

the clutchmastercylinder, hen slowly pump he

clutchpedaluntil no more bubblesappearatthe

bleederhose.. lt may be necessaryo llmit the movementof the

release ork (B )with a blockof wood to remove

all the air from the system.. Tighten he bleedscrew o I N.m (0.8kgf.m,6 lbf

ft); do not ovenig hten t,. Refil l he clutchmastercylinderwith f luid when

done.. Always use only HondaDOT3 brake luid.

Install he intakeair duct (seestep36 on page5-14).

Ins ta l l t he i r c leaner ous ing see tep37 on page

5-15) .

Install he battery ray.

Install he battery, onnect he posit ive +) cable

first, hen he negative - ) cable.

Reset he frequenciesor the radiostationpreset

buttons,

12 .

13 .

1 4 .

t 5 .

1 6 .

L



ClutchReplacement

Spscial Tools Required. Clutchalignmentdisc 07JAF-PM701A. Ringgear holder07LAB-PV00100r07924-PD20003

. Clutchalignmentshaft07ZAF-PR8A100

. Removerhandle07936-3710100

PressurePlateand GlutchDiscRemoval

1. Checkhed iaphragm pr ing ingers or he igh t

using he special ool and eelergauge. f the height

is more han he service imit, replace he pressure

ptate.

Standard Newl: 0.6 mm (0.02 n. )max.

ServiceLimit: 0.8mm {0.03 n. )

07zAF-PR8A10007936-3710100OTJAF-PM7O11A

2. Ins ta l l t he pec ialoo ls .

A

\-

A-.- nl I\ffim

9fra-I tP

|-07LAB-PV00100r07924-PD20003

To prevent arping, nscrewhe pressure late

mounting oltsA)

n a crisscrossattern

n sevesteps,hen emovehepressure late B) .

Inspecthe ingers f hediaphragm pring A) orwearat herelease earing ontact rea.

5. Inspect he pressure late1A ) urfaceforwear,

cracks. nd burning.

(cont'

12



ClutchReplacementcont'd)

6. Inspecl or warpageusinga straightedge A) an dfeelergauge B) . \4easure cross he pressure late(C). f th e warpage s more han he service imit,

replace he pressure late.

Standard New): 0.03mm (0.001n.) max.


7 . Removehe c lu tch i scandsDec ia l too ls .

Inspect thein ing f the c lu tch i sc o r s igns f

s l i pp ing r o i l . f hec lu tch i sc s burned lack r

oil soaked. eolace t.

1 d

9. lvleasue h e clutchd sc h ckness.fthethickness

is ess han he service imit, replace he clutchdisc.

Standard New): 8.3 8.9 mm

(0.33 0.35 n.)ServiceLimit: 6. 0mm {0.24 n.)

Measure he rivet depth rom the clutchdisc ining

surface A) o the rivets B)on both sides. f the

rivetdepth s less han he service imit, replace he

c lu tch i sc .

Standard New): 1.65 2.25mm(0.065 0.089 n.)

ServiceLimit: 0.7mm (0.03 n.)

10 .

L



Flywheel nspection

1. Inspect he ringgear eeth o r wear an d damage.

2. Inspect he clutchdisc matingsurfaceon the

flywheel or wear,cracks, nd burning.

3. Measure he flywheel A) runoutusing a dialindicator B) hrough at east wo full tur ns. Pushagainst he flywheeleach ime you turn it to take upthe cranksh ft h ustwasherclea ance . f the

runout s more han he service imit,replace heflywheeland recheck he runout.Resurfacingheflywheel s not recommended.

Standard New): 0.05mm (0.002n.) max.


FlywheelReplacement

1. Ins ta l l t he pec ia loo l .

2 .

3.

4 .

Remove he flywheel mountingbolts n a crisscropattern n severalsteps, hen remove he tlywheel

Installthe lywheelon the crankshaft, nd nstall

the mountingbolts ingertight.

Ins ta l l t he pec ia l too l ,hen orque he l ywhee l

mountingbolts n a crisscross attern n several

sreps.

12x 1 .0mm10 3N. m(10,s st.m.76 bf f t l

(cont'

12-



ClutchReplacementcont'dl

ClutchDiscand PressurePlate nstallation

' LTemporar i l yns ta l lhec lu tch i scon to thesp l ines

of the transmissionmainshaft,Makesure he clutch

discslides reelyon the mainshaft.

2 . l ns ta l l t he inggearho lder .

{P/N08798-9002)

07LAB-PVo0'100r0792,1-PD20003

Apply superhigh emp ureagrease P/N08798-

9002) o lhe splines A) of the clutchdisc(B), he n

install he clutchdisc using he special ools.

Installthepressure late A) and he mounting

bolts B) inger-tig t.

\---,/ v

07936-3710100

3.

O?ZAF.PRSAIOO

12-12

5. Torquehemounting olts n a crisscrossattern,Tightenhe bolts n several tepso preventwarp inghediaphragmpr ing.

PRESSURELATE OUNTING OLT OROUE:25 N.m 2. 6 gt.m, 9 bt.ft)

o

Remove he special ools.

Makesure he diaphragmspring ingersare all he

samehe igh t .

1 .



Release earingReplacement

'LRemove he release ork boot (A)from th e clutchhous ing B) .

Xrl-RlI t \ ' 1f-l\-._

- A

Remove he release ork (C)from he clutchhous ing B)by squeez inghe e leaseorkse tspr ing(D)wi thp l ie rs . emovehe re lease ear ing E) .

Check he release earing or playand noiseby

sp inn ingt by hand. f here s excess ive layorno ise , ep lacehe re lease ear ing i t h a newone.

NOTE:The release earing s packedwith grease.

Do not wash t in solvent.

2 .

3.

4. Apply super high emp ureagrease P/N08798-

9002) o the release ork (A), he release ork bolt(B) , he e lease ear ing C) , nd he re lease ear ingu de D) n heshaded reas.

1 .0 1 .610.04 0.06oz )

l- '..\\ \ \ \

!ac\ ) ) /

/ - /

0 .4 1 .010.01 0.04o

7 .

{re\I L!),l-*E

6.

" 0. t 1. 0 (0.01 0.04 z)

With th e release ork slid between he release

bear ing awls . ns ta l l t he e lease ear ing n he

mainshaf t h i le nser t inghe re leaseork hrough

the ho le n hec lu tch ous ing .

Align the detentof the release ork with the releasfork bolt, hen press he release ork over he

re leaseorkbo l tsquare ly . ake ure he re lease

forkse tspr ing F) s proper ly e t .

Ins ta l l t he e leaseorkboot E) .Make ure he boo

sea ls round he re leaseorkandc lu tch ous ing .

Move he release ork (A ) right and eft o make

sure ha t t i t sp roper ly ga ins the re lease ear in(B)and hat he re lease ear ing l i des mooth ly .

8 .

12-



ManualTransmission

Spec ia lToo lsTransmissionluid nspection

andReo1acement. . . . . . . . . . . . . . . . . . - .Back-UpightSwitch est ..........TransmissionemovalTransmissionnstallation..........Transmissionisassemblv.. . . . . .ReversehiftForkClearance

lnsoectionChange ever learance

lnsoectionChange ever ssembly

Disassembly/Reassembly.. . . . .ShiftForks learance

InspectionShiftForks

Disassembly/Reassembly.. . . . .Mainshaft ssemblv

Clearancenspection

Mainshaft isassemblyMainshaftnsoectionMainshaft eassemblyCountershaftssemblv

ClearancenspectionCountershaftisassembly.. . . . . . .Countershaftnspection .......... ..Countershafteassembly.. . . . . . . .Synchro leeve ndHub

InspectionndReassembly.. .

Synchro ing ndGearInsoection ....... 3-39

Mainshaft earing ndOilSealReplacement. . . . . . . . . . . . . . . . . . . . . . . , . . .3 -41

Cou ter shaft earingReDlacement .. 13-42

MainshafthrustClearanceAdiustment .. . . .13-43

Transmissioneassemblv........ 3-46Gearshift echanism

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . .3 -51

M/T DifferentialComoonentocationndex ........ 3-52Backlashnspection... . . . . . . . . . . . . . . . . .3-53FinalDrivenGear/Carrier

Replacement .. 13-53Carrier earings eplacement.. 13-54OilSealReplacement.. . . . . . . . . . . . . . . .3-55

DifferentialhrustClearanceAdiustment .....13-56

13-2

| 5-J

tJ - 5

13-4I J-at

1 3 - 1 4

13-19

13-19

13-20

13-21

13-22

13-23't3-25

13-26| 5-2.5

13-3113-3213-3313-34

13-39



Transmission luid nspection ndReplacement

'1 .Park he vehicleon levelground,and urn the

eng ineOFF.

2 . Removehe o i l f i l l e rp lug A)andwasher B) , heck

the conditionof the fluid, an d makesure he fluid s

at he proper evel C) .

l f he ransmiss ionlu id sd iny , emove he dra inp lug D)anddra in he lu id .

A44 N.m{4.5 gt.m,33 br.ftl

Reins ta l lhedra inp lugwi th a newwasher , nd

refi l l he transmission luid to the proper evel.

Oil Capacity1. 50 (1.6US (F )at t luid change

1. 70 {1.8US qt ) at overhaul

Always useHondaManualTransmission luid(MTF).Usingmotor oil can causestiffershift ing

and noisebecause t doesnot contain he proper

additives.

Re ins ta l lhe o i l i l l e rp lugwi tha newwasher ..

13

Back-Up ight SwitchTest

1. Disconnectthe ack-up ight switch (A )connector.

Check or continuitybetween he back up ightswi l ch Pconnector o.1 andNo.2 ermina ls .

Thereshouldbecontinuitywhen the shift ever s i

reverse.

lf necessar y, eplace he back-up ight switch.

App ly iqu id aske t P/N 8718-0001) ,nd ns ta l l t

on he ransmiss ionous ing .

2 .

3.



ManualTransmission

Transmission emoval

SpecialToolsRequired. Eng ine anger dapter .2 .0o 2 .4 i t e rVSB02C000015. Eng ine angerVSB02C000018.

Engine upporthanger,A & RedsAAR'T 12566'. SubframeadaDter OS02C000011* Ava i lab lehrough he Honda oo landEqu ipment

Program888-424-6857

NOTE:Us e endercovers o avoiddamagingpainted

surfaces.

4 .

1 .

7 .

Write down the frequencies or the radio'spreset

buttons.Disconnecthe negative ) cable irst,

then he posit ive )cable rom the battery.

Remove he battery.

Remove he intakemanifoldcover se epageg-3).

Removehea i rc leaner ous ing see age11-162) .

Remove he intakeair duct {seestep8 on page5-3).

Remove he battery ra y (A).

D isconnecthe ransmiss ionround ab le B) .

Disconnecthe ba ck-up ight switch connector A)

andveh ic le peed ensor VSS) onnectorB) .

13-4

8. Remove he cable bracket A) . hen disconnecthe

cab les B) rom he op o f he ransmiss ionous ing .

Carefully emoveboth cablesan d he bracket

togetherso as not o bend he cables.

9. Removeheharness l ip .

I

H A @

i l B



10 . Carefully emove he slavecylinderand clutch ine

bracket o as not o bend he clutch ine. Do not

operate he clutchpedalonce he slavecylinderha s

beenemoved,

Remove he enginewire harness over (A) bylift ingup on the lock ab (B), hen slide he harness

fo rward f f thea i rc leaner ous ingmount ing

bracket C).

1 1 .

12. Attach he special ool to the threadedhole in th e

cy l inder ead.

vsB02c0

I ns ta l l t he ng ine anger A)and he eng ine upp

hanger B) o the vehicle, hen attach he hook o t

sDeciai ool.

t J .

1 4 .

vs802c000015

Remove he two upper ransmissionmounting

bolts.

(cont'

13



Transmission

Transmission emoval cont'd)

15. Remove he transmissionmount bracket A)an d

t ransmiss ion ount ing o l t B ) .

Removehe a i rc leaner racke tC) .

Ra iseheveh ic le , ndmake ure t s secure ly

supponed.

Dra in he ransmiss ionlu id .Re ins ta l lhe d ra inbo l t

w i th a newwasher see age13-3) .

Removehe sp lash h ie ld .

€Ds

t o .

1 7 .

1 8 .

1 9 .

db-qF

20.

21.

22.

23 .

Remove he threeway catalytic onverter TWC)

assembly se estep30 on page5-5)

Remove he driveshaftsse epage16-3).

Remove he intermediate haft seepage16-19).

Remove he front enginemount bracketmounting

bolt.

Remove he three boltssecuring he transmission

rearmounI .

24 .



25. Support he subframewith th e subframeadapter

and a ack.

- - -

26.

EOS02C000011

Make eferencemarks A) on the front suspension

subframe B)an d mountingbolts C) . hen remove

th e front suspension ubframe.

27. Remove he clutchcover.

28 . Removehe ron teng inemount .

P lacehe ransmiss ionackunder he ransmiss i

an d remove he transmissionmountingbolts.29 .

(con

13



\

12x 1 .25mm64 N. m{6.5ksf.m,47 tbf.ft)

30.

TransmissionRemoval cont'd)

Pull he transmission way rom the engineuntilthe transmissionmainshaft lears he clutchpressure late, hen lower he transmission n th etransmissionack.

Remove he transmission ear mount (A )and hetransmission ear mount bracket B).

Remove he boot (A), he release or k {B).and he

re lease ear ing C) rom he ransmiss ionD) .32.

Transmissionnstallation

Special Tools Required. Enginehangeradapter, .0 o 2.4 iterVS802C000015. Eng inehangerVS802C000018. Engine upporthanger,A & RedsAAR-T-12566". subframe adaDterEoS02c000011* Available hrough he HondaTool and Equipment

Program888-424-6857

1. Check he two d owel pinsare nstalled n the clutchhousr g .

Apply super high emp ureagrease P/N08798-

9002) o the relea se ork (A) and he releasebearing(B). nstallthe elease ork and he release earing.

0.4 1.0 {0.01 0.04 zl

3 . Ins ta l l t heransmiss ionearmountbracke tA)and

the ransmiss ionearmount B) .

x 1 .25mmN m {6.5 gf.m,

Placehe ransmiss ionn he ransmiss ionack.an d raise t to the engine eve l.

't 2

6447

1. 0'1 .6g

{0.04 0.06oz )



5 . Ins ta l l he t r ans mis s ionmoun t i ng

12x 1 .25mm64 N.m 16.5 gf m.47 lbt f t)

12x 1 .25mm64 N. m (6.5 gf.m,47 bf. f t)

6 . Ins ta l l t he r on t eng ine moun t .

12x 1.25 trn64 N. m(6.5kgf m. 47 lbf.ft)

bolts.

12x 1.25mm64 N. m(6.5 st.m,47 bf t)

7 . l ns ta l l t he c lu tc hc ov e r .

6 x 1 . 0 m m12N. m {1.2 gI.m,9 lbf tl

8. Supportthe subframewith the subframeadapter

anda ack.

Ins ta l l t heron tsuspens ionubf rame A) n ts

or ig ina l os i t i on y a l ign inghe marks B) ou

made n the removalprocedure,

9 .

14x 1 .5mm

(cont

13



Transmissionnstallationcont'dl

'10.Installthe hree rearmountingbolls or th etransmission earmount.

59N. m 6. 0 gf.m,43bf.ft)

Loosely ighten he front enginemount bracketmountingbolt.

1 1 .

12 .

t 5 .

1 4 .

Install he ntermediate haft seepage16-24).

Installthedrivershafts seepage 16-17).

lnstall he threewa y catalytic onverter TWC)

assembly seestep 17on page5-12).

10 x 1.25mm

6 x 1 . 0 m m1 2 N m

15 .Install he transmissionmount bracket A)and het ransmiss ion ount ing ol t B) .

12x 1 .25mm

54 N.m {5.5 sf.m,40lbf. f t)

12x 1.25nn54 N.m(5.5 gf.m,40 tbt.ft)

1 6 .

1 7 .

/t':::= 12 x 1.25mm-) 54 N.m

(5.5 gf.m,40 tbf.ftl

Install he air cleanerbracket C).

Install he two upper ransmissionmountingbolts.

12 1.25mrn64N. m 6. 5 gt.m,47bf.ft l

18 . Removeheeng ine anger ndspec ia loo l romengrne .



19. Tighten he front enginemount bracketmounting

bolt.

'1 2x 1.25mm

64 N.m 16.5 gf.m,il7 lbf.ft)

20. Ins ta l lhesp lash h ie ld .

21. lnstallthe brakeboosteran d EVAP ine bracket

mounting bolts A).and air cleanerhousingbrack

mount ing o l t B) . igh ten he a i rc leaner ous in

bracketmountingbolt (C),an d nstall he water

pipe mountingbolt (D).

A9. 8N. m(1 ,0 q f

%,

' B

22N. ml2.2kglm,

16 bt.ft)

9 . 8 N m(1.0 gfm.7.2 bl{rl

22.

2 2 N m{2.2 gf m, 16 bf t)

Ins ta l l t he ng ine arness over .

(cont

1 3



ransmission

Transmissionnstallationcont'dl

Apply uper igh empurea reaseP/N 8798-9002)o heen dof heslave ylinder od. nstallheslave ylinder nd heclutch inebracket.ake ar enot to bend the clutch l ine.

8 x 1.25mm22 N.m (2.2kgf.m, 16 bf ft)

6 x 1 . 0 m m9. 8N. m(1.0 gf.m,7.2 tbt.ftl^_

#._gEEa9En(P/N08798-9002)

24 . Ins ta l l t he arness l i p .

25 . Ins ta l l t he ab le racke tA)andcab les B) .

BWZ[i:i'u'T!'*n'-'

lPlN 08798-9002)

Apply a lightcoat of superhigh emp ureagrease(P/N08798 9002)to he cableends.

Connect he back-up ightswitchconnector A) an dtheveh ic le peed ensor VSS)connectorB) .

26.

t1



28. Connect he transmission roundcable A) .

8 x 1.25mm

B

22 N.m (2.2 gf.m,16lbf.ft)

[---.-.---ee

6 x 1 , 0 m m9.8 N.m{1.0 gl m. 7 lbf f t l

29 .

30.

8 x 1 2 5 m m2 2 N m12.2 gt m, 16 bf ft)

lnstall he battery ray (B).

Installthe ntakeair duct (seestep36 on page5-14).

Ins ta l l t he i rc leaner ous ing see tep39 on page

5-15) .

Installthe ntakemanifoldcover se estep 41 on

page5-15) .

Install he battery.Connecttheposit ive +) cable

first, hen he negative -)cable to the battery.

Ref l l l t heransmiss ionlu id see age13-3) .

Test-drive he vehicle.

Check he clutchoperation.

Check he front wheel alignment seepage18-4).

Enter he anti-theft ode or the radio, hen enter

th e customer's adiostationpresets.

Do he eng ine ont ro lmodu le ECM)d le earnprocedure see age11-139) .

32.

33 .

34 .

35 .

36.

3 1 .

38.

39 .

13



Transmission isassembly

Exploded iew-Clutch ousing

,.Y

-'- R

,ot/u

,t - v -1A' i6 t3 l

\?q'/V^

.!) DIFFERENTTALSSEMBLY

r2 lSHIFT ORKASSEMBLY

a9l mm FLANGEBOLT12N. m 1 .2 g f m,9 lb f f t l

..4] EARING ET PLATE

G, COUNTERSHAFT SSEMBLY

O NEEDLE EARING

3 OI LGUIDEPLATEC

e 14 x 20 mm DOWELPI N

.9-iMAGNETi.!!MAINSHAFTASSEMBLY

U 28 mm WASHER

t€4

i[, 28 mm SPRINGWASHERiO BALLBEARING(l 28 x 43 x 7 mm OIL SEAL

R ep lac e .

.D REVERSE EA RSHAFT

1' REVERSEDLERGEAR

f r 6 mm SPECIALBOLT15 N.m (1.5 gt.m,11 bf.ft)

(!I REVERSE HIFTFORK

.4' REVERSE OCKCAM

Q-t 5 x 58 x 8 mm OIL SEALR ep lac e .

n""

?]] BACK-UPLIGHTSWITCH29 N m (3.0 gf.m,22 bf tl

.?1O.RINGReplace.

1! ) EHICLEPEEoENsoRVss).O8 mm FLANGE OLT

22 N.m (2.2 gf m, 16lbf.ftl

. ' CLUTCH OUSINGiI6) RANSMISSIONHANGER

tl 10 mm FLANGE OLT44 N.m {4.5 gt.m,33 bf.ft}

:

r'<__J'.@t / ,,tl

' j=-X ri ,1.-6' -==-Yh,_-9



o,. @\'\b eP \ B

z-W €:i q { "

Exploded iew-Transmissionousing

@------

t t -P

"= -@

{i) 80 mm SHIM0 8 x 14mm DOWEL IN

[A CHANGE EVER SSEMBLYa06 mm FLANGE OLT

12N m {1.2 gf.m,9 bf t}

O DETENTOLT22N. m 2. 2 gf.m, 6lbf.ft)

O 12mm waSHERReDlace.

(D SPRING

[I STEELBALL(D TRANSMISSION ANGER(9 CLUTCHLINE CLIPBRACKET

@

rai\€:/

o

f /dd

\@

O=-rlF,z

O TRANSMISSION OUSING

O 10 mm WASHERReplace.

@ 10 mm FLANGEBOLT44 N.m {4.5 gf.m,33lbf.ft)

O 8 mm FLANGEBOLT27 N.m 12.8 gf m,20lbl.ft)

.' TRANSMISSIONHANGERA

O INTERLOCK OLT39 N m (4.0ksf.m,29lbf.ft)

O OILGUIOEPLATEM

€.1 2 mm SHIM

.' OIL GUTTEBPLATE

,-1 _\

(g/----------__-"^\

\-/r*---------..-,

@)20 mm WASHERR ep lac e .

q,]FILLERPLUG44 N m {4.5 gf.m,33 bf.f t)

@ 40 x 56 x 8 mm OILSEAL

Replace.qO 4 mm WASHER

Replace.

q' DRAIN PLUG39 N. m (4.0 gf.m,29 bf.f t l

@ 32 mm SEAL INGCAP34 N m (3.5kgf.m, 25 lbf.ft)

o

(con

13



ransmission

TransmissionDisassemblycont'd)

NOTE:Place he clutchhousingon two piecesof wood

thickenough o keep he mainshaft ro m hitt ing he

workbench.

1. Remove he detentbolts A),springs, teelballs,

an d back-up ight switch(B).

Remove he vehiclespeedsensor VSS) A)and

O-r ing B) .

13-16

3, Remove he interlockbolt (A), he change ever

assemblyB) , x 1 4mm dowelp ins C) , nd the

c lu tch inec l ipbracke tD) .

€

Removehe dra inp lug A) , i l l e rp lug B) , nd

10mm f lange o l t C) .



6.

5. Remove he 8 mm flange bolts n a crisscross

Datternn severalsteos.

Remove he transmission angerA, andt ransmiss ionangerB.

Removehe32 mm sea l ing ap A) .

Expandhe72 mm snap ing B)on he

countershaft all bearing,an d remove t from the

grooveusinga pairof s nap ring pliers.

Removehe ransmiss ionous ing C) nd

14x 20mm dowelp ins D) .

7 .

L

10. Remove he reverse oc kcam.

g

t.l Yg

1 1 .Remove he reverse dlergear {A) and reverse ea

shaf t B) .

(,

^ A

(cont

13-



Transmission

TransmissionDisassemblycont'd)

12. Remove he reverse hift ork.

Apply vinyl tape o the mainshaft plines o protect

the seal, hen remove he mainshaft ssembly A)and countershaft ssembly B)with the shift orks

{C) f rom hec lu tch ous ing D) .

14 . Removehe28 mm spr ingwasher E) nd28mm

washer F) .

t7t 1I

15. Remove he differential ssembly A) and magnet( B) .

Remove he oil gutterplate A) ,72mm shim (B),ando i l gu idep la teM.

1 6 .



Reverse hift ForkClearanceInspection

1. Measure he clearance etween he reverse dler

gearA)

and he reverse hift ork (B )with a feeler

gauge C) . f the clearances more than he service

limit, go to step2.

Standard: 0.20-0.59 mm (o.oo7 0.024 n.l

ServiceLimit: r.3 mm {0.051n. )

Measu e he width of the reverse hift ork.

. l f d i s tances no tw i th in thestandard ,ep lace the

reverse hift ork with a new one.. lf distance s within the standard, eplacethe

reverse ea rwrln a new one.

Standard:13.4 13.7mm (0.527 0.539 n. l

I

ChangeLeverClearancenspectio

1 . Measure heclearance etween hange ever Al

and he select ever B)with a feelergauge Cf. f

the c learances more han heserv iceimi t , o ro

step 2.

Standard: 0.05 0.25mm (0.002-0.010 n.)


2. Measure he grooveof the change ever'

. lf distance s not within the standard, eplace h

changeeverw i th a newone.. l f d i s tanceswi th in the tandard ,ep lace the

select everwith a new one.

15 .00 15 .10mm (0.591-0 .594n. )tandard:

,tlIq I

13



Transmission

ChangeLeverAssemblyDisassembly/Reassembly

Prior o reassembling, leanall he parts n solvent,dry them, and apply ubricant o any contactsurface.

BREATHERAPTurn hearrow oward he ronto{ hevehicle,nd nstallt.

SELECTEVER

Becareful ot o damagehedust ealwhen ns ta l l i ngt .@).1 Il L r lr r lI

DUSTCOVEB

a^^7 Fr"irr6-rooa

(P/N 08798-9002)

ROLLER

6 x 1 . 0 m m12 N.m(1.2

gl .m,8.7 bf. f t)

'^E-='-

Fl !-d 1sr/2Noq )-=^l sELEcr

i €2

sPntruc

,.*(A)tace.ix#,,l

H\lV srx

SELECT-z:-=:l-': SPRINGr \tr7,/u

/

\op

(g)'\r' -, OILSEAL

,/ ReDlace./-r,s

\__/

INTERLOCK

SHIFT RM

SELECTSTOPPLATE

REVERSEOC KCA MSTRIKER

SHIFTARM COVER

WASHER

9 . 8 N m{1.0 gf.m,7.2 bf. f t)



Shift ForksGlearancenspection

NOTE:Th e synchrosleeveand synchrohub shouldbe

replaced s a set.

1. Measu e he clearance etweeneachshift or k (A )

and ts matchingsynchrosleeve B) . f the

clearance xceeds he service imit,go to step2.

Standard: 0.35 0.65mm {0.014 0.026in.1

ServiceLimit: 1.0mm 10.039n.l

A

l\4easurehe thickness f the shift ork f ingers.

. l f he th icknessofhesh i f t o rk f inger s no t

within the standard, eplace he shift ork with a

new one.. l f he th icknessofhe sh i f t o rk f inger sw i th in

the standard, eplace he synchrosleevewith anew one.

Standard:7.4 7.6 mm (0.29-0.30 n.)

2 .

3. Measure he clearance etween he shift ork (A )

an d he shift arm (B). f th e clearance xceeds he

service imit,go to slep 4.

Standard: 0.2-0.5 mm (0.007 0.020 n. )


Measure he width of the shift arm.

. l f hewid thof hesh i f ta rm s no tw i th in the

standard, eplace he shift arm with a new one.. l f hewid tho f hesh i f ta rm swi th in the tanda

replace he shift ork and shiftpiecewith a ne w

one.

Standard:16.9-17.0 mm (0.665-0.669 n. )

4 .

13



ManualTransmission

Shift ForksDisassembly/Reassembly

Prior o reassem bling, leanall he parts n solvent,dry them, and apply ubricant o any contactparts.

sTH SHIFTFORK

13-22

PINDRIVER, mm



MainshaftAssemblyClearancenspection

NOTE: f replacements required, lwaysreplace he

synchrosleevean d hu b as a set.

1. Support he bearing nner acewith an appropriate

sizedsocket A).an d pushdown on the mainshaft(B) .

Measure he clearance et\ iveen nd (C)and 3rd (D)

gearswith a feelergauge E) .

. l f he c learances more han heserv iceimi t . o

to step3.. lf the clearance s within the service imit, go to

step4.

Standard: 0.06 0.16mm

{0.002 0.006 n.l

ServiceLimit: 0.25mm (0.010n. l

Measure he thickness f 3rd gear.

. l f he th ickness f 3 rdgear is ess thanthe erv ice

l imi t , ep lace rdgearw i tha newone.. l f he th ickness f 3 rdgear isw i th in theserv ice

limit, replace he 3rd/4thsynchrohub with a new

one.

Standard: 23.92-23.97 mm(0.941 0.944 n.)


4. Measure he clearance etween4t hgear (A )an d

thed is tance o l la r B)w i th a dia l nd ica to rC) .

. lf the clearances more than he service imit,go

to s tep 5.. lf the clearances within the service imit, go to

step7.

Standard: 0.06 0.16mnl(0.002 0.006 n.)


MeasuredistanceO on the distance o[ar .

. lf distance't is notwithin the standard, eplace

th e distance ollarwith a ne w one.

. lf distancee is within the standard, o to step6

Standard: 24.03 24.08mm

{0.946-0.9/un. }

(cont

13-



ManualTransmission

MainshaftAssemblyClearancenspection cont'd)

6. Measure he thlckness f 4t hgear.

. l f he th ickness f 4 thgear s ess thantheserv ice

limit, replace4t h gearwith a new one.. l f he th icknessof thgear isw i th in heserv ice

limit. replace he 3rd/4thsynchrohub with a new

one.

Standard: 23.92 23.97mm(0.941 0.944 n. )


7. l\4easurehe clearance etween he distance ollar(A )andsth gear B)wi th a d ia l nd ica to rC) . f the

clearances more han he service imit.go to step

8. f he c learanceswi th n heserv iceimi t ,go o

steD10 .

Standard: 0.06 0.16mm(0.002-0.006 n.)


13-24

Standard:

Standard:

Service Limit:

8. MeasuredistanceO on the distance ollar.

. l f d i s tance is no tw i th in thestandard ,ep lace

th e distance ollarwith a new one.' l f d i s tanceO swi th in the tandard , o tos tep9.

24.03 24.08mm(0.946 0.947n. )

9. Measure he thickness f 5th gear.

. l f he th icknessof thgear is ess thantheserv ice

limit, replace5t h gearwith a new one.. lf the thickness f st h gear swithin the service

limit. replace he 5th synchrohub with a new one.

23-92 23.97mm10.9410.944n. l23.80mm (0.937n. l



' 10 .Measurehe h ickness f the MBSdis tance o l la r .

. l f he h ickness f MBSdis tance o l la r s ess

than he standard, eplace he MBS distance

co l la rw i th a new one.

Standard: 23.95 24.05mm{0.9(3 0.947n.)

E- f

MainshaftDisassembly

1 . R e m o v ehe angu la r a l lbear ing A)and he

taperedcone ring usinga commerciallyavailable

bear ing epara to rB)anda commerc ia l l yva i lab

bear ing u l le r C) .Besure he bear ing epara to rs

under he apered one ing .

Support5t h gear (A) on steelblocks,an d press he

mainshaftout of the sth synchrohu b (B).Use of ajaw-typepullercan damage he gear eeth.

(cont

13-



ransmission

MainshaftDisassemblycont'dl

3. Supportthe3rd gear (A) on steelblocks,and press

th e mainshaftout of the 3rd/4thsynchrohub (B).

Us eof a aw-typepullerca n damage he gear eeth.

Mainshaftnspection

1. Inspect he gearsurfaceand bearingsurface orwearanddamage,henmeasurehe mainshaf t tpointsA, B,C, D,an d E. f an y partof the mainshaft

is ess han he service imit, reDlacet with a ne w

one.

Standard:

A Ball bearingsurface transmission ousingside):

27 .987 28 .000mm (1.1019 1.1024 in . )

B Distance collar surtace:

31.984 32.000mm {1.2594 1.2598in.)

C Needlebearing surlace:

38.984-39.000mm (1.53/t8 1.5354n. )

D Ball bearingsurface clutchhousingside):27 977 27 .990mm (1.1015 1.1020 in . )

E Bushing surface:

20.80 20.85mm (0.819 0.821 n.)

ServiceLimit;A : 27 .93mm 11.100n. l

B: 31.93 mm |.1.257n.l

C: 38.93mm 11.533n.l

Di 27.92mm {1.099n. l

E: 20.75mm 10.817n. l



SpecialTools Required. Dr iver ,40mm 1.D.07746-0030100. Attachment,30mm l.D.07746-0030300

NOTE:Refer o the ExplodedView as neededduringthis procedu e.

2.

4 .

'1 .Cleanall he parts n solvent,dr y them, and apply

lubricant o all contactsu faces xcept he 3rd/4th

and 5th synchrohubs.

Ins ta l l t he eed le ear ing nd3rdgearon he

mainshaft.

I ns ta l l t he ynchro ingand he synchro p r ing .

Ins ta l l t he rd /4 th ynchro ub A)by a l ign inghe

synchro ing ingers B)with 3rd/4thsynchrohu bgrooves C) .

- A

lnstallthe3rd/4thsynchrohu b {A ) using he special

too l .

07746-0030100

6. Installthe3rd/4thsynchrosleeve A) by aligning

the stops B)with the 3rd/4thsynchrosleeveand

hub.After nstall ing, heck he operationof the 3rd4t h synchrohub set.

@--

7. Ins ta l l t he ynchro pr ing A) .

Ins ta l l t he ynchro ing B)by a l ig ing he synchro

cone ingers C)with3rd/4thsynchrohu b grooves(D) .

Ins ta l l t he thgear , eed le ear ing , i s tance o l la

need le ear ing , ndsthgear .

(cont

9 .

13-



ManualTransmission

MainshaftReassemblycont'dl

10. Ins ta l l t he ynchro ingand he synchro p r ing .

11.

Ins ta l l t he thsynchro ub A)by a l ign inghe

synchrocone ingers B)with sth synchrohu bgrooves C).

Ins ta l l t he thsynchro ub A)us ing hespec ia l

too ls .

07746-0030100

07746-0030300

13. Ins ta l l t he thsynchro leeve .

12 .

13-30

\.

\

14. Ins ta l l the ynchro p r ing A) .

Ins ta l l t he ynchro ing B)by a l ign inghesynchrocone ingers C)with sth synchrohu b grooves D) .

Ins ta l l t heMBSdis tance o l la r nd he apered

cone ing .

Ins ta l l t he ewba l lbear ing A)us ing he spec ia l

too lsanda press B) .

t 5 .

1 6 .

1 1 .

U

07746-0030100



Countershaft ssemblyClearancenspection

1 .Measure he clearance etween he 1s tgear A)

and hed is tance o l la r B)w i tha fee le r auge C) .

. l f he c learances more han heserv iceimi t ,go

to step2.. l f he c learanceswi th in he serv iceimi t . o o

step4.

Standard: 0.06 0.16mm 10.002 0.006in.lServiceLimit: 0.25mm (0.010n. l

2. fvleasurehe thickness f the distance ollar.

. l f he th icknesss no tw i th in he s tandard ,ep lacethe d is tance o l la rw i tha newone.

' lf the thickness s within the standard, o to

Standard: 23.03 23.08mm (0.907 0.909n.l

3. Measu e he thickness f the 1stoear.

. l f he th icknessofs t gear i s ess thanthe erv i

l imi t , ep lacestgearw i th a newone.. lf the thickness f '1stgear s within the service

limit, replace he lst/2nd synchrohub with a ne w

one.

Standard: 22-92 22.97 mm 10.902 0.904 n.l

ServiceLimit; 22.87mm {0.900n. )

Measure he clearance etween he 2nd gear (A )

and3rdgear B)wi th a fee le r auge C) . f heclearances more han he service imit,go tosteD5.

Standard: 0.06 0.16mm (0.002 0.006in.)

ServiceLimit: 0.25mm {0.010 n. l

4.

(cont'

13-



Manual ransmission

CountershaftAssemblyClearanceInspection cont'd)

5. Measure he h c kness f the distance o llar.

. l f he th icknesss no tw i th in he s tandard ,ep lace

the distance ollarwith a ne w one.. l f he th icknessswi th in the tandard , o to

step6.

Standard: 28.03 28.08mm {1.104-1.106 n. )

6. Measure he thickness f the2n d qear.

. l f he th ickness f 2ndgear is ess than he

service imit, replace2n d gearwith a ne w one.. l f he th icknessof ndgear isw i th in theserv ice

limit, replace he 1sV2nd ynchrohub with a new

one.

Standard: 27 92-21.97 mm|.1.099 1.r01 n.l

ServiceLimit: 27.87mm 11.097n. )

13-32

CountershaftDisassembly

1 . Securely lamp he countershaft ssembly n a

benchvlse with wood blocks.

Remove he specialbolt (left-handhreads).

Support he ball bearing A) on steelblocks, hen

use a press B)and an attachment C)to press he

countershaft ut of the ball bearing.

4 . Removehe35 mm sh imandd is tance o l la r .



5. Support thgear A)on steel locks,henus eapress ndanattachmentB) o presshecountershaftC) utofthe 5thgear.

6. Suppor t2n d gear A) on steelblocks, hen use a

Dress nd an attachment B} o press he

countershaft C)out of the 3rd gear.

Countershaft nspection

1. Inspect he gearsurfaceand bearingsurface orwearanddamage,henmeasurehe countershaat pointsA, B , andC. f an y partof the countersha

is less han he service imit, replace t with a new

one.

Standard:

A Ballbearingsurface transmission ousingside

30.02030.033mm {1.1819 1.1824 in . )

B Distance ollarsurface;39.937- 39.950mm 11.5723 1.572An. l

C Needlebearingsurface clutchhousingside):

35 .000 35 .015mm {r .3780-1 .3785n. )

Service Limit:

A: 29 .97mm {1.180n. )

B: 39.88mm {1.570 n.l

C: 34.95mm {1.376n. )

lnspect he runoutby supportingboth ends of he

countershaft. otate he countershaftwo completrevolutionswhen measuring he runout. f the

runoutexceeds he service imit, replace he

countershaft ith a new one.

Standard: 0.02mm (0.001n. )max.


2 .

13-



Manual ransmission

CountershaftReassembly

Exploded iew

SPECIAL OLTEeplace.118N.m 12 gfm,87 bf t )

BALL BEARINGCheck or wear andoperation.Note he direction f installation.

35 mm SHIM

REVERSE EAR

1ST/2ND YNCHROUB

SPRING

TRIPLECONESYNCHRO

1S TGEAR

NEEDLEEARINGCheckorwearan oopera!on.

DISTANCE OLLAR

ANCE COLLAR

GEAR

4THGEAR

Check or wear an doperation.

DISTANCECOLLAR

FRICTIONDAMPERCheck or wear and damage.

TRIPLECONESYNCHRO

SYNCHROSPRING

COUNTERSHAFT

13-34



SpecialToolsRequired. Driver, 0mm .D.07746-0030100. Aftachment.30 m 07746-0030300

NOTE: efero heExploded iewasneeded uringlhisprocedure.

1. Clean llpartsnsolvent, ry hem,andapplylubricantto llcontact urfaces.

I ns ta l l t he is lance o l la r , eed le ear ing , nd 1s tgearonto he countershaft.

Install he triple conesynchroassembly A)by

aligning he synchrocone ingers B)with'lstgear

grooves C) , hen install he synchrospring D) .

3.

I ns ta l l t he1st /2ndsynchro ub A)by a l ign inghesynchrocone ingers B)with 1sV2nd ynchrohu bgrooves C) .

5 . Ins ta l l t heeverse ear .

13-

6. Ins ta l l t he ynchro p r ing A) .

lnstall he riple conesynchroassembly B)by

aligning he synchrocone ingers C)with the1sv2ndsynchrohu b grooves D) .

Installthedistance ollar A)an d rictiondamper(B )by aligning h e frictiondamper ingers C)with

th e 1sv2ndsynchrohu b grooves D) .

1 .

8 .

(con t '



ManualTransmission

1 0 .

CountershaftReassemblycont'dl

9 . I n st a llheneed le ear ing .

Ins ta l l t he ndgear A)by a l ign inghe synchro

cone ingers B)with znd geargrooves C).

' l1. Supoort he countershaftA)on the steelblocks,

then ns ta l lhe 3 rdgear B)us ing he spec ia loo l

and a press C).Do not exceed he maximum

Dressure.

14,700N (1,500 gf ,3,307 bflmax.

07746-0030100

13-36

L,

12. Ins ta l lhe 4 thgear A)us ing hespec ia l too l ndapress B).Do not exceed he maximum pressure.

B

14,700 {1,500gt ,3,307bf) max.

07746-0030100

Ins ta l l t he thgear A)us ing hespec ia loolandapress B) .Do not exceed he maximum pressure.

14,700N (1.500 gl ,3.307 bf) max.

07746-0030100



ManualTransmission

CountershaftReassemblycont'd)

1 1 .Support allbearingA)on steel locksB), he nusea press C) ndan attachmentD) o presshecountershaftE) utof heballbearing.

l f necessary ,ns ta l l t he 5mm shimse lec tednstep 16, hen rec heck he clearance,

Install he distance ollar A).35mm shim, and new

ba l lbear ing B)us ing hespec ia l too ls nda press(c).

46-0030r00

1 8 .

1 9 .

20. Tighten he new specialbolt (A) (left-handhreads).

' l18N. m (1 2kgf.m,87 tbf.ftl



SynchroSleeveandHub nspectionandReassembly

1. lnspectthegearteethon ali synchrohubs and

synchrosleeves or roundedoff corners,whichindicatewear.

2. Installeachsynchrohu b (A ) n its matingsynchro

sleeve B),and check or freedomof movement.Be

sure o match he threesetsof longer eeth C) 120

degrees part)on the synchrosleevewith the three

setsof deepergrooves D) n the synchrohub. Do

not nstall he synchrosleevewith its onger eeth

in th e 1sv2ndsynchrohub slots E)because t wil l

damage he spr ing ing .

NOTE; f replacements required, lways eplace

the svnchrosleeveand svnchrohu b as a set.

SynchroRingandGear nspection

1 . Inspect he insideof eachsynchro in g (A) or wea

Inspect he teeth (Bi on eachsynchro ing or wear(roundedoff).

Example f synchro ing eeth

Inspect he teeth C)on eachsynchrosleevean d

matching eeth on eachgear or wear (roundedof

Exampleof teeth and gear eeth

(cont

II l

GOOD

synchro sleeve

GOOD

/ \I

WORN

t l

WORN

13



SynchroRingand Gear nspection cont'dl

3. Inspect he thrust surface D)on eachgearhub forwear.

Inspect he conesurface E)on eachgearhu b orwear ano rougnness.

Inspect he teethon all gears F) or unevenwear,scor ing , a l l i ng , ndcracks .

Coat he conesurfaceof eachgear (E )with oil, andplace ts synchro ing on it. Rotate he synchro ing,mak ing u re ha t t doesnots l ip .

\

7. Measure he clearance etweeneachgear (A) an di t ssynchro ing B)a l l t heway around.Ho ld hesynchro ing against he gearevenlywhile

measuring he clearance.f the clearance s lessthan he service imit, replace he synchro ing andgear.

Synchro Ring.to.GearClearanceStandard: 0.70 1.49mm 10.028 0.059 n.)ServiceLimit: 0.4 mm {0.016n. )

Triple Cone Synchro-to-GearClearanceSlandard:

O: OuterSynchroRing B}to SynchroCone Cl

0-70 1.19mm (0.028-0.047 n. )

@: Synchro Cone lC) o cear (A)

0.50- 1.04mm (0.020-0.041 n. )

O: Outer Synchro Ring (B) o Gear (Al0.95 1.68mm 10.037 0.066 n.)

ServiceLimit:

O: 0. 3mm (0.012n. )

: 0.3mm (0.012n. )

O; 0. 6mm 10.024n. l

\



MainshaftBearing ndOil SealReplacement

SpecialTools Required. Oi lsea ld r i ver 7JAD-P190100. Ad jus tab le ear ing u l le r ,20 40 mm

07736-4010008. Driver07749-0010000. Attachment,42 47 mm 07746-0010300. S l idehammer , ommerc ia l l yva i lab le

1. Remove he differential ssembly,

2 . Removeheba l lbear ing A) f rom he c lu tch

hous ing B)us ing he spec ial too l nda

commerc ia l l yva i lab le /8 " - l6 s l idehammer C) .

Remove he oil seal A) ro m the clutchside.Be

carefulwhen removing he sealso the clutch

hous ings no tdamaged.

4 . Drive he new oil seal n from the transmission id

using he special ools.

07749-0010000

07746-0010300

Drive he new ball bearing A) n from thet ransmiss ionideus ing hespec ia l too l .

13-



ManualTransmission

CountershaftBearingReplacement

SpecialTools Required. Adiustablebearingpuller,20-40 mm 07736-A0tOOOB. Oil sealdriver 07JAD-AP190100. S l ide ammer , ommerc ia l l yva i lab le

1. Remove he bearingse t plate A)from the clutchhous ing B) .

Remove he needlebearing A)using he specialtool and a commerciallyavailable /8 " - 16 slidehammer (B), hen remove he oi l guide plateC.

07736-A010008

3. Posit ion he oi l guideplateC and new needlebearing A) n the bore of the clutchhousing B).

Ins ta l l t he eed le ear ing s ing he spec ia l too l .

Installthebearingset plate A)wirh bolts B).

B6 x 1 . 0 n12N.m1.2 gtm,8.7 tbf.ft)



MainshaftThrustClearance diustment

Special Tools Required. Mainshaftbase07GAJ-PG20130. Mainshaf t o lder 7GAJ-PG20110

1. Removehe72 mm sh im A)ando i lgu idep la teM

from the transmission ousing B) .

,5---ov/

Installthe3rd/4thsynchrohu b (A), he distance

co l la r B ) , he 5 thsynchro ub C) . i s tance o l la r

(D) , ndba l lbear ing E) n he mainshaf tF) , hen

ins ta l l t he ssembled a inshaf tn he ransmiss ion

hous ing G) .

lnstall he washer H)on the mainshaft.

MeasuredistanceO between he end of the

transmission ousingan dwasherwith a straightedgeand verniercaliper.Measureat three

locations nd average he reading.

5. Measuredistance@ between he end of the clutch

hous ing A)and he bear ingnner ace B)wi tha

straightedgeand depthgauge.Measureat three

locations nd average hereadings.

A

Shim Selection Formula:

6, Select he proper72 mm shim rom the chan.

Follow he examplebelow,an d use he

measurements ou made n steps4 and 5:

(Bas ic ormula)

O+@ (0.8 0 .11) sh im h icknessmaximu

O + O (0.8+ 0.17) sh im h icknessmin imu

. Add distanceO (step5) o distanceO (step4)

. 0 .8mm (0.031n) :Spr ingwasher , d imens ion

th e installation.. 0 .11mm (0.004n) : v l i n imumhrust learance. 0 .17mm (0.007n) :Max imum hrust learance

(Forexample)

2 .32+ 0 .15 (0 .8+ 0.11)=1.56mm (0.061n. )

2 .32+ 0.15 (0 .8+ 0.17)=1.50mm (0.059n. )

Take hemidd le a lueof he min imum alueand

the maximum alue , ndse lec the 1.53mm(0.060n. ) h im.

{con

13



Transmission

MainshaftThrustClearance djustment cont'dl

72 mm Shim

PartNumber Thickness23931-P21-0000.60mm 0.0236n. )

B 23932-P21-0000.63mm

(0.0248n.c 23933-P21-0000.66mm 0.0260n.

D 23934-P21-0000.69mm (0.0271n.E 23935-P21-0000.72mm (0.0283n.F 23936-P21-0000.75mm 0.0295n.

23931-P21-000 0.78mm 0.0307n.- 23938-P2'l-0000.81mm(0.0319n

23939-P21-0000.84mm(0.0331nJ 23940-P21-0000.87mm {0.0343n,

23941-P21-000 0.90mm (0.0354n.L 23942.P21-000 0.93mm (0.0366n.M 23943-P21-0000.96mm(0.0378n.N 23944-P21000 0.99mm(0.0390n.o 23945-P21-000 1.02mm 0.0402n.

P 23946-P21-000 1.05mm (0.0413n.o 23941-P2't-000 'l.08mm (0.0425nR 23948-P2'l-000 '1.1 mm 0.0437n

23949-P21-000 ' 1 .14mm (0.0449n

T 23950-P21-000 1.17mm {0.0461n.U 23951-P21-0001.20mm 10.0472.

23952-P21-000 1.23mm (0.0484n .23953-P21-000 1.26mm 0.0496 .

X 23954-P21-0001.29mm (0.0508n.23955-P21-000 1.32mm 0.0520 .

z 23956-P21,000 1.35mm(0.0531n23957-P21-000 1.38mm(0.0543n

AB 23958-P21-000 1.41mm (0.0555nAC 23959-P21-000 1.44mm 0.0567 .

AD 2396 0-P2 1-000 1.47mm (0.0579n.AE 2 39 61 -P 21 -0 001.50mm (0.0591n .AF 23962-P21-OOO 1.53mm 0.0602 .AG 23963-P21-0001 56mm (0.0614n.AH 23964-P21-000 1.59mm (0.0626n.AI 23965-P21-000 1.62mm (0.0638nAJ 23966-P21-000 1.65mm(0.0650nAK 239 67-P 21-00 01.68mm 0.0661nAL 23968-P2r000 1.71mm 0.0673n.AM 23969 -P21 -0001.74mm(0.0685n.AN 23970-P21-000 1.77mm(0.0697n.AO 23971-P2 ' t -OOO1.80mm (0.0709n.

12 .

7. Ins ta l l t he 2 mm sh im A)se lec ted ndo i l gu idep la teM i n he ransmiss ionous ing B) .

,6,,-oV

Thoroughly lean he springwasher A) an dwasher B) before nstall ing he m on the clutchhous ing ideba l lbear ingC) .Note he ns ta l la t iondirectionof the springwasher.

8.

10 .

1 1 .

9 . l ns t al l t hemainshaf tn hec lu tch ous ing .

Place he ransmission ousingover he mainshaftand onto he clutchhousing.

Tighten he clutchan d ransmission ousingswithseveral8 mm bolts.

NOTE: t is not necessaryo usesealingagentbetween he housings.

Ta p he mainshaftwith a plastichammer.



13. Attach he special ool to the mainshaftas ollows:

. Back-ou the mainshaf t o lder o l t A )and loosen

the two hex boltsB).

. Fi t he holderover he mainshaft o its ip is

towards he ransmission.. Align he mainshaftholder's ip around he

grooveat the nsideof the mainshaftsplines,

then ighten he hex bolts.

14.

07GAJ-PG20130

Seat he mainshaft ully by tapping ts endwith a

p las t i c ammer .

Thread he mainshaftholderbolt n until t ust

contacts he wide surfaceof the mainshaftbase.

16 . Zeroa d ia lgauge A)on he endof the ma inshaf t

Turn he mainshaftholderbolt (B)clockwise; topturningwhen the dial gauge A)has reached ts

maximum movement.Th e readingon the dial

gauge s the amountof mainshaftend play

NOTE:Do not urn the mainshaftholder bolt more

than60 degreesafter he needleof the dial gauge

stopsmoving, his may damage he transmission

lf the reading s within the standard,he clearanc

is correct. f the reading s notwithin the standard

recheck he shim thickness.

Standard:0.11 0.17 mm (0.004 0.007 n.)

1 7 .

1 8 .

07GAJ-PG20130

13



Transmission

Transmission eassembly

NOTE: r io r to eassembl ing ,lean l l t hepar ts nsolvent,dry them, and apply ubricant o any contactsurfaces.

1. Install he magnet A)and differential ssembly B).

n-",-ol;-D

Install he 28 mm springwasher A)and 28 mmwasher B)over he ball bearing C) .Note heinstallation irectionof the springwasher A).

Apply vinyl tape o the mainshaft plines D) opro tec t the ea l . ns ta l l t hemainshaf t ndcountershaft E) nto he shift orks {F}.an d nstallt hemas an assembly .

\

4. Install he reverse hift ork.

6 x 1 . 0 m m15 N.m (1.5 gf.m,11 bf.ft)

f . )

Installthe everse dlergear (A )and reverse ea rshaf t B)by a l ign inghe mark C)wi th he reversegear ha f t o le D) .



ransmission

TransmissionReassemblycont'dl

9. Ins ta l lhe 14x 2 0mm dowelp ins A) .

34 N.m(3.5kgf.m,25 rbf.ft)

Set he taperedcone ring (B )as shown. Place hetransmission ousingover he clutchhousing,beingcareful o l ine up the shafts.

1 0 .

11. Lower he transmission ousing he restof the wayas you expand he 72 mm sna p ring {C).Releasethe snap ring so it seats n the grooveof the

countershaft earing.

12 . Check hat he 52 mm snap ring is securely eatedin th e grooveof the countershaft earing.

DimensionO as nstalted: 3.3 6.0mm

{0.13 0.24 n . l

Apply liquidgasket P/ N08718-0001)o the hreadsof the32 mm sea l ing ap D) , nd ns ta l l t on het ransmiss ionous ing ,

Ins ta l lhe ransmiss ionangers . and B,and he8 mm flangebolts inger-t ight.

13 .

't4.

1 5 .

8 x 1.25mm27 N.m(2.8 gf.m.20 rbf.ft)

(t

\A

e . /./

Tighten he 8 mm flangebolts n a crisscrossPattern n several teDs.



16 . Remove h e dirt and oil from the shift evercover

sea l ing u r face . pp ly iqu id aske t P /N 8718-

0001) o the sealing urface.

NOTE: f 5 minuteshavepassedafterapplylng

liquidgasket. eapply t a nd assemble he housings.

Allow it to cure at east20 minutesafterassembly

before i l l i ng he ransmiss ion i t h o i l .

- - -Liquidgasket

17 . Ins ta l l t he x 14mm dowelp ins A) . lu t ch inec l ip

bracke tB) , ndchangeever ssembly C) .

12N. m 1. 2 gf.m,9lbt t)

18 . App ly iqu id aske t P iN 08718-0001)o the hreads

of the nterlock olt (D),an d nstall t on the

t ransmiss ionous ing .

6 x 1 . 0 m m

19. Ins ta l l t he ra inp lug A) , i l l e rp lug B) , nd 10mm

f lange o l t C)w i th newwashers .

A3 9 N m(4.0kgf m,33 tbl.ft)

20.

/..l-.=,'-B

g ^ 44N .m@ Ut !?iJl'.'l,'R \ - : \

-.-t ?0, .ru44N m {4.5kgt m,33lbf.ft}

Installthedetentbolts A),spring,and steelballswith new washers.

{3.0kgf.m.22lbf.ft)

App ly iqu id aske t P/N 8718-0001} tohe hrea

o i the back-upigh t w i t ch B) , nd nsta l lt n he

t ransmiss ionous ing .

(cont

21.

13



Manual ransmission

TransmissionReassemblycont'dl

22. Installthevehiclespeedsensor VSS) A)andO-r ing B) .

22 N.m 2.2 gf.m, 6 lbf.ft)



GearshiftMechanismReplacement

SHIFTCABLECLIPReplace.

8 x 1.25mm22 N.m (2.2kgf.m, 16 lbt ftl

--SHIFT LEVERNOB

\ / ,.-,'-' 8 N m {0.8 sr.m.5.8lbf.ft}

l'/

SHIFTLEVERHOUSING

{P/N 08798-9002}

r-LlRotate he shiftcabletow a r d heopen ing .

6 x 1 . 0 m m9 . 8 N m

(1.0 gf.m,7.2 tbf.fr)

COTTERPINS

qrBemove he shift cablefrom the shift everbracket.{P/N 08798-9002)

13



/T Differential


DRIVENGEARBeplacement, ag e13-53

Backlashnsoection. aoe 13-53Feplacemeni, ao e 3-5-3

\

\

,<-=- ,/BALL BEARING

/ \ , /Beplacemenl, ag e13-54

I \c1 l/\ = /



Backlashnspection

1.P lace he differential ssemblyon V-blocks A) ,an d

installboth axles.

Measurehe back lash f bo thp in ion ears B)wi tha dial ndicator C) . f the backla sh s not within the

standard, eplace he differential arrier.

Standard New):0.05 0.15mm (0.002 0.006 n.)

FinalDrivenGear/CarrierReplacement

1. Remov e he bolts left-handhreads) n a crisscro

pattern n several teps, hen remove he finaldrivengear (A)from the differential arr ier B) .

\ t t x t .omm to)1 2 1 m(12.3 gf m,89 rbt.ft)

Install he final drivengearwith the chamferon th

ins ide iameterac ing he car r ie r . l i gn he mark

on he ina ld r i ven earand hecar r ie r . igh tenh

bolts n a crisscross attern n severalsteps.

13



/T Differential

CarrierBearingsReplacement

Special Tool Bequired

Driver,40 mm l.D.07746-0030100

1. Check he carrierbearings or wear and roughrotation. f they rotatesmoothlyand heir rollers

show no signsof wear, he bearingsare OK ,

2. Remove he carrierbearing A) with a

commerc ia l l y -ava i lab leear ing u l le r B) .

\

3. Install he new bearings A)with th e special ooland a press.Presseachbearingon until t bottoms.Thereshouldbe no clearance etween he bearinos

and he carrier.

NOTE: urn he sealed B)side of the bearingawayfrom the differentialto nstall t.

077i16-0030100

07746-0030100

6



Oil SealReplacement

Special Tools Required. Driver07749-0010000. Oil sealdriver attachment 7NAD-P20A100

1. Remove he differential ssembly.

2. Remove he oil seal A) rom the ransmission

hous ing B) .

3 . Removetheo i l ea l A) romthec lu tch ous ing B) .

4 . Ins ta l l t he ewo i l sea l n he ransmiss ionous in

with the special ools.

5 . Ins ta l l t he ewo i l sea l n he c lu tch ous ing i t hthe special ools.

13-



M/T Differential

Differential hrustClearance djustment

SpecialToolRequired

Driver.40 mm LD.07746-0030100

1. Ins ta l l n 80 mm sh im ha t ' s hesame ize s he

on eyo u removeo.

2 . Install he differential ssembly nto he clutch

hous ing .

5 .

Install he transmission ousingonto he clutch

housing, hen ighten he 8 mm flangebolts n a

crisscross attern n severalsteps se estep 15onpage13-48).

8 x 1 .25mm

27 N m (2.8kgf'm, 20 lbf.ft)

Use he special oolto bottom he differential

assemblyn he c lu tch ous ing .

00746-0030100

Measure he clearance e tween he 80mm shim

andbear ing u te r ace n he ransmiss ionous ing .

Standard:0 0.10mm l0 0.004 n.)

- i .w.t ..1

-- -- :, - -= .



Driveline/Axle

SpecialTools .. . . . . . . . . . . .6-2Driveshaftnspection .. . . . . . . . . . . . . . . . . . . . . . . .6-3

Driveshaftsemoval . . . . . . . . . . . . . . . . . . . . . . . . . .6-3Driveshaftsisassembly .. . . . . . . . . . . . . . . . . .6-5Dynamic amper eplacement . . . . . . . . 6-8Driveshaftseassembly .. . . . . . . . . . . . . . . . . . .6-9Driveshaftsnstal lat ion .. . . . . . . . . . . . . . . . . . . . .6-17lntermediatehaftRemoval . . . . . . . . . . . . . .6-19IntermediatehaftDisassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20lntermediatehaftReassembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-22lntermediatehaft nstal lat ion.. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . .6-24



Driveline/Axle

LpecialTools

\*

o @

g r ? )[ ] \J

,0)

Ref. No. ToolNumber DescriDtion Orvn]@

o@t9

6)o(D

07GAD-PH7020107MAC-S10020007NAF-SR3010107xAc-001010A07746-001040007746-003040007749-001000007947-S800100

Oi l Sea lDr iverBa l l Jo in tRemover , 8 mmHalfShaftBaseThreadedAdapter,22 x 1. 5mmAttachment, 2 x 55 mmuf lver , 5 mm LU.Driver

Oi l Sea lDr iver

1

111

11

11

16-2



Driveshaftnspection

1. Check he inboardboot (A )andthe outboardboot(B )on the driveshaft C) or cracks, amage, eakinggrease, nd ooseboot bands D) . f any damage sfound, reDlacehe boot and boot bands.

Turn he driveshaftby hand,and makesure hesplines E)an d oint are not excessivelyoose.

Makesure he driveshaft s not wisted or cr acked;if it is, replace t.

DriveshaftsRemoval

Special Tool RequiredBa l l j o in t emover , 8 mm 07MAC-S100200

1. Loosen he wheel nutsslightly

2. Raise he front of the vehicle,and support t withsafetystands n th e proper ocations se epage 1-8

3. Remove he wheel nuts and ront wheels.

4 . Lift up the locking ab (A )on the spindlenu t (B),

then remove he nut.

lf th e !eftdriveshaft r the intermediate haft s to

be removed,drain he ransmission luid. Reinsta

the dra inp lugus ing newwasher see age13-3

Hold he s tab i l i zera l l j o in tp in (A)wi tha hex

wrench {B),and remove he flangenu t (C).

Separate he front stabil izer in k (D ) rom the lowea m.

(cont'

16



DriveshaftsRemoval cont'd)

7. Removehe ockp in A) f rom he owerarm ba l ljoint castlenu t (B),and remove he nut.

NOTE:

. To avo iddamagingheba l l j o in t , ns ta l l hexnuton to the threadsof the ball oint,

. Becarefulno t to damage he ball joint boot wheninstall ing he remover.

07MAC-S100200

w^'e

Separate he ball oint from the lower arm (C)with

the special ool (seestep3 on page18-19).Be carefulnot o dislodge he lower ball oint fromthe knuckle.

Pull he knuckle utward,and remove hedriveshaft utboard oint from the front wheel hubus inga p las t i c ammer .

9 .

.."8

\

10 . Left driveshaft:Pry he nboard oint (A)from th edifferential asewith a prybar.Rightdriveshaft:Drive he inboard oint (A )off of the intermediateshaftwith a drift and hammer.Remove hedriveshaft s an assembly.Do not pull on thedriveshaft B) ,because he inboard oint may comeapart.Draw he driveshaft traightou t to avoiddamagingheo i l sea l .

Left driveshaft:

a

t

Right driveshaft:



Driveshafts isassembly

Special Tools Required. Threaded daDter .22 1 .5mm 07XAC-001010A. Sl idehammer , ommerc ia l l yva i lab le. Bootband pincers, ommercially vailable

InboardJoint Side:

1. Remove he se t rlng rom the nboard oint.

Remove he boot bands.Becarefulnot o damagethe boot and dynamicdamper.. lf the boot band s a welded ype (A),cut he boot

band B) .. lf the boot band s a double oop ype (C), ift up

the bandbend D) , ndpush t n to he c l ip E) .. lf the boot band s a lo w profile ype (F),pinch he

bootbandus ing commerc ia l l yva i lab le oo t

bandp incers G) .

Welded Type

Low Profile Type

(cont'

16



DriveshaftsDisassemblycont'd)

Makea mark A)on each o l le r B)and nboardo in t

(C) o identify he locations f rollersan d grooves

in he nboardo in t .Then emove he nboardo in t

on the shop o wel (D).Be carefulnot o drop the

rollerswhen separating hem from th e inboard

Jorn t .

N4ake mark (A )on the rollers B)and spider C) oidentify he locations f rollerson the spider, henremove he rollers.

Removehec i rc l ip D) .

Mark he spider C)and driveshaft E) o identify hepositionof the spideron the shaft,

Removehe sp ider C) .

6.

7 .

8. Wrap he splineson the driveshaftwith vinyl tape(A) o preventdamage o the boot.

9 . Removehe nboard oot .Becare fu l o t todamaoethe boot.

10. Remove he vinyl tape.

\



OutboardJoint Side:

1. Removehe bootbands. ecare fu l o t todamagethe bootanddynamic amper .

. l f he bootband s an earc lamptype A) , i f tupth e three abs (B )with a screwdriver.

Ea rClampType

Slide he outboardboot (A ) o the nboard ointside.Be carefulnot o damaoe he boot.

2 .

4 .

Wipe off th e grease o expose he driveshaft ndthe outboardo in t nner ace.

Makea mark (A )on the driveshaft B) at the samepositionof the outboard oint en d {C).

5. Carefullv lamp he driveshaft n a vise.

Remove he outboard oint (A)using he special

too l anda commerc ia l l yva i lab le /8"x18 l i dehammer B) .

Remove he driveshaft rom th e vise.

(cont'd

7 .

16



9.

DriveshaftsDisassemblycont'dl

8. Removehestop ing rom hedriveshaft.

Wrap he splineson the driveshaftwith vinyl tape

(A) o preventdamage o the boot.

Remove he outboardboot.Be carefulno t odamage he boot.

Remove he vinyl ape.

1 0 .

1 1 .

7 .

DynamicDamperReplacement

1. Removehe nboardo in t see age16-5) .

2, Remove he dynamicdamperbands.Be carefulno t

to damage he dynamicdamper seepage 16-5).

. l f he boo lband saweldedtype.cu t the oot

band.. l f he bootband sa doub le ooptype, i f tup the

band bend,and push t into he clip.. lfthe b oot band s a low profile ype,pinch he

bootbandus inga commerc ia l l y va i lab le oo t

bandpincers.

3. Wrap he splineson the driveshaftwith vinyl tape(A)to preventdamage o the dynamicdamper.

Remove he dynamicdamper.Becarefulnot o

damage he dynamic amper .

Adjust he positionof the new dynamicdamper o

the figure below.

Leftdriveshaft Directionall: 296 300mm( 1 1 . 6 - 1 . 8n . )

Right driveshaft Directionall: 301 305mm(11.9 12.0 n . l

5 .

6 . I ns t al l t he ynam ic am per and see tep onpage16 '12) .

Ins ta l lhe nboardo in t see age16-1 ) .



DriveshaftsReassemblycont'dl

Exploded iew

'03 model

INBOARO OINT

CIRCLIP

E .

@ (

ROLLEB

s l

DOUBLEOO P AN DReplace.(Boot an d eplacementnly.)

Use he grease ncludedin he nboardboot set.(^Y \

\_,/

Use he grease ncludedin he nboardboot set.

LO WPROFILEANDBeplace.

DOUBLE OOPBANDReplace.

DYNAMICDAMPER

OUTBOARD OINT

at-OUTBOARDOOT TPI

SE TRING

/ Replace.,

-"-,,,

>

(Bootband eplacement nly.)

Use he grease ncluded n heoutboardboot set.



Special Tools Required. Boot band ool, KD-3191 r equivalent, ommercially

ava i lab le. Boot bandpincers,Kent-Moore -359'10 r equivalent,

commerclally vailable. Boot bandpincers,commerciallyvailable

NOTE:Refer o the ExplodedView as neededduring

this procedure.

lnboard oint Side:

1. Wrap he splineswith vinyl tape (A ) o prevent

damage o the inboardboot.

Install he inboardboot onto he driveshaft, henremove he vinyl ape, Be carefulnot to damage

inboardboot.

Ine

4.

5

3. Installthespider A)onto he driveshaftby alignin

the marks B)on the spiderand he end of the

driveshaft.

Fit he circlip C) nto he driveshaft roove.Always

rotate he circlip n it s groove o makesure t is full

seated.

Fi t he rollers A) onto he spider B)with their high

shoulders acingoutward,and note hese tems:

' Reinstallthe ollers n their originalposit ionson

th e spiderby aligning he marks C) .. Hold he driveshaftpointedup to prevent he

rollers rom fall ingoff.

(cont'

@\

(u

1 6 -



6.

DriveshaftsReassemblycont'd)

Packhe nboardointwith he ointgreaseincludedn he newdriveshaftet .

Grease uantity

Inboardoint: 130 140g (4.6-4.9oz)

Use he grease ncluded n th einboardboot set.

Fit he inboard oint onto he driveshaft, nd notethese tems:

. Reinstallhe inboard oint onto he driveshaftbya l ign inghemarks A)on he nboardo in tandthe ro l le rs .

. Hold he driveshaft o he inboard oint ispointingup to prevent t trom fall ingoff.

7 .

1 1 .

8. Makesure he endsof the boot aresealed n thegrooves n the driveshaft nd oint, hen installtheboot bands.

. Fo r he double oop ype,go to step 12.(Replacement oot bandsonly)

. Fo r he ow profile ype,go to step9.

Installthenew ow profileband A)onto he boot

{B). hen hook he tab (C )of the band,

Close he hook portionof the band A)with acommerciallyavailableboot bandpincers B), henhook he tabs of the band.

Install he boot band on th e otherend of the boot,an d reoeat teos9 and 10.

9 .

\10 .



Fit he boot endsonto he driveshaft nd he

inboard oint, he n nstall he new double oop band

{A) onto he boot.

Pu l lup hes lack n he bandby hand

Marka pos i t ionA)on he band10- 14mm (0.4-

0 .6 n. ) rom hec l ip B) .

15. Thread he free end ofthe band hrough he nose

sectionof the commerciallyavailableboot band

tool KD-3191 r equivalent A),an d nto he slot on

thewind ingmandre l B) .

Place wrench on the winding mandrelof the boo

band ool, and ighten he band until he marked

spot (C)on the bandmeets he edgeof the clip

Li f tuD he bootband oo l obendthef reeendof

the band90 degrees o the clip. Center-punchhe

c l io , hen o ldover he remain inga i lon to hec l ip

1 6 .

1 7 .

(con

16



Driveline/Axle

DriveshaftsReassemblycont'dl

18. Unwind he boot band ool, an d cut off the excessfree end of the bandto leavea 5- 10 mm (0.2-0.4in.) ai l protruding rom the clip

19. Bend he band end (A) by tapping t down with anammer .

NOTE;. Makesure he bandand clip do not nterferewith

anythingand he band does not move.. Removean y grease emainingon the

surrounding urfaces

20. Repeat teps 12 hrough 19 or the bandon theotheren d of the boot.

2 '1 . ns ta l l t he ewset ing .



Outboard oint Side:

1. Wrap he splineswith vinyl tape (A) o prevent

damage o the outboardboot.

Ins ta l l t he ewearc lampbands B)andoutboard

boot, hen remove he vinyl tape.Be carefulnot o

damage he outboardboot.

Install he new stop ring nto he driveshaft roove

(A).3.

4. Insert he driveshaft A) nto he outboard oint (B)

until he stop ring (C) s close o the oint.

To completelyseat he outboard oint, pickup the

driveshaft nd oint, and drop hem from about 10

cm (4 n. )onto a har d surface.Do not use a

hammer as excessiveorce may damage he

driveshaft.Be carefulnot o damage he hreade

section A) of the outboard oint.

5 .

10cm(4 n. )

- ..,..,1 ,t :-,;

{con

16



Driveline/Axle

DriveshaftsReassemblycont'd)

Check he alignmentof the paintmark (A )with th eoutboardo in tend B) .

7. Packhe outboard

oint (A)withthe

ointgreaseincluded n the new ioint boot set.

Greasequantity

Outboard oint: 105 115g (3.7 4.1 oz l

/ rllt )

\ { (

-*>:;,"0'A?g.fffl:f'., o

8. Adjust he engthof the driveshaftso the figurebelow, he n adjust he boots o halfwaybetweenfull compression nd ull extension.Makesure heendsof the bootsseat n he groovesof th edriveshaft nd oint.

Leftdriveshaft:497 02mm (19.6 19.8in.)

Rightdriveshaft: 75 480mm {18.7

t-tTfi'.D.ilTD

18 . 9 n . l

Fi t he boot (A )endsonto he driveshaft B)andoutboardo in l (C) .

9 .



10. Close he ear portion A)of the bandwith a

commerciallyavailable oot bandpincersKent-

Moore J-35910 r equivalent B) .

Check he clearance etween he closedea r portlon

of the bands. f the clearances not within the

standard, lose he ear podion of the bands arther.

1 1 .

12 .Repeat teps 0and11 or he bandon he o ther

end of the boot.

6. 0mm 10.24n. )MA X

3. 0mm {0.12 n. }MA X

Driveshaftsnstallataon

1. Installa new set ring onto he set ring grooveof th

driveshaft leftdriveshaft .

Apply 0.5 1. 0g {0.02 0.04oz )of specif iedreas

to thewho lesp l ined ur face A)o f the r igh t

driveshaft. fter applyinggrease, emove he

grease rom the splinedgroovesat intervals f 2-

3 sp l ines nd rom he se t inggroove B) o hat

air can bleed rom the ntermediate haft.

(con

16



Driveline/Axle

Driveshaftsnstallation cont'd)

Clean he areaswhere he driveshaft ontacts hedifferential horoughlywith solvent,and dry withcompressedi r . nsenthe nboard nd A)o f thedriveshaft nto he differential B)or intermediateshaft C)until he set ring (D ) ocks n th e groove(E).

4. Install he outboard oint (A) nt o he front hu b (B).

5 . Wipeof f thegreaserom he ba l l o in tand owerar m taperedsurfaces. nstalltheknuckle A)ontothe lowerar m {B).Becarefulno t o damage he balljoint boot.Wipe off the grease

before ighteningthe nut at the ball oint.Torque he new castlenu t(C ) o the lower orquespecification,hen ighten ton ly a renough o a l ign hes lo tw i th he ba l l o in tp in ho le .Do nota l ign he nutby oosen ingt .

NOTE:Makesure he ball oint boot s not damageor cracks.

"-'t-

12x 1 . 25mm59 69 N.m(6.0 7. 0 kgf m,43 51 tbt.ftl

I ns ta l l t he ew ockp in D) n to he ba l l j o in tp inhole rom the nside o the outsideof the vehicle.

Connect he front stabil izerin k {A ) o the lowerarm.Ho ld hestab i l i zerinkba l l j o in t in (B)wi tha hex

wrench C) , nd igh ten he newf lange ut D) .

7 .

'10x 1.25mm39 N.m{4.0 gf.m,29 bf.f t)



8. Install newspindle ut A) , he n ighten henut.

After ightening,sea drift o stakehespindle ut

shoulderB)againsthe driveshaft.

{18.5 gf.m, 34lbt.ft)

9. Clean he matingsurfaces fthe brakediscand he

front wheel, hen nstall he ront wheel with the

wheel nuts.

10 . Turn he front wheel by hand,an d makesure he

clearance etween he driveshaft nd

circumference arts.

1 . Refil l he transmissionwith recommended

transmission luid (seepage13-3).

12. Check he front wheelalignment,and adjust t if

necessary se epage18-4).

108N. m(11.0 gf.m,80 tbt.ft)

/o

o oe

22x 1.5mm181N.m

1 .

2 .

lntermediateShaftRemoval

Remove he r ight driveshaft seepage 16-3).

Removehe heat h ie ld .

3 . Removehe lange o l t A)andtwodowelbo l t s (

€.---2"E J /

€w

(con

16



Driveline/Axle

ntermediateShaftRemoval(cont'dl

4. Remove he intermediate haft A) ro m th edifferential.Hold he intermediate haft horizontaluntil t is clearof the differential o preventdamageto the differential i l seal B) .

IntermediateShaft Disassembly

Special Tools Required. Oil sealdriver 07947-5800100. Halfshaftbase07NAF-SR30101

1. Removetheset ing A) , u tersea l B) , ndexterna lsnap ing C) .

Press he ntermediate haft A) ou t of theintermediate haft bearing B)usinga press.Becarefulnot to damage he metal rings(C )on th eintermediate haftduring disassembly.

LRESS



3. Remove he internal nap ring.

4. Press he ntermediate haftbearing A) out of the

bear ing uppor t B)us ing hespec ia loo lsandaoress.

07947-s800100

07NAF-SR30101

16



IntermediateShaftReassembly

Exploded iew

INTERMEDIATEHAFTRINGFLANGEBOLT10x '1.25

mm39I Vm{4.0 gf.m,29lbt. f t l

\^

,tto", *,"o p

\ E--'+7\

BEARINGUPPOBT

Pack he nteriorof the outerseal.



SpecialTools Required. Driver07749-0010000. Attachment,52 55 mm 07746-0010400.Attachment, 5 mm 1.D.07746-0030400. Oi l sealdriver07GAD-PH70201

NOTE:Refer o the ExplodedView as neededduring

this procedure.

1 . C leanhe d isassembledar tswi th so lvent , nddry

them with compressed ir .Do not wash he rubber

partswith solvent.

2. Press he ntermediate haftbearing A) ntothe

bear ing uppor t B)us ing hespec ia loo lsanda

press.

07746-0010400

Insta l l ,henseat he nterna l nap ing n to hegrooveofthe bearingsupPort.

ESIR

3.

PRESS

I

4. Press he intermediate haft A) ntotheshaft

bear ing B)us ing hespec ia loo landa press.

07746-0030400

Insta l l ,henseat heexterna l nap ing A) n to h

grooveof the intermediate haft B) .

(con

16



IntermediateShaft Reassembly(cont'd)

6. lns ta l l t he uter ea l A) n to thebear ingsuppor t (B)using he special ool and a press.

7 . Ins ta l l t he et ing .

PRESS

I

Pack he interiorofthe outerseal.

IntermediateShaft nstallation

1. Useso lvent r b rake leanero horough ly leanthe areaswhere he intermediate haft A)contactsthe transmission differential), nd dry withcompressed ir. Insert

he ntermediate haftassembly nto he differential.Hold heintermediate haft horizontalo preventdamage othe differential i l seal B).

2 . Ins ta l l t helangebo l t A )and wo dowelbo l t s Bl .

A10 x 1.25mm3 9 N m(4.0 gf.m,29lbf. f t)

Bl0 x 1 . 25m m39 N.m(4.0 gf.m,29 tbf.ftl



3. Install he heatshield,and ighten he three bolts.

4 . Ins ta l l t he igh tdr i veshaf tsee age16-17) ,

8 x 1.25mm

2 2 N m12.2

16



Steering

SteeringSpec ia loo ls . . . . . . . . . . . . .7 -2

Comoonentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 -3

Steering heelRotational layCheck ... . . . . . . . . . . . . . . . . ." .7-4

Power ssist heck ... . . . . . . . . . . . . . . . . . . . . . . . .7-4

Steering inkage ndGearboxnspection... . . . . . . . . . . . . .7-5

Steer ing hee l emoval. . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .7 -6

Steering heelDisassembly/Reassembly.. . . . . . . . . . . . . .7-7

Steering heel nstallation ... . . . . . . . . . . . .7-8Steering olumnRemoval nd nstallation... . . . . . . . ' . . .7-9

Steering olumnnspection ... . . . . . . . . . . .7-11

Steering ockReplacement.. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . ' .7-'12

Rack u ide d ius tment . . . . . " . . . . . . . . ' . . ' . .7 -13

Electrical owerSteering EPS) 17-15



SpecialTools

Ref.No. ToolNumber Description Otyo 07MAA-S100200 LocknulWrench.43 mm

E-.tt)-

- - -<, /L\2 r

.V-6Y

o




DRIVER'SIRBAGASSEMBLYRemoval/lnstallatipage 3-113

STEERINGWHEELRemoval, ag e17-6Disassembly/Reassemblypage 17 7

Installation, ag e17-8

STEERING OLUMNSteeringColumnRemoval nd Installation,page 7 '9SteeringColumn nspection,page 7 - 1 ' lSteering ockReplacement,page 11-12

STEERINGEARBOXRack uide djustment,ag e17-13

17



SteeringWheelRotationalPlayCheck

1. Turn he front wheels o the straightaheadposit ion.

2. Measurehow far you can urn the steeringwheel

left and right without moving he front wheels.

. lf the play swithin th e imit, he gearboxand

l inkage reOK.. l f he p layexceedstheimi t , d jus t the ack u ide

{seepage 17-13).lf the play s sti l l excessive fter

rackguideadjustment, nspect he steering

l inkage ndgearbox see age17-5) .

BOTATIONALLAY: 10mm (0-0.39 n. l

+ :

PowerAssistCheck

Start he engine,an d et t idle.

Attacha commerciallyavailable pringscale o the

steer ing hee l .Wi th he eng ine d l ing nd he

veh ic le n a c lean , ry loor ,pu l l hesca le s

shown,an d read t as soon as he ires begin o turn.

\

1 .

3 . l f he sca le eads o more than 9 N (3 .0 g f ,6 .6 b f ) ,

th e powerassist s OK. f it readsmore,check hese

items:

. Front ire pressure

. Steering inkage seepage 17-5)

. Rackguldeadjustment seepage 17-13)

. EP S ystem se epage 17-18)



SteeringLinkageand Gearbox nspection

Check or looseness,andb ind ing .

TIE.RODLOCKNUTSCheck or looseness.

BOOTInspector damage nddeterioration.

12 mm BOLTSInspect or looseness.

STEERINGOLUMNInspector oose olumnmounting ardware

STEERING EARBOXInspect or loosemountinghardware.GEARBOXMOUNTING CUSHIONSInspect or deterioration.

STEERINGOINTSCheckor loose ointbolts,and oose r bindingoints.

TIE.RODENOBALLJOINTlnsoector ooseness,b ind ing ,nd amage.

BALLJOINTOO TInspector damage nddeterioration.

17



Steering

SteeringWheelRemoval

SR Scomponents re ocated n this area.Review heSR Scomponent ocations se epage23-13), ndprecautions nd procedures seepage23-14) n the SRS

sectionbeforeperforming epairsor service.

1. Align he front wheelsstraightahead, hen remove

the driver'sairbag rom the steeringwheel (see

page23-113) .

2. Disconnecthe cruisecontrolsevresume witch

connector A),an d oosen he steeringwheel nut

{B) .

i

3. Installa commerciallyavailable teeringwheelpuller A)on the steeringwheel (B).Free he

steeringwheel rom the steering olumn shaftby

tu rn ing hepressure

o l tC)

o f thepu l le r .

Note these items when removing the steeringwheel:. Do not ap on the steeringwheel orthesteering

column shaftwhen removing he steeringwheel.. l f you hread hepu l le r o l t s D) n to thewhee l

hub more han 5 threads, he boltswill hit he

cable eeland damage t. To prevent his, nstalla pa i rof am nuts5 h reads p on eachpu l le r o l t .

D

Bemove he steeringwheel puller, hen remove he

steeringwheel nut and steeringwheel rom the

sleerinocolumn.



SteeringWheelDisassembly/Reassembly

CONTACTPLATE

MOOULESETBRACKET

STEERINGWHEELREABCOVER

STEERING HEEL

ACCESSPANELA

75*-=offi,/*

ffi)Y /fb accEss ANEL

CRUISECONTROLSWITCH

CONNECTOR OLDERS

17



SteeringColumnRemovaland Installation

SR Scomponents re ocated n this area.Review he SRScomponent ocations se epage23-13) nd precautions ndprocedures seepage23-14) n the SRSsectionbeforeperforming epairsor service.

Removal

1, Record he radiostationpresets, nd disconnect he battery.

2 . Removethedr iver ' sa i rbagassembly(seepage23-113)nd hesteer ing hee l see age17-6) .

3 . Removethe r i ver ' s ashboardowercover (see age20-59) ndundercover (see age20-60) .

4. Remove he column covers A:

I x 1.25mm16 N.m (1.6 gf.m,12 bl.fr) b

5.

6.

Disconnecthe wire harness onnectors rom the combination witchassembly B).

Remove he combination witchassembly rom the steering olumn shaftby removing he screw(C)on the top othe combination witch.

7. Disconnecthe connectors rom th e ignit ionswitch,an d release he wire harness lips ro m the steering olumn.

8. Disconnecthe steering oint (D),and remove t from the column shaft.

9. Remove he steering olumn {E )by removin gthe attachingnuts and bolts.

(cont'

17



Steering

SteeringColumnRemoval

lnstallation

1 .

4 .

Ins ta l lhes teer ing o lumn, ndmake ure he

wires are not caughtor pinchedby any parts.

Inserttheupperend ofthe steering oint onto he

steering haft A) (l ineup the bolt hole (B)with the

flat portion C)on the shaft).

8 x 1 ,25mm28 N.m{2.9kgf m,21 br.ft)

A

Slip he lower end of th e steering oint onto hepinionshaft D) lineup the bolt holewith th egroove E) round heshaf t ) , nd oose lynsta l l t he

lower oint bolt.Be sure hat he lower oint bolt s

securely n the groove n the pinionshaft.

Pullon the steering oint o makesu e hat he

steer ingo in t s u l l ysea ted . hen ns ta l l t he pperjoint bolt,and ighten t to the specif ied orque.

Tighten he lower oint bolt o th e specif ied orque.

Finish he installation, nd note hese tems:. Makesure h e wire harness s routedan d

fastenedproperly.. Makesure he connectors re properlyconnected.. Re ins ta l l t heteer ing hee l see age17-8) .. Reconnecthe battery.

- Do he powerwindow controlunitresetprocedure seepage22-128).

- Enter he anti-theft ode or the radio, hen

enter he custmer's adio stationpresets.- Set he clock.

. Verifyhorn, ur n signalswitch,and cruisecontrol

switch operation.. Checkwheel alignment, f necessaryseepage

18-4) .. Do heeng ine on t ro lmodu le ECM)d le earn

procedue see age 11-139) .

17-10

and nstallationcont'd)



SteeringColumn nspection

. Checkhesteer ing o lumnba l lbear ing(A) nd thesteer ing jo in tbear ings(B) fo rp layandpropermovement .fanybearing s noisyor hasexcessive lay, eplace he steering olumn as an assembly,

'Checktheabsorb ingp la tes(C) ,absorb ingp la tegu ides(D) ,s top(E) ,andcoat ingp la tes(F)fo r d is to r t ion ndbreakage.f there s distortionor breakage, eplace he steering olumn as an assembly.

17-



RackGuideAdjustment

Special Tool Required

Locknutwrench,43 mm 07MAA-S100200

1. Set he wheels n the straightaheadposit ion.

2. Remove he heatshield A).

3.

9. 8N. m r. 0kgf.m,7.2lbtft)

Remove he transmissionmount bracket seestep

32 on page13-8).

Loosen he rackguidescrew ocknut A)with th e

special ool, hen remove he rackguidescrew B).

Remove he old sealant rom r ackguide screw,an d

apply new sealant o the middle of the threads A).

Loosely nstallthe ackguidescrewon the steeringgearDox.

'-.i. '' '

07MAA-S100200

6. Tightenhe ack uide crew A)ro25N.m 2. 5

kgf.m, 8lbf.ft).hen oosent.

5" Max.

ji-rrrr-,

I 4il N.m

{a.5 gf.m,33lbt.ft

Retighten he rackguidescrew o 6 N. m (0.6kgf m

4 lbf.ft), hen back t off to the specif ied ngle.

Specified Return Angle: 5' Max.

Hold he rackguidescrew stationarywith a wrenc

an d ighten he locknutby handuntil t' s ully

seated.

Ins ta l l t he pec ia loo lon he ocknut B) , ndho ld

the rackguidescrew(A )stationarywith a wrench,

Tighten he locknutan addit ional30 "with th espec ia l too l .

Reinstallhe transmissionmount bracketan d heat

sh e d ,

Check or unusualsteeringeffort hrough he

comple teurn ing rave l .

Check he steeringwheel rotationplay (seepage

17-4) nd he powerassist se epage17-4).

1 1 .

7 .

9 .

10 .

12 .

17-



EPSComponents

Rel.No. Tool Number Description otv(!)at'

o

07MAC-S100200070AD-P0A010007zAA-S5A0100

Bal l o in tRemover , 8 mm

Attachment, 2 mm

LocknutWrench

'1

1'l

SpecialTools \

,.^G) C\_---1t

-))h5--d-'

u_r-.c_-t t )\L-,

t

17-16




UNDER.HOODFUSE/RELAYOX

EPSCONTROL NITEP SControl nitRemoval/lnstallation,page17 67

UNDER.DASHUSE/RELAYOX

- , ' / . , . . . .

' . , i ,

X \ ]

DATA LINK CONNECTOR16P)

TOROUEENSOR

STEERINGGEARBOXSteeringGearboxRemoval, ag e17-51SteeringGearboxOverhaul, ag e17-55SteeringGearbox nstallation, ag e17-63

Removal/lnstallation,

page 7-49

GAUGE SSEMBLY

MOTOR

17-



EPSComponents


EPS ndicator

Under ormal ondit ions,heEP Sndicatoromes nwhen

the gnit lon witchs urnedo heON ll )posit ion,he ngoes

of fafterheenginesstarted.his ndicateshat hebulband

it scircuit reoperatingorrectly.

lf here sany roublen hesystem fter heenginesstarted,

th eEP Sndicator i l lstay n,an d hepower ssists urned

off.

WhenEP Sndicatoright omes n, hecontrol ni t

memorizesheDTC.n hiscase,hecontrol ni twil l not

activateheEPS ystem fterheengine tarts gain, ut t

keepsheEPSndicatorn.

WhenDTC 2,16 ,17, 8or 67 sstoredn hecontrol nit, he

EP Sndicator i l l stay n until heDT Cserased. hen

problemsdetectednd heEPSndicatoromes n, here recases hen he ndicatortays n untilthegnit ion witchs

turned FF, nd ases hen he ndicatoroes ff

automaticallyhen hesystemeturnso normal. venhough

th esystemsoperatingormally,heEPSndicator i l l come

on underhe ollowin g ondit ions:

Cond i t ion1 :

. The ehicle as raveling t east 2.4mph 20 m/h),he n

. A rapidchange n vehiclespeedwa s detected,he n

. Th e ehicleor hevehicle peed ensor ignal) toppedor

at east seconds. The ng inepeed as t i l l

l , 640rpmorh igher fo ra t leas tS

seconds

Cond i t ion :

After hevehicleor hevehicle peed ensor ignal) as

stoppedor at east 0 econds,et heengine peed assti l l

1,640pmor higherfor t east 0seconds.

Cond i t ion :

Whenhe nginepeeds28 0pm r ess,ndhe ehicles ravelingt

aspeedf6, 2mph 10 m/h)rmoreor seconds.

To determineheactual ause ftheproblem, uestionhe

customer boutheconditionsuringwhich heproblem

occured,akingheabove ondit ionsnto onsideration.

Diagnostic roubleCode DTCI

. lf heCPU annot eactivated,r tfails,the PSndicator

comes n,but heDT Cs notmemorized.. Th ememory anholdan ynumber f DTCS. owever, hen

thesameDTCs detected ore hanonce,hemost ecent

DT Cswritten ver hepriorDTC,hereforenl yon e

occurrences memorized.. Th eDTCSre ndicatedepeatedlynti lthe gnit ion witchs

turnedOFF.. lf heDTCs notmemorized,thePSndicator l inks.

. Th eDTCSrememorizedn heEEPRO| non-volati le

memory)hereforehememorized TCSannot eerased

by disconnectinghebattery. erformhespecif iedprocedureso clearDTCS.

Self-diagnosis

Self-diagnosis an be classif ied nto wo categori es:. In i t i a l d iagnos is :e r fo rmed igh ta f te r he eng ine

startsand until he EPS ndicatorgoesoff.. Regular iagnosis: erformed ight after he init ial

d iagnos is n t i l he gn i t ion w i t ch s u rnedOFF.

The EPS ontrolunit performs he following unctions

when a problem s detected y self-diagnosis;

'1 .Turnson heEPS nd ica to r .

2. Memorizes he DTC.3. Stopspowerassistan d manualsteeringoperation

begrns.

NOTE:. When DT C23 (a problemwith the circuit or

enginespeedsignal) s detected,he power

ass is t i l l re tu rn o normalwhen heveh ic le

speed s 0 .62mph (1km/h) r above.. Fot DfCs 22,23, 64,or 66 he EPS ndicatorgoes

off automaticallywhen th e system elurns o

normal . o ra l lo ther odes,he EPS nd ica to rgoesoff when the system s OK after he ignit ion

switch s urned rom OF F o ON (ll).

Restriction n PowerAssistOperation

Repeated xtremesteering orce.suchas urning he

steeringwheel continuouslyback-and-forth ith the

vehiclestopped, ausesan ncrease f power

consumption n the EPSmotor.The ncr ease f electric

cur ren t auseshe motor o heatup .Becauseh isheat

adversely ffects he system, he controlunit monitors

the electric urrentof the motor.

When he controlunit detectsheatbuild-up n the motor,

it reduces he electric urrent o the motor gradually oprotect he system,and t restricts he power assist

opera t ion . heEPS nd ica to r oesnotcomeon dur ing

th is unct ion .

When steering orque s not applied o the steering

wheel,or when th e ignit ion s urned off,an d he motor

cools, he controlunit wil l restore he power assistgraduallyuntil t 's ully restored afterapproximately 5

minu tesmax imum).



How to TroubleshootEPSDTCs

The roubleshootinglowchartprocedures ssume hat

th e causeof the problem s stil l presentand he EPSindicator s sti l l on, Following he flowchartwhen the

EPS ndicatordoesno t come on can result n incorrect

d iagnos is .

The connector l iustrations how he female erminal

connectors i t h a s ing le u t l i ne nd he male e rmina l

connectorswith a doubleoutline.

1. Ouestion he customerabout he conditionswhen

th e problemoccured, nd ry to reproduce he

sameconditions or troubleshooting. in dou t

when the EPS ndicator ame on, such aswhile

tu rn ing . f te r tu rn ing , hen heveh ic le asa t a

ce ta n speed,etc.

2. When he EPS ndicatordoes not come on durin g

th e test drive,but roubleshootings done basedon

th e DTC, heck or looseconnectors, oo r erminal

contact. tc n the affected ircuit,beforeyo u start

troubleshooting.

3. After roubleshooting, lear he DTCand est-drive

the vehicle.Be sure he EPS ndicatordoes not

comeon.

How to RetrieveEPSDTCs

Honda PGM Tester Method:

1, With th e gnitionswitchOFF, onnec t he Honda

PGMTester A) o the 16 Pdata in kconnector DLC)

(B) ocatedunder he dashon the driver'sside of

the veh ic le .

2 . Turn he gn i t ionON ( l l ) , nd o l low he prompts

the PGMTester o display he DTC(s) n the scree

After determining he DTC, efer o the DTC

Troubleshootingndex.

NOTE:See he HondaPGMTesteruser'smanual

for specif ic nstructions.

ServiceCheckSignalCircuitMethod:

1 . Wi th he gn i t ion w i t chOFF, onnecthe Honda

PGMTester A) to he 16P a ta inkconnectorDL

(B ) ocatedunder he dash on the driver'sside of

the vehicle.

Short he SCScircuit o body groundusing he

HondaPGN4 ester.

Turn he gn i t ion w i t chON { l l ) .

Record he DTC.

(con

17



PSComponents

GeneralTroubleshootingnformation cont'dl

5. The blinking requency ndicateshe DTC.DTCS reindicated y a seriesof long and short blinks.On elongb l inkequa ls 0shor tb l inks . dd he ongand

short blinks ogether o determine he DTC.Afterdetermining he DTC, efer o th e DT CTroubleshootingndex.

Th esystemwill not n dicate he DTCunless heseconditionsar e met:. Se t he front wheels n the straightaheaddriving

position.. The gnitionswitch s turnedON (ll).. Th e engine s stopped.. The SCScircuit s shorted o body ground before

th e ignit ionswitch s turnedON (ll).

Example f DTC 3

Longblinks Short blinks(two times) (three timesl

6.

7 .


Disconnecthe HondaPGMTester rom the DLC.

How to ClearEPSDTCs

HondaPGM Tesler Method:

1. With the gnitionswitchOFF, onnect he HondaPG MTester A) o the 16Pdata inkconnector DLC)(B) ocated nder he dashon hedr iver ' s ideofthe vehicle.

Turn he ignit ionswitchON (ll),and clear heDTC{s) y following he screenpromptson thePG MTester.

NOTE:See he HondaPGMTesteruser'smanualfor specif ic nstructions.



Service Check Signal Circuit Method:

NOTE:Use his procedurewhen the PGMTester

softwaredoes not match heyearlmodel

ehicleyou

ar eworking on.

1. With the ignit ionswitchOFF, onnect he Honda

PGMTester A) o the 16 Pdata in kconnector DLC)(B) ocatedunder he dashon the driver'sside of

th e vehicle.

With the vehicleon the ground,set he front wheels

in the straightaheaddrivingposition.

Short he SCScircuit o body ground using he

HondaPG MTester.

Turn he ignit ionswitchON (ll).The EPS ndicator

comeson for about6 seconds.Within 4 seconds f

turning he switchON ,while the EPS ndicator s on,

turn the steeringwheel 45 degrees o the eft rom

the straightaheaddriving position, nd hold he

steeringwheel n ha t posit ionuntil he EPS

indicatorgoesoff.

Within 4 seconds fterthe EPS ndicatorgoesoff,

return he steeringwheel o the straightahead

driving positionand release he steeringwheel.

The EPS ndicator omeson again4 seconds fter

releasing he steeringwheel,

Within 4 seconds fter he EPS ndicator omeson ,

turn the steeringwheel 45 degrees o the left againand hold t in that posit ion.

The EPS ndicatorgoesoff after4 seconds.

4.

1 . Within 4 seconds fter he EPS ndicatorgoesoff,return he steeringwheel o the straightaheaddriving positionagainan d release he steering

wheel.The EPS ndicatorblinks wic e 4 secondsafter releasing he steeringwheel, ndicating ha tthe DT Cwa s erased.

NOTE: f th e EPS ndicatordoesnot blink wice,an

errorwas made n the procedure nd he DTCwa s

not erased.Turn he ignit ionswitchOFF,an d

repeat he operation rom step3.

Turn he ignit ionswitchOF Fafterthe EPS ndicat

blinks wice.

9. Disconnecthe HondaPGMTester rom the DLC.

10. Perform he DTCcode output operation, nd besure hat he code has beenerased.

17



PSComponents

DTCTroubleshootingndex

DTC Detection ltem Note

DTC; 2 A problemwith voltage or torque sensorT/SlG (seepage17-28)

DTC: 6 A problemwith averageof voltage or torquesensorVT3 and VT6 (seepage 17-29)

DTC:17 A problem ith hevoltageor orque ensor 2V power ource cc1 (see age17-31)

DTC:18 A problemwith the voltage or torque sensor5 V powersourceVcc 2 (see age17-31)

DfC:22 A problemwith the average or vehiclespeedand enginespeed (see age17-33)

Excessive hangeof the vehiclespeedsensorsignal {seepage17-33)

DTC: 3 A problemwith the enginespeedsignalcircuit (see age17-33)

DTC: 7 A problemwith the circuit or input motor voltage n the EPS ontrolunit (seepage17-35)

DTC:41 A problemwith the motor voltage (see age1736)

DfC: 42 A problemwith the motor drivencurrent opencircuitor short o grounol (seepage 17-38)

DTC: 3 A problemwith the motor drivencurrent short o power) (see age17-41)

DTC: 5 A problemwith the motor drivencurrent opencircuitor short o grounol (seepage 17-38)

DfC: 47 A problemwith the motor relav n the EPS ontrolunit {see age17-42)

DTC: 0 A problemwith the CP U n the EPS ontrolunit (see age17-43)

DTC: 1 A problem ith EEPROMn heEPS ontrol nl t (seepage17-43)

DTC: 2 Fail-safe elaystuckON (see age17-44)

DTC: 4 A problemwith low batteryvoltage

Fail-safe elaycontact ailure

(seepage17-44)

(seepage17-44)

DTC: 6 A problemwith th e motor drivenvoltage {seepage17 45)

DTC: 7 A problemwith the torque sensor /Fcircuit (see age17 '45)

DTC:68 A problemwith the interlock ircuit torque) {seepage 17-45)

DTC:69 A prob lemwi th he n ter lock i rcu i t cur ren t ) (see age17-46)




Symptom Diagnostic procedure Also check fo]

EPS ndicatordoesno t

come on

EPS ndicatorCircuitTroubleshooting se epage 17-47)

EPS ndicatordoes not go

off and no DTC s stored

EP S ndicatorCircuitTroubleshooting se epage 17-47)

EPS ndicatordoes not stay

on , no DTC s stored,an d

there s no powerassist

1. Check he motor wires between he EPS ontrolunit and he

motor or a short o ground.Repairas needed.

2. lf th e motor wires are OK,replace he steeringgearbox

{short n the motor).

17



EPSGomponents

SystemDescription

EPSGontrolUnit nputsandOutputsat Connector (2pl

EPSCONTROLUNIT CONNECTOR {2P)


EPSControlUnit nputsand Outputsat Connector (2P)

EPSCONTROL NITCONNECTOB {2P}


Termanal

numbol

Wirecolor Terminal ign

(Terminal amel

Description Measurement

Terminals Conditionslqnitiqr switch ON (lll Voltage

WHT/BLU -' BAT(Plusafterv)

Power ourceor heactuatormotor

l G ro un d C on st an t Battery voltage

2 8LK PG Groundortheactuator 2-Ground

TerminalnumDer

Wire colol Terminalsign{Te.mioalname)

Description MeasuremenlTerminals Conditions

lqnitionswitch ON lllVoltage

1 RED M 1(Motor 1

Driveshe actuator otor 1-Ground

2 GRN M2 Drives the actuator motor 2'Ground



EPSGontrolUnit nputsand Outputsat Connestor (20P1

EPSCONTROL NIT CONNECTOR(2OP)


Terminal

numbel

Wirecolor Terminal ign

{Terminel ame}

Descriplion Measuremeni

Terminals Conditions{lqnitionswitch ON {lll)

Voltage

2 P N K T/ SGN D(Torque ensor round)

Groundor he orque

OR N vccl(Voltaqeommon1

Power ourceortorque 3 -G ro un d t ar tt heenqrne Ba$erv oltaqeO V

5 YEUBED VT6(Voltaqeorque )

Detectsorquesensorstonal

5 Ground Startthe ngine ndturn he steerino heel

About

YEUBLU(Warninqamp)

Driveshe EPS ndicatorl idhr

6 Ground E PS ONtnotcatol uTl-

O VBanerv oltaqe

7 BLUAVHT VSP(Vehic le peedpulsei

Detectshe vehicle peedinput ignalor hespeedsensor r heEC M 4pulse/

Raise hevehicleoff theground ndspin he

Alternatingvoltage boutO V 5 V O V - 5

BRN SCS{Servjcoheck iqnal)

Detects ervice heck 8-Ground SCS ot grounded Battery oltage

1 0 YEL IG1llqnit ion

Powersource or activating 10-Ground onswitchON ll ) Batterv oltaqeonswitchOF F

1 1 GRN//EL vcc2(Voltaqeommon )Driveshe orque ensor 1'l-Ground tan heenoine Abou t 5V

on switch OFF

8LU/ORN VT3(Voltaoeoroue )

Detectsorquesensor 13-GroundStartthe ngine ndtrrrn hesteerino heel

About5 - 0 v

YEUBLK T/SIG(Torque ensor /S

Detectsorquesensorsrgnal

15-GroundStartthe ngine Momentarily V

1'l LTGRN/BIK

PSWiPowersteerino witch)

Provides owersteeringswitchsional

l7-Ground Startthe ngine ndnrrn hesteerino heel

0 - 1 2 V

19 BLU NEP Detectshe enginepulse 19-GroundStartthe ngine, nd et;t dte

20 GRY DIAG-H Communicationsit hHondaPGNI ester

20-GroundPGMTesternot 5 V

17



PSComponents

\ircuitDiagram

\

SPE€DSENSOR3P CONNECTOR

@

TOFOUESENSOR6P CONNECTOR

l l i 2 l 3 Fr;T;T-I(=J_:_LvJ

Wn. !ide ot f.m.l€ r.fmin.ls

GAUGEASSEMBLY 2PCONNECTON

GAUGEASSEMATY 2PCONNECTOR



EPS OI{IFOIUNITcou{EcToR A (2P)

F-l

A

EPSCONTNOLUNITco|lNEcTofi 8 {2P}

| l l

t2)Wir. !.le ol l.m.l. t.tman.r.

MOTOFCONNECTOR

riTt

OATA IN( CONN€CTOA T6P)

vTTrvaEvnrvwwzna

T.rmin.l.id. oll.m.l.r.rmin.l.

17



PSComponents

DTCTroubleshooting

DTC12:TorqueSensor /SIG

1. C lear he DTC.

2 . Stan he eng ine .

3. Wait at least10 seconds.

Does he EPS ndicatot comeon?

YES Go o step 4.

NO Check or loosewires or poor connections.fth e connections regood, he system s OK at thist i m e . l

4. Stop he engine,and verify he DTC.

ls DTC12 ndic ated?

YE S Go o slep 5.

NO-Perform the appropriate roubleshootingorthe code ndicated.

Makesure he gnitionswitch s OFF, hendisconnectEP S ontrol unitconnectorC (20P) ndthe torquesensor6P connector.

Check or continuitybetweenEP S ontrolunitconnector (20P) term ina lo .15andbodyground.

EPSCONTROL NITCONNECTOR{2OP)


ls therecontinuity?

YES- Repair hort o bodygroundn hewirebetweenhe orque ensor ndEPS ontrol nit.l

NO Go o step .

5 .

1 .

8 .


Measure he voltagebetweenEP S ontrolunit

connector (20P) term ina lo .15andbodyground.

EPSCONTROL NITCONNECTOR(2OP)

2 3 5 6 1 8 0

T/SIG{YEL/BLK)

Wire sideot emale erminals


YES-Repair short o power n the + circuitwirebetween he torquesensorand EPS ontrolunit. l

NO Go o step9.


Check or continuitybetweenEPS ontrolunitconnectorC (20P)erminal No. 15 and he torquesensor6Pconnector erminal No. 4.

EPSCONTROL NITCONNECTOR(2OPI

\9 .

1 0 .

T/SIG(YEL/BLK) Wi res ide f em a le e rm ina l s

TOROUEENSOR6PCONNECTOR

T/SIG(YEL/BLK)


YES Go o s tep 1'1,

NO Repairopen n the wire between he or quesensorand h e EPS ontrolunit.I




' I1 . Substitute known-goodEPS ontrol unit,an d

connect he all disconnected onnectors.

Sta t the engine.

Does he EPS ndicatorcomeon ?

YE S Go o step 13.

NO Check or looseEPS ontrolunitconnectors. f

necessary,eplace he EPS ontrolunit an d

retest.l

Stop he engine,and verify he DTC.

ls DTCl2 indicated?

YES Check or loose orque sensorconnectors.lf necessary, ubstitute known-good teeringgearboxan d recheck.l

NO-Perform the appropriate roubleshootingor

th e code ndicated.

1 2 .

1 3 .

DTC 6:Torque ensor T3andW6

1. C lear he DTC.

2. Start he engine.3 . Wai ta t east 0seconds.


YES Go o step4.

NO Check or loosewires or poorconnnections

the connections re good, he system s OK at this

t ime. l

4. Stop he engine,an dverify he DTC.

ls DTC16 nd icated?

YES-Go to step 5.

NO Perform he appropriate roubleshootingor

th e code ndicated.

5. Makesure he gnitionswitch s OFF, he n

disconnectEPS ontrolunit connectorC (20P) nd

the torque sensor6Pconnector.

6, Check or continuitybetween he appropriateEPS

controlunit connectorC (20P)erminal and bodyground (see able).

Termina l ame EPS ont ro l n it onnect orterminal o.

Vccl 3Vcc2 1 1

VT3 1 3VT6 5

T/S GND 2

W re s d€ oltemalelermi.als


YES- Repair hort o body ground n th eappropriate ensorcircuitbetween he torque

sensorand EPS ontrolunit,

NO Go o step7.

{cont

EPSCONINOT NITCONNECIOR 2OP)

17



PSComponents

7 .

8 .



Measure he voltagebetween he appropriateEPScontrolunit connectorC (20P)erminalan d bodyground (see able).

Terminal ame EPS ontrolnit onnectorterminalo.

Vccl 3Vcc2 11VT3 1 3VT6 5

T/ S GN D 2

ls thete battery voltage?

YES Repairshon to power n th e + circuitwire

between he EPS ontrolunit and orque sensor.l

NO Go to step9.

EPSCONTROL NITCONNECTOR {2OP}


9 .

1 0 .


Check or continuitybetween he appropriateEP Scontrolunit

connectorC {20P)erminaland hetorquesensor erminal see able).

TOROUESENSOR PCONNECTOR

Vccz(GRN/YELI

Wire sideoff em a lee rm ina l s

VT6{YEL/RED)

EPSCONTROL NITCONNECTORI2OP)

VT6 YEL/RED}\


ls there ontinuty?

YES Go o s tep 1.

NO Repair pen n heappropriateorque ensorwirecircuit etweenheEPS ontrol nitand hetorque ensor . l

\

Terminalname

Torque ensorterminal o,

EP S ontrolunitconnectorC erminal o .

Vcc l 2 3Vcc2 3 1 1VT3 'l ' t3

VT6 6 5T/S GND 6 2

T/S GND PNK)



1 1 .

' t2 .

Substitute known-goodEPS ontrolunit,an d

reconnect he disconnected onnectors.

Stat

he engine.

Does the EPS indicator come on?

YES Go o step 13.

NO Check or looseor poor connections t theEPS ontrol unit and he torquesensorconneclors.lf the connections regood, replace he EPS ontrol

un i tand echeck. I


ls DTC16 ndicated?

YES Replace he steeringgearboxan d recheck.l


th e code ndicated.l

1 3 .

DTC 7:Torque ensor ccl

DTC 8:Torque ensor cc2

1. C lear he DTC.

2 . Star t heeng ine .

3. Wait at east10 seconds.

4 .

Does he EPS ndicatorcomeon?

YES Go o step 4.

NO Check or loosewires or poorconnections.f

the connections regood, he system s OK at this

t i m e . I

Stop he engine,an dverify he DTC.

Is DTCl7 or DTCl8 ind ica ted?

YES Go to step5.

NO Do he troubleshootingor the DTc

ind ica ted . I

Makesure he gnitionswitch s OFF, hen

disconnectEP S ontrol unit connectorC (20P) nd

the torque sensor6P connector.

Check or continuitybetweenEPS ontrolunitconnector (20P) term ina lo .3 andbodyground

EPS ONTROLNITCONNECTOR(2OP)

Wire ide { emaleerminals

ls therecontinuity?

YES Repa i r hon o bodyground n hewi re

between he torquesensorand EPS ontrolunit.I

NO Go o step7.

(cont

17-



DTC 2: Vehicle peed ensor ignal

DTC 3: Engine peed ignal

NOTE:. lf th e MIL ndicator s ON, roubleshoot he PGIVI-Fl

system irst.. Even hough he system s operatingnormally, he

EPS ndicatorwill come on under he following

conditions.

- Cond i t ion :. The vehiclewas travelingat east

12.4mp h

(2 0km/h), hen. A rapldchange n vehiclespeedwas detected,then

. Theveh ic le or heveh ic le peed ensor igna l )

stopped or at least5 seconds, nd. The enginespeedwas sti l l 1,640 pm or higher or

at least5 seconds- Condition2:

After he vehicle or he vehiclespeedsensor

signal)ha sstopped or at least10 seconds, etthe

eng ine peedwas st i l l1 ,640 pm or h igher o r a tleast20 seconds.

- Condition3:When heveh ic le peed s 10km/h 6.2mph)or

above nd he eng ine s runn ing t 280 pmorbelow or 3 seconds.

1. Start h e engineand check he achometer.

ls the tachometer working correctly?

YES- Go o step2.

NO-Go to step .

2. Test-drivehe vehicleabove15 km/h {9.3mph).

ls the speedometerworking correctly?

YES Go o step3.

NO-Perform the speedometer ystemtroubleshooting se epage22-651.a

3. Block he rearwheelsand raise he vehicle,an dmakesure t is securely upported.


Block he right ront wheel, and slowly rotate heleft ront wheel,and measure he voltagebetwee

EPS ont ro l n i tconnector (20P) term ina lo .7

andbodyground.

EPS ONTROLNITCONNECTOR{2OP)

Does he voltagepulse 0 V and 5 V?

YES Go o step6.

NO Repairopen n the wire between he EPS

controlunit and he VSS. f the wire is OK,checko

a looseor poorconnections t the EPS ontrolunilf necessary, ubstitute known-goodEPS ontro

un i t , nd echeck. l

(conr

4.

5.


17-



PSGomponents

7.

8 .


Turn he gnitionswitchOFF,and disconnectEP Scontrolunit connectorC (20P).

Start h e engine,an d et t idle.

Measure he voltagebetweenEPS ontrolunitconnector {20P)ermina lNo.19 nd bodyground.

EPSCONTROL NITCONNECTOR{2OP)

ls there about6 V at idle? (With the meter set olt requency, s ther e 33 Hz per 1,000 ngine pm?

YES Check or looseEPS ontrolunit connectors.lf necessary, ubstitute known-goodEPS ontrolun i tand echeck. l

NO Repairopen n th e wire between he EP S

cont ro l n i tand he ECM. I

Turn he gnitionswitch OFF,and disconnectEPScontrolunit connectorC (20P).

Start he engine,and et t idle.

9 .

10 .


11. Measure he voltagebetweenEP S ontrolunitconnector (20P) term ina lo .19andbodyground.

EPSCONTROL NITCONNECTOR {2OPI


ls thereabout6 V at idle? (With the metet set tortrequency, is therc 33 Hz per 1,000 engine rpn?)

YES Check or looseEPS ontrolunitconnectors.lf necessary, ubstitute known-goodEPS ontrol

un i tand echeck. I

NO Go o step12 .


Disconnecthe EC MconnectorE (31P) onnector.

12.

1 3 .

!



PSComponents


DTC 1: Voltage orMotor

1. C learhe DTC.

2 . S tar t heeng ine .

3. Turn he steeringwheel rom lock-to-lock everal

t imes,an dwait 10 seconds r more,

Does he EPS ndicatorcome on?

YES-Go to step 4.



t ime. l


ls DTC 41 ndicated?

YES Go o step 5.


thecode nd ica ted . l

5. Makesure he gnitionswitch s OFF, he n

disconnectEPS ontrolunit connectorB (2P) nd

the motor 2Pconneclor.

6. Check or continuitybetweenEPS ontrolunit

connector (2P) ermina lNo.1 andbodyground.

EP SCONTROL NI TCONNECTOR {2P}

M1 RED}HF - - - t | |

I t r(f))T,L



YES Repair hort o body ground n the REDwire

between he EPS ontrolunit and he motor.

NO-Go to s tep7.

17-36

7. Check or continuitybetweenEP S ontrolunit

connector (2P) te rm ina l o .2 andbodyground.

EPSCONTROL NITCONNECTORI2P)

TitM2 GRN) J

-ro)TI



YES-Repa i r hor t o bodyground n he GRNwi re

between he EPS ontrolunit and he motor,l

NO Go o step 8.

Check or continuitybetweenEPS ontrolunit

connector (2P) te rm ina l o.1 and No.2 .

EPSCONTROL NITCONNECTOR{2P)



YES Repairshort between he RE Dand GRN

wires n th e motorcircuitbetween he EPS ontrol

un i tand he motor . l

NO Go o step9.

M2 (GRNI

\



9. Turn he ignit ionswitchON (ll),and measure hevoltagebetweenEPS ontrolunit connectorB (2P)

terminalNo. 1and body ground

EPSCONTROL NITCONNECTOR (2P)

M1 REDIHr- _ 1||

tr,<.)\uL,/YI

Wire id eoI emaleerminals

Is there battety voltage?

YES Repair hort o power n the + circuitwirebetween he EPS ontrolunit and he motor.I

NO-Go to s tep10.

Measure he voltagebetweenEP S ontrol unitconnector (2P) te rm ina l o .2 andbodyground.

EPSCONTROLNITCONNECTOR(2P)

1 0 .

razcnrrrr{l-t . I

I(v)YI



YES-Repair shortto power n th e - circuitwirebetween he EPS ontrolunit an d he motor.!

NO Go o s tep11.

1 1 .Turn he gnit ionswitch s OFF.

Substitute known-goodEPS ontrolunit,andconnectall the disconnected onnectors.

Start he engine,and urn the steeringwheel romlock o lockseveral imes.

Does he EPS indicatorcome on?

YES-Go to s tep14.

NO-Check for looseor poor connections ttheEPS ontrol unit and he motor connections.fthe

connections re good, eplace he EPS ontroluni

and echeck. l

Stop heeng ine , ndver i t y he DTC.

ls DTC 41 nd cated?

YES Replace he steeringgearboxmotor andrecheck. l


the code nd ica ted . l

1 3 .

1 4 .

17-



PSComponents

TCTroubleshootingcont'd)

DTC42,45: MotorDrivenCurrent

1. Clear h e DTC.


3. Turn he steeringwheel rom lock-to-lockeveralt imes, ndwai t 10seconds r more .

Does he EPS ndicator comeon?

YES- Go o step4.

NO-Check for loosewires or poorconnections.fthe connections regood, he system s OK at thist i m e . I


ls DT C 42 or 45 indicated?

YES-Go to step5.

NO - Perform he appropriate roubleshootingorthecode nd ica ted . I

Make ure he gn i t ion wi tch sOFF, hen

disconnectEPS ontrolunit B connector 2P ) ndthe motor 2Pconnector.

Check or continuitybetweenEPS ontrolunit

connector (2P) te rm ina l o .1 andbodyground.

EPSCONTROL NITCONNECTORI2P)

M1 RED}H

I f2-l(C))TI



YES Repair hort o body ground n the REDwirebetween he EPS ontrolunit and he motor,I

NO-Go to s tep .

6.

7. Check or continuitybetweenEPS ontrolunitconnector (2Pl te rm ina l o .2 andbodyground.

EPSCONTROL NIT CONNECTORI2PI

r',rzcnnrtl

-]-(o)TI


lsthere continuity?

YES Repair hort o body ground n the GR Nwirebetween he EP S ontrolunit and he motor.l

NO Go o step8.

Check or continuitybetweenEP S ontrolunitconnector (2P) ermina lNo.1 andNo.2 .




YES Repair hort between he REDand GRNwires n the motor circuitbetween he EPS ontrolun i tand hemotor . l

NO Go o step9.

M2 {GRN)



9. Turn he ignit ionswitchON (ll),and measure hevoltagebetweenEPS ontrolunit connectorB (2P)

term ina lNo. andbodyground.

EPSCONTROL NIT CONNECTOR (2PI

M1 RED}T-----l | |

li l(v)II

Wire ideo{ emaleerminals


YES-Repair short o power n the + circuitwire

between he EPS ontrolunit and motor.l

NO Go o step 10 .

Measure he voltagebetweenEPS ontrolunitconnector {2P} te rm ina l o .2 andbodyground.

EPSCONTROLNI TCONNECTOR(2P}

mz cnrurl-l

A(v)YI


ls ther e battery voltage?

YES Repa i r hor t o power n he + c i rcu i tw i rebetween he EPS ontrolunit and he motor.a

NO- Go o s tep11.

10 .

11. Check or continuitybetweenEPS ontrolunit

connectorB (2P) erminalNo. 1 and he motor 2Pconnector erminalNo. 2.

EPSCONTROL NITCONNECTOR12P)

MOTORCONNECTOR2PI

M1IRED)

M1 (RED}


ls there ontinuity?

YES-Go o step 12 .

NO-Repairopen n he RED irebetweenheEPcontrol nitand hemotor.l

(cont'

17-



EPSGomponents

DTGTroubleshootingcont'd)

12. Check or continuitybetweenEPS ontrolunitconnector (2P) te rm ina l o.2 and he motor2Pconnectorerm ina lNo.1 .

EPSCONTROLUNITCONNECTOR I2PI

MOTORCONNECTOR2P)

14.

M2 IGRN)



YES-Go to s tep13.

NO-Repair open n the GRNwire between he EPS

controlunit and he motor.l

Check or loosewires or poorconnections,f theconnections re good.substitute known-goodEPS ontrol unit,and connectallthe disconnectedconnectors.

Start he engine,and urn the steeringwheel rom

lock o lockseveral imes.

Does the EPS indicatot come on?

YES Go o step 15.

NO Check or looseEPS ontrolunitconnectors. fnecessary, eplace he EP S ontrolunit andrecheck.

17-40

L15 . Stop he engine,and verify he DTC.

ls DTC 42 or 45 indicated?

YE S Replace he steeringgearboxmotor an drecheck.l

NO Perform he appropriate roubleshootingorthe code ndicated.l



DTCli|: MotorDriven urrents ExcessivelyHish

1. C lear he DTC.

2. Start he engine.

3. Turn he steeringwheel rom lock-to-lock everalt imes,and wait

'1 0seconds r more.


YES Go o step4.

NO-Check for loosewires or poor connections.fthe connections regood, he system s OK at thist tme. I


ls DTC 43 ndicated?

YES Go o step5.

NO-Perform the appropriateroubleshootingorthe code ndicated.I

5. Makesure he gnitionswitch s OFF, hendisconnectEPS ontrolunit connectorB (2P) ndthe motor 2Pconnector.


7. Measure he voltagebetweenEP S ontrolunitconnector (2P) te rm ina l o .

1andbodyground.

EPSCONTROL NITCONNECTOR {2P}

M1 REo)HT------t I I

I t r(v)T-L

Wire id eot emaleerminals


YES Repair hort o power n the + circuitwirebetweenEPS ontrolunit and motor.l

NO-Go to s tep .

8. Measure he voltagebetweenEPS ontrolunitconnector (2P) te rm ina l o .2 andbodyground

EP SCONTROLNI TCONNECTORI2PI

TilM2 cRNlF-l

f---1 z I

(v)YI



YES- Repair hort o power n the - circuitwire

between he EPS ontorlunit and he motor.

NO-Go to step9.


Check or continuitybetweenEPS ontrol unitconnector (2P) ermina ls o .1 and No.2 .




YES Repair hort between he GRNand REDwires n the motor circuitbetween he EPS ontroun i tand he motor . l

N O G o t o s t e p 1 .

9 .

1 0 .

(cont

17-

M2 {GBN)



EPSComponents

1 1 .

12.


Substitute known-goodEPS ontrol unit,andconnectall he disconnected onnectors.

Sta t he engine,and urn the steeringwheel ro m

lock o lockseveral imes.

Does he EPS ndic ator comeon ?

YES Go o step 13.

NO Check for looseor poorconnections t heEPS ontrolunit and he motor connections.f th econnections regood, replace he EPS ontrolunitand recheck.l

Stop he engine,an dverity he DTC.

ls DTC 43 ndicated?

YES-Replace he steeringgearboxmotor an drecheck. l

NO-Perform the appropriate roubleshootingor

the code ndicated.l

13 .

DTC 7: EPSControl ni t nternal i rcuit(Power elay)

1. Clear h e DTC.

2. Start he engine.


YES-Go to step3,

NO-Check for loosewires or poorconnections,f

the connections regood, he system s OK at hist ime. I


ls DTC 47 indicated?

YES Check or looseEPS ontrolunit connectors.lf necessary, ubstitute known-goodEPS ontrolun i tand echeck. l

NO Perform he appropriateroubleshootingorthe code ndicated.I



DTC 0: EPSControlUnit nternalCircuit(CPU r Microcomputer)

1. Clear he DTC.



YES Go o step3.

NO Check or loosewires or poorconnections.fthe connections regood. he system s OK at thist ime.

3. S top he engine,and verify he DTC.


YES-Check or looseor poorconnections t theEPS ontrolunit connections.f the connections regood,substitute known-goodEPS ontrolunit. f

the symptom/indication oe saway, eplace heoriginalEPS ontrolunit. l

NO Perform he appropriate roubleshootingorthe code ndicated.

DTC 1: EPSControl ni t nternal ircuit(EEPROM)

1. C lear he DTC.

2. Start he engine.


YES-Go to step3.

NO-Check for loosewires or poor connections.f

the connections regood, he system s OK at thist i m e . I

3. S top he engine,and verify he DTC.


YES-Check or looseor poor connections t theEPS ontrolunit connections.f the connections rgood.substitute known-goodEPS ontrol unit. f

the symptom/indication oe saway,replace heoriginalEPS ontrolunit.


17-



PSComponents

DTCTroubleshootangcont'dl

DTC 2: EPSControlUnit nternalCircuit(Fai l-safeelay tuckON)

'1 .Clear he DTC.

2. Start he engine.


YES-Go to step3.

NO-Check for loosewires or poorconnections.f


t ime. I



YES-Check or looseor poor connections t the

EPS ontrolunit. f the connections regood,

substitute known-goodEPS ontrolunit. f th e

symptom/indication oe saway, replace he

originalEPS ontrolunit and recheck.l

NO-Perform the appropriateroubleshootingor

the code ndicated.

17-44

DTC 4: Battery oltages Excessivelyow(Fai l-safeelay ontact ailure ndMotorVoltage al lOff)

1. C lear he DTC.2. Start he engine.

Does he EPS ndic atot comeon ?

YES Go o step3.


the connections regood, he system s OK at this

t r m e . l


ls DTC 64 ndicated?

YES Go o step4.


th e code ndicated.

4. Check he No .'1 8(604) use n the under-hooduse/

relaybox,and reinstallthe use f it is OK.

Is the f use OK?

YES Go o step 5.

NO Replace he fuse and recheck.l

5. Disconnect PS ontrolunit connectorA (2P).

6. Measure he voltagebetweenEPS ontrolunit

connector (2P)ermina lNo. 1 andbodyground.

-Blwt{r/Bl.urHl

\9

I


YE S Check or looseor poorconnections t he

EPS ontrolunit connectors, nd check or a poor

groundat G151. f necessary , ubstitute known-good EPS ontrol unit and recheck.l

NO Repairopen n he WHT/BLUwire between

the No.18 60,4) fusendEPS ont ro l n i t . l



DTC 6,68: EPSControl ni t nternal ircuit

1. Clear he DTC.


3. Turn he steeringwheel rom lock-to-lock everalt imes,an dwait 10seconds r more.


YES-Go to step4.

NO-Check for loosewires or poorconnections.fthe connections regood. he system s OK at thist ime. l

4. Stop he engine.and verify he DTC.

ls DTC 66 or 68 indicated?

YES-Check or looseor poor connections t theEPS ontrolunit. f th e conneclions regood,

substitute known-goodEP S ontrol unit. f thesymptom/indication oe saway, eplace heoriginalEP S ontrolunit and recheck.I


DTC67: TorqueSensor /FCircuit

1. Cle ar he DTC.

2 . Star t he eng ine .

3. Turn he steeringwheelfrom lock-to-lock everalt imes,and wait 1 0seconds r more.

Does the EPS indica tor come on?

YES-Go to step 4.

NO Check or loosewires or poor connections.

connectionsare good, he system s OK at this t im



YES Check or looseor poor connections t th eEPS ontrolunit. f the connections regood,

substitute known-goodEP S ontrol unit. f th esymptom/indication oe saway, replace heoriginalEP S ontrolunit and recheck.

NO-Perform the appropriate roubleshootingorthe code ndicated.I

17-



EPSComponents


DTC 9: EPSControlUnit nternalCircuit

1. C lear he DTC.

2. Start he engine.

3. Turn he steeringwheel rom lock-to-lock everal

t imes, and wait 10 seconds r more ,


YES Go to step 4.

NO-Check for loosewires or poorconnections.fth e connections re good, he system s OK at thist ime. l


ls DTC 69 ndicated?

YES-Check or looseor poor connections t the

EPS ontrol unit. f the connections regood,

substitute known-goodEP S ontrolunit. f the

symptom/indication oe saway, eplace he

originalEPS ontrolunit and recheck.l

NO- Perform he ap propriate roubleshootingor

the code ndicated.l

17-46



EPS ndicatorCircuitTroubleshooting

1.Turn he ignitionswitch ON (ll),start h e engine,

and watch he EPS ndicator.


YES lf the EPS ndicator omeson andgoesoff, t 'sOK. f the EPS ndicator tay son or blinks.go to

s tep12.

NO Go o step2.

Turn he gnitionswitchOFF, hen ON (ll)again,

an dwatch he brakesystem ndicator,

Does the brake system indicator come on?

YES-Go to step3.

NO Repairopen n th e indicatorpowersourcec i rcu i t . l. B lownNo.10 7.5A) fuse.. Open n the wire between he No. 10 7.5A) use

an d gaugeassembly.. Opencircuit nside he under-dashuse/relay ox,. Faultygaugeassembly.

Turn he ignit ionswitchOFF,

Connect umperwire between he gauge

assembly22 Pconnector erminalNo. 13 and bodyground,hen urn he gn i t ion w i t chON ( l l ) .

GAUGE SSEMBLY2PCONNECTORBlue onnector)



YES-Go to step 5.

NO InspectheEPS nd ica tor u lb , f hebu lb sOK, ep lacehe bu lbc i rcu i t oard n hegauge

assembly . l

3 .

4 .


6. Disconnect PS ontrolun t connectorC (20P).

7 . Turn he gn i t ion wi tchON ( l l ) .

8. ConnectEPS ontrolunit connectorC (20P)

terminal No. 6 to body groundwith a umperwire.

Wire s d€ o f lemale16rmina


YES Go o step9.

NO Repairopen n th e wire between he gauge

assemblyand he EPS ontrolunit. l


Disconnect PS ontrolunit connectorA (2P),

Check or continuitybetweenEPS ontrolunitconnectorA terminal No. 2 and body ground.

EPS ONTROLNITCONNECTOAI2PI

wire s de o f temale ermina ls


YES Check or looseor poorconnections t the

EPS ont ro l n i t . f heconnect ionsregood,

substitute known-goodEPS ontrolunit. f thesymptom/indication oe saway, replace heor ig ina l PS ont ro l n i tand echeck. I

NO Repa i r pen n he w i re or a badgroundatG 1 5 1 , t

(cont'

9.

10 .

' l1 .

EPSCONTBOLUNIT CONNECTOBC {2OP)

17-



PSComponents

12 .

EPS ndicatorCircuitTroubleshootingcont'dl


Disconnect PS ontrolunit connectorC (20P).

Turn he ignit ionswitch ON (ll).


YES-Repair short o ground n th e YEUBLUwirebetween he gaugeassemblyand he EPS ontrolunit,or replace he bulb circuitboard n the gauge

assembly . l

NO-Go to step 15 .

Measure he voltagebetweenEPS ontrolunitconnector (20P) term ina lo. 10andbodyground.

EPSCONTROL NITCONNECTORI2OP)


ls there attery oltage?

YES-Go o step 6.

NO-Repairopen n hewirebetween PS ontrolunitconnector (20P) nd heNo,10 7.5A)use.

13 .

14 .

16. Measure he voltagebetweenEPS ontrolunitconnectorA (2P)terminalNo .

1and body ground.

EPS ONTROLNITCONNECTON(2P}

+B (WHT/BLUIH

I t rvL

1 7 .1 8 ,1 9 .

20.



YES-Go to step 17.

NO-Check for a blown No. 18(604) use n theunder-hood use/relay ox or open/short n theWHT/BLUwire between h e under-hood use/relaybox and he EPS ontrolunit. l

Turn he ignit ionswitchOFF.Reconnect PS ontrolunit connectorA (2P).


Measure he voltagebetweenEPS ontrolunitconnectorC (20P)terminalNo. 8 and body ground.

EPS ONTROLNITCONNECTOR(2OP)


ls therc about 10 V?

YES Check or looseor poorconnections t th e

EPS ontrolunit. f the connections regood,

substitute known-goodEP S ontrolunit. f th esymptom/indication oe saway, eplace heoriginalEPS ontrolunit an d recheck.l

NO Repair hort o ground n the BRNwirebetween he data in kconnectorand he EPScont ro l n i t . I



Motor Removal/lnstallation

Bemoval

1. Makesureyo u have he anti-theft ode or th e radio,then write down the frequenciesor th e preset

buttons.

2. Disconnecthe negative able rom the battery,an d

wait 3 minutesbeforebeginningwork.

3. Remove he air cleanerassembly A).

4. Remove he connectorbracket A)onthegearbox

housing,and disconnect he motor 2Pconnector(B) .

9. 8N. m {1.0 gf.m,

5. Remove he motor{A ) rom the gearboxhousing.

6. Remove he O-ring B)and discard t.

(cont

17-



EPSComponents

Motor RemovaUlnstal lationcont'dl

lnsiallation

7. Clean he matingsurfaceof the motor (A) an dgearbox.

Apply a thin coat of sil iconegrease P/ N08733-8070E)to he new O-ring B) ,and carefully it it onthe motor.

Apply grease NipponGreaseWR-Sor equivalentsteeringgeargrease) nt o he motor shaft C) .

qE

8 x '1.25mm20N. m12.0 gt.m,7 2lbl ftl

L==-c].E@

9 .

r0.Install he motor on the gearboxby engaging hemotor shaftan dworm shaft D).Note he motorinstallation osit ion direction f motor wires).

Before ightening he bolts, urn the motor wo orthree imes right an d ef tabout45 degrees. vlakesure he motor s evenlyseatedon th e steeringgearboxand hat he O-ring s not pinchedbetlveen

the matingsurfaces.

Installthe emovedDarts n the reverse rder ofremoval.and note hese tems:

lvlake ure he motor 2P connector s properly

connected.lvlake ure he motor and EPSwires ar e no t

caughtor pinchedby any parts.

Reconnecthe negative able o the battery.Do he eng ine ont ro lmodu le ECM)d le earnproceduresee age11-139) .Enter he anti-theft ode or the radiostationDresets. eset he clock,

Do he oower window controlunit resetprocedure seepage22-1241.

After nstallation, tart he engine,and et t idle.Turn he steeringwheel rom lock-to-lock everalt imes.Check hat he EPS ndicatordoes not comeon.

1 1 .

12 .

13 .



SteeringGearboxRemoval

SpecialTool Required

Ball oint remover,2Smm 0TlvlAC-S100200

1. Rais e he front of vehicle,and makesure t issecurely upponed.

2. Remove he front wheels.

Removehedr iver ' s i rbag seepage23-113) .

Remove he steeringwheel (seepage17-6).

Remove he motor on the steeringgearbox (see

page T-49) .

Remove he driver'sdashboard ower cover se e

page20-59) nd undercover {seepage20-60).

Remove he steering oint bolts A),and disconnect

the steering oint by moving he steering oint (B)

toward he column.

4 .

5 .

6.

7 .

' i l

_ t \

l - ' /

,a.: --L-

8. Remove he cotterpi n (A)from th e tie-rodball join

nu t {B),and o osen he nut.

r0 mm HEXNUT07MAC-S100200

Separate he tie-rodball joint an ddampersteering

arm using he special oo l (seepage18-10). epe

on the othersideof the vehicle.

Grasp he r igh ts ide ie - rod , ndpu l l he rack l l h

way to the passenger's ide,

Remove he heatshield A)mountingbolts ro m

the bodystiffener, nd et he heatshield ay

against he exhaust.

1 1 .

9.

10 .

(cont

17



PSComponents

SteeringGearboxRemoval cont'd)

Disconnecthe EPS ire harnessPconnectorA) ,and emoveheEPSwireharnessB)andmountinobracketC) .

12.

Removeheground ableerminal A) rom hesteering earbox ousing.

..(.,/ a

b-H \

ry T,-.lt'^ \'" \--

13.

_ - 1 . . 1 . - '

-a--zii F--_1

14. Removeheeng inewi re harness lamps A) f romth e three mountingbrackets.

Remove he heaterhose B) ro m the bracket.

Open he heater alvecableclamp(A),anddisconnect he heater alvecable B).Remove heheater alve (C ) ro m the bulkhead, nd move t

aside.

t 5 .

16.

I



17. Remove he bodv stiffener A) .

Remove he steering tiffenerA from the eft side

of the steeringgearbox.

1 8 .

19. Remove he steering tiffenerB from the rightsid

of the steeringgearbox.

i t1-:: .,

20. Lower he steeringgearbox,an d rotate t so thepinionshaftpointsupward.

21. Remove he pinionshaftgrommet (A ) rom the o

of the torque sensor.

(con

17



PSComponents

SteeringGearboxRemoval cont'd)

22. Move he steeringgearboxand ie-rodendsas anassembly o the wheelwellopeningon thepassenger's ide.

23. Carefully aise he driver'sside (pinionside)ofthesteeringgearbox A) and ie-rod B)until clears hemastercylinderand under-hooduse relaybox,then remove he steeringgearbox.Be carefulnot odamage he hoses, inesand wtre narnesses.



I x '1.25mm20N. m 2. 0 gf.m,7.2lbttl

O.RINGReplace.

PINION HAFT ROMMET

-'t ''v\> - - . i*\{i#r^i. s(./t' JSLTDERUIDE \

-l

\ \

{^il \ stot *,tttc

\J " \Renrace

\ LocK cREw\ '162N. m\ l to .s g f m,119 lb ft )

BOOTBAND Beqtace.

- Replace.

@II

ASHER

rtE54

TIE.RODEND

CONNECTOR

SteeringGearboxOverhaul

ExplodedView

RACKGUIDE

6^:,;BOOTBAND

'"''/

Beplace.

. -@ -sPRrNG. DISCWASHEB @'---

g

L)-RACKGUIDE SCREW

6v---\'

\.oc**u.

SRACKET

LOCKWReplace.

-RODN m {5.5 gf.m,40lbf t)

kgf.m,

(cont

17-

33 bt.ft)4 N m {4.5



PSComponents

SteeringGearboxOverhaul cont'dl

SpecialTools Required. Locknutwrench 07ZAA-S5A0100. Pincers,Oetiker1098or equivalent, ommercially

ava i lab le .

NOTE:. Refer o the ExplodedView as neededduring hi s

procedure.. Do not allow dust,dirt,or other oreignmaterials o

enter nto he steeringgearbox.

Eemoval

1, Remove he steeringgearbox se epage17-b1).

Disassembly

2. Unbend he ockwasher A).

. - - , ' i .

Hold he bracket A)with one wrencn,anq unscrewboth ie-rodends(B )with anotherwrench.Removethe lockwashers.

4. Remove he stop plate A). he 12 mm flangebolts(B), he O-rings C) ,and he bracket D) ro m th esleeringgearbox.

Loosen he locknut A), hen remove he rackguidescrew B),sprlng (C),discwasher D) ,and rackgu ide E) rom he s teer ing earbox.

i::..:4,. , ---. - :.--. '



6. Remove he two boot bands A) rom boot (B).

Compress he boot by hand,and applyvinyl tape(C )so the boot ends staycollapsed nd pulledback

Attach he yoke A)of a universalpuller o the

steeringgearboxmountswith bolts.Securely

clamp he yoke n a viseas shown.Do not clamp

th e steering earboxhousing n the vise.

1 .

1 0 .

8. Installthespecial ool (A )on the lockscrew(B )

securely.he n loosenan d remove he ockscrew

from the steeringgearboxhousing.

07zAA-S5A0r

Remove he special ool.

Pullon the rackhousing A) o remove t from the

steeringgearboxhousing,Remove he boot {B )a

s l ider u ide C) rom hecy l inder .

(con

17



PSComponents

SteeringGearboxOverhaul cont'd)

' l l .Check he sliderguide or damageand cracks.Usingverniercalipers o measure he thickness fth e sliderguide. f the thicknesss less ha nservice

l im i t , ep lacehes l ider u ide ,

f Z,-----:-r-.--------.t.t'E-r

I (fr--', -.----/i\ I

l i l ( t t , , ) ) )|i @ r

25.3mm{0.925n. }

Remove nddiscardhestop ing A)on hecylinder yexpandingt withsnap ingpliers.Remove nddiscardhe ock crew B}.

13. Install he new lockscrewon the rackhousing.

14 . Ins ta l l t he ewstop ing n hegroove C)on hecylinderby expanding t with a s nap ring pliers.Becarefulnot to scratchor damage he housingsurfacewith the stop ring edges.

25.3mm{0.925n. l

1 2

15. Applymultipurposereaseo he ndicatedart{shaded art) f heouter urface f he rackhousing. ono tapply o hedents ndgrooves.

\

I



EPSComponents

teeringGearboxOverhaul cont'dl

22. Apply multipurpose rease o the slidingsurfacean d circumference fthe rackguide A) ,and nstallit onto he gearboxhousing.Wipe the greaseof f

the threaded ectionofthe housrno.

...'.

,. ,l

.j

23. Ins ta l l t he iscwasher B)wi th tsconvex idefac ing he rack u ide . ns ta l l t he pr ing C) . pp tysealant o the middleof the threadson the rackguidescrew D) , hen installand ighten t to 25N m (2.5kgf.m,18 bf.ft).Loosely nstatlrhe ocknut(E) .

24. Apply multipurpose rease o the slidingsurfaceofth e sliderguide(A).Keepgreaseoff of the rack-to-sliderguide matingsurfaces nd he boot-to-sliderguide matingsurfaces.

Slide he steering ackall the way to left,an d placethes l ider u ide n hesteer ing ack y a l ign inghebolt holes B) .

'1 - .-=-1,

29 .

25 . Centerthesteering ackwithin ts stroke,an d alignthes l ider u ide A)wi th hehotes B) n he boot C) .Fi t he sliderguide o the boot by pressingaround

the edgesof the holessecurely

E25 N.m12.5 gt.m,18 bt.ft)

26 . Before nstall ing he bracket D),clean he matingsurfaceofthe 12 mm flangebolts E)an d hebracket.Coat he new O-rings F)with multipurposegrease, nd ns ta l l t hem n he 12

mm f lange o l t s .

27 . Loosely nstall he bracket n the steering ackbytightening he 12 mm flangebolts o 25 N.m (2.5kgf.m,18lbf.ft).

28. Hold he gearboxhousingusinga

yoke,hen installthe specialtoolon the lockscrew A).Retightenhe

lockscrew o the specified orquevalues.

{16.5 gt.m, 119 bf .f t}

Remove he special ool.

A



30, Retightenhe 12 mm flangebolts A) o the

soecified orouevalue.

After ightening he 12 mm flangebolts, nstallane w stop plate B)over one of the bolt heads.Be

sure he tabs (C)of the stop plateare alignedwith

the flat surfaces f the bolt head.

Cleanoff any greaseor contaminationrom the

boot ns ta l la t ionrooves n hehous ing .

Expand he boot (A )by removing he vinyltape,

and it the boot ends(B) n the nstallation rooves

on hecy l inder ous ing .

5 t .

3 2 ,

74 N.m (7.5 gf.m,5ir bf. f t)

34. C lose heearpor t ion A)o f the bands B)wi th

commerc ia l l vva i lab le incers , e t i ker 098 r

equ iva len tC) .

35 . Ins ta l l t he ew ockwasher A)wi th t s ad iused

side acing B) he tie-rod C) ,an d screw he tie-ro

on the bracket D) .Repeat his step or the other

sideof the tie-rod.Hold he bracketwith one

wrench,and ighten he tie-rods o the specified

torquewith anotherwrench.

,,";=-.. , . ,

(con

*=,,',

17



PSComponents

SteeringGearboxOverhaul cont'dl

36. Bend he ockwasheragainst he flat spotson th ebracketwitha Iargepairof pliers.

37. Adjust he rackguidescrew se epage17-13).



SteeringGearbox nstallation

2 .

' 1 .Before nstall ing he steeringgearbox, lide he

rackall he way to thepassenger's id e(right

d i rec t ion) .

Pass he right sideof the steeringgearbox ogether

with the tie-rods hrough he wheelwellopeningon

th e passenger's ide.Continuemoving he steering

gearbox oward he passenger's id euntilthe

driver'sside ie-roden d an dgearboxclears he

mastercylinderand under-hooduse elay box.

Lower he steeringgearbox.and move t toward

thedr iver ' s ideunt i l t he teer ing earboxs n

Dosition.

Be carefulnot o damage he hoses, ines

an dwire harnesses.

3 . Ins ta l l t he in ion haf t rommet A) .

4. Insert he pinionshaftup through he bulkhead,

then slip he right sideof the steeringgearbox

housing A) over he mountingstud (C)on the

gearboxmountingbracket.

\ - - - ' ' . ' ' , i

10x '1.25mm61 N. m{62 kgl m, 45 b{ tl

Install he steering tiffenerB, and ightly ighten

th e steeringgearboxmountingnuts.

Install he steering tiffenerA with the gearbox

mount ing o l t s . hen igh ten l l t hesteer inggearboxmountinghardware o the specified orq

10x 1 . 25m m6l N.m(6.2kgt.m, 45 lbt.ft)

: --.-{. .

(con

: - 1. . . .

17



PSComponents

SteeringGearbox nstallation cont'd)

7. Installthe odystiffenerA), nd orque hemounting olts o hespecifiedorque.

8 x 1.25mm

29 N.m {3.0 gf.m,22lbf. f t l

L Install he heater alve (A )on the bulkhead, ndconnect he heater alvecableend (B ) o the heatervalvear m (C).Readjust he heater alvecable seepage21-46).

9. 8N. m(1.0 gf m,7.2 bf.ftl

L-t ,:.i.t'

9. Reinstallhe heaterhose A)on the hosebracket.

Install he enginewire harness lamps B) o the

three harnessbrackets.

Under he steeringgearbox, nstall he groundcable erminal A)on the steeringgearboxhousing.

1 0 .

' It .

9. 8N. m{1.0 gf.m,7.2lbf. f t)



12. nstallthe PS ireharness racketA)on hegearbox ousing, ndconnecthe6PconnectorB)propefly.

9. 8N. m{1.0 gt m,7.2 bt. f t l

13. Ins ta l l t he ea t h ie ld A) .

,.!,..' ' 6 f

14.

1 5 .

Center he steering ac kwithin its stroke.

Wipe off any greasecontaminationro m lhe ball

joint taperedsectionand hreads.Then reconnecthe tie-rodends1A)to he dampersteeringarms.

lnstall he ball oint nu t (B) and ighten hem.

Install he new cotterpins (C),and bend hem as

shown.

(con

B10 1.25mmi€ N.m{4.4kgf.m.32 tbt.ftl

t o .

, ', ' 'l: 1 )

17



EPSComponents

1 7 .

18.

SteeringGearbox nstallation cont'dl

Install he motor on the steeringgearbox se epage17-49).

lnstall he steering oint (A).an d reconnecthesteering haft B) an d pinionshaft C).Makesurethe steering oint s connected s ollows:

. Inser t the pperend f thesteer ingo in ton to the

steering haft l ineup the bolt hole (D)with theflat portion E)on the shaft).

. Slip he lower end of the steering oint onto hepinionshaft l ineup the bolt holewith th e groove(F )around he shaft), nd oosely nstallthe owerjoint bolt. Be sure hat he ower oint bolt ssecurely n th e groove n the pinionshaft.

. Pullon the steering oint to makesure hat hesteering oint is fully seated. hen nstall he

upper oint bolt, and ighten t to the specifiedtorque.Tighten he lower oint bolt o thespecified orque.

8 x '1.25mm

28 N.m{2.9 gf.m,21 tbt.ft)

19 .

20.

Installthedriver'sdashboard owercover se epage20-59) nd undercover (seepage20-60).

lf the steeringwheel was turned,center he cablereelby first rotating t clockwise ntil t stops.Thenrotate t counterclockwiseabout wo and halfturns)untilthe arrow mark on the labelpoints

straightup. Reinstall he steeringwheel (seepage17 8) .

Install he front wheels.1

22. After nstallation, erform he followingchecks.

. Perform he front oe nspection.

. Checkhesteer ing hee lspokeang le .f s teer ingspokeangles o the right and eftar e no t equal(steeringwheel an d rackare not centered),correct he engagement f the oinvpinionshaftserrations,hen adjust he front oe by turningth e tie-rods, f necessarv.

\



EPSControlUnit Removal/Installation

1. Remove he passenger's nderpanel.

2. Turn up the floor carpel, emove he EPS ontroluntr.

Disconnecthe EPS ontrolunit connectors.

lnstallthe EPS ontrolunit n th e reverse rder of

removal.

After nstallation, tart he engine,an d et t idle.Turn he steeringwheelfrom lock-to-lock everal

t imes. Check hat he EPS ndicator oe s not come

on.

3.

E

Tie-rodBallJoint Boot Replaceme

SpecialTool Required

Attachment, 2 mm 07OAD-P0A0100

l. Remove he boot ro m the tie-rodend, andwipe thol d greaseoff the ball pin.

2 . Pack he owerareaof he ba l lp in (A)wi lh f resh

mulr purposegrease.

3. Pack he interiorof the new boot (B )and ip (C )withfresh multipurpose rease.

Note hese temswhen install ingne w grease;

. Keepgreaseoffthe boot nstallation ection D)

and he taperedsection E)of the ball pin.. Do not allow dust,dirt, or other oreign material

to enter he boot.

4. Installthenew boot (A ) using he specialtool.Th e

boot must not havea ga p at the boot nstallation

sections B) .After nstall ing he boot.check he bapi n aperedsection or greasecontamination, ndwipe it if necessary.

07(lAD-P0A0100

*-4r/ -,______i.l+_D

-6rA

17-



Suspension

FrontandRearSuspensionSpecialTools .............8-2Componentocationndex .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. .8-3Wheel l ignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 -4WheelBearing ndPlay nspection... . . . . . . . . . . . . . . . . . . . . . . . .8-8WheelRunoutnspection ..................8-9Bal l o in tRemoval . . . 18-10

FrontSuspensionKnuckle/HbAVheelBearingReplacement

Bal l o int BootReolacement . . . . . . . . . . . .. . . . .

Stabi l izer arRep|acement . . . . . . . . . . .. . . . . . . .

Stabi l izer inkRemoval/ lnstal lat ionLowerArm Removal/ lnstal lat ion.. . . . . . . . . . . . .

Damper/Spr ing eplacement

RearSuspension

HubBear ing n i tRep lacement. . . . . . . . . . . . . . . . . . . .Knuckle eolacementStabil izerarReplacement.. . . . . . . . . . . . . . . . . .Stabil izerink Removal/lnstallati on... . . . . . . . . . . . . . . . . . . . . . .UpperArm Removal/lnstallati on... . . . . . . . . . . .Trail ing rm Removal/lnstallati onDamper/Springeplacement

18-118-1618-1718-1818-1918-20

18-2618-2818-3018-3118-3218-3318-34




FrontSuspension:

LOWEBARMRemoval/lnstallation,age 18 19

Rear uspension:

DAMPER/SPRINGReplacement,age'18-34

DAMPER/SPRINGReplacement,ag e 8-20

STABILIZERARReplacement,ag e 8-17

STABILIZERINKRemoval/lnstallation,ag e 8 18

STABILIZERARReplacement.ag e 8-30

KNUCKLE/HU8/WHEELBEARINGReplacement,age 18-1

Ball Joint BootReplacement,age'18-16

UPPER RMRemoval/lnstallation,page'18-32

HUBBEARING NITReplacement,ag e 8'26

KNUCKLEReplacement,ag e 8-28

TRAILINGARMRemoval/lnstallation,age 18 33

18



FrontandRearSuspension

WheelAl ignment

The suspension an be adjusted or front camber, ront

toe, and rear o e. However,eachof theseadjustments

are nterrelatedo eachother.For example,when you

adjust he toe, he camberchanges. herefore, ou

must adjust he front wheel alignmentwheneveryou

adjust he camberor toe.

Pre-Alignment hecks

Fo r proper nspection nd adjustment f the wheel

alignment, o thesechecks:

1. Releasehe parkingbrake o avoid an ncorrect

measurement.

Makesure he suspensions no t modified.

Checkhe i res ize nd i repressure

Tire size:

Front/rear: 195/60R15

Tire pressure:

Front: 23 0kPa 2. 3kgf/cm',33 psil

Rear: 210 kPa |'2.1 gf/cm', 30 psi)

Check he runoutof the wheelsand ires.

Check he suspension al l oints. Holda wheel

with your hands,and move t up and down and

right and eft o check or wobbling),

2 .

3.

Bounce he vehicleup and down several imes o

stabil izehe suspension.

18-4

Front Caster nspection

Usecommerc ia l l vva i lab leomDuter i zedourwhee l

a l ignment qu ipmento measure hee la l ignment

(caster, amber, oe, and urning angle).Follow he

eouiomentmanufacturer'snstructions.

Check he casterangle. f the casterangle s not within

the specif ication, heck or bent or damaged

susoensron omoonents.

Frontcasterangle: 1'40't 1"

\



FrontCamber nspection

Us ecommerciallyavailable omputerizedour wheel

alignmentequipment o measurewheel alignment


equipmentmanufacturer'snstructions.

Check he camberangle. f the camberangle s not

within the specif ication, djust he camber.

Front camber angle: 0"30' t 45'

FrontCamberAdjustment

The ront cambercan be adjustedby exchanging ne o

both of th e damDerDinchboltswith the smaller

diameteradjustingbolt(s). he difference etween he

adjustingbolt diameterand he pinchbolt hole

d iameter l l ows smal l ange f ad jus tment .

DamDerPinchBolt : AdiustingBoh:

P/N 90188-55A-000

Raise he front of the vehicle,and support t with

safetystands n th e proper ocation seepage1-8)

Remove he front wheels.

Loosenhe damper inch nutsandbo l t s A) , nd

adjust he camberby moving he bottom of the

damperwi th in he range f hedamper inchbo l t

free play.

1 .

- + + t A16x 1. 5mm15 7N. m(16.0 gf.m,116 bf.ftl

3 .

4 .

Tighten h e bolts o the specif ied orque.

Reinstallhe front wheels.Lower he front of the

veh c le o theground, nd bouncehe veh ic le

severa limes o s tab i l i zehesuspens ion .

Checkhecamber ng le . f i t sw i th in he

specif ication, heck he front toe. f it is not within

the specif ication, o to step6.

(cont'd

5 .

18




WheelAlignment(cont'd)

7 .

Raise he front of the vehicle,and support t with

safetystands n the proper ocation se epage1-8).


Replacehe damperpinchboltswith the adjustingbolts A),and adjust he camberangle.

NOTE:Th ecamberanglecan be adjustedup to t

15 ' center f tolerance) y replacing ne damperpinchboltwith the adjustingbolt.Th ecamber

anglecan be adjustedup to a 30' by replacing ot h

upperan d owerdamperpinchboltswith th e

adjustingbolts.

15x 1 .5mm15 7N. m{16.0 gt.m,116 bf.ft)

8. Tighten he bolts o the specif ied orque.

Reinstallhe front wheels.Lower he front of thevehicle o the ground,and bounce he vehicle

several imes o stabil izehe suspension.

Check he camberangle. f it is within the

specif ication, heck he front oe. and adjust it if

necessary.f it is not within he specif ication,

readjust, nd recheck.J he camberanglecannot

be adjusted o the specif ication, heck or bent or

damagedsuspension omponents.

10 .

'rntr

i,iY..:r,//

18-6

RearCambernspection

Usecommercially-availableomputerizedour wheel

alignmentequipment o measurewheel alignment


eouiDmentmanufacturer'snstructions.

Checkhecamber ng le . f he camber ng le s not

within the specif ication, heck or bentor damagedsusDenston omoonenrs.

0"55't 45'

bo l t s n he ra i l i ng rm.

Rearcamberangle: 0

NOn-dElDo not oosen he special

\



FrontToe nspection/Adjustment

Use commercially-availab leomputerizedour wheel



equipmentmanufacturer'snstructions,

1. Center he steeringwheel spokes.

2. Checkthetoe. f it is not with n the specifcation, o

to step3.

Front oe-in: 0 t 3 mm {0 t 0.12 n.)

3. Loosen he ocknut A) while holding he tie-roden d( B .

A14x 1 .5mm,14N.m(a.5kgt m,33 lbt.ftl

5.

Turn he tie-rod C)untilthe toe is correct.

After adjusting, ighten he ocknutwhile holding

the tie-rodend. Makesure he toe settingdoes not

change.

1,;

RearToe Inspection/Adiustment

Use commercially-availableomputerizedour wheel



equipmentmanufacturer'snstructions.

1 , Re leasehe park ing rake .

2. Checkthe oe. f it is not within the specif ication.

to step3.

Rear oe-in {inspection):1 1 3 mm (0.04a 0.12 n. )

3. Loosen he self-locking ut (A)while holding he

adjustingbolt (B).

Do not oosen he specialbolts C)on the

lower arm to adjust he alignment.

4. Replacehe self-locking ut with a new one, and

l igh t l y igh ten .

NOTE:Always usea new self-locking ut wheneve

it has been oosened.

Turn he adjustingbolt unti l he toe is correct.

Rear oe.in (adiustment):

2 ' , mm {0.08"' ,. in.}

Tighten he self-locking ut o the specif ied orquewhi leho ld ing he ad jus t ing o l t .

(con t

18



andRearSuspension

WheelAlignment(cont'dl

TurningAngle nspection

Us ecommercially-availableomputerizedour wheel

a l ignment qu ipmento measure hee la l ignment(caster. amber, oe, and urning angle).Followthe

equiDmentmanufacturer'snstructions.

1 . Turn he s teer ing hee l u l l y to ther igh tand le f t

while applying he brake,and check he turning

anglesof both ront wheels, f the turning angle s

not within the specif ication r the nward urning

anglesdiffer between he right and eft side,go to

steD2.

Turningangle:

lnward: 34'00'+ 2'

Outward: 28'00' {reference)

Check he toe. f it is correct,but he turning angle

is not within the specif ication, heck or bent or

damagedsuspension omponents,

WheelBearingEnd Play nspec'tion

1. Raisehe vehicle,and support t with safetystands

in th e proper ocation seepage1-8).Remove he

whee ls .

2. Install uita le at washe s (A )an dwheel nuts,an d

tighten he nuts o the specif ied orque o hold he

brake i scsecure ly ga ins the hub.

Front:

108N. m(11.0 gf.m,80 rbf.ft)

Rear:

10 8N. m

3. Setup hed ia lgauge ga ins the hub lange s

shown,and measure he bearingend playmoving

th e brakedisc nward and outward.

Bearing end play:

Standard:

Front/rear: 0 0.05mm {0 0.002 n.}

4. lf the bearingen d play s more han he standard,

replace he wheel bearing.

\

(11.0 gf.m,80 bf. f t)



WheelRunout nspection

1 . Raise he vehicle,and support t with safetystandsin the proper ocation se epage1-5,.

Check or a bentor deformedwheel.

Set up the dial gaugeas shown,and measure he

axial runoutby turning he wheel.

Front and rear wheel axial runout:

Standard:

Aluminum wheel: 0-0.7 mm (0-0.03 in.)

Service imit: 2.0 mm {0.08 n. l

4 . Resethed ia lgaugeto thepos i t ion hown, nd

measure he radial unout.

Frontand rear wheel radial unout:

Standard:

Aluminum wheel: 0 0.7 mm (0 0.03 o.)

Service imit: 1.5mm {0.06 n. }

lf th e wheel runout s no twithin the specif ication

checkthewheel bearingen d play(seepage 18-8)

and makesure he matingsurfaces n the brake

disc and he insideof the wheel are clean.

lf the bearingend play s within the specif ication

but he wheel runout s more han he service imi

replace he wheel.

18




BallJointRemoval


Ball oint remover.2Smm 07MAC-SL00200

Alwaysus ea ball oint remover o disconnect balljoint.Do not strike he housingor any otherpart of

the ball oint connection o disconnect t.

' 1 ,Ins ta l l hexnut A)on to the th readsof theba l l j o in t

{B) .Make ure he nu t s lushwi th he ba l l j o in tp in

end o preventdamage o the hreadedend of the

ba l l o in to in .

Apply grease o the special ool on the areasshown(A).This wil l ease nstallation f the ool andpreventdamage o the pressure ol t {B) hreads.

2 .

3. Loosen he pressure ol t (A),an d nstallthespecial

tool as shown. nsen he aw s carefully,making

sure not o damage he ball oint boot.Adjust heja w spacingby turning he adjustingbolt (B).

10 mm HEXNUT

5.

07MAC-S100200

After adjusting he adjustingbolt,makesure he

head C)of the adjustingbolt s in he posit ion

shown o allow he aw to pivot.

With a wrench, ighten he pressure olt unti l he

ba l l o in tp in pops oose rom he s teer ing rmor

knuckle. f necessary. pplypenetratingype

lubricant o loosen he ball oint pi n

NOTE:Do not use pneumatic r electric ools on

th e pressure olt.

Remove he tool, hen remove he nut rom the endof the ba l l j o in tp in ,andpu l l t heba l l j o in t u t o f the

s teer ing rm or knuck le .nspect the a l l j o in t oo t ,

and replace t if damaged.

6.



Suspension

Knuckle/Hub/Wheel earingReplacementcont'dl

Special Tools Required. Hu bdis/assemblyool 07GAF-SE00100. Ball joint remover,2Smm 0TlvlAC-S100200. Attachment 2 x 68 mm 07746-0010500. Driver07749-0010000. SuDDort ase07965-5D90'100

1. Raise he front of thevehicle,and support t with

safetystands n he proper ocation se epage1-8).

2. Remove he wheel cap,wheel nuts,and ront wheel.

3. Remove he brakehosebracketmountingbolt (A).

108N. m(11.0 gf m,80 rbf.ftl

A8 x 1.25mm22N.m12.2ksl.m,

26 bf.ftl

B12 x 1.25mm10 8N. m{11.0 gf.m,80 rbf.ftl

4. Remove he caliperbracketmounting bolts (B),an d

remove he caliperassembly C) rom the knuckle.

To preventdamage o the caliperassemblyor

brakehose,use a short pieceof wire to hang he

caliperassembly rom the undercarriage. o not

twist he brakehosewith force.

18-12

5. Raise he stake A),an d remove he spindlenu t (B).

- B' 2 2 x 1 . 5 m m

, 181N.m('18.sgf.m,134 bt.ft)

6. Remove he brakedisc retaining lat screws A) .

A6 x 1 . 0 m m9. 8N. m{1.0 gt.m,7.2 tbl.ttl

7. Screw wo 8 x 1.25mm bolts B) nt o he disc o

oush t awav rom the hub.Turn eachbolt wo turns

at a t ime o preventcocking he discexcessively,

\

\



8. Remove he flangebolt {A )andwheel sensor(B)

from the knuckle.Do not disconnecthe wheel

sensor onneclor.

Remove he flangenut (A) while holding he oint

pi n (B)with a hex wrench C) ,and disconnect he

stab i l i ze rink D) rom he owerarm (E) .

A5 x 1 . 0 m m9. 8N. m(1.0 gl .m,7.2 tbt.ftl

9.

10x 1.25mm39 N.m (,1.0gf.m,29lbf.ft)

10. Remove he lockpi n (A)from the ower arm balljoint,and remove he castlenu t (B).

NOTE:During nstallation,nsert he ock pi n into

the ba l l j o in t in rom he ns ide o theouts ide f

th e vehicle.Th eclosedend of the lockDi nmust be

in he range hown.

07MAC-SL00200

€--....-"12x 1.25mm59 69N m

'R.

1 1 .

12 .

(6.0 7.0 kgl m,43 -51 lbf tt)

Disconnecthe lower arm from the knuckleusing

the special oo l (seepage l8-10).

Loosen he damperpinchbolts A) while holding

th e nuts(B),an d remove he boltsand nuts.

'13.Remove he driveshaft utboard oint {C) romthe

knuckle D)by tapping he driveshaft nd (E )with aplastichammerwhile drawing he knuckle utwar

then remove he knuckle.

NOTE:Do not Dull he driveshaft nd outward.Th

driveshaft oint may come off.

(con t

18



Suspension

Knuckle/Hub/WheelearingReplacementcont'd)

14. Separate he hub (A)from the knuckle B) using he

special oo l and a hydraulicpress.Be carefulnotto

deform he splashguard.Hold onto he hub o keep

it from fall ingwhen pressed lear.

. / . - ' ' - . |

a'\s

Press he wheel bearing nne r race A)off of the

hub B)us ing hespe i ia l too l , commerc ia l l y

ava i lab le ear ing epara to rC) , nda press.

1 5 .

07GAF-SE00100

\ Press

\ r

07GAF-SE00100

16. Removehesnap ing A)and he sp lash uard B)

f rom heknuck leC) .

Press he wheel bearing A) out of the knuckle B

using he special ool and a press.1 1 .

Pross

+\



1 8 .

1 9 .

Wash he knuck le nd hub horough lyn h lgh lash

pointsolventbefore eassembly.

Pressa new wheel bearing A) nt o he knuckle B)using he old bearing C) ,a steelplate D) . he

special o ol, and a press.Placehe wheel bearing

on the knucklewith the packsealside acing metal

color) oward he nside.Becarefulnot o damage

the sleeveof the packseal.

" - t - _ " * , , ' '

_, '. . a-)./

..-.

20. Ins ta l lhesnap ing A)secure lyn he knuck leB) .

D6 N.m10.6gf.m,4lbf t)

lnstall he splashguard (C),and ighten he screws(D ) o the specif ied orque.

23 .

22. Press newhub bear ing n i t A)on to thehub(B)

using h e special ools and a press.

Ins ta l l t he nuck le /hub/hubear ing n i t n he

reverseorder of removal,an d note hese tems:

. Becare fu l o t to damagethe a l l j o in tbootwh

ins ta l l i nghe knuck le .. Tightenall mountinghardware o the specif ied

lOrque a lues.. Torque he castlenut o the lower orque

specif ication,hen ighten t only fa r enough o

a l ign he s lo tw i th he ba l l o in tp in ho le .Do not

align he castlenut by loosening t.

. Installa new lookpi n on the castlenut after

to rqu ing .. Usea newsp ind le u ton reassembly .. Be forensta l l i nghesp ind le u t ,app lya smal l

amountof engineoil to the seatingsurfaceof th

nut.After ightening,use a drift o stake he

sp ind le u tshou lder ga ins the d r i veshaf t .. Be forensta l l l nghebrake i sc , lean he mat in

surfaceof the front hub and he insideof the

brake isc .. Be forensta l l i nghewhee l , l ean he mat ing

su faceof the brakediscand he nsideof the

wneet ..

Check he front wheel alignment,an d adjust t inecessary se epage18-4).

18



FrontSuspension

BallJoint BootReplacement


Fronthub dis/assemblyool 07965-5450500

1. Remove he boot.

2. Pack he nteriorand ip (A )of a new boot with freshgrease.Keep he greaseoff of the boot-to-knucklematingsurfaces B).

-6r

rffil

- - B

Wipe th e greaseof f the taperedsectionof th e pi n(C),an d pack reshgreaseonto he base D) .

tI

Inst€ll he boot onto he ball oint pin, hen squeezeit gently o forceout any air. Do not et dlrt or otherforeignmaterials et nto he boot.

Presshe boot with the special ool until he bottomseatson the knuckle A) evenlyaround.

pross

07965-SA50500

6. Af ter nsta ll ing boot,wipe any greaseoff theexposedportionof the ball oint pin. i



StabilizerBarReplacement

1 .Ra ise he front of th e vehicle,and support t with

safetystands n the proper ocation seepage1-8).


Remove he self-locking ut s(A)while holding hejoint pi n (B )with a hexwrench (C),and disconnect

the s tab i l i ze rinks D) f rom hestab i l i ze rar E) n

th e right and eft.

D

10x 1 .25mm3 9 N m(4.0kgf m,29 tbl,ft)

Remove he flangebolts A) and bushingholders

{B),he n remove he bushings C)an d he stabil izer

bar D) .

FORWARDA10x 1 .25mm3 9 N m(4.0 sf.m,29lbl.ft l

,.'i i''i]

. i.',.:-l I

\' ,r' ' i :..r'j-- r-'1 _: i'

i-ii::;i

;4-llt,-'j--;

4. lnstallthestabil izer ar n th e reverse rder of

removal.an d note hese temsl

. Us enew self-locking uts on reassembly.. Note he right and eft directionof the stabil izer

oar .. A l ign heendsof the pa in tmarks A)on he

stabil izer ar with eachend of the bushings 8) .

. Note he forelaftdirectionofthe bushingholde

. Refer o stabil izerLinkReplacemento connect

the s tab i l i ze rar o the inks see age18-18) .

18-



Suspension

StabilizerLinkRemoval/lnstallation

1. Ra ise he front of the vehicle,and support t withsafetystands n the proper ocation seepage1-8).Remove he front wheels.

Remove he self-locking ut (A) and langenu t {B )while holding he respectiveoint pi n (C )with a hexwrench (D),an d remove he stabil izer in k (E).

3 . lns ta l l t he tab i l i ze rink A)on he s tab i l i ze rar B)and ower ar m (C )with the oint pins (D )set at th ecenterof their rangeof movement.

4. Install he self-locking ut an d langenut,andlightly ighten hem.

NOTE:Use a new self-locking ut on reassembly.

5. Place he floor ac kunder he lower arm ball joint,and raise he suspensiono load t with the vehicle'sweaght.

mri-dElDo not place he ack against he ower ar mba l l j o in t .

6. Tighten he self-locking ut (A )and langenu t (B) othe specif iedorque valueswhile holding herespectiveoint pins (C)with a h ex wrench (D).

A10x 1.25mm38 N.m(3.9 gf m,28 lbf.ft)

\

..,

1 .

B10 x 1.25mm39 N.m{4.0 gf.m,29lbf. f t}

After 5 minutesof driving, e-tighten he self,lockingnut again o the specif ied orque.



FrontSuspension

Damper/SpringReplacement

ExplodedView

DAMPERMOUNTINGBEARING

UPPER PRING OUNTINGCUSHIONCheckordeteriorationan ooamage,

DAMPER PRINGCheckor ree ength.

./ SELF-LOCK|NG UT

/. '12

x 1.25inm,,/ 44 N.m {4.5 gt.m,33lbf. f t l,/ neDtace.

^atae9

-€.- - DAMPER OUNTING ASE

1, @-:'\--""'check or delormation

lF \-:-./ - ,

E9-

DAMPERUNITCheck or oil eaks,

ga s eaks, nd smoothoperatron.

\



Special oolsRequiredBalloint emover,28 m 07MAC-S100200

Removal1. Raise he front of the vehicle,and support t with

safetystands n the proper ocation seepage1-8).


Remove he cotterpi n (A) rom the tie-rodend ball

ioint,an d remove he nu t (B).

10 mm HEXNUT

07MAC-S1002000

Disconnecttheie-roden d ro m th e steeringar m

on hedamper s ing he spec ia l too lsee age18-

1 0 .

Remove he bolts,an d remove he wheel sensor

harnessbracket A)an d brakehosebracket B)

from the damper.Do not disconnecthe wheel

4.

sensorconnector.

A 6 x 1 . 0 m m

/.8

x 1.25nm

q

5. Remove he damperpinchbolts A)while holding

the nuts B) .

6. Remove he flangenuts(A)from the top ofthedamper,

A10x 'l.25mm

7. Lower he lower arm, and remove he damper

assemblyB) .

(con

18



FrontSuspension

Damper/Spring eplacementcont'd)

Disassembly/lnspection

1. Compresshedamper p r ingwi th a commerc ia l l y

available trut springcompressor A) according oth e manufacturer'snstructions.hen remove hese l f - lock ingu t B)wh i le o ld ing he damper haf t(C )with a hex wrench (D).Do not compress he

spring more han necessaryo remove he nut,

Releasehe pressure rom the strut springcompressor, hen disassemblehe damperasshown n the ExplodedView.

4.

Reassemble ll the pans,except or the upperspr ing ea t ndspr ing .

Compress he damperassemblyby hand,an dcheck or smoothoperation hrough a full stroke.both compression nd extension. he dampershouldextendsmoothlyand constantlywhen

compression s released.f it doesnot, he gas sleakingand he dampershould be replaced.

Checkor o i l eaks , bnormal o ises , ndb ind ingduring hese ests.

\



Suspension

Damper/Spring eplacementcont'dl

Rightside:

9.

Hold he bottom of the damperwith your hand,an d

compress he spring.Do notcompress he springexcessively.

Ins ta l l t he 2mm nut A)on hedamper ha f t B) .

Hold he damper shaftwith a he xwrench (C),andtighten he 12 mm nut o the specif ied orque .

(4.5kgt.m, 33 lbf ft)

Removehedamper ssemblyrom hestrut pringcompressor.

1 0 .

Installation

1. Lower he lower arm, an d posit ion he damper

assembly n the body,Turn he damper mountingbaseso he

"AL"or

"AR"mark (A) aces oward

the outsideof the vehicle.

B10 1.25mm,14N.m{4.5 gt.m,33bf.ft)

,1,6Loosely nstall he flangenuts(A )onto he op ofthe damper. L



1 . Raise he rearof the vehicle,and support t with

safetystands n the proper ocation se epage l-8).

Remove he wheelcap.wheel nuts,and rearwheel.

10 8N. m 11.0 gf.m,80bf t l

Remove he hub cap (A), aise he stake B),an d

remove hesp ind le ut C) .

O\

A

22 x 1 ,5mm181N .m(18.5 gf.m,134lbf.ftl

5.

7 .

Releasehe parkingbrake ever.

Remove he brakehosemountingbolt (A).

B10 1 .25 m5 5 N m

C {5.6 gf m.41 bf.ft}

(2.2 gtm, 16lbt.ft l

Remove he caliperbracketmountingbolts B),an

hang he caliper C) o one side.To preventdamag

to the caliperor brakehose,use a short pieceof

w i re o hang he ca l iperrom he undercar r iage .

Remove he brakedisc retaining crews A).

Screw wo 8 x 1.25mm bolts B) nto he disc{C) ooush t awav rom the hub.Turn eachbolt wo turn

at a time to prevent ocking he disc excessively.

Remove he brakedisc.

(con t

ap

t\

IA6 x 1 . 0 m m9.8N .m(1.0 gf.m,?.2lbf.ftl

18-



Suspension

HubBearingUnitReplacement(cont'd)

9. Remove he hub bearingunit (A ) ro m the spindle.

Install he hu b bearingunit n the reverse rder ofremoval,and note hese tems:

. Tightenall mounting hardware o the specif ied

torquevalues,. Before nstall ing he brakedisc,clean he mating

surfaceot the hub and he insideof the brakedisc.

. Use a new spindlenu t on reassembly.

. After ightening,use a drift o stake he spindlenutshou lder ga ins the sp ind le .

. Us ea new hub cap on reassemb ly.

. Before ns tall ing he wheel,clean he mating

surfaceof the brakedisc and he insideof thewneel.

1 0 .

,=, , ,

Raise he rearof the vehicle,and suppon t withsafetystands n the proper ocation seepage1-8).Remove he rearwheels.

Removehe brake i scandhubbear ing n i t see


Remove he flangebolts A) and splashguard B)

from the knuckle.

11.0gf.m, .2 bf t)

4. Remove he wheelsensor(A),braKe ose

mount ing racke tB) , ndpark ing ab lemount ing

bracket C) ro m th e knuckle.Do not disconnect hewheel sensorconnector.

8 x 1.25mm22N.m{2.2 gfm,16 bf t l

KnuckleReplacement

1 .

6 x 1 . 0 m m9. 8N, m{I.0 kgt.m,7.2 bf f t)

tt



5. Place he floor ac kunder he trail ingar m {A), o

support t.

Do not place he ac kagainst he plate

sectionof the ower arm, Be carefulnot o

damageany suspension omponents.

12x 1.25mm59N. m{6.0 sf.m.43lbf.ft)

1 .

Remove he flangebolt (B),and disconnect he

upperar m {C ) rom the knuckle.

Mark he cam positionsof the adjustingbolt (A )an d

adjusting am (B), he remove he self-locking ut

{C},adjusting am, and adjustingbolt. Discard heself-locking ut.

12x 1.25mm59N m( 6 .0k g f .m,43 bI.ftl

12x 1.25mm59N. m 6. 0 gf m,43lbl . f t )

8. Remove the flange bolt (D),an d remove the

k nuc k le E ) .

9. Ins ta l l t he nuck len he everse rdero f remova l

an d note hese tems:

. F i rs t ns ta l l l l hesuspens ionomponents ,ndlightly ighten he bolts and nuls, he n placea

floor ac k under he ower a m, an d raise he

suspension o load t with the vehicle'sweight

before ully ightening he boltsan d nuts o the

specif ied orquevalues.. Align he cam positions f the adjustingbolt (A)

and adjusting am (B )with the markedposit ions

when igh ten ing .. Use a new self-loc king ut on reassembly.. T igh ten l l t hemount ing a rdwareo the

specif ied orquevalues.. Usea newsp ind le u ton reassembly .. Be forensta l l i nghesp ind le u t ,app lya smal l

amount of engineoi l to the seatingsurfaceof thenut.After ightening,us ea drift o stake he

sp ind le u tshou lder ga ins the d r i veshaf t .. Before nstall ing he brakedisc,clean he mating

surfaceof the hu b an d he nsideof the brake

drsc .. Usea new hubcapon reassembly .. Before nstall ing hewheel,clean he mating

surfaceof the brakediscand he nsideof the

whee l .. Check he wheel alignment,and adjust t if

necessaryse epage18-4).

18-



RearSuspension

1 .

StabilizerBar Replacement

Raise he rearof the vehicle,and support t with

safetystands n the proper ocation seepage 1-8).

Remove he rearwheels.

Remove he self-locking ut s (A )while holding hejoint pins (B)with a hex wrench (C),and disconnect

the s tab i l i ze rinks D) rom he s tab i l i ze rar E) n

th e right an d eft.

A10x 1 .25mm38 N.m(3.9kgf.m,28 lbf.ft)

Remove he flangebolts A) and bushingholders(B), hen remove he bushings

C)an d he stabil izer

bar D) .

18-30

4. Inslallthestabil izer ar n the reverse rder ofremoval,and note hese tems:

. Use new self-locking utson reassembly.. lMake ure he right and eft endsof the stabil izer

bar are nstalled n their respective idesof the

vehicle.. Align he endsof the paintmarks A) on the

stab i l i ze rarw i th he bush ingsB) .. Refer o Stabil izer in kReDlacemento connect

the s tab i l i ze rar o the inks see age18-31) .

Al......:

.

.----'';-r'--\---r-

-tt'.,'t),



RearSuspension

UpperArm Removal/lnstallation

1 .Ra ise he rearof the vehicle,and support t with

safetystands n the proper ocation se epage1-8).


P lace f loor ackunder he ra i l i ng rm,and

support he suspensron.

Remove he flangebolt (A) an dwheel sensor

harness racke tB) .

8 x 1 .25 m22N. m 2. 2 gf.m,16 bf.ft)

Remove he flangebolts A) ,and remove he upper

arm B) .

12x 1 .25mm59 N. m {6.0 gf.m,ir3 bf.ft)

12x 1 .25mm59 N.m 16.0 gf m,43 tbf.ft)

18-32

5. Installtheupperar m in the reverse rder of

renloval,and note h ese tems:

. F i rs t ns ta l l l l t hesuspens ionomponents nd

lightly ighten he boltsand nuts, hen placeajackunder he ra i l i ng rm,and a ise he

suspension o loa d t with the vehicle'sweight

before ully ightening he bolts and nuts o the

specif ied orquevalues.. T igh ten l l t hemount ing a rdwareo the

specif ied orquevalues.' Be forensta l l i nghewhee l , l ean he mat ing

surfaceof the brakedisc and he insideof the

whee l .. Check he wheel alignment, nd adjust t if

necessaryse epage18-4).



3.

TrailingArm Removal/lnstallation

1 .Raise he rearof the vehicle,and suppon t with

safetystands n he proper ocation seepage1,8).Remove he rearwheels.

Remove he knuckle se epage18-28).

P lacehe loor ackunder he ra i l i ng rm (A) o

support t.

B10 1 .25 m3 8 N m

(3.9 gl.m,28 bf.ftl

12 1 .25 m61N m (6.2 gt m.

A4s bf,ft)

Remove he flangenu t (B),an d disconnecthe

stab i l i ze rink C) rom he ra i l i ng rm.

Remove he flangebolt {D),and disconnect he

damper E) rom he ra i l i ng rm.

Remove he rail ing arm front mounting bolts A).

A12x 1.25Jn m10 8N. m {11.0 gt.m,80 tbf.ft)

, 'a ' : r

7. Remove he trail ingarm re ar mountingbolt (A).

Do not oosen he specialbolts B)on the

t ra i l i ng rm.

A12 x 1.25mm59N. m

-----\':,'.ttg'.,--1..-r.':1

Lower he ack,and remove he trail ing arm.

Install he trail ing arm in the reverse rderof

removal,and note he se tems:

. F i rs t ns ta l l l l t hesuspens ionomponents nd

lightly lghten he bolts and nuts, hen placeajackunder he ra i l i ng rm,and a ise he

suspension o load t with the vehicle'sweightbefore ully tightening he boltsand nuts o the

specif ied orquevalues.. Tightenallthe mounting hardware o the

specifed orque values.. Before nstall ing he wheel,clean he mating

surfaceof the brakediscan d he insideof thewneei.

. Check he wheel alignment,and adjust t if

necessary seepage'18-4).

8.

9 .

18-



RearSuspension

amper/Spring eplacement

ExplodedView

DAMPER PRINGCheck or weakenedcompression nd damage.

9-----.---.-.I€tI-=\ SELF-LoCK|NGNUT

t=J 10 x 1.25mm29 N m {3.0 gf.m,22 bf. f t}Replace.

DAMPER OUNlINGCOLLAR

DUSTCOVER

-t-9...

r€) \qnJ/ \E Z \

\

n \BUMPro PPLArE

l t \

/ t \ BUMP TO PCheckorweaknessan d d a m a g e .

OAMPER NITCheck or oi l leaks,ga s eaks, nd smoothoperation,

18-34



Removal

1. Raise he rearof the vehicle.and support t with

safetystands n the proper ocation se epage 1-8).


2. Remove he flangebolt {A) rom the bottom of the

damper .

Remove he rearbulkhead over se epage20-51).

Remove he flangenuts(A) ro m the top of th e

damper n the runk.

3.

5. Remove he damperassembly rom the body.

i

(con t

18-



Installation

1. Posit ion he damperassembly n the body. Note

the directionof the damper mounting baseso hatthe smallholedot on it is toward he front an dinsideof the vehicle.

Loosely nstall he flange nuts A)onto he top of

the damper,

A10x 1 .25mm59 N.m16.0 gt.m, ia lbt ft)

3. Loos ely nstallthe langebolt (A )on the bottom of

the damper .

12x1 .25 m61N m {6.2 gf.m. 5 bf.ft)

Raise he suspensionwith a f loor ac k o load he

vehicleweight,and ighten he nuts and bolt o the

specif ied orquevalues.

C lean he mat ing ur face f the b rake i scand heins ide f hewhee l , hen nsta l lhe rearwhee l .

Check he wheel alignment,and adjust t if

necessary se epage18-4).

18-3



Brakes

Conventional rakeComponentsSpecial ools .. . . . . . . . l9-2Componentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 -3BrakeSystem nspection ndTests .............. . . . . . . . . . .9-4

BrakePedal nd BrakePedalPosition witchAdjustment .. . . . . . . . . . . . .9-6

Parking rake heck ndAdjustment .. . . . . . . . . . . . .9-7

Brake ystem leeding .......... ........... .9-8BrakeSystem ndicatorCircuitD iagram . . . . . . . . . . . . . . . . . . .9 -9

Parking rake witch est .......... .......9-10Brake luid ev el witch est . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .9-10FrontBrake adsnsoectionndReplacement ...........9-11

FrontBrake isc nspection ... . . . . . . . . . . . .9-13FrontBrake alioer verhaul .. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . .9-14Master ylinder eplacement .. . . . . . . . . .9-15Master ylindernspection .. . . . . . . . . . . . . . .9-16BrakeBooster

Pushrod learancedjustment .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-16Brake oosterTest.. . . . . . . . . . . . . . . . . . . . . . . . . . .9-18Brake ooster eolacement .. . . . . . . . . . . . .9-19Rear rake ads nspectionndReolacement .. . . . . . . . . .9-20

RearBrake isc nspection .......... ......9-22RearBrake aliper verhaul ......................................9-23Brake oses ndLines nsoection .... 19-24Brake oseReolacement .. . . . . . . . . . . . . . . . . .9-25Parking rake ableReplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .9-26

ABS(Anti-lockBrakeSystem)Gomponents ... 19-29



Conventional rakeComponents

SpecialTools

Ref.No. Tool Number DescriDtion Qty

o 07JAG-SD40 00 PushrodAdiustmentGauoe 1

19-2




FRONT RAKESFrontBrakePads, nspection nd

Replacement,ag e19-1FrontBrakeDiscInspection, ag e19'13FrontBrakeCaliperOv e r hau l ,age19 - 14

INDICATORBrakeSystem ndicatorCircuitD iag r am, age19 - 9ParkingBrakeSwitchTest,page19 10BrakeFluidLevelSwitchTest,page19-10

BRAKECABLE

BRAKEBOOSTERBrakeBoosterTest,page19-18BrakeEoosterReplacement,ag e19 19

P a r k ing r ake ab leReplacement, age 19 26

REARDISCBRAKERearBrakePads Inspection ndReplacement, ag e 9-20RearBrakeDiscInspection, ag e19'22

R ea r r ak e a l i pe r v e r hau l ,page19'23

PARKINGRAKE EVERParkino rakeCheck ndAdjustment,ag e 9-7

BRAKE EDALBrake edal ndErake edal osit ion witchAdjustment,age 9- 6

BRAKEHOSES nd LINESBrakeHoses nd LinesInspection, ag e19 24BrakeHosesReplacement,ag e19 25

MASTERCYLINDERMasterCylinderF l 6 ^ 1 . ^ 6 m 6 n r ^ 2 ^ o 1 O - 1 8

Mas te r y l i nde rns pec t i on ,age19 - 16BrakeBoosterPushrodClearanceA d jus tmen t ,age '19 - 16BrakeSystemBleeding, ag e19-8

19



rakeComponents

Component Procedure Also check for:

l\4aster ylinder Look or damageor signsof fluid leakage t;.

Reservoir r reservoirrommets

. L ine o in ts

. Betweenmastercvlinderand booster

Brake oses Look or damageor signsof f luid eakage t:. Line ointsand banjobolt connections. Hosesand ines.also nspect or twistingor

damaqe

Bulging, wisted or bent ines.

Ca l iper Look or damageor signsof f luid eakage t:. Pistonseal. Banjoboltconnections. Bleeder crew

Seized r s t i ck ing a l iper ins .

ABS \ilodulator Look or damageor signsof fluid leakage t:. Line oints. Modulator

BrakeSystem nspection nd Tests

BrakeSystemTest

Brakepedal sinks/fades when braking

1. Start he engine,and et t warm up to operating emperature.

2. Attacha 2-inchpieceof masking ape along he bottom of the steeringwheel,and draw a horizontal eference

mark across t.

With the transmission n Neutral,pressand hold he brakepedal ightly, hen re lease he parkingbrake.

While sti l l holding h e brakepedal,hook he end of the tape measurebehind t. Then pull he tape up to the

steeringwheel, notingwhere he tape measure inesup with the referencemark yo u made on the masking ape.

Apply steadypressure o the brakepedal or 3 minutes.

Watch he tapemeasure.

. if it moves ess han 10 mm, the mastercylinder s OK.

. if it moves more han 10mm replace he mastercylinder.

t-3.

5.

6 .



Rapid brake pad wear. Vehicle vibration {after a longdrivel,or High,hardbrakepedal

1 . Dr i ve heveh ic len t i l he b rakes ragor un t i l t hepedal s high and hard.This can ake20 or more

brakepedalapplications uring an extended est

d r i ve .

2 . Wi th heeng ine unn ing , a iseheveh ic le n a l i f t ,

andsp ina l l ourwhee ls y hand.

ls therebtake drag at any of the wheels?

YES Go o step3.

NO Look or othercauses f the pa dwear, highpeda l , r veh ic le ib ra t ion . I

3. Turn he engineoff, pump he brakepedal o

deplete he vacuum n the brakebooster, nd he n

spin he wheelsagain o check or brakedrag.

ls therc brake dtag at any ot the wheels?

YES-Go to step4.

NO Replace he brakebooster.I

4. Without removing he brake ines,unboltan d

separate he mastercylinder ro m the booster, hen

spin he wheels o check or brakedrag.

ls there btake drag at any of the wheels?

YES Go o step5,

NO-Check the brakepedalposit ionswitchadjustment nd pedal re e play.I

5. Loosen he hydraulic inesat the mastercylinder,

then spin he wheels o check or brakedrag.

ls there brake drag at any of the wheels?

YE S Go o step6.

NO- Replacehe mastercylinder.l

6. Lo osen he bleeder crewsat eachcaliper, hen

spin he wheels o check or brakedrag.

Is there brake drag at any of the wheels?

YES Disassemble nd repair he caliperon the

whee l (s ) i t h brake rag . l

NO Inspectbrakehose s)/l ine s).

19




BrakePedalandBrakePedalPosition witchAdjustment

PedalHeight

1 . Disconnecthe brakepedalposit ionswitch

connector, urn the brakepedalposit ion

switch(A )

counterc lockwise ,ndpu l l t backunt i l t s no

longer ouch inghe brake eda l .

Lift up the carpetand he insulator utout B) .

l\4easurehe pedalheight C) rom the middleof

the eft sideof the pedalpa d (D).

StandardPedalHeight (with carpet emoved):

18 4mm (7 4/16 n.)

Loosen he pushrod ocknut A) ,and screw hepushrod n or out with pliersuntil he standardpedalheight rom the floor is reached. fter

adjustment, ighten he ocknut irmly. Do not

adjust he pedalheightwith the pushrodpressed.

15N .m(1.5 gl m. 11 bl t)

19-6

7. Checkhe brake eda l reep layasdescr ibed e low.

PedalFreePlay

4. With the engineoff, nspect he play (A )on th epeda l ad B)

bypush ing

hepeda l

y hand.

FreePlay :0 .4 - 3.0mm {0.016 0. ' l 18 in . )

lf th e pedal re e play s out of specif ication, djust

the brakepedalposit ionswitch C) . f the pedal ree

p lay s nsu f f i c ien t ,t may resu l t n b rake rag .

Push n th e brakeoedaloosit ionswitch until ts

p lungers u l l yp ressedthreadednd A) touch ing

th e pa d (B )on the pedalarm).Then, urn the switch

45" clockwise o lock t.Th ega p between he brake

pedalposit ionswitchand he pa d s automatically

ad jus tedo 0 .4 o 3 .0mm (0.016 0.118n. )by

lock inghe swi t ch .Make ure he b rake igh ts o

otf when he pedal s released.

t6.



ParkingBrakeCheckandAdiustment

Check

1. Pull he parkingbrake ever A) with 196N (2 0kgf,

44 bf)of force o fully apply he parkingbrake.Th eparkingbrake evershould be ockedwithin the

specif ied umberof clicks B).

Lever ockedclicks: 7-8

- l2okqf,a4lbl)

2. Adju st heparking rakef he ever licks reno twithin hespecification.

Adjustment

1. Releasehe parkingbrake ever ully.

Loosen he parkingbrakeadjustingnut, start he

engine,an d press he brakepedalseveral imes o

set he self-adjusting rakebeforeadjusting heparkingbrake.

Block he front wheels, he n raise he rearof thevehicle,an d support t with safetystands n theproper ocation seepage 1-8).

Makesure he parkingbrakear m (A )on the rear

brakecalipercontacts he brakecaliperpi n (B),

NOTE: he parkingbrakearm will only contact he

brakecaliperpin when the parkingbrakeadjusting

nut s oosened.

Remove he rearconsole se epage20-57).

Pull he parkingbrake everup one click,

7, Tighten he adjustingnut {A }until he parking

brakesdrag slightlywhen the rearwheelsar e

tu ned.

A /

Releasehe parkingbrake ev er ully, and check

that he parkingbrakesdo not drag when the rear

wheelsare urned.Readjust f neces sary.

Makesure he parkingbrakesar e ully applied

when the parkingbrake ever s pulledup fully.

Reinstallhe rearconsole.

8 .

9 .

1 0 .

19



ConventionalBrakeComponents

BrakeSystemBleeding

NOTE:. Do not spil l brake luid on the vehicle; t may damage

th e painU f brake luid doescontact he paint.wash t

off immediatelywith water.. The reservoir n the mastercylindermust be at the

MA X (upper) evel mark at the startof the bleedingprocedure nd checked fter bleedingeachbrake

ca l iper . dd lu idas requ i red .. Do not reuse he drained luid.. Always use HondaDOT3 brake luid. Non-Honda

brake luid can cause orrosionand shorten he life of

the system.. Makesure no din or other oreign matter s allowed

to contaminate he brake luid.

1 . Make ure he brake lu id eve l n he reservo i rsa tthe MAX (upper )eve l ine A) .

Slidea pieceof clearplastichoseover he flrst

bleedscrew,and submerge he otherend n a

containerof ne w brake luid.

Havesomeoneslowly pump he brakepedal

severalt imes, hen app ly steadypressure.

Startingat he left-front, oosen he brakebleedscrew o allow air o escape rom the system.Then

tighten he bleedscrewsecurely.

2 .

19-8

5. ReDeatthe rocedure or eachwheel n th esequence hown below until air bubblesno longer

appearn he lu id .

BLEEDINGEOUENCE:

OFrontRight ORe.r Right

O Front Left ORoarLoft

Refil l he mastercylinder eservoir o the MAX{upper) evel ine.

FRONTBRAKE:

9 N.m 10.9 gf.m,7 bl.ft)

t-

REARBRAKE:

9 N m 10.9 gf.m, 7 lbf ft )



GRN/ORN

,tk ,o"","o""o*.(b, 3s1E8,.""",,"

I

oPEN,Leve,down

I

-=:

I

AY

BtK

+csor

BrakeSystem ndicatorCircuitDiagram

UNDER.OASHFUSE/FELAYBOX

EBAK€FLUIDIEVELSwlICH

19




ParkingBrakeSwitch Test

1. Remove he rearconsole, nd disconnectheconnector A)from the switch(B).

Check or continuitybetween he switch erminaland bodyground:

. With the brake everup , hereshouldbecontinuity.

. With the brake everdown, hereshould be nocontinuity.

R

'dFu! E!UF-

Y

BrakeFluidLevelSwitch Test

Check or continuitybetween he terminals A)with th efloat n the down posit ionand he up posit ion.

. Remove he brake luid completely rom the reservoir.With the float down, hereshouldbe continuity.

. F j l l t he eservo i r i t h brake f lu id toMAX(upper )eve l(B).With the float up, hereshould be no continuity.

\



Frequentnha la t ion f b rake addust , egard lessf

mater ia l ompos i t ion ,ou ldbehazardouso your

FrontBrakePads nspection ndReplacement

. Avoid breathing us t particles.

. Neverusean a i rhose r b rush o c lean rake

assembl ies .sean OSHA-approvedacuum

cleaner .

lnspection

1. Raise he front of the vehicle,and support t with

safetystands n th e proper ocation se epage 1'8).


2. Check he thickness f the nner pa d A) an d outerpad B) .Do no t nc ludehe h ickness f he b rake

pa d backingplate.

Brakepa d hickness:

Standard: 9.5 10.5mm (0.37 0.41 n. l

Service imit: 1. 6mm (0.06 n. )

Innerpad:

Outer pad:

l f the brakeDa d hickness s ess han he service

l imi t , ep lace l l t hepadsasa se t .

Replacement

1. Removehe bo l t A) , ndp ivo t heca l iper B)upou

of the way. Check he hosean d pi n boots ordamage nddeter io ra t ion .

' . . ', . a

&

\

A

2. Removehe padsh im A) andpads{B) .

. ^ h v /\ \ \ J Iv

."r------B

(con

1 9



FrontBrakeDisc nspection

Runout

1. Rai se he front of the vehicle,and support t with

safetystands n the proper ocation se epage 1-8).Remove he front wheels.

2 . Removehebrake ads see age19-11) .

3. Inspect he disc surface or damageand cracks.

Clean he disc ho roughly,and removeal l rust

4. lnstallsuita le lat washers A)andwheel nuts,and

tighten he nuts o the specif ied orque o hold he

brakediscsecurely gainst he hub.

Set up thedial gaugeagainst he brakedisc as

shown,an d measure he runoutat 10 mm (0 4 in.)

from the outeredge of the disc.

BrakeDiscRunout:

ServiceLimit: 0.10mm (0.00ttn. l

lf the disc s beyond he service imit, refinish he

brakedisc.

Max. Retinish imit: 19.0mm (0.75 n.)

NOTE:. l f he b raked iscs beyondtheserv iceimi t fo r

re f in i sh ing ,ep lacet (see age18-1 ) .. A new disc shouldbe refinished f its runout s

grea terhan0.10mm (0.004n. ) .

Thickness ndParallelism

1. Raise he front of the vehicle,an d support t with

safetystands n the proper ocationse epage

1-8)Remove he front wheels.

2. Remove he brakepads seepage 19-11).

3. Usinga micrometer,measuredisc hickness t

eight points,approximately 5" apartan d 10 mm

{0.4 n. ) n from the outeredge of the disc.

Brake OiscThickness:

Standard:20.9 21.8mm {0.82-0.86 n. }

Max. Refinishing imit: 19.0mm 10.75n. )

Brake Disc Parallelism: 0.015mm 10.0(X)6n.)

max.

NOTE:This s the maximum allowabledifference

between he thicknessmeasurements

10 mm lo. i t n. l

l f he smal les tmeasurements ess han he max

refinishing imit, replace he brakedisc(seepage

1 8 - 1 1 ) .

lf the disc s beyond he service imit or paralleli

refinish he brakediscwith an on-carbrake athe

The Kwik-Lathe roducedby Kwik-way

ManufacturingCo .and he"Front BrakeDisc

Lathe" offeredby Snap-onTools Co.are approve

for this operation.

4 .

': .--'t-'" '-

t , .

19




rontBrakeCaliperOverhaul

Frequent nhalationof brakepa ddust, egardless f material omposit ion, ould be hazardouso your health..

Avoid breathingdust particles.' Never sean a i rhoseor b rush o c leanbrake ssembl ies .se an osHA-approvedacuum leaner .

Remove, isassemble,nspect, eassemble, nd nstall he caliper,and note hese tems:' Do no tsp i l lb rake lu idon heveh ic le ;t maydamage hepa in t ; f b rake f lu idge tson thepa in t,wash i to f f

immediatelywith water.. To preventdripping,coverdisconnected ose ointswith ragsor shop owels.. C leana l l a r t s inbrake f lu idanda i rd ry ;b lowouta l lassageswi thompressed i r .. Before eassembling, heck hat all partsare ree of dust and other oreignparticles.. Replace artswith new onesas specif ied n the il lustration.. Makesure no dirt or other o reign matter s allowed o contaminatehe brake luid,' When reusingpads,always reinstallthem n their originalpo s ti ons o prevent ossof brakingefficiency.. Do not reusedrainedbrake luid.' A l w a y s u s e H o n d a D O T 3 b r a k e f l u i d . N o n ' H o n d a b r a k e f l u i d c a n c a u s e c o r r o s i o n a n d s h o r t e n t h e l i f e o f t h e s v s t e m

. Do not mix differentbrandsof brake luid as hey may not be compatible.

. Coat the is ton , i s ton ea lg roove, ndca l iper orewi thc lean rake f lu id .

. Makesure no greaseor oi l getson the brakediscsor pads.

. Replace ll rubberpartswith new oneswheneverdisassembled.

. After nstall ing he caliper, heck he brakehoseand ine or leaks, nterference, nd wistinq.

>:@:Honda calipersreaso plN 08C30-80234M)

Boors 3i,l'1.'"-ffiFA /

isli\ii ^ zsw tt

/paq\t l l l /, \ L , . ' i E / [

-ffi \--l u";;;lqEtCALIPERIN / 3.4N.m y' >v r

\ / {3.5 ef m, / ,,'\ / 25 lbf ft) //'t / SEAL|NG)- I ---=-? WASHEaS

BRAKEOS E/ /8LEEOCREW/ / / e N m

/ / / (o.s gr'm./

/ |itbt.ftl

, 1(}', ^ l^ /caLl

-ffi \:7 "=;lGoX-*fL-f

/) I .===? WAStrtXS \

t9..-\ | #.'@ RepracF/7\- (hA PADRETATNERS !s-

\t/ \

*d':ffi/rkr) ,-o/vlJ ffiEs,lry:' E*,e,a"fif:i#l1t*"_,,.==f@ tz x t.zsmm ourEBpa DsHrM

10 8N. m111.0gf .m,80 tbt.ft)



MasterCylinderReplacement

NOTE:Do not spil l brake luid on the vehicle; t may

damage he paint; f brake luid doescontact he paint,

wash t off immediatelywith water,

1 , Removehe a i rc leaner ssemblyA) .

2, Disconnecthe brake luid evelsensorconnector

(A).

15N. m{1.5kgt.m,11 bt.ft)

3. Removehe c lu tch eservo i rB)andeng inewi re

harness lip (C)from he mastercylindermountin

base D) .

4. Remove he reservoir ap and brake uid from the

reservoir.

5. Remove he reservoir E)on the mastercylinder

mount rng ase.

6, Disconnecthe brake ines F)from he master

cylinder G) .To preventspil ls,cover he hose oin

with ragsor shop owels.

7. Re move hemastercylindermountingnuts{H)an

washers.

8. Remove he mastercylinder rom the brakeboosBe carefulnot o bendor damage he brake ines

when removing he mastercylinder.

9. Remove he rod seal l) rom the mastercylinder.

10. Installthemastercylinder n the reverse rder of

removal,an d note hese tems:

. Replace ll the rubberpartswith new ones

whenever he mastercylinder s removed.. Check he pushrodclearance efore nstall ing h

mastercylinder. nd adjust t if necessary see

page19-16) .

. Us ea new rod sealon reassemblY

. Coat he innerbore ip andouter circumferenc

of the new rod seal A)with the recommended

sealgrease n the mastercylinderset.. I ns ta l l t heodsea lon to themaster y l inder i t

it s groovedside (B)toward he mastercylinder. Check he brakepedalheightan d re e playafte

ins ta l l i nghe master y l inder , ndad jus t t f

necessary seepage 19-6).

19




MasterCylinder nspection

NOTE:. Before eassembling, heck hat al partsar e re eof

dust and other oreign particles.. Donot t ry to d isassemble the

astercy l inderassembly.Replacehe mastercylinderassemblywitha ne w part f necessary.

. Do not allow dirt or foreignmatter o contaminatehebrake lu id .

RESERVOIBAPI unecKor otocKage

of vent holes.

RESERVOIR

,--l RESERvOIR EALCheck or damaoe

RESERVOIROSESInspect oses ordamage, eaks, nddeterioration.

r ' , , . J \ +

v

MASTER YLINDERCheckor eaks,ust, nddamage

and deterioration.

STRAINERRemove ccumulateds eo tmen t .

BrakeBoosterPushrodClearanceAdjustment


Pushrod djustment auge07JAG-SD40100

NOTE:Brakeboosterpushrod-to-pistonlearancemustbechecked nd adjustmentsmade, f necessarV, eforeinstall ing he mastercylinder.

1. Set thespec ia loo l A )on the mastercy l inderodv(B),push n the centershaft C)until he top of itcontacts he end of the secondary iston D)bytu rn ing he ad jus t ing u t E) .

Without disturbing he centershaft 'sposit ion,

installthespecialtool A)backwards n the booster.

Install he mastercylindernuts(B),an d ightenthem to the specif ied orque.

Connecl he booster n l inewith a vacuumgauge

{C) -101 kPa 0 ' -760mmHg,30 n .Hg)o thebooster'senginevacuumsupply,and maintainaneng ine peed hatw i l l de l i ve r 6 kPa 500mmHg,20 n .Hg) acuum.

15N m r .511 bf.ftl



5. With a feelergauge A),measure he clearance

between he gaugebody and he adjustingnu t (B )

as snown,

lf the clearance etween he gaugebody and headjustingnut s 0.4mm (0.02 n.), he pushrod-to-

pistonclearances 0 mm. However. f the clearance

between he gaugebody and he adjustingnut s

0 mm, the pushrod-to-pistonlearances 0 4 mm

{0.02 n. )or more.Therefore t must be adjusted

an d rechecked.

Clearance: 0-0./t mm (0-0.02 in.)

lf th e clearances ncorrect, oosen he star ocknut

(A).and urn the adjuster B) n or out to adjust.

. Adjust he clearance hile he specif ied acuum

is appiied o the booster.. Hold he clevis C)while adjusting.

A0 0. 4mm 0 -0.02in.) 22N.n

07JAG-SO40100

7. Tighten he star ocknutsecurely.

8. Remove he special ool (D).

9 . Checkhe pushrodength A)asshowni f the

booster s removed, f the length s incorrect,

loosen he pushrod ocknut B) ,an d urn the clevis

(C )n or ou t to adjust.

A116mm 4.6n. )

10 . Ins ta l l t hemaster y l inder see age 9-15)

10x 1 .0mm1. 5N' m11.5 gf.m,11 bf. f t l

19



Gonventional rakeComponents

rakeBooster est

Functional est

1. With the enginestopped,press he brakepedalseveral imes o deplete he vacuum

reservoir, henpress he pedalhard,and hold tfor 15seconds. fth e pedalsinks,either he mastercylinder sbypassing nternally, r the brakesystem master

cy l inder ,ines .modu la to r , r ca l ipers)s eak ing .

2. Start he enginewith the brakepedalpressed. f thepedalsinksslightly, he vacuumbooster s workingproperly. f th e pedalheightdoes not vary, heboosteror checkvalve s faulty.

3. With the engine unning,press he brakepedall i gh t l y .f t he brake eda l inksmore han1Omm{3/8 n, in 3 minutes, he mastercylinder s faulty.

A slightchange n pedalheightwhen the Ay'Ccompressor ycleson and off is normal. Th eA,/Ccompressor oadchanges he vacuumavailable othe booster.)

LeakTest

1. Press he brakepedalwith the engine unning, he nstop he engine. f the pedalheightdoes not varywhile pressed or 30 seconds,he vacuumboosteris OK. f the pedal ises, he booster s faulty.

2. With the enginestopped,press he brakepedal

several imes using normalpressure.When he

pedal s f irst pressed, t should oe row.On consecutive pplications,he pedalheightshou ld radua l l y i se . f the peda l os i t i on oesnotvarv,check he boostercheckvalve.

3. Disconnecthe brakeboostervacuumhose check

valvebuilt-in) A)at the boosterside.

5 .

4 . S ta rt he engine,and et t idle.Thereshouldbevacuum va i lab le .f no vacuum s ava i lab le ,hecheckvalve s notworking properly.Repiacehebrakeboostervacuumhoseand checkvalve,an drelesI.

Reconnecthe brakebooster acuum nose.Start he engine,and hen pinch he brakeboostervacuum hosebetween he checkvalveand hebooster,

Turn he gnit ionswitchOFF,an dwait 30 seconds,Press he brakepedalseveral imes using normalpressu e,

When he pedal s f irst pressed,t shouldbe ow.On consecutive pplications,he pedalheightshou ld radua l l yi se .

. lf the pedalposit iondoesnotvary, replacethebrakebooster.

. lf th e pedalposit ionvaries, eplace he brakeboostervacuumhose/check alveassembly.



BrakeBoosterReplacement

1 . R e m o v ehemaster y l inder see age19-15) .

Remove he mastercylinderbrake ines A) ro m

the brake inec l ip .

c

6 x 1 . 0 m m9. 8N. m(1.0 gf.m,

7.2 tbf.ft)

Remove he vacuum hosemountingbracket B) .

Disconnecthe vacuum hose C) rom the brake

booster.

' - /

. , . , . . . .a l u

i'. .

5. Removehec l ip A)and he o in tp in (B) . nd

disconnectthe oke rom the brakepedal.

7 .

{' l .3 gf.m,9 bf.ft l

Remove he brakeboostermountingnuts(C).

Remove he brakebooster A)from the engine

comparlmenr.

INdAdEI. Be carefulnot to damage he booster

surfaces nd hreadsof the boosterstud

bolts.. Be carefulnot o bendor damage he

brake ines.

lnstallthebrakebooster n the reverse rder of


. Adjust he pushrodclearance efore nstall ing

the brakebooster se epage19-16).. Usea newcl ipwheneverns ta l l i ng .. After nstall ing he brakeboosteran d master

cylinder, il l th e reservoirwith new brake luid,

bleed he brakesystem se epage19-8), nd

adjust he brakepedalheightand ree play (see

page19-6) ,

19



rakeComponents

RearBrakePads nspection nd Replacement

Frequent nhalationof brakepa ddust, egardless fmaterial

omposit ion, ould be hazardouso yourhea h .. Avoid breathingdust particles.. Neverus ean air hoseor brush o cleanbrake

assemblies,Us ean OSHA-approvedacuumcleaner .

Inspection

'1 .Raise he rearof the vehicle,and support t withsafetystands n th e proper ocation se epage1-8).Remove he rearwheels,

2. Check he thickness f the nnerpa d (A )andouterpa d(B).Do not nclude he thickness f the brakepa dbackingplate.

Brakepa d hickness:

Standard: 8. 5 9.5 mm {0.33-0.37 n. }Service imit: 1. 6mm (0.06 n. )

B - : : - -

lf the brakepad hickness s less han he servicel imi t , ep lace l l t hepadsasa se t .

3 .

Replacement

1. Remove he bolt (A )and brakehose B} ro m th e

mountingbracket.

Remove he caliperbolts C) ,and remove hecaliper D) ro m the caliperbracket.

Removehepadsh ims A)andpads B) ..

At {\

tI

A

A

\

r\) )\



4. Remove he pa d retainers A).an dcheck he caliper

pins or free movement.

:. i _ _l

7 .

8 .

5. Clean he caliper horoughly; emovean y rust.an d

check or groovesand cracks.

6, Check he brakedisc or damagean dcracks.

Apply Dow CorningMolykoteM77 grease o the

retainers n their mating surfaces gainst he

caliperbracket,

Installthepa d retainers.Wipe excessgreaseoffthe

retainers. ontaminated rakediscsan d pads

reducestoppingabil ity.Keepgreaseoff the discs

andpads.

Apply Dow CorningMolykote vl77 rease o both

sidesof the pa dshims{A), he backof th e pads B),

and he otherareasndicated y the arrows.Wipe

excessgreaseoff the s him. Contaminated rake

discsan d pads educestoppingabil ity.Keep

greaseof f the discsan d pads.

9 .

.. - .

10. Ins ta l l the rake adsandpadsh ims or rec t l y .

Ins ta l l t he adswi rh hewear nd ica to rsC)on he

ins ide .

lf yo u are reusing he pads,always einstall he

brakepads n their originalposit ions o preventa

momentary ossof brakingefficiency.

11. Rotate he caliperpistonclockwise nto he cylinde

then align he cutout A) n the pistonwith the tab

{B) on the nner pa dby turning he pistonbackso

theca l iper anbe ns ta l led n hepad.Lubr ica tethe bootwith rubbergrease o avoid wis ting he

Distonboot. f the pistonboot s twisted,back t ou

so it is posit ionedproperly.

8 x 1 .25 m22N. ml2.2kgt m,16 bl.ttl

. a r

D8 x 1.25mm2 3 N m{2.3 gf.m,17 bf.ft)

1 3 .

1 4 .

Ins ta l l t he rake a l iper C)andca l iper o l t s D) .

an d ighten he bolts o the specif ied orque.

Ins ta l l t he rake ose E) .

Press he brakepedalseveral imes o makesure

th e brakeworks, hen est-drive.

NOTE:Engagement f the brakemay requirea

greeterpedalstroke mmediatelyafter he brake

padshave been eplaced s a set.Severalapplications f the brakepedalwill restore he

normalpeda l t roke ,

15 . Checkhe park ing rake d jus tmentsee age19

16. Af te r ns ta l la t ion ,heck or eaks t hose nd ine

jointsor connections, nd retighten f necessarY

19-




RearBrakeDisc nspection

Runout

1. Raise he rearof the vehicle,and support t with

safetystands n the proper ocation se epage1-8).Remove he rearwheels,

2. Remove he brakepads se epage19-20).

3. Inspect he disc surface or damageand cracks.Clean he disc horo ughly,and removeall rust,

4. lnstallsuita le at washers A)and wheel nuts,an dtighten he nuts o the specif ied orque o hold hebrakedisc securelyagainst he hub.

10 8N. m 11.0gf.m,80lbf.ft)

Set up the dial gaugeagainst he brakediscasshown.and measure he runoutat 10 mm (0.4 n. )from the outeredgeof the disc.

BrakeDisc Runout;


lf the disc s beyond he service imit, refinish hebrakedisc.

Max. Refinish imit: 9.0mm (0.35 n.)

NOTE:. l f he b rake i sc s beyondtheserv iceimi t fo r

refinishing, eplace t (seepage18-26)..

A new discshould be refinishedf its runout sgrea terhan0.10mm (0.004n. ) .

Thicknessnd Parallelism

1. Raise he rearof the vehicle,and supportwith

safetystands n the proper ocation seepage l-g).Remove he rearwheels.

2. Remove he brakepads seepage19 20).

3, Usinga micrometer,measuredisc hickness te igh tpo in ts , pprox imate ly5 'apar tand 10mm

{0.4 n. ) ro m the outeredgeof the disc.

BrakeDiscThickness:Standard:9.9-10.1 mm (0.389 0.397 n.lMax. Retinishing imit: 9.0 mm (0.35 n. )BrakeDiscParallelism: 0.016mm 10.0006n. )

max.

4 . l f t he smallestmeasurement s less han he max.refinishing imit, replace he brakedisc (seepage18-26).

lf the disc s beyond he service imit for parallelism,refinish he brakediscwith an on-carbrake athe.



RearBrakeCaliperOverhaul

Frequent nhalation f brakepa ddust, regardless f material omposit ion, ould be hazardouso your health.

' Avoid breathing ust particles.. Neveruse an air hoseor brush o clean brakeassemblies. se an OSHA-approvedacuum cleaner'

Remove, isassemble,nspect, eassemble, nd ns tallthecaliper,and note hese tems:

. Donotsp i l lb rake lu idon heveh ic le ;t maydamage hepa in t ; f b rake u idgetson he pa in t ,wash t o f f

immediatelywith water.. To preventdripping. overdisconnected os e ointswith ragsor shop owels.. C leana l l a r t s inbrake f lu idanda i rd ry ;b lowouta l lassageswi thompressedi r '. Before eassembling, heck hat all partsare ree of dust and other oreignparticles

. Replace an s with new onesas specif ied n the llustration.

. Makesureno dirt or other oreign mattercontaminateshe brake luid.

. When reusingpads,always einstallthem n their originalposit ions o prevent oss of b aking eff icie cy.

. Do not reusedrainedbrake luid.

. Useon lyc leanHondaDOT3 brake lu id .Non-Honda rake lu idcancause or ros ion ndshor tenhe i feo f he

system.. Do not mix differen tbrandsot brake luid as hey may no t be compatible.. Coat the is ton , i s ton ea lg roove, ndca l iper o rewi th c lean rake lu id .. Makesure no greaseor oil getson the brakediscsor pads.

. Rep lacea l lubber ar t sw i th new oneswhenever i sassembled .

. After nstall ing he caliper, heck he brakehoseand ine or lea ks, nterference. nd wisting.

oG , nonau."rip6r qreas€ P/N 08c30-aoa4Ml 3 4N. m 3. 5 gf m,25lbtft)BOLT

WASHERS

BRAKE OSE

a

l,,,'IltE" !!;,ff

olT-J,.o"c.O.RING CUPBeplace. Beplace.

.ARKINGUr lii. 'i rz.rgr.. Gd ff i2 7 N m { 2 . 8 k g t m ,

\-"o, V((rA ",1 ;[.,.JF;;;;---

t H\a \l / t,i*t'*"?,,.t/*"^.,,.:,"","V4#

ADJUSTING OLT

,/

2 7 N m { 2 . 8 k g f . m ,20 bf.ftr PADSPRING

A,n Na 7lfl,lif,loffi,,0,n, \ ,,:,o"

--t\)(*ff l^7k ''"'t!1'ry#'INNEBPA'SHIM/ .r.:._U i*E( ":;*" *dF ,.2>a>-

fr.x{_>@ fftt **-->**^'",,.-"iV ,/q &'"o.,"."""o"^.,

: 10 MM FLANGE BOLTS.:r=,9!q!q}l 55 N m (5.6 lgf-m, 4r lbt ft)

19




rakeHosesand Lines nspection

1. Inspect he brakehosesfordamage,deterioration,eaks, nterference, ndtwisting.

2. Check he brake ines or damage, usting.and eakage. lso check or bent brake ines.

3. Check or leaksat hosean d in e oints or connections, nd retighten f necessary.

4. Check he mastercylinderand ABS modulatorunit or damageand eakage.

NOTE:Replace he brakehoseclip whenever he brakehose s serviced.

15 N. m (1.5 gf.m,11 bf.ftl

ABS MODULATOR NIT-Io-BRAKE INE15N. m 1. 5 gf m.11 bf.ft l

BRAKE OSE-to-CALIPERlBANJOBOLTI3il N.m{3.5 gf.m.25 bt'ft)BLEEO CREW9 N.m 0. 9 gf.m,7 bf.ft l

MASTERCYLINDEB-to-BRAKEINE15 N m {1.5 gt.m, l lb f . f t )

CONTROLVALVE-to-

L

BRAKEHOSE.tO-CALIPER{BANJOBOLTI34N. m {3.5 gf.m,25 bl . f t )BLEEDSCBEW9 N.m10.9 gf.m, 7 lbf ft)

BRAKE INE15N.m11.5gf m, 11 bf.ft)

BRAKELINE-Io-BRAKEHOSE15 N.m (1.5 gf.m,11lbf.ftl

BRAKE INE-to-BRAKE OSE

t''/,i'i',/ ,l

t t,.. -)

19-24



BrakeHoseReplacement

NOTE:. Do not spil l brake luid on the vehicle; t may damage

th e paint; f brake luid getson the paint,wash t of f

immediatelywith water.. To preventdripping, over disconnectedin e oints

with ragsor shop owels.. Before eassembling, heck hat all partsare re e of

dust and other oreignparticles.. Replace artswith new oneswheneverspecif ied o

do so.

1 Replacehe brakehose A) f the hose s wisted,

cracked, r if it leaks.

Disconnecthe brakehose rom the brake in e(B)

usinga 10 mm flare nut wrench C)

Remove he flangebolt (A),an d remove he brake

hosebracketsrom the damper.

Remove ndd iscardhehose l i p B) .

Remove he banjobolt (C),an d remove he brakehose D) rom heca l iper .

4.

I x 1 .25mm

6. Installthebrakehosebracket A)on the damper

with the flangebolt (B ) irst, hen connect he brake

hose C) o the caliperwith the b anjo bolt {D)an d

newsea l ing ashersE) .

7. lnstallthe hoseonto he hose bracket n the bodv

with a new hoseclip (A).

10x 1 .0mm15 N.m

i (1.5 gf.m,

! 1t tbt.ftl

Connect he brake ine o the brakehose.

After nstall ing he brakehose,bleed he brake

system seepage l9-8).

Do he following checks:

. Check he brakehoseand ine oint for leaks, nd

tightenf necessary.

. Check he brakehoses or interference nd

twisting.

9 .

1 0 .

19-




arkingBrakeCableReplacement

Exploded iew

PARKING RAKEswtTcH

ADJUSTINGUT

L

PARKING RAKE ABLECheckor stiffness,inding, nddamage.

e8 x 1.2522 N.m12 .2k g l

19-26



NOTE:. Th e parkingbrakecablesmust not be bent or

distorted. hiswill lead o stiff operationan dpremature ailure.

. Refer o the ExplodedView as neededduring hisproceoure.

1 . Re leasehe park ing rake ever u l l y .

2. Remove he rearconsole seepage20-57).

Remove he parkingbrakecableclip (A ) ro m th e

brake ab le B) .4.

6.

Disconnectthe arkingbrakecable ro m th e lever

{c).

Remove he parkingbrakecablemounting

hardware, he n remove he cable.

7 . lns ta l l t he ewcab le n he reverse rdero f

removal.and note hese tems:

. Be carefulnot o bend or distort he cable.

. Make ure hepark ing rake ab le l i p s u l l y

seatedon the cablehousing.. Do he parkingbrakecableadjuslment seepag

19-7.

19-



Brakes

Conventional rakeComponents ...............9-1

ABS(Anti-lockBrakeSystem)Components

Comoonentocat ionndex . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . .9 -30General roubleshootingnformation .. . . . . . . . . . . . .. . . . . . . .9-31DTC roubleshootingndex ... . . . . . . . . . . .9-34Symptom roubleshootingndex .. , . . . . . . . . . .. . . . . . . . . . . . .. . . .9-35System escription... . . . . . . . . . . . . . . . . . . . . . . . .9-36Circuit iagram .. . . . . . . . 9-42DTC roubleshooting... . . . . . . . . . . . . . . . . . . . . .9-45ABS ndicator ircuitTroubleshooting... . . . . . . . . . . . . . . . . . .9-52Brake ystemndicator ircuit

Troub leshoot ing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -55ABSModulator-ControlnitRemoval nd

lnstallation ... . . . . . . . . . .9-57WheelSensornsoection ...................9-59WheelSensor eolacement .. . . . . . . . . . . . .9-59



BSGomponents


UNDER.HOODUSE/RELAYOX

RIGHT-REAR HEELSENSORInspection,ag e 9-59Replacement,ag e 9-59

UNDER.OASH USE/RELAY OX

\L

LEFT.REAR

WHEEL ENSORInspection, ag e19-59Replacement,ag e19-59

DATALINKCONNECTOR16PIRIGHT.FRONT HEEL ENSORInspection, ag e19-59Replacement,ag e19-59

ABSMODULATOR.CONTROLNITRemovalnd nstallation,age 9'57 LEFT-FRONT HEELSENSOR

Inspection,age 9-59Replacement,ag e 959



GeneralTroubleshootingnformation

ABS ndicator

. lf the system s OK,theABS ndicator oe sof f 2

seconds fter urning he gnit ionswitchON

(ll)

without starting he engine ,and hen comeson againan d goesoff 2 seconds aterafterstarting he engine.

This occursbecause he ABS controlunit isturned

on by the G2 powersource.. The ABS ndicator omes on when he ABScontrol

unit detects problem n the system.However,even

though he system s operatingproperly, he ndicator

will come on under heseconditions:- Only he drivewheels otate- One drivewheel s stuck- The vehiclegoes nto a spin- Th eABS continues o operate or a long ime.- The vehicle s subjected o an electrical ignal

disturbance

To determine he actual auseof the problem,question

the customerabout he problem. aking he above

condil ions nt o consideration.

. When a Droblem s detected nd he ABS ndicator

comeson, hereare caseswhen th e indicator tays

on until he gnit ionswitch s urned OFF,and cases

when the indicator oe soff automaticallywhen the

sYstem eturns o normal.- DT C61:The ABS ndicator oe soff automatically

when the system eturns o normal.- DTC11,13 ,15 ,1731,32 ,33 , 4 ,35 ,36,37 ,38 ,54 ,

or 81:The ABS ndicator tayson until he ignit ion

switch s urnedOF Fwhetheror not the system

returns o normal.- DfC 12 ,14 ,16 ,1a ,21 ,51 ,52 , r 53 ;TheABS

indicator oe soff when the vehicle s drivenagain

and he system s OK after he gnitionswitch s

tu rned rom OFF o ON { l l } .

Diagnostic roubleCode DTCI

. The memory can hold hreeDTCS. owever,when

the same DTCs

detectedmore

han once, hemore

recentDTC s writtenover he earlierone.

Therefore,when the sameproblem s detected

repeatedly,t is memorizedas a singleDTC.. The DTCsar e n the order hey occurred, eginning

with th e most recent.. Th e DTCS re memorized n the EEPROMnon-

volati lememory).Therefore. he memorizedDTCs

are not clearedwhen th e battery s disconnected,he

ignit ionswitch s turnedoff, or the system eturns o

normal.Do he specif ied rocedureso clear he

DTCs.

Self-diagnosis

. Self-diagnosisan be classif ied nto wo categories:- In i t i a l i agnos is :

Done ight after he enginestartsan d until he ABS

indicatorgoesof f- Regu la r iagnos is :

Done igh ta f te r then i t ia l i agnos is n t i l he

ignit ionswitch s turnedOF F. When a problem s detectedby self-diagnosis,he

systemdoes he following:- Turns he ABS ndicatoron- Memorizes he DT C- StopsABS control

Kickback

Th e pump motoroperateswhen the ABS s functioning

and he fluid n th e reservoir s forcedout to the maste

cy l inder , aus ing ickback t he b rake eda l .

PumpMotor

. Th e pump motor operateswhen the ABS s

funct ion ing .. The ABS controlunit checks he pump motor

operationwhen the vehicle s started he first ime

after he gnitionswitch s turnedON (ll).You may

hear he motor operateat this ime, but t is normal.

(cont'd

19-



ABSComponents

GeneralTroubleshootingnformation cont'd)

How to TroubleshootABS DTCs

The roubleshooting lowchartprocedures ssume hatthe causeof the oroblem s sti l l Dresent nd he ABS

indicator s sti l l on. Following he flowchartwhen the

ABS ndicatordoes not come on can result n incorre ct

d iagnos is .

Th econnector llustrations how he female erminal

connectorswith a singleoutlineand he male erminal

connectorswith a doubleoutline.

1. Ouestion he customerabout he conditionswhen

th e problemoccured, nd ry to reproduce he

sameconditions or troubleshooting. in dou t

when the ABS ndicator ameon, such as during

ABS control,afterABS control,when the vehicle

was at a certainspeed,etc.

2. When he ABS ndicator oes not come on during

the test-drive, ut troubleshootings done basedon

the DTC, heck or looseconnectors. oo r erminal

contact, tc.,beforeyo u start roubleshooting.

3. After roubleshooting, lear he DTC,disconnectheHondaPG MTester.an d est-drive he vehicle.

Makesure he ABS ndicatordoes not comeon .

How to RetrieveABS DTCs


1, Wjth the gnit ionswitchOFF, onnect heHonda

PGMTester A) o the 16Pdata ink connector DLC)(B) under he driver'sside of the dashboard.

19-32

2. Turn he gn i t ion w i t chON ( l l ) , nd o l low hepromptson the PGMTester o display he DTC{S)

on the screen.After determining he DTC, efer o

the DTCTroubleshootingndex.

NOTE:See he HondaPGMTesteruser'smanual

for specif ic nstructions.

Service Check Signal (SCS)Circuit Method:

1. With the gnit ionswitchOFF, onnect he Honda

PGMTester A) o the 16Pdata inkconnector DLC)(BI under he driver'ssideof the dashboard.

2. Short he SCScircuit o body ground using he

HondaPGMTester.

3. Turn he ignit ionswitchON (ll).



4. The blinking requency ndicateshe DTC.DTCS reindicated y a seriesof long and shortblinks.On elongb l inkequa ls 0shon b l inks . dd he ongandshort blinks ogether o determine he DTC.After

determining he DTC, e fer o the DTCTroub leshoot ingndex.

NOTE:. lf the DTC s not memorized, he ABS ndicator

will go off for 3.6seconds, nd hencome backon.

. l f th e ABS ndicatorstays n, roubleshootfor"ABS indicatordoes not go off" (seestep 1 onpage19-53).

Th€ system will not indicate the DTC unless hese

conditions are met:.

Th e brakepedal

s notpressed.

. Th e gnitionswitch s turnedON {ll).

. Th e SC Scircuit s shorted o body ground beforethe gn i t ion wi t ch s u rnedON ( l l ) .

Examplet DTC 5

Long blinkShort blinks{fivetimesl

Examole of DTC 22

Long blinks two times)

Turn he gnit ionswltchOFF,

Disconnecthe HondaPGM Tester rom the DLC.

5 .

How to ClearABS DTCs


1. With the ignit ionswitchOFF, onnect he Honda

PGMTester A) to he 6Pdata inkconnectorDL{B}under he dr i ver ' s ideo f the dashboard .

Turn he gn i t ion wi t chON ( l l ) , ndc lear the

DTC(s) y following he screenpromptson the

PG MTester.

NOTE:See he HondaPG \4Testeruser'smanual

fo r sDeclfc nstructions.

Cycling the lgni tion Switch Method:C lear he DTCby urn ing he gn i t ion w i t chON ( l l ) he

OFFat east 0 imes.

19-



ABSGomponents


DTC Detection ltem Note

DTC:11 Rioht-frontwheel sensor ooen/shorto bodv qround/short o power) (seeoaoe19-45)

DTC:12 Faultv iqht-frontwheel sensoroulsesiqnal {seeoaoe 19-46)

DTC:13 Left-frontwheel sensor oDen/shorto bodv qround/shorto power) (seeoaqe19-45)

DTC:14 Faultv eft-frontwheel sensorDulse rqnal (seepaqe19-46)

DTC;15 Riqht-rear heel sensor oDen/shorto bodv qround/shorto power) (seeDaqe19-45)

DTC:16 Fau l t v iqh t - rear hee lsensor u lse iqna l (seepaqe19-46)

DTC:17 Left-rearwheel sensor open/shorto bodv qround/short o power) (seeDaoe19-45)

DTC:18 Faultv eft-rearwheel sensorDulse iqnal (seeDaqe19-46)

Drc:2l Cont inuous Dera t ionch ioDed u lser ) (seepaqe19-47)

DTC:3'l Soleno id (seeDaoe19-48)

DTC:32 Soleno id {seeDaqe 9-48)

DTC:33 Soleno id {seeDaoe19'48)

DTC:34 Soleno id lsee oaqe19-48)

DTC:35 Soleno id (seepaqe19-48)

DTC;36 So eno d (seeDaqe19-48)

DTC:37 So eno id (seeDaqe19-48)

DTC:38 Sole o d (seeDaoe19-48)DTC:51 lvlotorIocked (seeDaqe 9-48)

DTC:52 lvlotor stuck off (seeDaoe19-49)

DTC:53 lMotor tuckon (seeDaoe19-50)

DTC:54 Main relavstuckof f (see aqe19-51

DTC:61 lG2 voltaqe {see aqe19-5 ' l

DTC:81 cP U (CentralProcessinq nit) {seepaqe 19-52)

19-34



Symptom Troubleshootin Index

Symptom Diagnostic procedure Also check forABS ndicatordoesno l come on ABS IndicatorCircuitTroubleshooting se epage

19-52)ABS ndicatordoes not go off and noABS DTC s stored

ABS IndicatorCircuitTroubleshooting se estep 1on Daqe19-53)

Brake ystem ndicator oes nol comeon

BrakeSystem ndicatorCircuitTroubleshooting(seepaqe 19-55)

Brake ystem ndicatordoes not go of fand no ABS DT C s stored

Brake ystemndicator ircuit roubleshooting(see teo1on Daqe 9-55)

19-



ABSGomponents

SystemDescription

ABSControlUnit InputsandOutputs or 31PConnector


1 2 4 5 6 7 B I 1112 1 41 5

1 6 1 1 1B 1 920?1/t/t/l/t/

Terminalnumber

Wirecolor

Terminalign Description MeasurementTerminals Conditions lgnit ionswitch ON (ll))

Voltage

BLU/YEL

RRS Detectsighfrearwneetsensorsrgnal

; a - _ - l

6- 7

Wheel

Sp in hee la t

I turn/second

AC: .053 or

above

Oscil loscope

0.15 p-p r

above

GRN/YEL

RRS+)

BLU F R S - ) Detects ight-front

wneetsensor

srgna l

5 GRN/

BLK

FR S+)

6 BRN/

WH T

FLS _) Detectseft-front

wneetensorsrgnalBLU/

ORNF LS + )

8 GRY/

R E D

RLSH Detectseft-rear

wneetsensor

srgna l

8 9

9 YEURED

RLS +)

1 1 LT BLU DIAG K Communications

withHonda GM

rester

12 BRN DIAG L DTCndication

19-36



Terminal

number

Wirecolor

Terminalsign Description MeasurementTerminals Conditions {lgnition

switch oN ll l))

Voltage

1 4 WHT/BLK

STOP Detects rake

switch iqnal

I4 -GND Brake edal Pressed Eatteryvoltaoeeleased

t 5 BLVORN

rG2 Powerourceoractivatinghesvstem

1 5 - G N D Bafteryvoltage

16 BLK M-GND Groundor he0umD otor

16-GND Below .3V

WHT/RED

+ B-MR Power ource or

th eoumDmotor

17-GND Ata l l t imes Batteryvoltaoe

1 8 WHT/G R N

+ B-FSR Power ource or

th evalve elav

,18-GNDAta l l t imes Battery

voltaoe'1 9 BLK G N D Groundor he

modulator

assemDtv

19.GND Below .3V

20 BLU/REDABS Drives BS

indicator20-GND ABS

indicatorON About 1VOFF Below 1 V

BRN/

YEL

EBD(Electronicrake

distribution)

Drives rake

systemndicator

2 1 - G N D B ra ke y st em

indicator

O F F Below.3VON orbulbcnecK

8atteryvoltage

(con t '

19-



ABSGomponents

SystemDescriptioncont'd)

Features

When he brakepedal s pressed uring driving, he wheelscan ockbefore he vehiclecomes o a stop. n such an

event. he maneuverabil ity f the vehicle s reduc ed f the front wheelsare ocked, nd he stabil ityof the vehicle s

reduced f the rearwheels are ocked, reatingan extremelyunstable ondit ion.The ABS precisely ontrols he slip

rateof the wheels o ensuremaximum grip force rom the tires, herebyensuring he maneuverabil ity nd stabil ityof

theveh ic le .

Th eABS calculateshe slip rateof the wheels basedon the vehiclespeedand he wheel speed, hen it controls he

brake luid pressure o reach he targetslip rate.

Grip Force of Tire and RoadSurface

TARGETSLIPRATE

COEFFICIENTFFRICTION

SLIPRATE

19-38



ABSControlUnit

Main Control

Th eABS controlunit detects he wheel speedbasedon the wheel sensorsignal t received,hen it calculateshe

vehiclespeedbasedon the detectedwheel speed.Th e controlunit detects he vehiclespeedduring deceleration

basedon the rateof deceleration.

The ABS controlunit calculateshe slip rateof eachwheel and ransmits he controlsignal o the modulatorunit

solenoid alvewhen the slip rate s high.

Th e pressure eduction ontrol has hree modes:pressure educing, ressure etaining, nd pressure ntensifying.

Self-diagnosis unction

1 . T h e A B S c o n t r o ln i t i s e q u i pp e d w i t h a m a in C P U a n d a s u b - C PU . E a c h C P U c h e c k s th e o t h e r f or p r o b

2. TheCPUS heck he circuitof the system.

3 . TheABScont ro l n i tt u rns n theABS nd ca to rwhen he un i tde tec tsa rob lem ndtheun i ts tops he sys tem.

4. The self-diagnosis an be classif ied nto hese wo categories:. ln i t i a l i agnos is. Regu la r iagnos is

On-boardDiagnosis unction

The ABS can be diagnosedwith the HondaPGMTester.

The ALB Checker annotbe usedwith this system.Fo rair bleedingand checkingwheel sensorsignals.us e he Honda

PGMTester.See he HondaPGMTesteruser'smanual or specif ic perating nstructions.

(con t '

T - - -

19-



ABSComponents

SystemDescription cont'd)

ABSModulator

Th eABS modulatorconsists f the inletsolenoid alves,outletsolenoid alves, eservoir, ump, pump motor,and hedampingchamber.The modulator educes he caliper luid pressure irectly. t is a circulating-type odulatorbecausethe rake f lu idc i rcu la tes th roughtheca l iper , reservo i r ,and themastercy l inder .Thehydrau l i ccon t ro lasthree modes:pressure ntensifying, ressure etaining, nd pressure educing. he hydraulic ircuit s an independent

four -channe l t ype ,nechanne lor eachwhee l .

Pressurentensifyingmode: Inletvalveopen,outlel valveclosed

Master y l inderlu id s pumped ut o theca l iper .

Pressure etainingmode: lnletvalveclosed,outletvalve closed

Caliper luid is retainedby the nlet valve andoutletvalve.

Pressure educingmode: Inletvalve closed,outletvalveopenCaliper luid f lows through he outletvalve o the reservoir.

lvlotoroperationmode: When starting he pressure educingmode, he pump motor s ON.When stoppingABS operation, he pump motor s OFF.Theca l iper lu id s pumped utby he pump, hrough hedamping hamber ,o themaster v l inder .



WheelSensors

Th ewheel sensorsare he magnetic ontactlessype.As the gear pulser eeth otatepast he wheel sensor'smagnet

coil,AC current s generated. he AC requency hanges n accordance ith the wheel speed.The ABS controlunitdetects he wheel sensorsignal requencyand herebydetects he wheel speed.

!t LOW SPEED

Wheel Speed and Modulator Control

8E!EEETqEEJ!q!ESPEEq

5

PRESSURE

OUTLETVALVE 9p

OFF

INLETVALVE oN

OF F

MoroR I- , . l

t lOF F

When he wheel speeddropssharplybelow he vehiclespeed, he nletvalveclosesand l necessary,he outletvalv

opensmomentarily o reduce he caliper luid pressure. he pump motor startsat this ime. As the wheel speed s

restored, nd he outletvalvecloses, he inletvalve opensmomentarily o increase he caliper luid pressure.

GEARPULSERWHEEL €NSOR .r HIGXSPEED

19



*- :ffrre, *-

riq.r.srbm r.l q_ md/Y4

I L

7--:::

19



BSComponents

q,

CONNECTOR {12P)BRAKEPEDALPOSITIONSWITCH PCONNECTOR

CircuitDiagram cont'd)

UNDER-HOODUSE/RELAYOXCONNECTORSCONNECTOR{12P) CONNECTOR{2P}

UNDER.DASHUSE/RELAYOXCONNECTORSCONNECTOR{5P) CONNECTOR I17P)

MULTIPLEXONTROLUNIT 13PCONNECTOR

CONNECTORI22PI

1 l 2 l 3 l , / 1 5

GAUGE SSEMBLY ONNECTORSCONNECTORI22P)

WHEELSENSOR PCONNECTORS

FRONT

J --T:-l Lt q t t / ) ll L_.:-:J r\-r-----Tr'

e:l

RIGHT.REAR LEFT-REAR

tslTt?t /J 1T-1\I t L | \ t r l z i J

Ter mina l i de f ma le e r m ina l s

ABSCONTROLNIT IPCONNECTOR

OATA LINK CONNECTOR 16P)



1 2 3 4 5 6 78 1011121 31 415 1 1

1 2 3 ,/ ,/

6 7 8 9 1011n213

1 2 4 5 6 7 8 I 1112 1 415

16 1 1 1 8 1 92021/1,/1,/vl,/l

/t,/t/t,/t/



BSComponents


7. Check he resistance etween he appropriatewhee lsensor +) and ) c i rcu i t e rmina lsseetable).

DTC Appropriate Terminal

l+) Side * l S i d e

11 Riq ht-front) N o. 5: R S*) N o . 4 : F R S- )'1 3

{Left-front) No. :FLS + i No.6: LS-15 Rioh t - rear ) No. :RBS+) N o . : R B S- )

17 (Left-rear) No.9 :RLS - No.8: LS-

ABSCONTROL NIT31PCONNECTOR


Is the rcsistance between 450 2,000 A ?

YE S Check or a looseABScontrolunit3lPconnector. f necessary. ubstitute known-goodABS modulator-control nit,and recheck.l

NO Go o step8.

Disconnecthe harness P connector ro m theappropriatewheel sensor,an dcheck he resistancebetweenhe +) and ) te rmina lso f hewhee lsensor.

ls the resistance between 450- 2,000 Q ?

YES-Repa i r pen n he +) or ( - ) c i rcu i t i re ,o rshort between he (+ ) circuitwire and he { )circuitwire between he ABS modulator-control

un i tand hewhee lsensor . l

NO Rep lacehewhee lsensor . l

DTC12,14,6,18:WheelSensor utseSigna l

NOTE: f the ABS ndicator omeson for the reasonsdescribed elow, he indicatorgoesoff when you test-d r i ve he veh ic le t 31 mph 50km/n l .

. Only he drivewheel rotated

. Theveh ic le pun

. Electrical oise

1 . V isua l l y heck o r appropr ia te hee l ensorandpulser nstallation nd condition see able).

DTC Appropriate Wheel Sensor12 Riqht-front1 4 Left-front

R iqh t - rear1 8 Left-rear

Ate they installed correctly and not damaged?

YES-Go to step 2,

NO Reinstall r replace he appropriatewheelsensor r pu lser , I

Disconnecthe ABScontrolunit 31Pconnector.

Measure he resistance etween he appropriate

whee lsensor f ) and ) c i rcu i t e rmina lsseetab le ) .

ls therc less than 450 Q ?

YE S Go o step 1.

NO-Go to s tep4.

\\|D

2.

3.

DTC Appropriate Terminal

l * ) S ide ) Side12 Rioht-front) N o . 5 : F B S* No.4 :FBS14 Left-front) No.7 ;FLS* No,6 :FLS16 Riqh t . rear ) No.2:RS* No. :BRS18 Left-read No.9 : LS - No.8 :RLS



4. Check or continuitybetween he appropriate

whee lsensor +) c i rcu i t te rmlna lndotherwhee l

sensor +) c i rcu i t e rmina lssee ab le ) .

DTC Appropiate

Terminal

OtherTerminal

12 N o . 5 :

FRW*iN o . 7 N o . 2 N o . 9

'1 4N o . 7 :

FLW T.)

N o . 5 N o . 2 N o . 9

t o N o . 2 ;

RRW T-)N o . 5 N o . 7 N o . 9

1 8 N o . 9 :

RLW *)N o . 5 No. N o . 2


YES Repair hort n th e wires between he

appropriatewheel sensorand he otherwheel

sensor a rnesses. l

NO Clear he DTC,disconnecthe HondaPG M

Tester, nd est-drivehe vehicle. f the AB S

indicator omeson and he same DTC s ndicated,

replace he ABS modulator-control nit. l

Disconnecthe harness2Pconnector rom the

appropriatewheel sensorand check he resistance

betweenhe +) s ideand he - ) s ideo f the whee l

sensor.

ls there less han450 Q ?

YES Replace he wheel sensor.

NO - Repair hort o wire between he appropriate

whee lsensor +) and - )c i rcu i t s . l

DTC 1:Continuous perationChippedpulser)

1. Clear he DTC, hen disconnect he HondaPGMtesler.

2. Test-drive he vehicleat 19 mph (3 0km/h)or more

Doesthe ABS ndicatorcomeon and s DTC 21

ind cated?

YES Go o step3.

NO The system s OK at this ime.l

3. Check he pulsergear or a chipped ooth.

ls thepulser OK ?

YES Check or a looseABS controlunit 31P

connector. f necessary, ubstitute known-good

ABS modulator-control nit,an d recheck.l

NO Replacehe driveshaft r hub unit (chipped

pu lser ear ) .1

1g



BSComponents


DTC 1,32.33,34,35,36,37,38:Solenoid

1. Clearhe DTC,hendisconnecthe Honda GN4

Tester.

2. Test-drivehevehicle.

Does he ABS nd catorcomeon andare DTCs 31,32, 33, 34,35, 36, 37, 38 ndicated?

YES ReplaceheABSmodulator-controlnit.t

NO Thesystems OKat his ime.

DTC 1:MotorLocked

' 1 .Checkhe No. 10 40A) fusen heunder -hoodfuse /

retayDox.

ls the use OK ?

YES-Reinstall he fuse,an d go to step2.

NO- Replacehe fuse,and recheck.l

2. Disconnecthe ABScontrolunit 31Pconnector.

3. Measure he voltagebetween he ABS controlunit31P onnectorermina lNo. 17and bodyground.


IWire ide f emaleerminals

ls thetebattery voltage?

YES Go o step4.

NO Repairopen n the wire between he(40A) us eand he ABS controlunit. l

N o .1 0



ABSComponents


4. Check or continuitvbetween he ABS controlunit31P onnectorermina lNo. 16andbodyground.


Wire id eol emaleerminals

ls therecontinuity?

YES-Check or loose erminals n the ABS controlunit 31 Pconnector. f necessary, ubstituteknown-goodABS modulator-control nit,an drecheck.l

NO Repairopen n the wire between he ABScont ro l n i tand bodyground G202) .1

3.

DTC 3:MotorStuckON

1. C lear he DTC,hend isconnecthe Honda GM

Tester.


Does he ABS ndicatotcomeon and s DTC 53indicated?

YES -G o to step3.

NO- lntermittent ailure, he system s OK at thist rme. l

Disconnecthe ABScontrolunit 31 Pconnector.

Check or continuitybetween he ABS controlunit31P onnectorermina lNo, 16andbodyground.

ABSCONTROL NIT3,IPCONNECTOR



YES-Replace he ABS modulator-control nit.t

NO-Repair open n he wire between he ABScont ro l n i tandbodyground G202) . I



DTC 4:MainRelay tuckOFF

1. Checkthe o .8 (20A)use n he under -hooduse/

re laybox,and e ins ta l l t heuse f t s OK.

ls the f use OK?

YES-Go to step2.

NO Replace he fuse,an d recheck.l

2. Disconnecthe ABS controlunit 31Pconnector.

3. l\4easurehe voltagebetween he ABS controlunit

connectorermina lNo.18andbodyground.

ABSCONTROLNIT 1PCONNECIOR


Is therebattety voltage?

YES Replace he ABS modulator-control nit. l

NO-Repair open n th e wire between he ABS

controlunit and he under-hooduse/relay ox.I

DTC 1: G2Voltage

NOTE: heckhe No. 11 7 .5A)use n heunder -das

fuse/relay ox before roubleshooting.

1 . C lear heDTC, hend isconnectheHondaPGM

tesler.

2. Test drive he vehicle.

Doesthe ABS ndicator comeon and s DTC 61

ind cated?

YES Go to step3.

NO The system s OK at this time.l

3. D isconnectheABScont ro l n i t3 lPconnector .


5. Measure he voltagebetween he ABS controlun

31P onnector te rmina lo .15andbodyground

AB SCONTROLNI T 1PCONNECTOR


YES Replacehe ABS modulator-control nit. l

NO Repairopen n he wire between he ABS

controlunit and he under-hood use/relay ox.l


19



ABSComponents


DTC 1:CPU Central rocessingnit)

1. Clear he DTC, hen disconnect he HondaPGM

Tester.


Does he ABS ndicatorcomeon and s DTC 81indicated?

YES Replacehe ABS modulator-control nit. l

NO-The system s OK at this ime.

ABS ndicatorGircuitTroubleshooting

ABS ndicatordoes not come on

1. Turn he gn i t ion wi t chON ( l l ) , ndwatch heABSindicator.

Does he ABS ndicatorcomeon?

YES Th e system s OK at this ime.I

NO Go o step2,

Pullup th e parkingbrake ever.

Does the btake system indicator come on?

YE S Go o step3.

NO Repairopen n the indicatorpowersourcecircuit. f necassary, ubstitute known-goodAB Smodulator-control nit,and recheck.. BlownNo, 10 7.5A) use.. Open n he w i rebetweenhe No.10 7.5A) fuse

and he gauge ssembly ,. Opencircuit nside he fuse box.


Disconnecthe ABS controlunit 31Pconnector.


Does the ABS ndicator come on?

YES-Check or loose erminals n the ABS control

unit 31Pconnector. f necessary, ubstituteknown-goodABS modulator-control nit,an drecheck.l

NO Go o step 6.


Remove he gaugeassembly se epage22-64).

3.

5.

6.

7 .



8.

9.

Disconnecthe gaugeassembly onnectorA (22P).

Check or continuitybetweengaugeassembly

connectorA {22P)erminalNo, 12 and body ground.

GAUGE SSEMBLY ONNECTOR(22P)



YES- Repair hon to body ground n the wire

between he gaugeassemblyand he ABS control

un i t . l

NO Go o step 10 .

Disconnecthe gaugeassembly onnectorB (22P).

Check or continuitybetweengaugeassembly

connectorB (22P)erminal No. 12 an d body ground.

GAUGE SSEMBLY ONNECTOR(22PI



YES Check or loose erminals n th e gauge

assembly onnectors.f the connectors reOK ,

replace he gaugeassembly.l

NO Repairopen n th e wire between he gauge

assembly ndbodyground G501) .1

'10.

1 1 .

3.

ABS ndicatordoes not go off

1. Checkthe o.8 (20Alfusen heunder-hooduse

relay ox,and einstallhe use f t sOK.

ls the use OK?

YES Go o step2.

NO-Replacehe use, nd echeck.f the use s

blown, heckor a shon o bodygroundn hi s us

circuit.l thecircuits OK, eplaceheAB Smodulator-controlnit.

Check he No. 11 7.5A) use n the under-dash

fuse/relay ox, and reinstall he fuse f it is OK.

ls the f useOK ?

YES Go o step3.

NO Replace he fuse,an d recheck. f the fuse s

blown,check or a short o body ground n this us

circuit. f the circuit s OK,replace he ABS

modulator-control nit.

Disconnecthe ABS controlunit 31Pconnector.

Measure he voltagebetween erminalNo. 8 and

body ground.

A8S CONTROLNIT3lPCONNECTOR


YES-Go to step5.

NO Repairopen n the wire between he No. 8(20A) use and he ABS controlunit. l

(cont


19



BrakeSystem ndicatorGircuitTroubleshooting

Brakesystem ndicatordoes not come on

'1 .Discon ect he m ult iplexcontro unit l3Pconnector

and he ABS controlunit 31Pconnector.

2. Check or continuitybetween he ABS controlunit

3 l Pconnectorermina lNo,21andbodyground.

ABS CONTROL NI T31 PCONNECTOR


ls therecontinuity?

YES Repair hort o body ground n the wire

between he multiplexcontrolunit and he ABS

cont ro l n i t . l

NO Go o multiplexcontrolsystem

troubleshooting seepage22''172).a

Brakesystem ndicatordoesnot go off

1. Turn he gn i t ion w i t chON { l l ) .

2 . Re leasehe park ing rake .

Does he brake system ndicatot go ofl after

severalseconds?

YES The system s OK at this t ime.l

NO Go o step3.

3. Check he brake luid evel.

ls th e evel OK?

YES Go o step4.

NO Refil l he brake luid, and recheck.l

4. Check he ABS ndicator.

Does he ABS ndicatorstay on?

YES Read he ABS DT C se estep 1 on page19-3

and do the applicable roubleshootingor the DTC

NO Go o step5.


6. D isconnectheABScont ro l n i t3 lPconnector .

7 . Connecthe ABScont ro l n i t31P onnector

te rmina lNo.21 andbodygroundwi th a umper

ABS CONTROL NIT31 PCONNECTOR

(cont

Wir esrde f ema le e r m ina l s

19



ABSComponents

8.

9 .

10 .

1 1 .

12 .

13 .

BrakeSystem ndicatorGircuitTroubleshootingcont'd)

Turn he gnititonswitchON (ll).

Check he brakesystem ndicator.

Does the brake system indicatot go off?

YES-Replace he ABS modulator-control nit. l

NO-Go to step 10.

Turn he gnit ionswitch OFF.

Connect he multiplexcontrolunit 13P onnectorte rmina lNo.

landbodygroundwi tha umperwi re .

MULTIPLEXONTROL NIT13PCONNECTOR

JUMPERWIRE



Check he brakesystem ndicator.

Does the btake system indicatot go off?

YES Repairopen n th e wire between hemultiplexcontrolunit and he ABS controlunit. l

NO Go o multiplexcontrolsystem

troubleshootin (seepage22-17 ).a

\



ABS Modulator-ControlUnit Removaland nstallation

NOTE:. Donotsp i l lb rake lu idon heveh ic le ;t maydamage he pa inUf b rake f lu idge tson thepa in t ,wash i to f f

immediatelywith water.. Becarefulno t o damageor deform he brake inesduring removalan d nstallation.

. To prevent he brake luid from flowing,plug and cover he hoseends and ointswith a shop owel orequivalent

malenal.

Removal

'1 .Turn he ignit ionswitchOFF.

2 . Pu l lup the lock(A) f theABScont ro l n i t3 lPconnector (B) , thend isconnect theconnector .

FLARE UTl5 N.m 1. 5 gt.m,11bt.f t l

6)o

CI I mm NUT8. 8N. m 0. 9 gl m.6.5lbf t)

6 mm BOLT9. 8N. m11.0 sf.m,7.2lbf.ft)

\.

--/Q \,\ - - - '

(cont'

19-



ABSGomponents

ABS Modulator-ControlUnit Removaland Installation cont'dl

3. Disc onnectthe ix brake ines.

4. Remove he two I mm nuts.

5. Remove he ABS modulator-control ni t (C).

Installation

'1 .Ins ta l l t heABS odu la to rcon t ro ln i t , hen igh ten he wo 8 mm nuts .

2. Align he connecting urfaceofthe ABS controlunit 3' lPconnector.

3 . Push in the locko f theABScont ro ln i t31P onnector n t i l ou hear t c l i ck n top lace .henconnectheconnector .

4. Connect he six brake ines.

5. Bleed he brakesystem,startingwith the front wheels.

6. Connect he PGMTester,and do the solenoid unction est or eachwheel.

7. Bleed he brakesystemagain,staningwith the front wheels.

8. Start he engine,and check hat he ABS ndicatorand brakesystem ndicatorgo off.

9. Disconnecthe HondaPG MTester.Test-drivehe vehicle,and check hat he ABS ndicatorand brakeqvqtem

ind ica to r o no tcomeon.

19-58



WheelSensor nspection

1 .

2.

Inspect he front and rearpulsers or chippedor

damaged eeth.

Measure he air ga p between he wheel sensorand

th e pulserall he way aroundwhile rotating hepulser.Remove he r ear brakedisc o measure he

ga p on the rearwheel sensor. f th e ga p exceeds

1.0mm (0.04n. ) , heck or a bentsuspens ionrm.

Standard:

Front; 0.4- 1. 0mm (0.02-0.04 n. )

Rear: 0.2 1.0mm (0.01 0.04 n.l

Front:

0. 4 '1.0mm

10.02 0.0'l n.l

I

t

Bear:

0.2 1.0mm{0.01 0.04n. }

WheelSensorReplacement

NOTE: nslall he sensors arefully o avoid wis ting he

wtres.

Front:

6 mm BOLT9. 8N. m{1.0 gf.m,7.2lbf. f t l

6 mm BOLT9. 8N. m{1.0kgf.m,7.2 bf.ftl

Rear:

6 mmBOLT9. 8N. m11.0 gf.m,7.2 bf.ft)

WHEEL ENSOR

6 mm BOLT9. 8N. m(1.0 gf 'm,7.2 br.ft)

19-



Body

DoorsComponentocat ionndex . . . . . . . . ..DoorPane l emova l / lns ta l la t ion. . . . , . . . . . . . . . .DoorOuterHandleReplacementDoorLatchReplacementDoorGlass ndRegulator

ReplacementDoorSash r imReplacement. . . . . . . . . . . . . . . . . . . . . .DoorGlassOuterWeatherstrip

ReplacementDoorWeatherstrip eplacementDoorGlass d jus tment . . . . . . . . . . . . .. . . . . . . . .. . . . . . . . . .DoorPos i t iond jus tment. . . . . . . . . . . . . . . . . . . . . . . . . . . .DoorSt r i ker d ius tment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MirrorsComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . .PowerMi r ro rRep lacement. . . . . . . . . . . . . . . . . . . . . . . . . .M i r ro rHo lder ep lacement. . . . . . . . . . . . . . . . . . . . . . . . . .Rearv iew i r ro rRep1acement. . . . . . . . . . . . . . . . . . . . .

GlassComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . .

Windsh ie ldep lacement

BearWindowRep1acement. . . . . . . . . . . . . . . . . . . . . . . . . .Ouar te r lass ep lacement. . . . . . . . . . . . . . . . . . . . . . . . .

MoonroofComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . .Symptom roubleshootingndexGlass e igh t d jus tment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G lass ep lacementWindDefector ep1acement. . . . . . . . . . . . . . . . . . . . . . .Dra in hanne l ep1acement. . . . . . . . . . . . . . . . . . . . . . . . .Sunshadeep lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MotorReplacementFrame ndDrainTubeReplacement...........Dra in hanne l l i der ndCab le ssembly

Rep lacementL im i tSwi tch d jus tment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Closino orce ndODenina raqCheck ......lnterioiTrimComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . .Trim Removal/lnstallationoorArea ..........Trim Removal/lnstallation

-Rear id eAreaTrim Removal/lnstallation

-Cargo loorAreaTrim Removal/lnstallation-Hatchrea .........Headliner emoval/lnstallation

* Carpet ep1acement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Consoles

Consoles, ront nd RearRemova/lnstalation

FrontConsole isassembly/Reassembly....

20-220,420-620-7

20-920 t0

20- 1020-1120-1120-1220 13

20-1420-1520-1520-16

20 11

20-1920-2520-29

20,3520-3620-3720-3120-3820 3920-4020-4120,42

20 4420-46

20,44

20-4920 50

20-51

DashboardInstrument anelRemoval/lnstallation.......Driver'sDashboard owerCover

RemovatnstallationDriver'sDashboard nderCover

RemovaInstalation

Oriver's ocket emoval/lnstallation...........ShiftLever rim Removal/lnstallation.........Center ane l emova l / lns ta l la t ion. . . . . . . . . . . . . .Passenger'sashboard owerCover

Remova/lnstalat onx GloveBo xRemoval/lnstallation

Dashboard ideVentRemova l / lns ta l la t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -64

Beverage olderRemoval/lnstallation....... 0-64Driver'sTray emoval/lnstallation..............0-65Passenger'sra yRemoval/lnstallation....... 0 65

* Dashboard emoval/lnstallation.................0-66Steer inq anqer eamReolacement. . . . . . . . . .0 -68

Seats"

Component ocationndex ...........................0-10*

FrontSeatRemoval/lnstallation..................0-11* FrontSeatDisassembly/Reassembly-Dr iver ' s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 -73

* FrontSeatDisassembly/Reassembly-Passenger ' s. . . . . . . . . . . . . . . . . . . . . . . . . .0 -74

* Front eatCover ep lacement. . . . . . . . . . . . . . . . . . . .O-75Rear eatRemova l /1nsta11at ion. . . . . . . . . . . . . . . . . . . .0 -80RearSeat-backatchReplacement.............0-81RearSeat-backStrikereplacement...........0-81

20-59

20-59

RearSeat-back overReplacement............0-82Rear eat ush ion over ep lacement. . . . . . 0.84

BumpersFront umper emova l / lns ta l la t ion. . . . . . . . . . . .Rear umoer emova l / lns ta l la t ion. . . . . . . . . . . . . .

HoodAdjustment

HoodSea lRep lacementHood nsu la tor ep1acement. . . . . . . . . . . . . . . . . . . . . . . .Hatch

20-60

20,60206120-62

20-6320-63

20,8520-86

20-47

20,8820,89

20-5220-5320-5420-55

20-5720-58

Adjus tment . . . . . . . . . . . . . . . . . . .0 -90Hatch uppon t ru tRep lacement. . . . . . . . . . . . . . .0 -91HatchWeatherstriDeo1acement................0-92

FuelFillDoorAdiustment . . . . . . . . . . . . . . . . . . .0 -93

Exterior rimFrontGr i l l e ep lacement. . . . . . . . . . . . .CowlCoversReplac"rn""t .. . .....................A p i l l a r orner r imReplacement. . . . . . . . . . . . . . .Roof Mo ld ingep lacement. . . . . . . . . . . . . . . . . . . . . . . . . .Rear icense rim ReplacementHatch po i le r ep1acement. . . . . . . . . . . . . . . . . . . . . . . . . .Emblem ep1acement. . . . . . . . . . . . . . . . . . . . . . . .

20-9420-9520-9620-9720,9820-9920-100



FenderwellFront nnerFender eplacementFront ender a i r ing ep lacement. . . . . . . . . . . . . .FuelPipeProtector eplacementRear i rOut le t ep1acement. . . . . . . . . . . . . . . . . . . . . . . .

OpenersComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . . . . . .HoodOpener ab le ep lacement. . . . . . . . . . . . . . .

* Fue l i l lDoorOpener ab leReplacement

Hood a tch ep1acement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fue l i l lDoorOpener ep lacement. . . . . . . . . . . . .Hatch and le ep lacement. . . . . . . . . . . . . . . . . . . . . . . . . .Hatch a tch ep lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hatch ock y l inder ep lacement. . . . . . . . . . . . . . .

FrameSubf am eReplacement................................0-112FrameStiffener, race, ndGusset

Replacement .............0-113r F r e m p R F n r i r C h r r r . . . . . . . . . . . . . . . .0 - 1 1 4

20-10220-10320-10420-'to4

20-10520-106

20 10720-10820-10920-1 020-11020-111



Doors


POWERWINDOWswtTcH

DOORSASHTRIMReplacement,ag e20-10

DOORGLASSOUTERWEATHERSTRIPReplacement,ag e20-10

DOORPosition diustment,page 0-12

t

\POWERDOOR OCKSWITCH(Driver's)

DOOROUTER RIM

K-pIJ A'A

dq

W2"'Ya\J aita.

DOORWEATHERSTRIPReplacement,ag e 0-'l ' l

20-2



IMMOBILIZER ABEL

REGULATORReplacement,ag e 0- 9

CYLINDERROOPROTECTOR

GLASSReplacement,ag e20-9

Adjustment, ag e20-11

@

/6X@- W (STRIKER

Adjustment, ag e20 -13

LATCHReplacement,ag e20-7

RETAINERCLIP

POWERDOORLOCKACTUATOR

OUTERHANDLEPROTECTOR

LOCK YLINDER

\\

LOCKKNOB O

,-\t t \

v4,,(E ) i l

20



Doors

Door PanelRemoval/lnstallation


Trim pa d remover,Snap-onA 177Aor equivalent,

commerc ia l l yva i lab le .

NOTE:When pryingwith a flat-t ipscrewdriver,wrap it

with protective ape,and applyprotectiveape around

the relatedparts. o preventdamage.

1 Remove he mirror mount cover (seepage20-15).

2. Inserta hex wrench hrough he hole (A) n the doorgrip base B) ,Push he door grip cover (C )out to

re leasehe hook D)and ab E) , ndpu l lou t he

cover o release he tabs (F)and hook(G )by hand,

then remove he cover.

20-4

3. Remove he armrestcover (A).Takecarenot o

scratch he door panel.

-1 Pryou t

the front edge of the cover o release

the hooks B) .-2 Pry ou t the bottom and rearedge of the cover

to release he hooks C) .-3 Pry out along he op to release he tabs (D).

Remove he screws A, B) ,and release he tabs (C),

then remove he door grip base D) .Remove he

screw A) securing he door panel rom the armrest

portion.

Fastgngr ocationsA> : Screw,3 B> : Screw,5

4 .



5. Pullout the switchpanel A)to release he hook(B),

then remove he panel ro m the door panel.

Disconnecthe powerwindow switchconnector C) .

Releasehe clips hat hold he door panel A)with acommercially vailable rim pad remover B), he nremove he door panelby pull ing t upward.Remove he door panelwith as itt le bendingaspossible o avoidcreasingor breaking t,

FastenerLocations95 mm (3.74n. l

12 mm r q----------i.0.17n.l r <_--'r-

> :Clip,9

ffiEtA l m m{0.04n. l

45 mm {1.77n. l

7. Disconnecthe inner handlecable A) rom th einnerhand le B) , ndd isconnect theowerdoorlockswitchconnector C) driver's). ak ecare not obend he

cable.

8. Detach he harness lip (A)from the door panel B)

B

Install he door panel n th e reverse rder ofremoval,and note hese tems:

. Replace ny damagedclips.

. Makesure he cable s connected ecurely, ndthe connector s plugged n properly.

. Check he window and power door ockoperatrons,

9 .

20



Doors

DoorOuterHandleReplacement

NOTE: uton gloveso protect ourhands.

1, Removehesetems:

. Doorpanel seepage20-4)

. Plastic over,as necessary se epage20-2)

Ra iseheg lass u l l y .

Remove he lock rod protector A).

-l Remove he screw.-2 Releasehe protector rom th e latchprotector

(B) .-3 Pull he protectordown to releasehe hook(C )

from the door.

Fastener ocation) : Screw,1

2 .

5 .

20-6

4. Disconnecthe cylinder od (A),and release he

retainer li p (B). he n remove he oc kcylinder C) .

Disconnecthe outer handle od (A).

Fastenor ocations

> : Bolt,2

6 x 1 . 0 m m9.8 N.m{1.0 gf.m,7.2 tbt.ft')

6. Remove he maintenance ap (B),and remove he

bo l t s ecur inghe outerhand le C)whi leho ld ing

the handle rom outside.Releasehe hook(D). he nremove he outer handleprotector E).



7. Pullout the outer handle A) , hen remove t.

Installthehandle n th e reverse rder of removal,


. Makesure each od s connected ecurelv.

. Makesure he door locksand opensproperly.

. When nsta l l i nghe ock y l inder .eavetheouter

door handlebolts ooseso the nner protector

doesnot nterferewith the oc kcylinderinstallation,hen ighten he handlebolts.

. Install he lockcylinder etaining lip on th e

handle, hen install he lockcylinder.Be sure he

c l ip s u l l yseatedn he s lo ton he ock y l inder .. When e ins ta l l i nghe doorpane l ,make ure he

plastic over s nstalledproperly,and s sealedaround h e coversDerimeter.

Door LatchReplacement

NOTE:Puton gloves o protect our hands.

1. Remove hese tems:

3.

4 .


. Plastic over,as necessary se epage20-2)

Raise he glass ully.

Remove he lock rod protector seestep3 on page

20-6).

Pullthe glass un channel A) away as necessary,

an d remove he bolt, hen remove he center owe

channel B)by pull ing l downward

Fastenor ocation

> : Bolt,

IIilE

q6 x 1 . 0 m m8 N.m{0.8kgf.m, 6 lbf.ftl

(cont'

20



Doors

Door LatchReplacementcont'dl

5.

6.

7 .

Disconnecthe cylinder od (seestep4 on page20 -6) .

Disconnecthe outer handle od (seestep5 onpage20-6).

Disconnecthe actuator onnectors A),and release

the nnerhand le ab le B) f rom he doorby

detach inghecab le l i p Ci .

Remove he screws, he n remove he latch A)through he hole n the door.Takecare not o bendthe outer handle od (B),cylinder od (C), ock rod(D) , nd nnerhand le ab le E) .

Fastener ocations

8.

) : Screw

U.#

6 x 1 . 0 m m5 N m{0.5 gf.m,4 tbf.ft)

20-8

9. Installthe atch n the reverse rder of removal,an dnote hese rtems:

.[Vlake ure he actuator onneclors re plugged nproperly, nd hat each od and cablear econnected ecurely.

. When e ins ta l l i nghe doorpane l ,make ure heplastic over s installedproperly,an d s sealedaround he coversperimeter.

. Make ure he door ocks ndopens roper ly .



DoorGlassand RegulatorReplacement



. Door panel se epage20-4)

. Plastic over.as necessaryseepage20-2)

2 . Care fu l l ya ise heg lass A)unt i l oucanseethe

bolts, hen remove hem. Carefullypull he glass

out hrough he window slot.Takecareno t o drop

th e glass nside he door.

Fastener ocations

) : B o h , 2

@

6 x 1 . 0 m m9. 8N m {1.0 gl.m,7. 2 bf.f t l

3. Disconnect nd detach he connector A) andharness l i p B) rom he door .

Fastonor ocations

C>: Bo l t .1 D>: Bo l t ,5

6 x 1 . 0 m m8 N.m(0.8 gf.m,6 rbf.ftl

Removehe bolts C) , nd oosenhe bolts D), heremovehe regulatorE) hroughhe hole n hedoor,

Applymultipurposereaseo all heslidingsurfaces f he regulatorA)where hown.

Installtheglassand regulator n the reverseorder

of removal,an d note hese tems:

. Ro l l theg lass p anddown o see f t movesfreelywithout binding.

.Makesure hat here s no clearance etween heg lass ndg lass unchanne l hen heg lass s

ctoseo.. Adjust he positionof th e glassas necessary se

page20-1 ) .. Check or water eaks se estep7 on page20-12. Test-drive nd check or wind noiseand rattles.. When e ins ta l l i nghe doorpane l ,make ure he

plastic over s installedproperlyand sealed

around ts perimeter.

20



Doors

oorSashTrim Replacement

NOTE: ak ecare not o scratch he door.

1. Remove he door glassouterweatherstrip.

2. Pull back h e door weatherstrip A) at the rearuppercorner,and remove he screw.

Fasten6r Location

) : Screw, I

Liftup the door sash ri m {B ) o releasehe hooks(C), hen remove he trim.

lnstallthe rim in the reverse rderof removal.

3.

20-10

DoorGlassOuterWeatherstripReplacement

NOTE:.

Put on gloves o protectyour hands.. Takecareno t o scratch he door

1 . Removehepowermi r ro r see age20-15) .

2. Startingat he front, pr y he door glassouterweatherstrip A) up to detach he clips(B),an drelease he weatherstrip rom the door sash ri m(C), hen remove he weatherstrip.

FastenerLocations

Install he weatherstripn th e reverse rder otremoval,and replace ny damagedclips.

3.

B > : C l i p , s



DoorWeatherstripReplacement

NOTE:. Takecare not o scratch he door.. Us ea clip remover o remove he clips.

1. At the A-pil lar, emove he door stop mountingbolt(A) .

Fastener ocations

A > : B o t t , B > : C l i p , 1 C > : C l i p , 8

Detach he clips (8, C), hen remove he door

weatherstrip D) .

Install he weatherstripn the reverseorderof

removalan d note hese tems:


.Makesure he weatherstrip s nstalled

n the

ho lder E) ecure ly .. App ly iqu id hread ock o doors topmount ing

bolt before nstallation.. Check or water eaks se estep7 on page20-'121.. Test-drive nd check or wind noase.

14.----''

'r ,. , 'o-, , tL' .

. r r t

Door GlassAdjustment

NOTE:. Check he weatherstrips nd glass un channelfor

damageor deterioration, nd replace hem if

necessary.. Wipe he ru n channelcleanwith a shop owel.. Lubricatehe ru n channelwith Shin-Etsu rease

P/ N08798-9013.

1. Place he vehicleon a firm, levelsurface.



. Plastic over se epage20'2)

3. Carefullymove he glass A) untilyo u can see he

glassmountingbolts B) , he n loosen hem.

B6 x 1 . 0 m m9. 8N. m 1. 0 gf.m, .2lbf.ft)

Push he glassagainst he channel C) , hen ighte

the glassmountingbolts.

Check hat he glassmoves smoothly.

(cont

20-



Doors

DoorGlassAdiustmentcont'd)

6. Raise he glass ully, and check or gaps.Check hatth e glass A) contacts he glass un channel B)

evenrv.

7. Check or water eaks.Ru nwaterover he roof an don the sealingareaas shown,and note hese tems:

. Usea 1 2mm (1/2 n. )d iameter ose A) .

. Adjust he rateof water low as shown {B).

. Do not use a nozzle.

. Ho ld he hoseabout 00mm (12 n. )awayf romthe door (C).

12mm1112in, l !

\e

Attach he plastic over,and nstallthedoor panel(seepage20-4).

9. Test-drive nd check or wind noise.

30 0mm {12 n. l

Door PositionAdiustment \

NOTE;Check or equalgapsbetween he front, rear,an d bottom door edgesan d he body.Check hat hedoor and body edgesar e parallel.

1. Place he vehicleon a firm, levelsurfacewhenadjusting he door.

2. Adjustat the hinges A) :

. Remove he front inner ender se epage20-102)and ront fender airing (seepage20-103).Loosen he hingemounting bolts B) slightly,an dmove he door backwardor forward,uDor downas necessaryo equalize hegaps.

. Place shop owel (C )on the ack (D) o prevent

damage o the door when adjusting he door.

t , 8x1 . 25m m29N.m (3.0 gf.m,22 tbt.trl

\



3. Check hat he door and body edgesar e parallel. f

necessary, djust he door cushions A) o make he

rearof the door flush with the bodv.

Apply body paint o the hinge mountingboltsan d

around he h inges.

Check or water eaks se estep7 on page20-12).

Test-drive nd check or wind noise.

5.

Door StrikerAdjustment

Make ure he door a tches ecure ly i thout lammin

it. lf necessary, djust he striker A):Th e strikernuts

are ixed,but he s t r i ker anbe ad jus ted l i gh t l y p or

down,andn or ou t .

1. Loosen he screws B) , hen nserta shop owel (C

between he body and striker.

Lightly lghten he screws.

Wrap he strikerwith a shop owel, hen adjust he

st r i ker y app ing t w i th a p las t i c ammer D) .Do

not ap the striker oo hard.

Loosen he screws,an d remove he shop owel.

Lightly ighten he screws.

Hold he outer handleout, and push he door

against he body o be sure he strikerallowsa

flush it, lf th e door atchesproperly, ighten he

screwsand recheck.

5.

6.

8 x 1 . 25mm18 N. m 11.8 gf m, 13 bf.f t)

20-



PowerMirror Replacement

1 .

2.

5.

Lower he door glass ully.

Carefully ry out he mirror mount cover (A )by

hand n th e sequence hown.Disconnecthetweeterconnector B),an d release he wire harness(C ) ro m th e hook(D).

Fastener ocation

) : Clip,1

3. Removehedoorpane l seepage20-4) .

4. Disconnectthe onnector A) ,and detach he

harness l i p B) .Whi leho ld ing he mi r ro r C) ,remove he nuts, h en remove he mirror.Takecare

not o scratch he door.

Fastener ocrtions

O:Nut .3

lnstall he mirror n th e reverse rder of removal,and note hese tems:

. Makesure he connector s plugged n properly.

. Attach he harness lip.

MirrorHolderReplacement

1. Care fu l l y u l lou t thebot tomedgeof the mi r ro r

holder A) by hand.Takecarenot o scratch he

mrr ror .

5 .

Separate he mirror holder rom the actuator B)by

slowly pull ing he m apartwhile detaching he clip(C). f equipped,disconnect he mirror defogger

connectors{D)rom the heaterpa d erminals.

lf equipped, econnecthe mirror defogger

connectors.

Reattachhe clipsof the mirror holder o the

actuator, he n position he mirror holderon the

actuator.Carefullypushon the clip portionsof the

mi r ro rho lder n t i l t hemi r ro rho lder ocks n to

prace.

Check he operationof the actuator

20-



Mirrors

RearviewMirror Replacement

1. Turn he mirrorbase A)90. neither irection.

Slide he rearviewmirror (A )down toward hebottom of the windshield, hen detach t from th espring B) n the mount (C),and remove herearviewmirror.Takecare notto scratch he mirrorDase.

3. lf necessary,emove he spring rom the mount.

2.

4, Fit he mirror baseover he mount,and secure hemirror by turning he base90".



Glass


PASSENGER'S IRSAGCAUTIONLABEL

FASTENER,2{Self-adhesive-type,lassside)

SIDERUBBER AM

WINDSHIELD IDETRIM

m-_-==}ln,S{|---..------'RErA'NER,6

f..N\tJ \e N8*?'CLIP,4Blue

CLIPINDSHIELDBeplacement,ag e20-19

SPOILERFASTENER,(Selt-adhesive-type)

LOWER UBBER AM

UPPER UBBER AM,4

(cont

4

'9>

LOWERRUBBER AM

20-



\


OUARTERLASS - UPPER LIPFRONT EAL

..,////

tsetl adhesive-typel

\n iT- \

/ J "n ll l/ / Pv I -

/LowER Lrp

.--"..---.-_

(Self-adhesive-type) bI€ARCLIP

(Self-adhesive-type)OUARTER LASSBeplacement,ag e 0-29

-.,--''

LEVEMBLEM( '03model)Replacement.ag e20-100



WindshieldReplacement

NOTE:. Puton gloveso protect ou rhands,. Weareyeprotection hile uttingheglass dhesive

withpianowire.. Use eat overso avoiddamagingheseats.

1. Removehesetems:

. Rearview irror se e ag e 0-16)

. Windshield iperarms see age22-145)

2. Pullup heside rim(A) o releaseheclips B) romtheretainersC) , ndpull he r imrearwardoreleaset rom hecliD D) hen emovehe rimfromeach ideof hewindshield.

4.

Remove he cowl covers se epage20-95).

Remove he molding (A ) rom the upper edgeof th

windshield B) . f necessary, ut he moldingwith autil i tyknife.

lf the old windshield s o be reinstalled,make

alignmentmarksacross he glassand body with a

greasepencil.

Pulldown the front portionof the headliner seepage20-54). akecarenot o bend he headliner

excessively, r yo u may creaseor break t.

Apply protectiveape along he edgeof the

dashboard nd body.Usingan awl, makea hole

through he rubberdam,adhesive. nd dashboar

seal rom inside he vehicleat the cornerponion o

th e windshield.Pusha pieceof pianowire through

th e hole,and wrap eachend arounda pieceof

wood.

(cont

7 .

20-



WindshieldReplacementcont'd)

Witha he lper n heouts ide , u l l t hep ianowi re A)backand orth n a sawing motion.Hold he pianowire as close o the windshield B)as possible opreventdamage o the body and dashboard.Carefully ut hrough he rubberdam andadhesive(C) round heent i rewindsh ie ld .

-A\, ,.-

,,t""""""""',-\i - . .

-1 : - , -

-= - . - -

10 . With a knife,scrape he old adhesive mooth o athickness f about 2 mm (0.08 n. )on the bondingsurfacearound he entirewindshieldopening

f lange:

. Do not scrapedown to the paintedsurfaceofthebody;damagedpaintwill interferewith proper

bond ing .. Remove he rubberda m and asteners rom the

oooy.

11. Clean he body bondingsurfacewith a spongedampened n alcohol.Aftercleaning, eepoil,greaseand water rom gettingon the cleansurface.

12. lf the old windshield s o be reinstalled, sea puttv

knife o scrapeof f all of the old adhesive, he

fasteners nd he rubberdam from the windshield.Clean he inside ace and he edgeof thewindshieldwith alcoholwhere new adhesive s tobe applied.Makesure he bondingsurface s keptfree of water,oil, and grease.

\



t 5 . Glue he side rubberdams (A )and ower rubber

da m (B)with adhesive ape (NITTO 01M,orequivalent).Glue he fasteners C)with adhesive

tape (3 M 4215,or equivalent)o the inside aceofthewindsh ie ldD)asshown:

. Be sure he rubberdams and asteners ine uD

wi th he a l ignmentmarks E) .. Be carefulnot o touch he windshieldwhere

adhes ive i l l be aoo l ied .

t 3 .

14. G lue he mold ing A)wi thadhes iveape B)(3M4212, r equ iva lent ) tohe upper dgeof the

windsh ie ldC) ;

. Besure he a l ignmentmark D)o f he mold ing

l ines p wi th hea l ignmentmark E) f he

windsh ie ld .. Be carefulno t o touch he windshieldwhere

adhes ive i l l beapp l ied .

Install he fasteners A), etalners B,C) ,and clips(D) o lhe body.

Fastener ocations

A>:Fastener .2 B>:Reta iner ,2

q\C>: Reta iner ,6O> :Cl ip ,2

(cont'

20-



19. With a sponge,apply a lightcoat of body primer othe originaladhesive emainingaround hewindshieldopening lange,Let he body primerdr y

fo r at east10 minutes:

. Do not applyglassprimer o the body,and be

carefulnot o mix up glassand body primer

sponges.. Never ouch he primedsurfaceswith your hands.. l\4ask ff the dashboard eforepaintingthe

f lange.

20mm(0.79n.l

Before i l l ing a cartridge, ut a "V " in the end of the

nozz leA)asshown.20.

12 mm (0.47n. )

7 mm {0.27n. )

21 . Packadhesive nt o he cartridgewithout air pocke

to ensurecontinuous elivery.Put he cartridge n

caulkinggun,and ru n a beadof adhesive A)

around he edgeof the windshieldB)

between hedams C)andmold ing D)asshown.App ly he

adhesivewithin 30 minutesafterapplying he glas

primer.Makea slightly hickerbeadat eachcorne

l'1fifr.,1:? m m n10.28n.l ,..-

A . .) t

$?I.",x1"u.80trl

., r []\"Inside

- '

A

Usesuct ion ups o ho ld hewindsh ie ld ver he

open ing , l i gn t w i th hea l ignmentmarksmade n

step 16,and set t down on the adhesive. ightlypushon hewindsh ie ld n t i l t sedges re u l l y

seated n he adhes ive l l t heway around.Do not

openor close he doors until he adhesive s dry.

c.. N\ F 12 m m I n l{0.08n. }

'Zl

. / "

(cont'

20-



Glass

23.

24.

WindshieldReplacementcont'd)

Scrapeor wipe the excess dhesive ff with a putty

knifeor towel.To removeadhesive rom a painted

surfaceor the windshield,wipe with a so ft shop

towel dampensdwith alcohol.

Let he adhesive ry for at east hour, hen spraywaterover he windshieldan d check or leaks.Mark eakingareas,an d et he windshielddry, hensealwith sealant:

. Let he vehiclestand or at least4 hoursafterwindshield nstallation.f the vehiclehas o beusedwithin the first 4 hours, t must be drivenslowly.

. Keep he windshielddr y fo r th e first hour afterinstallation.

Reinstallthe owl covers se epage20-95).

NOTE:The owl coverclips may not set properly fthe windshieldadhesive s oo wet.

Install he clips(A, B) on b othside rim {C). f theclip (D ) s damaged, eplace he side rim and clipsas an assembly.

A: GreyB:Blue

27. On both sidesofthe windshield, nstall he sidetrim (Alto the clip (B), hen set he bottom edge ofthe side rim over he cowl cover(C),an dalign he

c l ipsD)wi th

he re ta inersE) ,

ndpushon he c l ipportionsof the trim until he trim is ully seatedonthe w indsh ie ld .

Re ins ta l ll l remain ingemoved ar ts . ns ta l l t herearviewmirror after he adhesive asdriedthorough ly .

NOTE:Advise he customernot o do the following

things or 2 to 3 days:

. S lam hedoorswi tha l l t hewindows o l led p .

. Twist he body excessivelysuchas when going

in andout o f d r i veways t an ang le r d r i v ingover rough,uneven oads).

28.



RearWindow Replacement

NOTE:. Put on gloves o protect our hands.. Wearey e protectionwhile cutting he glassadhesive

wi thp ianowi re .. Us eseatcovers o avoid damagingany surfaces.. Do not damage he rearwindow defoggergrid lines

and erm ina ls .

1 . Remove hese tems:

. Hatch ower rim panel seepage20-53)

. Hatchspoiler se epage20-99)

Remove hese tems:

. High mount brake igh t {seepage22-821

. Rearwindow wiper motor {seepage22-1461

Disconnecthe rearwindow defogger onnectors(A).

4. l f the o ld rearwindow is to be reinstalled,make

alignmentmarksacross he glassand body with agrease encr l ,

Apply protectiveap ealong he insideand outside

edges f hehatch .Us ingan awl ,makea ho le

through headhes iverom nsideheveh ic le t he

cornerportionof the rearwindow. Push he piano

wi re hrough he ho le , ndwrapeach ndaroundpieceof wood,

6. With a helperon the outside,pull he pianowire (A

backan dJorth n a sawingmotion.Hold he piano

wire as close o the rearwindow (B )as possible o

preventdamage o the hatch,an dcarefully utth rough he adhes iveC}around heent i re ear

Cutting positions:

7 . Care fu l l yemove he rearwindow.

(cont'

20-



Glass

RearWindow Replacementcont'd)

With a puttykniie.scrape he old adhesive moothto a thickness f about 2 mm (0.08 n. )on thebondingsurfacearound he entire earwindowopening lange:

. Do not scraDe own to the Dainted urfaceof thebody;damagedpaintwill interferewith proper

bonding. Remove he fasteners rom the ailqate.

Clean he hatchbondingsurfacewith a spongedampened n alcohol.After cleaning, eepoil,greaseand water rom gettingon the surface,

lf the old rearwindow is o be reinstalled, se aputtyknife o scrapeoff all of the old adhesive,hefasteners nd he rubberdams rom th e rear

window. Clean he nside acean d he edgeoi therearwindow with alcoholwhere new adhesive s obe applied.Makesure he bondingsurface s keptfree of water,oil and grease.

1 0 .

20-26

11. Glue he s ideupper as tenersA)ands ide lowerfasteners B)with adhesive ape 3M 5312,orequ iva len t ) . lue heupper ubber ams C)wi th

adhesive ape(NITTO

01fM, r equivalent) ndglue he lower rubberda m (D )with adhesive ape(3M 4216,or equivalent)o the nside aceof th erearwindow (E)as shown.Before nstall ing helower rubberdam, applyprimer (3 M N-200, requivalent)o the areasbetween he alignmentmarks F) , he n glue he rubberdam on. fnecessary, lu e he spoiler asteners G)with

adhesive ape (3 M 5671,or equivalent)o theoutside aceof the rearwindow:

. Be sure he side upper asteners, nd upperrubber ams ineup wi th a l ignmentmarks H, ) .

. Besure both endsof the ower rubberdam line

up with the edgeof the glass,. Be sure he spoiler asteners ine up with

a l ignmentmarks J) .. Be carefulno t o touch he rearwindow where

adhes ive i l l be aDol ied .

1,1,.,1,'Applyprimerhere.

E

"6'J1r-,G



12 . Glue he side upper asteners A)andsidelowerfasteners B)with adhesive ap e(3M 5312,orequivalent)to he hatchas shown.

Fastoner ocations

A>: Fastener, B>: Fastener,

T-8.cl

a r \ \

i t f ,

t 5 . Set he rearwindow in the opening,and center t.Align he clips(A )of the rearwindow with the holesin heopen ing lange.Make l ignmentmarks B)

across he rearwindow, hatch,and bodywith agreasepencilat th e four pointsshown. Be carefulnot o touch he rearwindow whereadhesivewillbeapp l ied .

14 . Removehe rearwindow.

15. Wi tha sponge, pp lya l i gh t oa to f g lass r imer

along he edgeof the rearwindow (A),upperrubberdams (B),an d ower rubberdam (C )as

shown, hen ightlywipe it off with gauzeorcheesecloth:

. With the printeddots(D)on the rearwindow as aguide,apply he glassprimer o bothsideportionsof the rearwindow.

. Do not apply body primer o the rearwindow,an d do not ge t hatchan d glassprimerspongesmixedup.

. Never ouch he primedsurfaceswith your handlf yo u do, he adhesivemay not bond o the rearwindow properly. ausinga leakafter he rearwindow s ns ta l led .

. Keepwater,dust,and abrasivematerialsaway

from the primedsurface.

.. : Applyglasspiimerhere.

(cont '

20-2



Glass

16 .

RearWindow Replacementcont'd)

With a sponge,apply a l ight coat of body primer otheor ig ina l dhes iveemain ing round he rearwindow opening lange.Let he body primerdry for

at east 10minutes;

. Do not applyglassprimer o the body,and be

carefulnot o mix up glassand body primer

sponges.. Never ouch he primedsurfaceswith your hands.

',,,,, ': Apply odyprimer e.e.

20mm10.79n. l

2 m m{0.08 n. )

17 .Before i l l ing a cartr idge, ut a"V " in the end ofthe

nozzle A} as shown.

7 mm (0.27n. )

I18. Packadhesive nto he cartridgewithout air pockets

to ensurecontinuousdelivery.Put he cartridge n a

caulkinggun, and run a beadof adhesive A)

around he edgeof the rearwindow(B)

as shown.With the glassprimer (C)you applied n step 15asa guide,apply he adhesive o both sideportionsof

the rearwindow.Apply he adhesivewithin 30 minutesafterapplying he glassprimer. Make slightly hicker

beadat eachcorner.

12 mm r,10.47n. ) ,\

ii'-A (0.28n. l

\

aru'.1{-----"



19 . Use suctioncups o hold he rearwindow over heopening.align t with th e alignmentmarksyou

made n step13 ,

and set t down on the adhesive.

Lightlypush

on the rearwindow until ts edgesarefully seatedon the adhesive ll he way around.Donot open or close he doorsuntil he adhesive s dry.

20. Scrapeor wipe the excessadhesive ff with a putty


surfaceor the rearwindow, usea soft shop oweldampenedwith alcohol.

21 . Let he adhesive ry for at leastlhour,thenspray

water over he rearwindow and check or leaks.Mark he eakingareas, et he rearwindow dry,then sealwith sealant. et he vehiclestand or atleast4 hours after earwindow installation,f th e

vehiclehas o be usedwithin the first 4 hours, tmust be drivenslowly.

22 . Re ins ta l la l lemain ingemoved ar ts .

NOTE:Advise he customernot o do the followingthings or 2 to 3 days:

. S lam he doorswi th a l l hewindows o l led p.

. Twist he body excessivelysuchas when going

in andout o f d r i veways t an ang le r d r i v ingover rough,uneven oads).

OuarterGlassReplacement

NOTE:. Pu ton gloves o protectyour hands.. Wear eye protectionwhile cufting he glassadhesiv

with pianowire,. Use seatcovers o avoid damagingany surfaces.

1 . RemoveheC-p i l l a rr im (see age20-51) .

lf necessary,emove he rearside rim panel se e

page20-51 and B-pil larupper rim (seepage20 -50) .

2. Remove he front seal A) ro m th e front edge of thglass B) . f necessary, ut he sealwith a uti l i tyknife.

(cont'

20-



Glass

3.

OuarterGlassReplacementcont'dl

Apply protective ape o along he insidean d

outsideedgesof the body.Usingan awl, makeahole hrough he adhesive rom insid e he vehicle.Pusha pieceof pianowire through he hole,an dwrap eachend arounda pieceof wood.

With a helperon the outside,pull he pianowire (A )

backan d orth n a sawing motion. Hold he piano

wire as close o the quarterglass B) as possible opreventdamage o the body,and carefully utthrough he adhesive C)around he entirequarter

grass.

Cuttingpositions:

5. Carefully emove he quarterglass.

20-30

6. With a putty knife,scrape he old adhesive moothto a thickness f about2 mm (0.08 n. )on thebondingsurfacearound he entirequaner glass

open inglange:

. Do not scrapedown to the paintedsurfaceof the

body;damagedpaintwill interferewith proper

bonding. Remove he clips rom the body.

Clean he body bondingsurfacewith a spongedampenedn a lcoho l . f t e r lean ing . eep i l ,greaseand water rom gettingon the surface.

lf the old quarterglass s o be reinstalled, se aputty knife o scrapeoff all of the old adhesive nd

th e rubberda m from the glass.Clean he inside

faceand he edgeof the glasswith alcoholwherenew adhesive s to be applied.Makesure hebondingsu face s kept ree of water,oil, andgrease.

7 .



9. Set he quarterglass A) n the opening,and centeri t .F rom ns ide heveh ic le ,make n a l ignmentmark(B) o the quarterglasswhere he rearclip will beinstalledwith a greasepencil.Be carefulno t olouch heg lasswhereadhes ive i l l be app l ied .

10. Remove he quarterglass.

11 . A l ign he upper l i p A)and ower l i p B)wi th he

edgeof the quarterglass C) , hen anach hem witadhesive ape (NITTO 71 ,or equivalent)o theinside aceof the quarterglass,and align he centof the rearclip (D )with the alignmentmark (E )yo u

made n step9, and attach t with adhesive ape (3

M 4215,or equivalent)o the inside ace of thequarterglassas shown.Be carefulno t o touch heglasswhere he adhesive ape will be applied.

25.5mm{1 . 0n . )

(cont'

20-



OuarterGlassReplacementcont'dl

Firstglue he front seal A)with adhesive ape {31\44213, r equ iva len t ) .ndg lue he rubber am (B)

with adhesive ape (NITTO 01M,or equivalent)oth e nslde ac eof the quarterglass C)as shown.Before nstall ing he front seal and rubberdam,

app lypr imer 3MN-200, r equ iva len t ) tohe ns idetaceof the glass. he n glue he sealon :

. Be sure he front seal inesupwiththe bottomand ront edgesof the glass.

. Be carefulnot o touch he glasswhereadhesivewi l l beaoo l ied .

.,1.,,/:/ ApplyprlJnerhete.

-"-c

i--l'100mm{3.9i1in.)

45 mm{1 . 77n . }

3. 5mm{0.r4 n. l

30mm

11.18n. l50mm I{1 .97 in .1/

\ t

6 mm (0.24n.)

n Lv - -

'13.With a sponge,apply a lightcoatof glassprimer

along he edge of the rubberda m (A )and ront seal(B )as shown, hen lightlywipe it off with gauzeor

cheesecloth:

With th e printeddots (C )on the quarterglass D)

as a guide,apply he glassprimer o the upperand ower cornerponionsof th e quarterglass.

Do not apply body primer o the quaner glass,

and do not ge t body and glassprimersponges

mrxed p .Never ouch he primedsurfaceswith your hands.lf you do, he adhesivemay not bond o thequarterglassproperly, ausinga leakafter hequarterglass s inslalled.

Keepwater,dust,and abrasivematerialsawayfrom th e primed surface.

11mmlo.i(} n. )



14, With a sponge.apply a light coat of body primer otheor ig ina l dhes iveemain ing round hequar te rglassopening lange.Let he body primerdry for atleast10minutes:

. Do not applyglassprimer o the body,and becarefulno t o mix up glassand body primer

sponges.. Never ouch he primedsurfaceswith your hands.

)'/ii,/ii. I Apply bodv prime.here,

mm(0.08n. l

20mm(0.79n. )

2 m m{0.08n. )

Before i l l ing a cartridge, ut a "V " in the end ofthenozzle A) as shown.

'10mm (0.39 n. )

20mm{0.79n. )

t 5 .

7 mm 10.27n. )

20-3

16. Packadhesive nt o he cartridgewithout air pocke

to ensurecontinuousdelivery.Put he cartridge ncaulkinggun, and run a beadof adhesive A)

around he edgeof the rubberdam (B) as shown.Wi th heg lass r imer C)youapp l iedn step13onth e quarterglass D)as a guide.apply he adhesiv

to the upperan d owercornerportionsof thequarterglass.Apply he adhesivewithin 30minutesafter applying he glassprimer. vlakeslightly hickerbeadat eachcorner.

l.:J611,\7 m m{0.28n. )

3 m m

{0.'12 n. }

I

I

( con l ' d



Glass

OuarterGlassReplacementcont'd)

17 . Use suctioncups (A)to hold he quarterglassoverthe opening.align t with the clips(B)and set tdown on the adhesive. ightlypushon the quarterglassuntil ts edgesare ully seatedon th e

adhesive ll the way around.Do not openor closethe doors untilthe adhesive s drv.

18. Scrapeor wipe the excessadhesive ff with a putty


surfaceor the quarterglass,us ea soft shop owel

dampenedwith alcohol.

19. Let he adhesive ry for at east hour,thenspray

water over he quarterglassand check or leaks,

Mark he leakingareas, et he quarterglassdry,then sealwith sealant. et he vehiclestand or at

least4 hoursafterquarterglass nstallation.f thevehiclehas o be usedwithin the first 4 hours. tmust be drivenslowlv.

20. Reinstall l l remaining emovedparts.

NOTE:Advise he customernot o do the following

things or 2 to 3 days:

. Slam he doorswith all the windows rolledup .

. Twist he body excessively suchas when going

in an dout of drivewaysat an angleor drivingover rough,uneven oads).

20-34



Moonroof


WINDDEFLECTORReplacement,ag e20-38

GLASS

HeightAdjustment, ag e20 37Replacement,aq e20-37C los ino o rce ndOoen ino raoCheck; ag e20-48

"

DRAINCHANNELReplacement,ag e20-39

,5

?a<&,@

..t'-?

.@-@c

_ a

@

/,BR^CKEI

COVER

LIMITSWITCH(AUTO.STOPWITCH)Adjustment,age 0-46E R

I

CABLE UBEREARBRACKE

E

@

E STOP.a'

MOONROOFCONTROL NIT

FRAMEReplacement,ag e20-42

CABLEASSEMBLYBeplacement, ag e20-44

* \

)REARDRAIN VAI-VE

_-""-\\q

Replacement,ag e20'41

gJ-.- REARDRA'NTUBE

20-3




Symptom Diagnostic rocedure Also check for

Water eaks'1 .

Check or a cloggeddrain ube.

2. Check or a ga p between he glassweatherstrip nd he roofpane l .

3. Check or a defective r an improperly nstalled lass

weathers t r ipr dra inchanne l .

4. Check or a ga p between he drainsealand he roof panel.

G ass e igh t

adJustment

Windnolse 1. Check or excessive learance etween he glassweatherstrip

and he root panel.

G lass e igh t

adjustment

Deflector oise 1. Check or a imDrooer learance etweendeflector ea lan d

roof panel.

2, Check or a insufficient eflectorextension.

3. Check or a deformeddeflector.

Motor noise 1. Check or a loosemotor.

2 . Checkor a worngearor bear ing .

3. Check or a deformedcableassembly.

Check losing orce

Glassdoesnot move,

but motor turns

1. Checkor a de fec t i ve earor inner ab le .

2. Check or foreign matterstuckbetween he guide rail an d he

s l ide .

3 . Checkor a loose nner ab le .4. l\,4akeure he cableassembly s attachedproperly.

Glassdoesnot move

an d motor doesno l

tu rn g lass anbe

movedwithmoonroofwrench)

1. Check or a blown use.

2. Check or a faulty moonroof switch.

3. Check he limit switch.

4. Check or a run down battery.5. Check or a defectivemotor.

6. Check or a faulty relay.

20-36



GlassHeightAdjustment

The roof panel A) shouldbe evenwith th e glassweatherstrip B) . o within 2*0.5/ 1 mm (0.08+0.02l

0.04 n.)all the way around. f not,make he followingadjustment:

B

2 + 0 . 5 / 1m m{0.08+ 0.02/-0.0i1 n.}

2.

1 ,

\ o

Remove he bracket over rom eachside.

Loosenhe nuts A) , nd nsta l l t he h ims B)

between he glass rame (C )an dglassbracket D)

on eachside.

Shim hickness: Frontand rear max. 2 mm 10.08n.l

Forward

A6 x 1 . 0 m mI N.m 0.9 gf.m,7 bt.ft)

3. lf necessary,epeaton the oppositeside.

B

\

GlassReplacement

'LC lose heg lass u l l y .

S l ide hesunshade l l t heway back.

Remove he screws A), hen removeboth bracketcovers B).Remove he nuts (C )and shims{D ) ro m

both glassbrackets E) .

Fastengr ocations

c O ,

6 x 1 . 0 m m9 N.m{0.9 gf.m,7 bf.ft}

4. Remove he glass A) by lift ing t up. Do notdamage he roof panel.

5. Install he glass n th e reverseorder of the remova

andad jus t heg lass

e igh t l i gnment .

6. Check or water eaks.Use ree-flowingwater roma hosewithout a nozzle.Do no t use high-pressurewater.

Nut. il

@A } : Screw, 2

E

20-3



Moonroof

WindDeflectorReplacement

2 .

1 . Open heg lass u l l y .

Remove he screws A, B),an d release he hooks(C),

hen remove he wind deflectorD) .

FastenerLocations

A>: Sc r ew, 2 B> : Screw, 2

20-38

3. Installthedeflector A) n th e reverse rder ofremoval,and check hat he deflectorarm base B)

an d deflector ink pivot base C) ine up with the

sameal ignmentinesD) .

f necessary ,d jus t hemforward or backward o the edgeof the deflectorseal E) ouches he roof panel F)evenly.Each

basemust be moved he same amount or

adjustment. f the deflector ealand roof panel

makea rubbingsound,move he deflectorbackwardas necessaryo position t properly.

4il mm(1 . 7n. )_ - l

' a - ' -

\



1 .

2 .

DrainChannelReplacement

Remove he moonroofglass se epage20-37).

With th e moonroofwrench,move both glass

bracketsA)

o th eposition

where he moonroofnormallypivotsdown, and remove he screwssecur inghedra in hanne l B) .

Fastener ocations

) : Screw,

@

Releasehe drain channel A) rom both hooks B)o f he dra in hanne l l i der y pu l l i ng he dra inchannel orward,

4 . Removehedra in hanne l A) .

Ins ta l l t he hanne ln he reverse rdero f remova


Push hedra in hanne l n to he hooks n t i lafaint click s heard.

Check he glassheightadjustment seepage20-

31).

Check or water eaks.Let he water run reely rom

a hosewithout a nozzle.Do not use a high-pressuspray.

20-



Moonroof

Sunshade eplacement

1 . R e m o v ehedra in hanne l .

Slide he sunshade A)until you can see both

sunshade l ider pacersB) .

Fastener ocations

> : Screw,4

tF

3. Remove he screws, hen remove both spacers.

20-40

4. While ift ing he front portionofthe sunshade A) ,

move he sunshade orward untilyo u can see both

sunshadeearhooks B) .Do notdamage he

sunshade ndhooks.Fastener ocations

) : Screw,

(F

5. Remove he screws, hen removeboth hooks.

\



6. Remove he sunshade A),

::lll'=r'"'---

----.-..-.,

\ 'l'i

? ,

7 . Rem oveboth ront sunshade asesliders A)an d

both ear unshade ase l i ders B)

t ' - ^ '

' a {

8.

9 .

Ins ta l l t he unshaden he reverse rdero f remova l ,

an dcheck he glassheightadjustment seepage

20-37 .

Check or water eaks.Let he water run reely rom

a hosewithout a nozzle.Do not use a high-pressure

spray.

1 .

Motor Replacement

Remove he headliner seepage20-54).

Pu ton gloves o protectyour hands.Disconneclheconnector A) ,and remove he bolts, hen remove

the motor (B).

Fastener ocations

> : B o l t , 2 A

@@

. .

{0.9 gf.m.7 rbf.ftl

Installthemotor n th e reverseorder of removal,

and note hese tems:

. lvlake ure the connector s plugged n properly.

. Check he motor operation.

20-



1 .

Frame ndDrainTubeReplacement

Remove hese tems:

. Headliner se epage20-54)

. Moonroofglass seepage20-37)

Pu ton gloves o protect ou hands.Disconnecthe motor connector A) ,open/close-ti lt/closewitchconnector

{B),moonroofcontrolunit connector C) ,auto-stop witchconnector D) ,and h e drain ubes Ei,and remove hemoonroofelaysF) .

FastenorLocations

> :Bolt, 0

{um

/^

6 x 1 . 0 m m9. 8N. m(1.0 gf.m,7.2lbft)

4 .

5.

2.

i r l

@

Remove he interiorharness G)by detaching he harness lips(H).

With an assistant olding he frame (l). emove he bolts,startingat the rear,and release he rearhooks J)bymoving he f rame orward, he n remove he frame.

With the help of an assistant, arefully emove he frame hro ugh he passenger's oo r opening.Takecare not oscratch he interior rim and body,or tear he seatcovers.



6. To removea front drain valve(A)from the body,remove he kickpanel, eft or right (seepage20-50).Tie a string o the end of the drain ube, hen pull

th e front drain ub e (B )down out of the front pil lar.

To removea reardrainvalve (A ) rom the cargo

compartment, emove he rearside rim panel see

page 0-51) .Detachhec l ips B) , hen emove he

dra in ube C) ,

B

1 .

8 . Ins ta l l t herameanddra in ube n he reverse rd

of removal,and note hese tems:

. Beforensta l l i nghe rame, lear he dra in ubean d drainvalvesusingcompressed ir.

. Check he frame seal.

. C lean hesur face f the rame.

. When nstall ing he frame, irst attach he rear

hooks nto he body holes.. Makesure he connectors re plugged n

properly.. When connecting he drain ube, slide t overth

f ramenozz le t east 0mm (0.39n. ) .. I n s t a l l t h e t u b e c l i p ( A )n h ed r a i n u b e B ) s

shown.

Upward

t -II

B

Check or water eaks.Let he water run reely roa hosewithout a nozzle.Do not use a high-press

spray.

9 .

20



Moonroof

DrainChannel liderandCableAssemblyReplacement

1. Remove he frame (seepage20-42).

2. R emove heseparts rom the frame:

. Sunshade seepage20-40)

. Moonroof motor (seepage20-41)

3. Pu ton gloves o protectyour hands,Remove hescrews A, B), hen remove he slidestops C)an dcable ube rear brackets D) .Remove he bolts E)

from the cable ube side bracket F)an d he cabletube mountingscrews G) rom both sidesof thef rame H) .

Fastener ocations

A> rScrew.2 B) : Screw,2

@ @r ) :

Position switch side:

6 x 1 . 0 m mA c g ,aN .m

No switch sidel

o

E > : B o l t , 2

Screw

6\-'1

6 x 1 . 0 m m C9. 8N. m11.0 gf.m,7.2 bf.f t)

Detach he onen switchconnector l ip {l)from th eframe.

B

V

5. P ivo t the lass racketA)down by s l id ing he inklifter B)back, h en slide bothglassbrackets ackwith the link ifter.

S l ide hecab le ssemblyA)and bothg lass

brackets B) back, he n remove hem from thef rame C) .



7. Removehedra in hanne l l i der (A)romtheg lass

bracket B) .8 . Ins ta l l t he l i der ndcab le ssemblyn he revers

orderof remova l , ndnote hese tems;

.Damaged ar ts hou ld e rep laced.' Apply multipurpose rease o the glassbracket(A)andgu ide a i lpor t ion f he rame B)

indicated y the arrows.. Before einstall inghe motor,makesure both

l ink i f t e rs repara l le l , nd n he u l l yc losedposition.

. Before einstall inghe motor, nstallthe rame

andg lass,hencheck heopen ing rag see ag

20-481.

B ---

\ -':rdrt'Irrt

\ f l u,t L-----lll a/J' I lll$=-r:-

20



Moonroof

Limit SwitchAdjustment

1. Remove he headliner se epage20-54).

Fullyclosedpositionadiustment

2. With the moonroofwrench,close he glass A) ully:

. Makesure both l ink ifters B)ar e parallel, nd n th e positionshown.

. Check he g ass it to th e roof panelan d he glassheight seepage20-37).

5 x 0 . 8 m m5 N.m {0.5 gf.m,4lbf. f t)

3. Wi than open-end rench, oosen he im i tswi t chmount ing o l t s C) .

4. Adjust he limit switch(D):

' Move he switchplate E)a litt leat a time, hen secure t atthe positionwhereyo u heara faint clickwhen th eswitchca m (F)pushes he positionswitch(open/close).

.Check hat he switchplatecontacts he switch bracket G) .

20-46



Auto-stoppositionadiustment

5. With the moonroofwrench.operate he glass A) o the auto-stop osition.

With an open-endwrench, oosen he auto-stop witch

Adjust he auto-stop witch(D):

5 N.m {0.5 gt.m,4 bt t)

m oun t ing bo l t s C) .

. N4ovethewi tch la te E) l i t t l ea ta t ime, thensecure i ta t thepos i t ionwhereyouheara fa in tc l i ckwhenth

switchcam (F )pushes he switch(auto-stop).

. Check hat he switchplatecontacts he switch bracket G .

Check he operation f the glassby operating he moonroofswitch:From he ti lt-upposition o the fully closed

position, rom the fully open position o the auto-stop osition, rom the auto-stop osition o the fully closed

pos l t ron .

Check or water eaks.Let he water run leely rom a hosewithout a nozzle.Do not us e a high-pressure pray

/--:.!Jtr+rtl

\_-_:_t+#1 <F. / \

, / \G i ! . . I

7 .

8.

L

20-



Moonroof

\

Closing orce ndOpeningDragCheck

1. Removehe head l inersee age 0-54) .

2. Closing orcecheck:

. With a shop owel {A) on the eadingedgeof theg lass B) , f tach spr ing ca le C) s shown.

. Havean assistant old he switch o close heglasswhile yo u measure he force required ostop t.

. Read he forceas soon as he glassstopsmoving,then mmediately eleasehe switchand springscale.

Closing Force; 200 290 N (20 30 kgf,44 66 tbl)

lf the force n not within specification,emove hemoonroof motor (seepage20-41),he n check:

. Th e gear portionand he innercable or breakagean d damage. f the gearportion s broken,rep lacehe motor . f he nner ab le s damaged,remove he frame (seepage20-42), nd replacethe cableassembly se epage20-44).

' Themoonroofmotor see age22-112) .f themotor ails o ru n or doesn't u rn smoothlv.replace t (seepage20-41),

. Th eopeningdrag.Go o step 4.

4. Openingdrag check:Protect he eadingedgeof theglasswith a shop owel (A).Measure he effortrequired o open he glassusinga springscale B)

as shown.

5 . lf the oad s over 40 N (4 kgf,9 lbf),check;

. Th e sideclearance ndglassheightadjustment(seepage20'37),

. Forbroken r damaged l id ing ar ts . f anys l id ing ar ts redamaged,ep lacehem.



InteriorTrim


HATCH OWER RIM PANELoaoe 0-53

HATCHSIDETRIMpage 053

C-PILLARRIMpage 0'51

REARSIDESHELFpage20 5l

REARSIDETRIM PANEL

page20-51

B.PILLARUPPEBTRIMpage20-50

DOOROPENING RI Mpage20-50

A.PILLAR RIMpage 0-50

Rem ova l / l ns t a l l a t i on ,age 0 54

KICKPANELpage20 50

DOORSILLTRIMpage20-50

Replacement,page20-55

CARGOAREAFLOORpage20-52

REARCENTER HELFpage20-51

CARGOFLOORMAT

page20-52

REAR RI MPANELpage 20-52

20



InteriorTrim

Trim Removal/lnstallationDoorArea

NOTE:. Puton gloves o protectyour hands.. When pryingwith a flat-t ipscrewdriver,wrap it with protective ap e o preventdamage..

Takecare not to bend or scratch he trim an d panels.

1 . Removehe r im as shown. o remove hedoors i l l t r imand B-p i l l a r pper r im , emove he ear ide r im pane las necessaryseepage20-51).

2. Installthe rim in the reverse rder of removal,and note hese tems:

. Rep lace nydamaged l ips .

. Apply l iquid hread ock o the anchorbolts before einstallatior,.

. Before nstall ing he anchorbolts,makesure hereare no twists or kin ks n the belts.

Fastenerocations

B > r C l i p , 3 C > : C l i p , ?{White)

FRONT EATBELTUPPERNCHOR OLT7/16-20 NF32N m (3.3 gf m,24 bf.ft)

A-PILLAR RIM

il-::7/

ao----- LowER NcHoRAP

FRONTSEAT BELTLOWERANCHOR OL T7/16-20UN F32 N.m (3.3 gt.m,24lbl. f t l

,"lF\r{

A>: Cl ip ,2(B lack )

2ffiTl|t

\

KICKPANEL

REARSIDETRIMPANEL



Trim Removal/lnstallationRearSideArea

NOTE:. Pu ton gloves o protectyour hands.. When pryingwith a flat-t ipscrewdriver, rap it with protective ape o preventdamage.

. Takecarenot o bend or scratch he trim and panels.

'1 .To remove he rearside rim panel, emove hese tems:

. Rearseatcushionand rearseat-backse epage20-80)

. Cargo loor mat and cargoarea loor (seepage20-52)

. Rear r im pane l see age20-52)

Remove he trim as shown.On the right side,disconnect he cargocompartment ight connector.

Installthe rim in the reverse rder of removal,and note hese tems:


. Makesure he cargocompartment ight connector s plugged n properly.

. l f t he threadsontherears ide t r impane lmount ing e l f - tapp ingTscrews rewornout ,useanovers izede l f -

tapp ingETscrew P/N 0137-S1A-Eo1)madespec i f i ca l l yor h isapp l i ca t ion .. When nsta l l i nghe rear ide he l f , l i p herear eatbe l t h rough he s l i t n he r im .' App ly iqu id hread ockto he anchor o l t sbefore e ins ta l la t ion .. Before nstall ing he anchorbolts,makesure here areno twistsor kinks n the belt.

2 .

3.

Fasten€r Locations

A > : C l i p , 1 1 B > r C l i p , 2

SELF-TAIscREws5 x 0 . 8 m m

{0.4 gf m,3lbf. f t)

REARBULKHEAOCOVER

TRIM

SIDESHELF

REARSEATSELT

SIDETRIM PANEL

SEATSTRIKER AP

FRONTSEATAELTLOWERANCHORBOLT7/16-20UNF32 N.m{3.3 gf m,24lbt.t t)

c > r C l a p , l

-..:.:'

SILLTRIM

. F . - * - . n \ : : : : \,/\ I

,/\*J REARSEAT BELTLOWER \

ANCHOF BOLT \7/16-20UNF \32 N m (3.3kgf m, 24 lbf ft, \

LOWERREARSPEAKERCOVER

ANCHORCAP

20-



lnterior rim

TrimRemoval/lnstallationCargoFloorArea

NOTE:. Put on gloves o protectyour hands..

Whenrying with a flat-t ipscrewdriver,wrap it with protective ape o preventdamage'

. Takecarenotto bend or scratch he trim an d panels.

1. To remove he rear r im pane l , emove hech i ldseat e ther nchor see age23-11) '

2. Remove he trim as shown.

3 . Ins ta l l t her im n he reverse rdero f remova l , nd ep lace nydamaged l ips '

FastenerLocations

A> :Cl ip ,3 B> :

REARSEAT-BACK OVER

To rearside rimpane l .

C l i p . 4

j-=E T r

\t FLOORMAT

-t

CARGOAREA FLO

7To rearsadet r im pane l .

20-52

REAR BIMPANEL



Trim Removal/lnstallation HatchArea

NOTE:. Puton gloves o protectyour hands.. When pryingwith a flat-t ipscrewdriver,wrap it with protectiveape o preventdamage.

. Takecare not o bendor scratch he trim and panels.

1. Remove he trim in th e sequence hown.

. Hatchupper rim panel

. Lefthatchside rim

. Righthatchside rim

. Hatch ower rim panel

2 . Ins ta l l t her im n he everse rdero f remova l , nd ep lace nydamaged l ips .

Fastener Locations

A>;crip,a B>:crip,2 .>,l, l,Ji l, l3>3il;1,

E>:crip.2

"-{q .1 n n itr^Y , ] . g g l f l tO HATCH owERTRrM

PANELHATCH OWER RIMPANEL

a- ,,)It7,f .

) a =- -1 a ->

HATCH UPPER RIM PANEL

HATCHSIDE RI M

.D HATCHUPPER RIM PANEL

20



Trim

Headliner emovaUlnstallation

NOTE:. When pryingwith a flat-t ipscrewdriver,wrap itwith

protectiveape o preventdamage.

. Takecare no t o bend and scratch he headliner.. Becarefulno t to damage he dashboard nd otherinterior rim.


. A-pil lar rim, both sides seepage20-50)

. B-p i l l a r pper t r im , o ths ides see age20-50)

. Hatchweatherstrip, s necessary se epage20 -92\

. C-p i l l a rr im ,boths ides see age20-51)

. Moonroofswitch(seepage22-'112)

. Spotlights seepage22-961

. Ceiling ight (seepage22-96)

Remove he sunvisor A)and holder B) ro m bothsrdes.

-1 Remove he caps C) .-2 Remove he screws.-3 Remove he sunvisor rom the body and holder.-4 Usinga flat-t ipscrewdriver, ush he hook(D),

and urn he ho lder 0 ' . henpu l l t ou t .

Fastener ocations

> : Screw,4

r(\'-r

\)*

5 x 0 . 8 m m5 N . m{0.5 st m.4lbf f t}

3. From both rearpassenger's,emove he caps A) ,

an d remove he screws, hen remove he grab

hand lesB) .

Fastener ocations

> : Screw,

t , t;---iJ

)e

5 x 0 . 8 m m4 N.m{0.4kgf.m, 3 lbf.ft}



4. Remove he headliner.

-1 Remove he socketplug (A).

-2 Removehe remain ing ooropen ing r im {B}from each oo f portion.

-3 Detach he clips C) ,and release he fasteners(D)by pu l l i ng he rontpor t ion f the head l iner(E)down.

-4 With the help of an assislan t, elease he clips(F)of the headliner ro m the moonroof rame(G) , nd e leasehe head l inerrom he c l ips H)

by sliding he headliner orward,and oweringthe head l iner .

-5 Remove he headliner hrough he passenger's

open ing .

Fastener ocations

C > : C l i p , 3

ao

5. Insta l l he headliner n th e reverse rder of removal,

and note hese tems:

. When e ins ta l l i nghe head l inerhrough hepassenger's oor opening,be carefulnot o fold

or bend t,Also,be carefulnot o scratch he

DOOy.. Checkhatboths ides f he head l iner re

securely ttached o the trim.

. Rep lace nyc l ips ha t emain n he roofdur ingremova l . e ins ta l l t hel ipsback n he head l iner

before nstallation.

F > : C l i p , 2 H > : C l i p , 2

CarpetReplacement

SR Scomponentsar e ocated n this area.Reviewthe

SR Scomponent ocations se epage23-13) nd heprecautions nd procedures se epage23-14) n the SR


NOTE:. Put on gloves o protectyour hands.. Takecare not o damage,wrinkle.or twist the carpe. Be carefulnot o damage he dashboard r other

interior r im pieces.


. Frontseats,both sides seepage20-111

. Driver'sdashboard nder cover seepage20-6

. Passenger's ashboard owercover (seepage

20-631

. Rearseatcushion seepage20-80)

. Kickpanels,bothsides seepage20-50)

. Door sil ltrim, both sides se epage20-50)

. Consoles,ront and rear(seepage20-57)

2 . Removehe nut A) , ndus inga hexwrench,

releasehe clip (B), hen remove he footrest C).

Fastener ocations

A a : N u t , 1 B ) : C l i p , ' l

--'1I

-- \ -JrL

tj I ;tt4f\-/ l[ilA6 x 1 . 0 m m9 . 8 N m11.0 gf m,7.2 bf.f t)

-o

(cont

20-



InteriorTrim

CarpetReplacementcont'dl

Usinga util i tyknife, ut he carpet A) under heheaterareas B) ,and cut out the parkingbrake everarea C)as shown, hen pull back he carpet.

A B

Remove he clip (A),and release he fasteners B).

Pull he carpetout from both rear side rim panels(D), hen remove he carpet C).

Fastener ocation

A>: Clip.

4 .

&z

tr

5. Installthecarpet n th e reverse rder of remov al,and note hese tems:

. Take arenot to damage, r ink le , r tw is t thecarpeL

. Makesure he seatharnesses re routed

correctly.. S l ip he carpet nder he ear ide r im pane l n

eachsideproperly.. Rep lacehec l ip f i t ' sdamaged.. Reattachhe cut areasunder he heateraround

th e parkingbrake everwith a wire tie.. When nstall ingne w carpet, ut he carpet A)

under he heaterareas B) ,and around heparkingbrake ever C) .After nstall ing he ne wcarpet, l ip he carpet ro m the driver'san dpassenger's ide hrough he spacebetween he

heaterunit and body,and reattach he cut area{C)around he parkingbrake everwith wire ties.

t



Consoles

Console, rontand RearRemoval/lnstallation

NOTE:Takecareno t o scra tch he front seal,dashboard, nd relatedparts.

1 . Removehe rear onso le A) .

-1 Slide he front seat orward ully on eachside.-2 Remove he screws B)from the rearportionof

the rearconsole,-3 Slide he front seat earward ully on eachside.-4 Pu l l the ron tpor t ion f he ear onso le p o

detach he clips (C )an d hooks D) , he n release

the rearconsole rom the front console E) .-5 Star t ing t the ear , u l l t he ear onso le p ,

then remove t.

Fastener ocations

B>:Screw, C>: Clip,

2. Remove he front console A) .

-1 Pu l lou t he dashboard en ter ower over B)

to detach he clips C) .-2 Dlsconnecthe accessory ower socket

connectorD) .

3 Removeheconso le ox mat E) .-4 Removehe bo l t s F) , c rews G) , ndc l ips H-5 Gentlypull out the front console o release he

hooks l )andp ins J) .

Fastener ocations

C>:Cl ip ,3 F> i Bo l t ,2 G>:Screw.2H) :C l ip ,2

..4- 4!-- fF- ,-('E9'/' * q ' J - L } * J \ . / - d

9 8 N m(1.0 gt.m,7.2lbf.ft)

Install he console n the reverseorder of remova

and note hese tems:


. Makesure he accessory owersocket onnect

i s p luggedn proper ly .. Push hec l ips ntop lace ecure ly .

6 x 1 . 0 m m

20-



Consoles

FrontConsoleDisassembly/Reassembly

NOTE;Takecare not o scratch he consoleand relatedparts.

Fastener Locations

):Screw,8

C*FRONTCONSOLE

\

BEVERAGE OLDERASSEMBLY

,/',/

CONSOLEOX



Dashboard

InstrumentPanelRemoval/Installation

NOTE:. When prying

with a flat-t ipscrewdriver, rap it withprotectiveape,and applyprotective ape around herelatedparts, o preventdamage.

. Takecare not o scratch he dashboard nd relatedpa ts .

1. Tilt he steering olumn down.

2. Remove he steering olumnuppercover seepage17,9) .

Remove he instrumentpanel A).

-1 Gentlypull out along he bottom o releasehe

c l ips B)andhooks C) .-2 Gentlypull out the upperportion o releasehe

c l ips D)andhooks E) .

FastenerLocations

B> : c l i p . 2 D D ,Cl ip , 2

^*,

4. Insta ll thepanel n the reverse rder of removal,an d push he clip and hook portions nt o place

securery.

Driver'sDashboard owerCoverRemoval/lnstallation

NOTE:Takecare not o scratch he dashboard nd

relatedParts.

1. Remove he driver'sdashboard owercover (A).

-1 Turn he lock knob (B )90".-2 Gentlypull out the left side o releas ehe

hooks C) ,-3 Pullout the panelto release he hooks D).

Installthecover n the reverseorder of remova l,an d push he hookportions nt o placesecurely.

20-



Dashboard

Driver'sDashboardUnderCoverRemoval/lnstallation

NOTE:Takecare not o scratch he dashboard nd

relatedparts.

1 Remove he driver'sdashboardundercover (A).

-1 Turn he ockknob B)90 ' .-2 Gentlypull down the rearedge o re lease he

c l ip C) .-3 Pull he cover away o release t from the clip

{D) .

Fastener ocations

C>: Clip.

n

Installthecover n th e reverse rder of removal,

an d push he clip portion nt o placesecurely.

)

20-60

Driver'sPocketRemoval/lnstallation

NOTE:.

Pu tongloves

oprotectyour

hands.. Takecare not o scratch he dashboard nd relatedpans.

1. Remove he driver'spocket A)

-1 Remove he driver'sdashboard ndercover.-2 Remove he screws B) .-3 From behind he dashboard, us h he pocket

backby hand o re leasehec l ips C) .

4 Re leasehe hook D) .

Fastener ocations

B :Screw,2 C>: C l ip ,2

Installthepocket n the reverseorderof removal,

and push he clip portions nt o place ecurely.

','"\5

;;t='

\

2 .



Shift LeverTrim Removal/lnstallation

NOTE:. Takecare not o scratch he dashboard nd related

pa ts..

Put ongloves

oprotect our

hands.

1. Remove he glovebo x (seepage20-63).

2. Remove he shift knob.

Us ing ra tchet rench ndan 11 nchextens ion(A )wrappedwith a shop owel (B), arefully nsertthe extension hrough he glove box opening,an dpush he shift ever rim (C ) ro m under he trim torelease he clips (D )and hooks E)of the leftside.

Fastener

D>clip,

i : F\V

Locations

2 E>Hook,2

.-a7\r-t1u

4. Pull outthe shift evertrim (A) by hand o releasethe remain ing l lps 8 ,C)andhooks D) , nddisconnecthe hazardwarning switchconnector E

then remove he trim.Fastener ocations

B>:Clip,1 C>: Cl ;p , D>: Hook,3,,.;w

Install he trim in the reverseorder of remova l,an dnote hese tems.

. Makesure he hazardwarning switchconnectotis plugged n properly.

. Push he clip and hookportions nt o place

securely,

-

, ,

20-



Dashboard

DashboardCenterPanelRemoval/lnstallation

NOTE:. Puton gloves o protectyour hands.. When pryingwith a flat-t ipscrewdriver,wrap it with

protectiveape,and applyprotective ape around herelatedparts, o preventdamage.. Takecare not o scratch he dashboard nd related

parts.

1. Makesureyou have he anti-theft ode or th e radio,

the write down the frequenciesor the preset

buttons.

Remove hese tems:

. Driver'sdashboard ower cover se epage20-59)

. Passenger's ashboard ower cover (seepage

20-63).

. Glovebo x (seepage20-63).

. Shift ever rim {seepage20-61).

From he glovebox and driver'sdashboard ower

coveropenings, oosen he bolts (A )securing he

centerpanel B) .

2 .

FastenerLocations

A): Bolt ,2 x 0.8mm5 N m

;.'

20-62

4. Pullout the centerpanel A) o release he clips B)

and hooks C) ,an d remove he harnessholder D)

from th e bracket E).Disconnecthe audio unit

connectorF) ,

antenna eadG) ,

heaterswitchconnector H)and heater ontrolunit connectors l) .

Fastener ocations

B : Clip,

Installthepanel n the reverse rder of removal,


Makesure eachconnector s plugged n properly,

and antenna ead s connected roperly.

Push he clip portions nt o placesecurely.

Reconnecthe negativecable o the battery.

Do he ECN4/PCt\4dle earnprocedure se epage

1 l - 1 3 9 ) .Enter he anti-theft ode or th e radio. hen enter

the customer's adiostationpresets.

Reset he clock.

*4, F

\



Passenger's ashboard owerCoverRemoval/lnstallation

NOTE: ak ecare not o scratch he dashboard ndrelatedparts.

1. Remove he passenger's ashboard ower cover(A).

-1 Gentlypull down the rearedge o release hect ips B) .

-2 Pull he cover away o release he pins (C)from

the ho lders D) .

Fastener ocations

B>: Cl ip ,3

AI j l

Install he undercover n the reverse rderofremoval,and push he clip ponions nt o place

securety.

GloveBox Removal/lnstallation

SR Scomponents re oc ated n this area.Review heSRS omponentocat ionssee age23-13) nd heprecaut ionsndproceduressee age23 14) n he SR


NOTE:Takecare no t o scratch he dashboard ndrelatedpa ts .

1. Remove he passenger's ashboard ower cover.

2. While holding he glovebox (A), emove he glove

box stop (B)on eachside.

Fastener ocalions

>Boh.2.-6\{Ill fir-"b.-<,/

B

tJ

r-3t.oi,t-'10.5 gf m,4 tbf.ft)

4.

Remove he bolts, hen remove he glove box.

lns ta l l t he lovebox n he reverse rdero fremova l .

20-6



Dashboard

Dashboard ideVent RemovaUInstallation

NOTE:. Take

carenot o scratch he dashboard.

. Pu ton gloves o protectyour hands.

1. Remove he dashboard se epage20-66).

2. Remove he steeringhangerbeam ro m th e

dashboard seepage20-68).

3. Remove he screws, hen remove he air duct (A )

f rom he dashboardB) .

Fastener ocations

):Screw, 7

6hDt

4. Remove the screws, lhen remove the slde vent (A).

FastenerLocations):Screw,4

5. lns ta l l t he ide ent n he everse rdero f remova l .

20-64

Beverage olderRemoval/lnstallation

NOTE:. Takecare not o scratch he dashboard,. Puton gloves o protect our hands.

1. R emove he dashboard seepage20-66).

2. Remove he screws, hen remove he beverageho lder A) .

Fastener ocations

) :Screw.2

Installthebeverage older n the reverse rder

removat.

of.



Driver'sTray Removal/lnstallation

NOTE:. Takecare not o scratch he dashboard.. Pu ton gloves o protect ou r hands.

1. Remove he dashboard seepage20-66).

2. Remove he beverage older se epage20-64).

3. Remove he screws, hen remove he driver's ray(A) .

Fastener ocations

):Screw.3

4, lnstall he tray in the reverse rder of removal.

Passenger's ray Removal/Installation

NOTE:. Take ar enot o scratchhedashboard.. Pu ton gloveso protect ourhands.

1 .

2 .

3 .

4 .

Remove he dashboard se epage20-66),

Remove he steeringhangerbeam rom thedashboard se epage20-68).

Remove he air duct (seestep3 on page20-64).

Remove he screws, hen remove he passenger's

t ray A) .

Fastener ocations

):Screw,8

5. lnstall he trav in the reverseorder of remov al.

20-6



Dashboard

Dashboard emoval/lnstallation

SRScomponents re ocated n this area.Review he

SRScomponent ocations se epage23-13) nd heprecautions nd procedures se epage23-14) n the SRS


NOTE:. When pryingwith a flat-t ipscrewdriver,wrap it with

protectiveape,and applyprotectiveape around he

relatedparts o preventdamage.. Havean assistant el pyou when removingan d

ins ta l l i nghedashboad.. Takecarenot o scratch he dashboard, ody,an d

other relatedparts.. Puton gloves o protectyour hands.

1. Makesureyo u have he anti-theft ode or th e radio,

then write down the frequenciesor the preset

buttons.

Disconnecthe negative able rom the battery,an d

wait at east hree minutesbeforebeginningwork.

Remove hese tems:

. Driver'sdashboard owercover (seepage20-59)

. Driver'sdashboard ndercover(seepage20-60)

. Passenger's ashboard ower cover se epage

20-63). Glovebo x (seepage20-63). Consoles,ront and rear(seepage20-57). Shift ever rim {seepage20-61)

. Centerpanel se epage20-62)

. Kickpanels,both sides seepage20-50)

. A-pil lar rim. both sides seepage20-50)

. Steering olumn(seepage17-9)

20-66

4. From he centerpanelopening, emove he screws,

then remove he centerbracket A) .

FastenerLocations

):Screw,2

Remove he sh ft lever seepage13-51).

From outsideof the passenger's oor,gently pull

out along he edgeof the dashboard idecover(A)

to release hehooks B) , hen release he upper

hook(C), o remove he cover.



Driver's side:

7. From under he dash,disconnecthe interiorwireharness onnector A),driver'sdoor wire harnessconnectors B) ,side urn signal ight connector C) .

roof antenna onnector D) ,antenna ead(E). lutchswitchconnectors F) ,and brakeswitchconnector(G),and disconnecthe floor wire harnessconnectors H)an denginecompartmentwireharness onnectors l)from the under-dash use/re lav ox (J) .

Middleportion:

8. Disconnecthe floor wire harness onnectors A)

andcombinat ionubharnessonnectorB) .

Passenger's ide:

9. From under he dash,disconnect he dashboardwire harness onnectors A),EPSsubharnessconnectors B) ,enginecompartmentwire harnessconnectors C) ,A,/C ubharness onnectors D) ,passenger's oo r wire harness onnectors E),an ds ide urns igna l igh t onnectorF) .

10 . Detach l l o f he harness ndconnector l i ps .

(cont'd

20-6



Dashboard

DashboardRemoval/lnstallation(cont'd)

11. From outside he driver'sdoor, remove he caps A) ,

then remove he bolts8,

C, D) ,an d if t up on thedashboard E) o release t from the guidepins(F .G) on the body.

Fastener ocations

B>rBo l t .3 C>: Bo l t ,2 D>: Bo l t ,2

m6[-,,,,",",,-,F6't---''fi'!--v{/- Kr* w-

B

$7:^/761:

/ , -,. r: ; 8 x 1.25mm

2 2 N m(2.2 gf.m, 6lbf.ft)

1 3 .

{2.2 gf m, 16lbf. f t l

Carefully emove he dashboard hrough he front

dooropen ing .

lnstall he dashboard n the reverse rder of


. Makesure he dashboard it s onto he guide pins

correctly.. App ly iqu id hread ock o the dashboard

mountingboltsof the middle portionbefore

re ins ta l la t ion .. Before ightening he bolts,makesure eachwire

harnessand controlcablesar e no t pinched.. Makesure he connectors replugged n

properly,and he antenna ead s connectedpropeny.

. Reconnecthe negative able o the battery.

. Enter he anti-theft ode or th e radio, hen enter


. Reset he clock.

. Do he ECM/PCMdle earn rocedureseepage

11-139) .

20-68

SteeringHangerBeamReplacement

NOTE:Pu ton gloves o protectyour hands.

1, Remove he dashboard se epage20-66).

2. Remove hese tems rom the dashboard:

. lnstrumentpanel seepage20-59)

. Driver'spocket seepage20-60)

. Gauge ssemblysee age22-64)

. Passenger's irbag seepage23-'l 4)

Removehescrews,hen emovehegloveboxstrikerA) .

Fastenea ocations

):Screw,4

\



4. Remove he bolts A) and screws B)securing hedashboardC)andsteer ing anger eam D), nddisconnecthe power mirror switchconnector E)

and cruisecontrolmain switchconnectorF) .

Separa tehedashboard ndsteer ing anger eam.

Faslener ocations

A > r B o l t , 4 B > : S c r e w , 9

5 N.m {0.5 gf m,4lbf, f t l

5. Ins ta l l t he eam n he everse rdero f remova l ,an d note hese tems:

.N4akeure he dashboard i re harnessG) s nop inched.

. Makesure he connectors re plugged nproperly.

20-



Seats


REARSEATRemoval/ lnstallat ion,ag e20-80Seat-back atchReplacement,page20-81Seat-back tr ikerReplacement,page20-81Seat'back overReplacement,page 20-82

SeatCushionCoverReplacement,page20-84

FRONTSEATRemoval/ lnstallat ion,ag e20-i1Disassembly/Reassembly-Driver's,ag e20 73

Disassembly/Reassembly-Passenger's,ag e20-74

SeatCoverReplacement, ag e20-75

20-70



FrontSeatRemoval/lnstallation

Fo rsome models:SRScomponents re ocated n thisarea.Review he SRScomponent ocations se epage

23-'13) nd he precautions nd procedures se epage

23-14) n the SRSsectionbeforeperforming epairsorservice.

NOTE. When pryingwith a flat-t ipscrewdriver,wrap it with

protectiveape o preventdamage.. Takecare not o scratch he body or tear he seat

covers.. Put on gloves o protectyour hands.

1, Makesureyo u have he anti-theft ode or the radio,

then write down the frequenciesor th e preset

butlons.

Disconnecthe negative able rom the battery, ndwait at least3 minutesbeforebeginningwork.

Remove he seat rackend covers A) rom the backof both seat racks.

Outef:

lnner:

3.

\

4. Remove he bolts securing he front seat.

Fastener ocations

10x 1 . 25mm

> : Bolt,

@

(cont'

20-



Seats

FrontSeatRemoval/lnstallationcont'dl

Lift up the front seat, hen detach he harness li p(A).and disconnect he seatbelt switchconnector(B)andseatbe l tbuck leens ioner onnectorC) . f

equ ipped i th a s idea i rbag, i sconnecthe s idea i rbag onnectorD) , ndon he passenger ' seat ,

d isconnectheOPDS ni tconnectorE) . he

passenger ' seat s shown, he dr iver ' s ea t s

s im i la r xcept t hasno OPDS n i tconnector .

With the helpof an assistant, arefully emove he

front seat h rough he front door opening.

Ins ta l l t he eat n he reverse rdero f remova l , nd

note hesertems:

.l\4ake ureeachconnector s

pluggedn

properly.. App ly iqu id hread ock o the seatmount ing

boltsbefore einstallatlon.. Reconnecthe negative able o the battery.. Enter he anti-theft ode or the radio, hen enter

the customer's adio stationpresets.. Reset he clock.. Do he ECM/PCMdl e earnprocedure seepage

11 - 1 3 9 ) .

6 .

7 .

20-72



FrontSeat Disassembly/ReassemblyDriver's

For some models:SR Scomponents re ocated n this area.Review he SRScomponent ocations se epage23-13)and he precautions nd procedures seepage23-14) n the SRSsectionbeforeperforming epairsor service.

NOTE:. Takecareno t o tear he seamsor damage he seatcovers,. Puton gloves o protect our hands.. When pryingwith a flat-t ipscrewdriver.wrap it with protective ap e o preventdamage.' Apply multipurpose reasetothe moving portionof the seattrack.. To preventwrinkles n the seatcushioncover,stretch he materialevenlyoverthe pad.

Releasehe seatcushioncover rom the cushionf ram e p r ing .

SEAT-BACK

RECLINECOVER

RECLINEKNOB

10 x'l.25

mm47 N.m {4.8 gf.m,35 rbt.ft)

WIRETIE

4

20-



Seats

FrontSeatDisassembly/ReassemblyPassenger's

For some models:SRScomponentsare ocated n this area.ReviewtheSRScomponent ocations se epage23-'13)

and he precautions nd procedures se epage23-14) eforedoing repairsor service.

NOTE;. Takecarenot o tear he seamsor damage he seatcovers. Puton gloves o protectyour hands.. When pryingwith a flat-t ipscrewdriver,wrap it with protectiveap e o preventdamage

. Apply multipu posegrease o the moving portionof the seat rack

. To Dreventwrinkles n the seatcushioncover,stretch he materialevenlyover he pad.

. lvlake ure he rearseataccess able s connected roperlyon eachside

. Replace ny damagedclips,and replace he wire tieswith new ones

SIDEAIRBAGHARNESS

Releasehe seatcushioncover rom thecushionf ram e pr ing .

10 x 1.25mm47 N. m (4.8 gf.m,3s rbf.ft)

SEAT"BACK

HANGER PRING

OPDSHARNESS

CENTEB OVER

uWIRETIE

SEAT USHIONFRAME/SEATTRACKS

/REARSEATACC€SSCABLE

N*r(".o, /- IACCESSKNOB ,/ /

/ H o o K

SLIDE EVER

,/CLIP

v/

20-74

RECLINEKNOB

RECLINE OVER



FrontSeatCoverReplacement

For some models:SR Scomponents re ocated n this

area.Review he SRScomponent ocations se epage

23 13)and he precautions nd procedures se epage

23-'14)n the SRSsectionbeforeperforming epairsorservice,

NOTE:. Takecare not o tear he seamsor damage he seat

covers,. On he passenger's ea twith s ide airbag,do no t

touch h e OPDS ensor n the seat-back ad ,an d keep

it away rom oil. Oil cancorrode he sensorcausing t

to fa i l .. Pu ton gloves o protectyour hands.

Seat-backCover

Remove he front seat se epage20-71).

Wi ths idea i rbag: romunder heseat ush ion ,

detach he sideairbagconnector l ip (A),and on

th e passenger's eat,detach he OPDSunit

connector l i p B) .Re leasehe hookspr ings C)

f rom he seat ush ionramespr ing D) , henpu l l

th e guidecover E)back,and remove he wire ties(F).Th e passenger's ea t s shown, he driver'sseat

is svmmetrical xcept t has no OPDSunit

connector.

'L

2.

3 . Fold he seat-backorward.

Re leasehe hooks A) , ndunz ip he seat -back

cover B) .

4.

(con

20



8. Usinga flat-t ipscrewdriverwrappedwithprotective ape, nsert t into he hookportions(seven laces) f the headrestear r im A) rom he

headrest ront trim side.Pr vup the hooks B) orelease he abs (C)of the headrest ront trim (D i

wh i lepu l l i ng heheadrestron t r im orward , nd

remove he flm.

D

/

1 0 .

9. Un zip he headrest ortionof the seat-back over(A) , hen emove hez ipperB) ,and emove he

cover .

A

installthe cover n the reverseorder of removal,


. Fi tall the hooksof the headrest ront trim into h

ho les n heheadrestear r im, henpushon he

headrestr im unt i l he hooks nap n top lace.

. To preventwrinkleswhen install ing seat back

cover,makesure he material s stretched ven

over he pa d beforesecuring he clips,hooks,

and hookspr ings.. Make ure hes idea i rbag arness, PDS

harness passenger's eat).an d rearseatacces

cable passenger's eati are routedproperly.. lf necessary,einit ializehe OPDS ontrolunit

(see age23-124) .

(cont

20-



Seats

FrontSeatCoverReplacementcont'd)

SeatCushionCover

1. Remove he front seat se epage20,71).

2. Remove hese tems rom the front seat:

. Recline over,driver'sseat se epage20-73)passenger's ea t se epage20-7 l

. Frontseatbelt buckle se estep 4 on page23-6)

3. From underthe seatcushion,detach he sideairbagconnector l ip,and on the passenger's eat,detach he OPDSunit connector l ip. Releasehehook springs rom the seatcushion rame spring,then pull he guidecover back,and remove hewire ties.

4. Releasehe hooks A) .

Inside:

Outside:

Releasehe seat-back over (A)from the cushion

frame spring(B),and releasehe hooks C) ro munder heseat ush ion .



6. Removeheseat ush ion over A)wi th theseat

cushionpad rom the seatcushion rame.

Pull back he edge of the seatcushioncoverall heway around.and release he clips A) , he n remove

the seatcushioncover(B).

1 .

r {, ]

: F + r

r * ?

8. Installthecover n the reverse rder of removal,

and note hese tems;

.To preventwrinkleswhen install lnga seatcushioncover,makesure he material s

stretched venlyover he pad beforesecuring

thec l ipsandhooks.. Makesure he side airbagharness nd OPDS

harness passenger's eat)are routedproperly.. Replace ny clipsyo u removedwith new ones

(A) . ns ta l l t hem i thcommerc ia l l yva i lab le

upholstery in g pliers B).

20-



Seats

RearSeat Removal/lnstallation

NOTE: akecare not to scratch he body or tear he seatcovers.

'1 .Remove he rear seatas shown.To remove he seat-back,emove he ront portionof the cargo loor ma r se e

page 20-52).

2. Install he seat n th e reverse rder of removal,and note hese tems:

' B e f o r e i n s t a l l i n g t h e c e n t e r a n c h o r b o l t s o n t h e s e a t - b a c k w i t h t h e c e n t e r s h o u l d e r b e l t , m a k e s u r e t h e r e a r e n

twistsor kinks n the belt.. Makesure he seat-backsocksecurelv.

FastenerLocations

A > : B o l t , 2 B > r B o l t , C> : Bo t t , D >: C l i p ,

l l t l

agrf ( 1

Vt-r_r+*.

\'7

CUSHION

6 x 1 . 0 m m9 . 8 N m{1.0 gf.m,7.2lbf. f t)

/-<.{\.-- F.i\-- K\-| J ] . P t - H A P

CENTER IVOTBOLT8 x 1.25mm22N.m{2.2 gf.m,16lbf. f t l

RIGHTSEAT-BACK

CENTER ELT

PIVOTBUSHING

CENTER NCHOR OLT7/16-20UN F3 2 N m(3.3 gf m.24 lbt t l

SEATBELTBUCKLE

8 x 1.25mm22 N. m 12.2 gt m, 16lbf. f t)

SEAT.BACKCENTER INGE

BUSHING

LEFTSEAT.BACK

PIVOTBUSHING

HOOKSEAT



RearSeat-back atchReplacement

1 . Remove he seat-backse epage20-80).

Remove he seat-back over (seepage20-82).

Remove he seat-back ad{A) rom the seat-back

frame (B).On right seat-back ith centershoulder

belt,pass he centerbelt (C ) hrough he hole n the

seat-back ad .

Remove he bolts, hen remove he seat-backatch(A ) rom the seat-backrame (B),and release hepivot pin {C )of the atch ever D) rom the seat'

back rame.

Fastener ocations

lnstallthe atch n the reverse rder of removal,an d

makesure he seat-backocksand unlocksproperly.

RearSeat-back trikerReplacem

NOTE: akecareno t to scratch he nterior rim.

1 . Removehe rear ide r im pane l see age20-5 ' l

2. Remove he bolts, hen remove he seat-back

striker A).

Fastener ocations

) : Bolt,2

F

,-;1

8 x 1.25mm22 N m 12.2 gl rn,16 tbf.ft)

3. lns ta l l t he t r i kern he reverse rdero f remova l

and move he striker A)up or down until t is

centered n the seat-backatch B).

20



Seats

RearSeat-backCoverReplacement

NOTE:. Takecare not o tear he seamsor damage he seat

covers..

Put on gloves o protectyour hands.'1 .

Remove he seat-backseepage20-80).

Remove he headrest.

Pullup the latchcover (A ) o telease he clips. he nremove t.

FastenerLocations

) : Clip,4

1W

4 . Pullup the outsideedgeof the latch evercover (A)

to r elease heclips,and releasehe cover rom thep ivo tp ins B)o f the a tch ever C)wh i lepu l l j ng helatch lever.

Fastener Locations

D : Clip,2

i\r*rJ

5. On rightseat-backi sing a Torx T30bit, removethe bolts, hen remove he belt holder rim (A),an dremove he trim from the centerbelt (B).

Fastener

) : Bolt,

A*-\./-

Locations 6 x 1 . 0 m m9 . 8 N m(1.0 gf.m,7.2 bf. f t)

Releasehe hook(A),and unzip he seat-back over(B).Th e right seat-backs shown. he leftseat-backi ss i m i l a r .

\



7. Pull back he edgeof the seat-back over (A),an d

re leasehec l ips B) .

Pull back he edgeof the seat-back over,an d pullou t the seat-backrame {A ) rom the seat-back ad

{B) , henpu l lou t heheadrest u ide C)whi le

p inch ingheendof thegu ides, nd emove hem.

9. Remove he seat-back over (A)from the seat-bapa d (B).On right seat-back ith centershoulder

belt,pass he centerbelt (C) hrough he hole n th

seat-bacl(over.

lnstallthecover n the reverse rder of removal,

and note hese tems:

. To preventwrinkleswhen install ing seat-bac

cover,makesure he material s stretched ven

over he pa d beforesecuring he hooksand clip. On righ t seat-back:When nstall ing he seat-ba

frame o the pad,slip he centerbelt hrough h

hole n th e seat-back overand pad.. Replace ny clipsyo u removedwith ne w ones

Insta l lhemwi thcommerc ia l l yva i lab le

upholstery in g pliers.

1 0 ,

20



RearSeatCushionCoverReplacement

' 1 .Remove he rearseatcushion se epage2O-80).

Release ll the clips(A ) ro m under he seat

cush ion , nd o ld back heseat ush ion over B) .

B

Pullback he edgeof the seatcushioncoveral l th ewa y around,and releasehe clips(A), hen removethe seatcushioncover.

i w F 1 . , 1 L + . t s + '

i l1 rl - , + J , + l

l

4. Installthecover n the reverse rderof removal,and note he se tems;

. To preventwrinkles,makesure he material sstretched venlyover he pa d beforesecuringthec l ips .

. Replace ny clips A) yo u removedwith ne wones. ns ta l lhemwi thcommerc ia l l yva i lab leupho ls te ryingp l ie rs B) .

\



Bumpers

Front BumperRemovaUlnstallation

NOTE:. Have n ass is tan te lp ou when emoving nd ns ta l l i nghe ron tbumper .. Takecareno t o scratch he front bumper and body.

. Pu ton gloves o protectyour hands.

'LRemove he fr ont bumper as shown.

2 . Ins ta l l t he umper n he reverse rdero f remova l , ndnote hese tems:

. Makesure both ront sidemarker ight connectors re plugged n properly.

. Makesure he front bumperengages he hooksof the sidespacers nd upperbeamson b oth sidessecurely.


Fastener ocations

A ) , Screw, 2

{D[ ]

> : Bo l t . 4 D > : C l i p , 7 E > : C l i p , 2

f ' h - 6 4

k/- *S =$t

B >: Screw,2 C

ABSORBER

SIDESPACER

UPPER EAM

LEFT RONTSIDEMALIGHTCONNECTOR

BUMPER

FRONTNNERFENDER

FEONT UMPER

A

El

I

6 x9. 8

FRONT IRSPOILER

AI RSPOILERPLATE

1 .0mmN. m (1.0 gt.m,7.2 bf. f t)

' * D ;e 3

et i-\

SPOILER

PLATE

20



Bumpers

RearBumperRemovaUlnstallation

NOTE:' Havean assistant elpyo u when removingand nstall ing he rearbumper.. Takecare not to scratc h he rear bumperand body..

When pryingwith a flat-t ipscrewdriver,wrap it with protective ape o preventdamage.. Pu ton gloves o protectyour hands.

L Removehe rearbumDer sshown.

2. Installthebumper n the reverse rder of removal,an d note hese tems:

. Makesure both rearside marker ightconnectors re plugged n properly.' M a k e s u r e t he r e a r b u m p e re n g a g e s t h e h oo k s o f t h e s i de s p a c e r s , s i d eb r a c k e t s , a n du p p e r b r a c k e t s on b o t h

sidessecurely.. Makesure he upperspacers f the rearbumperengage he clipson the body securely.. Rep lace nydamaged l ips .

: Screw, 2

XJ

) : Clip,

?ri )\s

I

FastenerLocations

A > : B o l t , 2 B

/h-\-P-

) : Screw, 2

ffiI"-ut^*

c >

SIDEBRACKET

UPPERSPACER

UPPER RACKET\

SIDESPACER

:r' -

A

AD

LEFTREARSIDEMARKERLIGHTCONNECTOR

, 6x 1 .0mm/ 9.eN.n

,/ 11.0 gl m,./ 1.2tbt.ttl

a

\

CA P

REARBUMPER



Hood

' 1 .

2 .

Adjustment

3.

Slightly ooseneachhood hinge bolt,

Adjust he hood (A) alignment n this sequence.

. Ad jus t thehoodr igh tand le f t ,aswel ls orward nd earward , y us ing he e longated o les n he hoodh ing

( B ) .. Turn he hood edge cushions C) ,as necessary,o make he hood it f lush with the body at the front and side

edges.

6 x 1 . 0 m m9. 8N. m{1.0 gf.m,7.2lbf. f t}

Adjust he hood atch D) o obtain he properheightat he forward edge,and move he hood atch ight or left

until he striker E) s centered n the hood atch.

Tighteneachbolt securely.

(con

6 x 1 . 0 m m9. 8N. m{1.0 gl.m,7.2 bf.f t l

20-



Hood

Adjustment cont'd)

5. Check hat he hood opensproperlyan d ockssecurely.

6. Apply body paint o th e hingemountingboltsan daround he h inges.

7. Apply multipurpose rease o each ocationof thehood atchand hood hingeas ndicated y thearrows.

. : I

HoodSealReplacement

1 . Us inga clip remover,detach he clips, hen removethe hoodseal A).Takecare not o scratch he hood.

Fastenerocations

Ins ta l l t he eal n he reverse rdero f remova l , ndnote hese tems:


. Push he c l ips n top lace ecure ly .



Hood nsulatorReplacement

1. D isconnecthewindsh ie ld asher ubes A) .

Fastener ocations

) : Clip,10

t*'-&,2V..=-'

( \

H

Usinga clip remover,detach he clips.Releasehe

hooks B) , hen emove he hood nsu la torC) . ake

carenot to scratch he hood.

Ins ta l l t hensu la torn he reverse rdero f remova l ,

and note hese tems:


. Push he clips nto placesecurely.

20-



Hatch

Adjustment

1. Remove he supportstrut rom eachside (seepage20-91).

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 ) , a n d p u l lo w n t h e 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). akecareno t o bend he headliner xcessively.

3. Remove he rear rim panel se epage20-52).

4, Slightly ooseneachbolt and nut.

5 . Ad jus t the a tch A)a l ignmentn he o l lowing equence.

. Adjustthe hatchhinges B) ight and eft,as well as orward an d rearward,using he elongatedholes.' T u r n t h e h a t c h e d g e c u s h i o n s ( C ) , i n o r o u t a s n e c e s s a r y , t o m a k e t h e h a t c h ( D ) . f i t f l u s h w i t h t h e b o d y a t t h e s i d

edges.. Adjust he fi t between he hatchan d hatchopeningby moving he striker D) .

8 x 1.25mm18 N. m 11.8 gf.m,13 bf.f t)

\

8 x 1.25mm22N. m{2.2 gf.m,16 bf.ft}

20-90



7 .

Tighteneachbolt and nut securely.

Check hat he hatchopensproperlyan d ocks

securery.

Reinstallhe supportstrutssecurely.

Re ins ta l l l l emain ingemoved ar ts .

Apply multipurpose rease o the pivot portionof

the hatchhinges A) as ndicated y the arrows.

9 .

1 0 .

HatchSupportStrut Replacemen

1 .With the help of an assistant, sea flat-t ipscrewdriver A)to pr y th e supportstrutclips B)

from eachend of the supportstrut (C)at the hatch

and body, hen release he supportstrut rom thepivot bolts D) .Do not remove h e clips rom thesupportstrut.

Set he clips A) o the originalposit ion, he nreattach he supportstrut (B)on the pivot bolts C)

by pushingon the supportstrut.

2 .

D8 x 1.25mm22N.m 2. 2 gf.m, 6 bf t)

20-



Hatch

HatchWeatherstripReplacement

1. Removehe hatchweathers t r ipA)bypu l l i ngout

on t .

2 . Locatehe pa in ted l ignmentmark B)onthehatch

weatherstrip. l lgn the paintedmarkwith th e

alignment ab in the the centerof the hatchopening,

and nsta l lhe ha tchweathers t r ipl l t heway

around n the directionshown.Makesure here are

no wrinkles n the weatherstrip.

3. Check or water eaks.

20-92



2 .

FrontGrilleReplacement

1 .

3.

Remove he front bumper (seepage20-85).

Remove he front gril le (A),Takecare not o scratch

th e front bumperB).

-1 Remove he screws C) .-2 Remove he clips (D).-3 Releasehe bottom hooks E)ofthe gril le,-4 Pullout the boftom of the gril le o releasehe

upperhooks F) .-5 Pu l lou t hegr i l l e o re leasehe s l i t s G) f rom

th e ribs{H), hen remove he gril le.

FastqnErLocations

C >:Screw.4 D

I ns ta l l t he r i l l e n he reverse rdero f remova l ,and ep lace nydamaged l ips .

Reinstallhe

front bumper.

) : Clip, 4ll

-S---:i")

F

\



Cowl CoversReplacement

1. Removehewindsh ie ld iperarms see age22-145) .

2. Remove he windshieldside rim from both sides se estep2 on page20-19).

3. Pullthe hood rearseal A) away rom the cowl covers, hen remove t, and using a clip remover,detach he clips(B ) ro m the cowl covers.Takecare not o scratch he cowl covers.

Fastener ocations

B > r C l i p , 3 C > : C l i p , 8

:- ::::= - --::;-:

4. Detach he clips C)by carefullypull ing he passenger's owl cover {D )upward, o release he hooks E),an d pullout he cover orward o releasehe hooks F) , hen remove he cover.Takecarenot o scratch he body,

Detach he clips(C )by carefullypull ing he driver'scowl cover (G upward.an d pullou t th e cover orward orelease he hooks H) , hen remove he cover.Takecare not o scratc h he body.

Installthecovers n the reverse rderof removal,and note hese tems:


. Push h e clip portions nt o placesecurely.

. Reinstall oth windshieldside rim properly seestep26 on page20-24).

20-



Exterior rim

A-PillarCorner rim Replacement

1 . Open he door.

Wrap a flat-t ipscrewdriverwith protectiveape,

and applyprotectiveape around he body opreventdamage.Carefully nserta f lat-t ip

screwdriver ext o the upperclip, and detach he

c l ipby pry ing n heA-p i l l a r o rner r im (A) . ake

care not to s cratch he body and relatedparts.

Fastener ocation

Close he door half-way.

Pull he A-pil lercorner rim (A )out to detach he

lower clips, hen remove he trim.

Fastener ocations

3.

20-96

5 . R e pl a ce n ydamaged l ips .

Ho ld he r im up,and i t he upper l i pand ower

c l ips n to he ho les n he body, henpushon het r im unt i l he c l ips nap n top iace.

\



1 .

RoofMolding Replacement

Apply protectiveape o the body (A).Usingaflat-t ipscrewdriverwrappedwith protective ap e(B),pr y up on the roof molding C) .Takecare not toscratch he bodv.

Pullup and slide he roof molding o releasehefront bracket D) rom th e pi n (E).

Pullup the front portionof roof molding.

4, Pullup and release he rear bracket A)from th e p(B), hen remove he roof molding (C).

Install he molding n th e reverse rder of removaand note hese tems:

. Take arenot o damage hewindsh ie ldmold in

. Makesure he roof molding s nstalled ecurel

5 .

..:.::.l.g

20-



\

RearLicense rim Replacement

NOTE:Pu ton gloves o protect our hands.

1. Remove he hatch ower rim panel se epage20 -

2. On inside he hatch. emove he boltssecuring he

rear i censer im (A)andhatch ock y l inder B) .

Fastener ocations

> : Bolt,2

-)

6 x 1 . 0 m m9. 8N. m (1.0 gf.m,7.2lbf. f t l

3. From ns idehehatch , e leasehec l ips A,B)wh i le

ho ld ing he ear i censer im (C) , hen emovehetrim, Takecare not o scratch he hatch.

Fastener ocations

A > : C l i p , 2 B > : C l i p . 2

\ ! -

cHl €:t+

I ns ta l l t her im n he everse rdero f remova l , nd

note hese tems:


. Push he clip portions nt oplacesecurely.

4.



HatchSpoilerReplacement


'l .Remove he hatchupper rim (seepage20-53).

2. Remove he high mount brake ight (seepage22 -82).

3. From ns ide he hatch, emove he bolts A} an dnuts B) .

Fastener Locaiions

A>: Bol t ,2 Bar Nut ,

fi'f$t-- /,fluLt* v_/

5 x 1 . 0 m m9 . 8 N m

(1.0 gf.m.7.2 bf. f t)

$. A

4. F rom nside he hatch , e leasehe c l ips ,wh i lepu l l i ng he hatch po i le r A)away, nd e leasehefasteners B) , he n remove he spoiler.Takecare

no t o scr atch he body.

Fastener ocations

>: Cl ip .

t

I ns ta l l t he po i le r n he reverse rdero f remova l ,and note hese tems:

Rep lace nydamaged l ips .

Replace ny damaged asteners.Beforeinstall ing he fastener o the spoiler,clean hespoilerbondingsurfacewith a spongedampenedn a lcoho l . l ue he astener i thadhes iveape 3M5671, r equ iva lent ) tohespo i le r .Push he clip and astenerportions nto place

securely.

5 .

20-9



Exterior rim

EmblemReplacement

NOTE:When removing he emblem, akecare not to scratch he body.

1. To remove he front "H " emblem and ront type emblem, emove he front bumper se epage20-85)

2. Clean he bondingsurfacewith a spongedampened n alcohol.After cleaning, ee poil, grease, nd water rom

gettingon the surface.

3 . App ly he emblem,where hown.

. When nsta l l i nghe s ide -VTEC mblemon he body, l i gn he app l i ca t ionapewi th heedgeof thewhee larch ,

then press he emblem nt o place,and remove he application ape.. ' 03mode l :When nsta l l i nghe LEV mblemon hequar te r lass , l i gn he app l i ca t ionapewi th he edgeof he

b lack eramic nda l ignmentmarkon hequar te r lass ,henpress he emblem ntop lace, nd emove he

app l i ca t ionape.

FRONT YPEEMBLEM

FBONT H" EMBLEM

FRONT H" EMBLEMBASE FBONTGRILLE

PUSHNUTS

iSCREWS

FRONTSi EMBLEMPLATE

PINS

20-100

FRONT RILLE FRONT RILLE



LE VEMBLEM(Left ide nly)('03model)

SIDE -VTEC MBLEM

Unit: mm {in. lAdhesiveape: 3M 4213E, . equivalent

Thickness:0.8 m (0.03n. )

REARCIVICEMBLEM

REARVERSION MBLEM

REARH" EMBLEM

APPLICATIONAP E Edoeol the black eramic.

HATCHLINE

A l ign .

REAR ICENSETRIM

REAR i EMBLEM

LE VEMBLEMOnto nsideac eof the guarterglass

REARSi REMBLEM

, ilg

(1.93)=-t

50

CIVICEMBLEM Edge f theha t ch .

SIDE -VTECEMBLEM

{'!,9?)

SIDE.WECEMBLEM

ADHESIVE APE Edge of thehatch.

RightSide: 63 2.5)

F . l ^ 6 ^ l rh -

.=4,Li.Est'

BODYLINE

whee la r ch .

112

BODYLINE

o"f,r,ao.o"(5'5s)

Edgeof thewheelarch.

APPLICATIONTAPE TAPE

REAR H' ' EMBLEM

(Canada)

3411.3)

.,!!ll, 'ntI (1.s31

Left Side:

. 114 4.49)

4. After nstall ing he front "H " enblemand ront type emblem, einstall he front bumper.

20-1



Fenderwell

Front nnerFenderReplacement

NOTE:Takecare not o scratch he body.

1, Remove he front inner ender A).

-1 On he backofthe wheel arch, emove he screws B).-2 Fromunder the f ron t umper (C) ,emovethescrewB) ecu ing he ron tbumper . p lash h ie ld D) , nd f ron t

inner ender,an d remove he clip (E)securing he front air spoiler, ront bumper,and ront nner ender.-3 Fromthewhee l rch , emove he c l ips F ,G)secur inghe ron t nner ender and p lash h ie ld ) n thebody.-4 Re leasehe hook H)o f the sp lash h ie ld , thenemovethe f ron tnner fender .

Fastener ocations

B ) : S c r e w , 4 E > : C l i p , 1 F > : C l i p , G ) : C l i p , 8

0 * € ,ws

2. Install he inner ender n the reverse rder of removal,and note hese tems:

. Rep lace nydamaged l i ps .

. Push hec l ips n top lace ecure ly .

20-102



FuelPipeProtectorReplacement

1 . Removehec l ips , hen emove he ue lp ipe

protector A).Takecare not o scratch he body.

Fastener Locations> : Clip,4

4

I ns ta l l t he ro tec to rn he reverse rdero f remova l ,

and note hese tems:

. Rep lace nydamaged l i ps .

. Push hec l ips n top lace ecure lv .

RearAir OutletReplacement

1. Removehe rearbumper see age20-86) .

Ins ta l l t he i rou t le ts y push ing n he hook

por t ions n t i l t hehooks nap n top lace .

rne eara t r

th e body.



Openers


HATCH OCKCYLINDERReplacement,ag e 0-1'l

HATCHHANDLEReplacement,page 0-110

FUELFILLDOOROPENERReplacement, ag e20-109

HATCHLATCHReplacement, ag e20'1 0

FUELFILLDOORLATpage 0-107

FUELFILLDOOROPENEB AReplacement,ag e20-107

I{OOD RELEASEHANDLEpage20-'106

HOODOPENERCABLEReplacement, ag e20-106

z)-1



HoodOpenerCableReplacement

NOTE:. Puton gloves o protectyour hands.. Takecare not o scratch he body and relatedparts.

l. Remove hese tems:

. Frontbumper seepage20-85)

. F ron t nner ender ,e f t s ide(seepage20-102)

. Kickpanel, eft side (seepage20-50)

2. Disconnecthe hoodopenercable A) rom the hood atch B) see

remove he hood release andle D)from the body.

Fastener ocations

C > : B o l t , 2 E > : C l i p , 3

page20-108), nd remove he bolts C) , he n

6 x 1 . 0 m m9, 8N. m11.0 gl .m,7.2 bl.ft)

@m

4.

Usinga clip remover,detach he clips (E), nd remove he grommet (F)from he body, hen remove he hood

openercable rom the vehicle.Takecare not to bend he cable.

Ins ta l l t he ab le n he reverse rdero f remova l , nd ep lace nydamaged l i ps .

l,.t'.

W:"



2 .

5 .

FuelFill DoorOpenerCableReplacement

SR Scomponents re ocated n this area.Review he SRScomponent ocations se epage23-13) nd he precautions

an d procedures seepage23-14) n the SRSsectionbeforeperforming epairsor service.

NOTE;. Puton gloves o protect our hands.. Takecare notto scratch he body and relatedparts.

1. Remove hese tems rom the eft side of the vehicle:

. Doors i l l t r im see age20-50)

. Rear ide r im pane l see age20-51)

Pullthe carpetbackas necessary se epage20-55).

Disconnecthe fuel il l door openercable A) rom the opener B) seestep3 on page20-109).

Fastener ocations

C >:Cush ion tape, D >: C l ip , E > : Clip,

4. KCmode l :Removetheef tmidd le loorcross-memberusse t see age20-113) .

5 . Removehecush ionape C) , nd e leasehecab le rom hec l ips D,E) .

6.Removethe fue li l l door la tch F) f romthebodybyturn ing t90 ' .

7. Remove he fuel i l l door openercable rom the vehicle.Takecarenot o bend he cable

8 . I n s t a l 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

oamageo.

20-1



Openers

Hood LatchReplacement

NOTE:. Puton gloves o protectyour hands.. Takecare no t o scratch he body.

1. Remove he bolts, hen remove he hood atch A)

from the body.

Fastener ocations

> i Bolt,

Disconnecthe hood openercable B) ro m thehood atch.Takecare not o bend he cable.

--------------'6 x 1 . 0 m m9. 8N. m (1.0 gf.m,7.2lbf.ft)

Installthehood atch n the reverse rder of

removal,and note hese tems:

.Apply multipurpose

reaseo each ocationofthe hood atch ndicated y the arrows.

. Makesure he hood openercable s connectedproperly.

. Makesure he cableactuateshe latchbeforeyo u

close he hood,. Adjustthe hood atchalignment se estep3 on

page20-87).. Make ure he hoodopens roper ly nd ocks

securely.



FuelFillDoorOpenerReplacement

1 . Usinga flat-t ipscrewdriverwrappedwith

protectiveape,detach he hooks A) by prying he

front side cap (B), hen remove t from th e leftdoor

s i l l t r im C) , nd oosen hebo l t D) ecur inghe

fue l i l l dooropener .

6 x 1 . 0 m m9. 8N. m11.0 gf m,7.2 bf. f t)

Remove he left door sil l rim (seepage20-50i.

Removeheopener Al f rom he bo l t B) .

2.

3.

4. Disconnecthe fuel i l l door openercable A), he n

remove he opener B) .Takecare not o bend h e

cao e .

Installtheopener n th e reverse rder of removal

and note hese tem s:5 .

lMake ure he openercable s connected

properly.

lvlake ure he fuel i l l door opensproperlyan d

lockssecurely.

20-1



Openers

HatchHandleReplacement

NOTE:Pu ton gloves o protectyour hands.


. Hatch ower rim panel se epage20-53)

. Rear ic ense rim panel se epage20-98)

2. Remove he rearwindow wiper motor (seepage

22-1461.

3. Disconnecthe hatchhatch and le B) , nd

Locations

opener ab le A) f rom heremove he nuts.

6 x 1 . 0 m m9.8N. m

Fastener

a : Nut,

()r I

4. Pulloutthe hatchhandle A) , hen remove t.

Ins ta l l t he and le n he reverse rdero f remova l .and note hese tems:

lMakeure he hatch pener able sconnectedsecure ly .Make ure hehatch pens roper ly .

(1.0kg{.m,7 2 tbt.{t\

a, t .

20-110

HatchLatchReplacement

NOTE:Puton gloves o protect ou r hands.

'1 .Remove he hatch owertrim panel seepage20 -

53).

2. Disconnecthe hatchopenercable A) ,cylinder od(B).hatchactuator onnector C) .and hatch atch

switchconnector D) .an d detach he hatchactuator

connectorand hatch atchswitchconnector ro mthe ha tch .

Faslener ocations

) : Bolt,3

t t b

L-i-'-3;li9#-

11,0g tm,7 .2 lb ft l

Removehe bo l t s ,henpu l l t hehatch atch E) u t ,then remove t.

I ns ta l l t hea tch n he reverse rder f remova l , ndnote hese tems:

. Makesure eachconnector s plugged n properly,

and he rod and cableare connected roperly.. l\4ake ure he cableactuates he latchbeforeyou

c lose he ha tch .. Makesure he hatchopensproperlyand ocks

securely.



HatchLockCylinderReplacement

NOTE;Pu ton gloves o protect our hands.

'1 .Remove hese tems:

. Hatch ower rim panel se epage20-53).

. Rear icense rim (seepage20-98).

2. Disconnecthe cylinder od (A )

- . .

From outside he hatch, emove he bolt securing

the oc kcylinder A}.From nside he hatch,pull th e

lock y l inder u t by re leas inghe hook B) .

FastenerLocation

> : Bolt,1

rS'l-.u-ar

6 x 1 . 0m m9 . 8 N m(1.0 gf m,7.2lbt.ftl

*/t

4. Install he oc kcylinder n the reverse rder of


. Makesure he rod s connected roperly.

. Makesure he hatchopensproperlyan d ocks

securely.

20-1



Frame

SubframeReplacement

SubframeTorque

NOTE:After oosening he subframemountingbolts,be sure o replace hem with new ones.

Reference olesalignment:

SUBFRAMEREFERENCEOLE(Body ide)

INSTALLATIONREFERENCEOLE(Subframeide)

INSTALLATIONREFERENCEOL E

FRONTSUSPENSIONSCREWDRIVERor TAPERED UNCH INSTALLATION

REFERENCEOL E

SPECIALBOLTS' 14x 1 .5mm103N. m(10.5 gf.m,75lbf.ft)R ep lac e .

To body.

To body.I

n

E



FrameStiffener,Brace, nd GussetReplacement

FrameStiffener, race, ndGusset orque

NOTE:When nstall ing he middle loor cross member braceor gussets, orque he mountinghardware n th e

following sequence o avoid damage o thequarterpanel.

MIDDLELOOR

CROSS-MEMgERBRACE/GUSSET

SIDEFRAME TIFFENER

8 x 1 .25mm29 N.m(3.0 gf m,22 lbf t)

U.S.model:

10x 1 .25mm38 N. m(3.9 gf.m.28lbf.ftl

To body.

Canada odel:

MIDDLE LOORCROSS.MEMBERGUSSET

MIODLELOORCROSS-MEMBERBRACE

..__!:::--

| -

10x 1 .25m m38 N m (3.9kgt.m, 28 lbf.ftl

10x 1 .25mm3 8 N m(3.9 gf.m,28 bl . f t l

I

20-1



Frame

FrameRepairChart

Top view

Unit:mm {in.}o: Innerdiametel

a

b1b2b3c lc2c3

Fo rsublrame 1510.59)Fo renginemounte1 3 0.511

Fo renginemounto1 3 0.51)

Fo renginemount l3 (0.51)

Fo rmanual ransmission ouoto1 3 0.5'Fo rmanual ransmission ounto1 310.5'Fo rmanual .ansmission o!nt d1 3 0.51)

o

Ig

h

Fordampermounts11.5 0.45}For dampercentero78 (3.07)

Fo rdampermounts11.5 0.451

Fo rdampeimountd11.5 0.45)Fo rsubframe 15 0. 591Localingholes25 {0.98}Locating ol ee5 0 1.97)

\

VEFTICALUNE

20-114



t1, t2

x1

x2

K

m

n

pq

Locatinghole d25 (0.981

For rail ing.rm l3 10.51)Locatingholeo25 (0.981

Locatinghole s20 (0.79)

Trailingarm centerReardampercenterFo rupper rmo1 3 0.51)

For rail ing rmd1 3 0.511

For upper arm bracketcenter l5 {0.59)Locating oles1 3 0.51)

Fo ruppe.arm o13 0.511For ear ower arm cent€rLocating ol es5 0 1.97)

Locatinghole s20 (0.79)

Locatinghole o25 (0.981

(con

20-1



rameRepairChart cont'dl

Sideview

Unitrmm in.)o: InnerdiameteJ

a

b1b2b3c lc2c3

Forsubframe015 {0.59}Forenginemounto1 3 0.511

Forenginemount01310.51)Forenginemount11 3 0.511

Fo rmanual ransmission ount01 3 0.51)Fo rmanual rensmission ount61 3 0.51}Fo rmanual rrnsmissionmounro1 3 0.51}

Fordampermounto11.5 0.45)Fordampercenter 78 {3.07}Fordampermounto11.5 0.45)

Fordampermount 11.5 0./t5lForsubtrame l5 10.591Locatingholeo25 (0.98)

Locatingholes 11.97)

o

eI

sh

i

\

SECTIOiI A

BASEUNE

trr2xt.6 l

VERTICAILINE



x lx2

m

pq

Locatinghole o25 {0.98)For rail ing rm61 3 0.511Locatinghole d25{0.98}Locatinghole r20 {0.79)Trailingarm centerReardampercentelFo rupper rmo1 3 0.51)

11, 2

For rail ing rm s1 3 0.51}For upperarm bracketcentero15 {0.591Locating oleo1 3 0.51}Fo rupper rm d13 0.51)For ear ower arm centeiLocating oleo5 0 1.97}Locatinghole a20{0.79}Locetinghole s25 (0.98)

20-



21-2z t-'5

z t -o

z t -o

21-821-9

21-1021-1121-14z t - o

HVAC Heating, entilation,ndAirGonditioningl

Heating ndAir ConditioningSpec ia lToo lsComoonentocationndex . . . . . . . .A/CService iosand

PrecautionsA,/CRefrigerant il

ReDlacementGeneral roubleshooting

lnformationDTC roubleshootingndex . . . . . . .Symptom roubleshooting

1 n d e x . . . . . . . . . . . . . .System escript ion.. . . . . . . . . . . . . . . . . . .Circuit iagramDTC roub leshoot ing. . . . . . . . . . . . . . . . .Recirculat ionontrolMotor

CircuitTroubleshooting.. . . . . . . .1-25Heater ontrol ower ndGround

Circuits roubleshooting.. . . . . . 1-27CondenseranCircuit

Troubleshooting.. . . . . . . . . . . . . . . . . . . .1-28RadiatorndCondenserans

Common ircuit

Troubfeshooting.. . . . . . . . . . . . . . . . . . . .1-29Compressorlutch ircuitTroub leshoot ing. . . . . . . . . . . . . . . . . . . . .1-30

A,/C ressure witchCircuitTroubleshooting.. . . . . . . . . . . . . . . . . . . .1-32

Air Mix ControlMotorTestandReolacement.. . . . . . . . . . .1-34

ModeControlMotorTest ndReplacement.. . . . . . . . . . .1-35

Recirculat ionontrolMotorTest ndReolacement.. . . . . . . . . . .1-36

Evaporatoremperatureensor

ReolacementndTest . . . . . . . . . . . . .1-31Power ransistorest . . . . . . . . . . . .. . . . .1 38

Heater ontrol anel ndPushSwitch ssemblvRemoval nd nstal lat ion.. . . . . . 1-38

Dust ndPol len i l terReo lacement . .21-39

BlowerUnitRemoval ndlnstal lat ion .. . . . . 1-39

BlowerUnitComoonentsReDlacement. . . . . . . . . . . . . . . . . . . . . . . . . . .1 -41

EvaporatororeReo lacement . .21-42

*HeaterUnit /CoreReDlacement . .21-43

Heater alveCableAd jus tment . . . . .21-46

CompressorReplacement.. . . . . . . .1-47Comoressorlutch heck . . . . . . . . .1-48ComoressorlutchOverhaul . . . .21-49Compressorhermal rotector

Reo1acement. . . . . . . . . . . . . . . . . . . . . . . . . . .1 -51Comoressorel ief alve

Reo lacement. . . . . . . . . . . . . . . . . . . . . . . . . . .1 -51Condensereolacement.. . . . . . . . . .1-52Refr igerantecovery . . . . . . . . . . . .. . . . .1-53System vacuation.. . . . . . . . . . . . . . . . . . . .1-54System harginS... . . . . . . . . . . . . . . . . . . . . .1-55

Refr igeranteakTest . . . . . . . . . . . . .. . . .1-56A,/C vstem ests . . . . . . . . . . . . .. . . . . . . . . . .1-57



HVAC Heating, entilation, ndAir Conditioning)

SpecialTools

Ret.No. Tool Number DescriDtion Otvo 07sAz-001000A Backprobe et 2

---2att-,,- KCe/'Tt

"-t--'

e^t"'

21-2



Heating ndAir Gonditioning


SERVICEALVE{LOW.PRESSUBEIDEI

EVAPORATORORE(Built-inheheater nit)Bep lacement ,age 142

COMPRESSORBeplacement, ag e21 47ClutchCheck, ag e21-48C lu t chOverhau l ,age 1 -49ThermalProtector heck, ag e21-48ThermalProtector eplacement,ag e21 51Re l i e f a l veRep lacem en t ,age 151

SERVICEALVE{HIGH-PRESSUREIDEI

RECEIVER/DRYER

CONOENSEBReplacement,ag e21-52



Heating ndAir Conditioning

ComponentLocation ndex cont'dl

CONDENSER ANTest, page 22-51

RADIATOR AN RELAYTest,page22-51

Tesl, page 22-51CLUTCHRELAY

MOTORRELAYTest, page 22-5I


.. .A/C PRESSUREWITCH

RADIATORFAN

\

.\\

-

' - t

t _ ] ] l

/ l I T I -

- : : - -

l- -l -

CONOENSER AN

21-4



HEATER NIT/COREBeplacement,ag e 1-43

BLOWENNI TRemovalnd nstallation,ag e 1-39

HEATER ALVECABLEAdjustment,ag e 1-46

BLOWERUNITCOMPONENTSReplacement,ag e 1-41

DUSTAND OLLENFILTERReplacement,age 1'39

RECIRCULATIONONTROLMOTORTest, ag e 1-36Replacement,ag e 1-36

MODE CONTROLMOTORTest,page21-35

Replacement,age21-35

AIR MIXCONTROLMOTORTest, age 1'34Replacement,ag e 1'34

POWERTRANSISTORTest,page21-38

HEATERCONTROLPANELRemovaland nstallat ion, ag e21 38

PUSHSWITCHASSEMBLYRemoval nd Installat ion, ag e21'38EVAPORATOR EMPERATURE

SENSORReplacement,ag e21-37Test,page21-37

21




A/C ServiceTips and Precautions

Compressed ir mixed with R-134a orms a

combust ib leapor .Thevapor anburnor exp lode aus ing er iousin ju ry .

Never usecompressed ir o pressure es t

R-134a erv ice qu ipment r veh ic le i r

cond i t ion ingystems.

Ai r cond i t ion ingef r igerantr ubr i cant apor

can rritate our eyes,nose,or throat.

Be carefulwhen connecting erviceequipment.Do not breathe efrigerant r vapor.

Thea i rcond i t ion ingystem sesHFC-134aR-134a)

re f igerant ndpo lya lky leneg lyco lPAG) ef igerant i l ,

wh icharenotcompat ib le i t h CFC'12R-12)e f r igerant

andminera l i l .Do notuseR- '12ef r igerantr m inera l

oi l in his system,and do not aftempt o useR 12

serv ic ing qu ipment ; amage o thea i rcond i t ion ing

system r yourserv ic ing qu ipment i l l resu l t .

Useon lyserv ice qu ipmenthat s U.L . - l i s tednd s

certif ied o meet he requirements f SAEJ2210 o

removeR-134arom hea i rcond i t ion ingystem.

lf accidental ystemdischarge ccurs, entilate he

workareabefore esuming erv ice .

R-134a erv ice qu ipment r veh ic le i rcond i t ion ing

systems houldnot be pressure estedor leak ested

wi thcompressed i r .

Add i t iona l ea l th ndsafe tyn format ion ay be

obtained rom the refrigerant nd ubricant

manufacturers .

. Always disconnect he negative able rom the

bat te ry henever ep lac ing i rcond i t ion ingar ts .. Keepmoistureand dirt out of the system.When

d isconnect ingny ines, lugor cap he i t t i ngs

immediately; on't remove he capsor plugsuntiliustbe{oreyou reconnect ac h ine.

' Before onnect ing ny hose r ine , pp lya few drops

of relrigerant i l to the O-ring.. When igh ten ing r loosen ing f i t t i ng , sea second

wrench o support he matching itt ing.. Whend ischarg inghe sys tem, sea R- '134a

ref igerant ecovery/recycling/charg ingtation;don'trelease efrigerant nto he atmosphere.

21-6

A: 130m0 {4 l/3 t l.oz,4.6 mp.oz)

] , ^

A/C Refrigerant l l Replacement

RecommendedAGoi l :KEIHIN P 10:

. P/N38897-P3-A01AH:12 0

m0 4 fl oz)

. P/N38899-P13'A01:0 m0 1 1/3 l oz )

Add the recommended efrigerant i l in the amount

listed f you replaceany of the following parts.

. To avo id on taminat ion .o no t e tu rn he o i l t o he

conta iner nced ispensed,ndnevermix t w i tho therrefrigerant i ls.

. lmmedia te ly f ' t e r s ing he o i l , e ins ta l l t heapon

the container, nd seal t to avoidmoisture

aosorpron.. Donotsp i l l he ef r igeranti l on heveh ic le ;t may

damage he paint. f it getson the paint,wash t off

immedia te ly .

Condenser . . . . . . . . . .25A 516l .oz , .9 mp.oz)

Evapora tor. . . . . . . . . .5 m0 (1 113I l .oz ,1.4lmp.oz)

L ineor hose . . . . . . . . .10

m0 1/3 l .oz ,0 .4mp.oz)

Rece iver /Dryer. . .10

m0 ( '113l .oz ,0 .4mp.oz)Leakage epai ....25 m0, 51 6l oz,0.9 mp.oz)

Compressor . . . . . . . .o rcompressorep lacemenl ,subt rac thevo lumeof o i l d ra ined

from the removedcompressor ro m

130m0 (41/3 f l .oz , .6 lmp.oz) ,nd

dra in he ca lcu la tedo lumeof o i l

f rom the new compressor:13 0

m0

i .4113l .oz ,4 .6mp.oz) Vo lume fremovedcompressor= Volume o

dra in rom newcompressor .

NOTE:Even f no oil is drained ro m

the removedcompressor, on'td ainmore han 50 m0 \1 2/3 l.oz,'1 .8lmp oz) f rom he new

compressor .

\

REMOVEDCOMPBESSOR

r A\ l i\.. rJ

\tbI

,lEL.-"o*t tu"

NE WCOMPRESSOR

/- a\i t l

\r /

\:)-) -/

_ 0 L'r:l_I I I DRAINING_*lH I voLUME



Discharge ose o the compressor 6x 1.0mm) : 9.8N. m {1.0 gf.m,7.2 bl. f t}Discharge ose o the condenser5x 1.0mm l : 9. 8N. m {1.0 gt.m,7.2 bf f t)Condenserine o the condenser 6x 1. 0mm) : 9.8N. m {1.0 gf,m,7.2 bt. f t}Condenser ne o the receiver/dryer6x 1.0mm} : 9.8N. m (1.0 gt.f i,7.2lbt. lt lReceiverineAtothe receiver/dryer6x 1.0mm} : 9.8 N.m {1.0 gf m. 7.2 bf ft }Receiverin eA to the receivei ine B : 13 N.m (1.3 gr.m,9. 4 bf.f t)Receiverine B and he suction ine o the evaporator 6x 1.0mm) :9.8 N.m 11.0 gf.m,7,2 bf. f t)Suction line to the suction hose : 3l N m {3.2kgf.m, 23 lbf ftlSuctionhose1o he compressor 6x 1.0mm) : 9.8N. m 11.0 gf.m.?.2 bf. lt)Compressor o the compressor b.acket {8 x 1.25 mm) : 22 N m {2.2kgt.m, 16 bf.ft)Compr€ssor racket o the engineblock 10x 1.25mm} : ,1 4N. m 14.5 gf.m,33 bf.f t)

RECEIVERINEA

RECEIVER/DRYE

CONDENSERIN

21





How to Retrievea DTC

The heater ontrolpanelhas a self-diagnosisunction.To run he self-diagnosisunction,do the following:

1 . Turn he an swi t chOFF.

2. Pressandholdthe recirculation ontrolswitch andthe rearwindow defoooer witchdown.

3 . Turn he gn i t ion w i t ch N { l l i .

4. Releas e oth switches. he recirculationndicatorand he rearwindow defogger ndicator ome on. Therecirculationndicatorgoesoff 3 seconds aterand he Ay'Cndicator omeson. hen he self-diagnosis i l l begin.About 10seconds ater, he self-diagnosis il l f inish and he A,/Cndicatorgoesoff.

. l f anyt roub le is found. therec i rcu la t ion ind ica torb l inks thediagnost i c t roub lecode(DTC) to ind ica tea fau l t y

circuilor comDonent.. lf the system s OK, he recirculationndicator taysoff.

at c

@ rRECIRCULATIONCONTROL WITCH

BECIRCULATIONINDICATOB

/A\

-:@

INOICATOR

REARWINDOWOEFOGGERNDICATOR

REARWINDOWDEFOGGERWITCH

Examole of DTC ndication Pattern IDTC7)

DTC 7

Reseiting the Selt-diagnosisFunction

Turn he ignit ionswitch OFF o cancel he self-diagnosisunction.Aftercompleting epairwork, run he self-diagnosisfunct ion oa in o make ure ha t there reno o thermal funct ions.

Recirculation +indicatot

Recirculat ion +indicalorgo6s

of t

----->

21-8




In caseof multipleproblems, he recirculationndicatorwill indicate nly the DT Cwith the leastnumber of blin ks.ln caseof an ntermittent ailure, he heater ontrolpanelwill store he DTCuntil he ignit ion s turnedoff.

DTC RecirculationIndication links)

Detection ltem Page

7 An open n hea i r m ix cont ro lmotorc i rcu i t (see aqe21-16)

8 A short n the air mix controlmotor circuit (seeDaoe 1- '16)9 A prob lem n hea i rm ix cont ro l inkaqe, oor ,o r motor (see aqe21- 7 )1 0 An open or shon in the mode controlmotorcircuit (see aqe21-18)1 1 A prob lem n he modecont ro l i nkage, oors , r motor (see aqe2 1 1 9 112 A prob lem n he b lowermotorc i rcu i t (see aqe21-20)1 3 A problem n the EEPROMn th e heatercontrolpanel;

the controloanelmust be reolaced

(see age21-38)

1 4 An ooen n the evaDoratoremDerature ensorcircuit (seepaqe21-23)A short n the evaDoraloremoerature ensorcircuit (see aqe21-241

21



Air Conditioning

Svmptom Diagnostic rocedure Also check for

Recirculation ontroldoors do no t

changebetweenFreshand Recirculate

Recirculation ontrolMotor

CircuitTroubleshooting se epage21 251

Clean l inessnd igh tness f a l l

connectors

Bothheaterand Ay'C o not work Heater ontrol ower ndGroundCircuits roubleshootingse epage21-27)

BlownuseNo. 14(10A)n heunder-dashuse/relayoxPoor round t G501Cleanl inessnd ightnessfa l lconneclors

Condenseran doesnot run at all (but

radiator an runswith the Ay'C n)

Condenser anCi rcu i tTroubleshooting seepage21-28)

. Poorgroundat G301

. Clean l inessnd igh tness f a l l

connectors

Both ans do not run with theA,/C n RadiatorndCondenseransCommon ircuit roubleshooting(see age 1-29)

Blown useNo.1 (20A) ndNo.4(20A) n the under-hood use/relay

bo x

Poor roundat G30 l

C lean l inessnd igh tness f a l lconnectors

Compressor lutchdoes not engage(both ans run with A,/C n)

CompressorClutchCircuit

T roub leshoot inqseeDaqe 1-30)

Clean l inessnd igh tness f a l l

connectors

A/C systemdoes not come on (both

fans and compressor)

Ay'C ressure witchCircuitT roub leshoot ingsee age21-32)

Blown useNo. 1 (20A) ndNo.4(20A) n the under-hooduse/relay

bo xPoorgroundat G301Clean l inessnd igh tness f a l lconnectors

\SymptomTroubleshootingndex

\

!



SystemDescription

HeaterControlPanelnputsandOutputs

CONNECTOR{r/rP)

CONNECTOR

CONNECTOR

HEATER ONTFOLPANELCONNECIORS

CONNECTOR (22P)

W re s de o i tema e term na ls

Cavity Wirecolor_| \ ln Y AI RMIXPOTENTIAL5V

SionalOUTPUT

2 LTGRN SENSOROMMON ROUND INPUT

3 PNK/BLU AIR MIX HO T OUTPUTBLU A,/C RESSUREWITCH INPUT

5 GRNA/EL RECIRCULATE INPUT6 GRNA/VHT FRESH INPUT7 BLUI/EL POWERRANSISTOR OUTPUT8 BLU/RED BLOWER EEDBACK INPUTI G R N AIRMIX COOL OUTPUT1 0 YEL/RED MODEDEF OUTPUT1 1 . YEVBTU

YEL/BLKMODEVENTREARWINDOWDEFOGGER ELAY

OUTPUTINPUT

BLK G R O U N D OUTPUT1 4 BLK/YEL lG2 Power) INPUT

B onCavity Wire color Siqnal

1--T

23 BLIVRED REARWINDOWDEFOGGERWITCH ED INPUT4 LT GRN A./CSWITCH ED INPUT5 LTGRN/BLK RECIRCULATIONONTROL WITCH ED INPUT6 PNVBLK AIR MIX POTENTIAL OUTPUT7 B R N EVAPORATOREIMPERATUREENSOR OUTPUT891 0

GAUGE SSEMBLY al ' 'TDr r i1 REDRED/BLK TAILLIGHTS ELAY INPUT

1 4 BLU REARWINDOWDEFOGGER WITCH INPUTi c LT GRN/RED A/C SWITCH INPUT1 6 YEVRED RECIRCULATIONONTROL WITCH INPUT1 7 YEUGRN MODE4 OUTPUT1 8 WHT/BLU MODE3 OUTPUT1 9 RED/BLU MODE OUTPUT20 RED/YEL MODE1 OUTPUT

BRN^,^/HT IGN Powed OUTPUT22 REDA/r'HT (Notused)

(cont

21-




SystemDescriptioncont'dl

The air conditioning ystem emovesheat ro m the passenger ompartmentby circulating efrigera nthrough he

systemas shown below.

/

BLOWERAN

\ \\ r

\, u

EXPANSION ALVE(Meters he requiredamountof refr igerantinto he evaporator)

A/C PRESSURE WITCHWhen he refr iqerants below196 Pa 2.0kgi/cm',28psi)or above3,140 Pa 32kgf/cm'45 5psi), he Py'c ressureswitchopens he circuit othe Py'C witchand stops he

air condit ioning o protect hecompressor-

RECEIVER/DRYER(Traps ebris, ndremoves orsturel

APOBATOR EMPERATURESENSOR

THERMAL ROTECTOR(Openshe compressor lutchcircuitwhen the compressot emperaturebecomes oo high)

RELIEFALVE(Relievesressuret hecompressor

whenhepressures o oh igh)

A/C COMPRESSOR(Suction nd comoression)

\-^

I HrcH RESSUREAPoR

[ '.... -:--lLowPREsSUBErourD

tffi Low PREssUREAPoR

This vehicleusesHFC-134aR-'134a)efrigerantwhich doesnot containch orofluorocarbons. ayattention o the

followingservice tems:

. Donot mix re f r igerantsFC-12R-12) ndHFC-134aR-134a) .heyarenotcompat ib le .

. Useon ly the ecommendedo lya lky leneg lyco lPAG ref r igerat o i l (KElH lN P!0)

des ignedfor theR-134acompressor. ntermixing he recommended PAG) efrigerant il with any other retrigerant i l wil l result n

compressor ailu e..

AllAy'C ystempartscompressor,

ischarge ine,suction ine,evaporator, ondenser, eceiver/dryer. xpansionvalve,O-rings or joints)have o be designed or refrigerantR 134a.Do not exchangewith R-'12 arts.. Us ea halogenga s ea kdetectordesigned or refrigerantR-134a.. R-12 nd R-134a efrigerant ervicingequipmentare not nterchangeable. se only a recovery/recyc ling/charging

sta t ionhat s U.L . - l i s tednd scer t i f i edo meet he requ i rementsf SAE 2210 o serv ice -134a i rcond i t ion ing

system.. Always recover he refrigerantR-134a ith an approved ecovery/recycling/chargingtationbeforedisconnecting

an y Ay'Cift ing.

/ -

CONDENSER(Radiat ion f heat)

21-12



Heating ndAirConditioning

GircuitDiagram

UNDENcODFUSVRELIYSOXUNOER ASNfUSE/8EIlYBOX

|GNUION WTCfilG2HoI i 0l\l lll

+. C}F BLK/RED\ rG2

IIIII

n.

G301

A/C nESSUEtswTOt

t...iCF

RADIATOS

oT0n

\ NADIATOS) tAl'/

/ swtlcllj19S"F93"C) l

CONDEN$N

MOTOB

Iu(

ILX

IG301

l

;

/.I

\ IHEFMAI

YPBorEcro8

lTl *n*,*,| <l I CLUTCHtf_l

MUITIPLD(CONTFOIUNITI

-!10. irgF 8Ll

T TBLU

I ilnthoundor dasiuse/lelayox

21-14



- BU/YEL

-8lU/wH'I

EVAPORATOBTEMPERATUNESENSOR

sn 4-Lrenil

ffftH,,*u,*

YEUBLU

YEL/NED

BED/YEI

RED/8LU

WHT/8LU

YEL/GRN

LTGRI'l

GNNMHT

GRN/YEL

8LK--..-...-l( coNNEcroFrir.Pt

f mxr{EcroB{2P)G5'1

8U

IG602

m

::-:::: ., . a/c

M DEF

MODEl

Mq)EI

M00€2

M00t3

MOOE3

MOOEI

M00lco TnoLMOTOS

s

21-




DTCTroubleshooting

DTC :An Open n heAir MixControlMotorCircuit

1. Test he air mix control motor {seepage2'l-341.

ls the air mix control motor OK?

YES-Go to step2.

NO-Rep lace he a i r m ix cont ro lmotor . l

2. Disconnecthe air mix controlmotor 5Pconnector.

3. Disconnect eatercontrolpanelconnectors {14P)andB (22P) .

4. Check or continuitybetween he following

terminalsof heatercontrolpanelconnectors(14P) nd B (22P) nd he air mix controlmotor 5P

connector,14P: 5P:N o .1 N o . 5

N o . 2 N o . 4

N o . 3 N o . 2

N o . 9 N o .1

22P: 5P:N o . 6 N o . 3

Wire side ol lem.letehi.6ls

ls therecontinuity?

YES-Check or loosewires or poor connections t

heatercontroloanelconnectorsA (14P) nd B (22P)

and at the air mix con trol motor 5Pconnector. f theconnections re good.substitute known-goodai r

mix controlmotor, and recheck,f the symptom/

indication oe saway, replace he originalair mix

controlmotor. f the symptom/indication ontinues,

substitute known-goodheater ontrolpanel,an d

recheck. f the symptom/indication oe saway,

replace he originalheatercontrolpanel.l

NO Repa i r nyopen n thewi re(s) e tweenthe

heatercontrolpanelan d he air mix control

motor.l

21-16

DTC :A Short n heAir MixControlMotorCircuit

1. Test he air mix controlmotor(see page21-341.

ls the ai t mix controlmotor OK ?

YES-Go to step2.

NO-Replace the air mix contorolmotor.I

2. Disconnecthe air mix controlmotor 5P connector.

3. Disconnect eatercontrolpanelconnectorsA (14P)

andB (22P) .

4. Check or continuitybetweenbodygroundan d

heater ontrolpanelconnectorA (14P)erminalsNo. 1,2, 3, and 9 individually, nd betweenbodygroundand heater ontrolpanelconnectorB (22P)

term ina lNo.6 .

HEATERCONTROLANELCONNECTOR {I4PI

HEATERCONTFOL PANELCONNECTOR I22P1


YES-Repa i r nyshor t tobodyground n he

wire(s)between he heater ontrolpaneland he air

mix controlmotor.l

NO-Go to s tep5.

Wireside f emale erminals

Wiresideo i lema e ermina ls



5. Turn he gnitionswitch ON (ll),an d check he sameterminals or voltage.

HEATER ONTROL ANELCONNECTOR {14PI

HEATER ONTROL ANELCONNECTOR I22PI


ls thereany voltage?

YES-Repair any short o power n th e wire(s)

between he heater ontrolpanelan d he air mixcontrolmotor.This short may also damage heheater ontrolpanel.Repair he short o power

before eplacing he heater ontrolpanel.l

NO Substitute known-good ir mi x controlmotor,and recheck.f the symptom/indication oes

away, replace he originalair mix control motor. f

the symptom/indication ontinues, ubstitutea

known-good eater ontrolpanel,and recheck.fth e symptom/indication oe saway, replace he

or ig ina l ea ter on t ro l ane l . I


DTC :A Problem n the Air Mix ControlLinkage, oor, r Motor

1, Test he air mix control motor (seepage21-34).

ls the air mix control motor OK?

YES-Substitute a known-goodheater ontrolpanel,an d recheck. f the symptom/indication oes

away, replace he originalheater ontrolpanel.l

NO-Replace the air mi x controlmotor,or repair

the inkage nddoor . l

21-1




DTCTroubleshooting.(cont'd)

DTC 0:An Open r Short n heModeControlMotorCircuit

1. Test he modecontrolmotor (seepage21-35).

ls the modecottol motor OK ?

YES Go o step 2.

NO Replace he mode controlmotor.I

Disconnecthe mode controlmotor 10Pconnector.

D isconnecteater on t ro l ane l onnectors (14P)

and B \22P1.


heater on t ro l ane l onnector (14P)ermina lsNo.2 , 10 ,and 11 nd iv idua l l y ,ndbetween odygroundandheater on t ro l ane l onnector (22P)

term ina ls o .17 ,

18,19,and20 nd iv idua l l y .

HEATERONTROLANEL ONNECTOR{14PI

2.

3.



YES Repa i r nyshor t tobodyground n hewire(s)between he heater ontrolpanelan d hemode controlmotor.l

NO Go o step 5.

HEATER ONTROL ANELCONNECTOR {22P)

Wire side o f femaLe ermina ls

21-18

5. Turn he gn i t ion w i t chON ( l l ) , ndcheck he sametermina lsor vo l tage.

HEATEBONTROLANEL ONNECTOR{14P)

Wire sideof female erminal

HEATER ONTROL ANELCONNECTOR {22PI

3 5 X 6

t l 12 15 T6 1 1 1 8 t 9 2A 21 22

RED/YELWHT

Wireside f emaleerminals

ls there any voltage?

YES-.Repairany short o power n the wire(s)

between he heater ontrolpaneland he mode

controlmotor.This short may a lso damage he

heater ontrolpanel.Repair he short o power

before eplacing he heatercontrolpanel.l

NO- Go o step6.



Turn he ignit ionswitchOFF,and check orcontinuitybetween he following erminalsofheater ontrolpanelconnectors (14P) nd B (22P)

and he mode controlmotor 10Pconnector.14P: 10P:

No.2 No.10

No.10 No,1

N o . 1 N o . 2

22P: 10P:N o .1 7 N o . 8N o .1 8 N o . 6 , 9N o .1 9 N o . 5

No.20 No.4,7

HEATER ONTROLANEL ONNECTOR(14PIWire ide f emaleerminals

HEATERCONTROLPANELCONNECTORB {22PIWire sideof female erminals


YES-Check or loosewires or poorconnections t

heater ontrolpanelconnectors (14P) nd B (22P),

and at the mode controlmotor 10P onnector. f the

connections regood,substitute known-goodmode controlmotor, and recheck.f the symptom/

indication oe saway. eplace he originalmode

controlmotor.lf he symptom/indication ontinues,substitute known-good eater ontrolpanel,an drecheck.f the symptom/indication oe saway,

replace he originalheater ontrolpanel.l

NO Repairan y open n the wire(s)between heheater ontrolDanel nd he mode controlmotor.l

MODECONTROLMOTOR OPCONNECTORWire ide f emaleerminals

DTC 1:A Problemn he ModeControlLinkage, oors, r Motor

1. Testthe mode controlmotor (seepage21-35).

ls the mode control motor OK?

YES Substitute known-goodheater ontrolpanel,an d recheck. f the symptom/indication oe s


NO Replacehe mode controlmotor,or repair hel inkage nddoors . l

21-



Heating ndAirGonditioning


DTC 2:A Problemn heBlowerMotorCircuit

' 1 .Checkhe No.12 40A) fusenthe under -hoodfuse/relay ox, and he No. 14 10A) use n th e

under-dashuse/relay ox.

Are the tuses OK?

YES-Go to step2.

NO Replacehe fuse(s), nd recheck.l

2. Connect he No. 2 terminalof the b lower motor 2P

connector o body groundwith a umperwire.

BLOWERMOTOB2P CONNECTOR

JUMPER BLU/BLK

Wire ide l femaleerminals

3 . Turn he gn i t ion w i t chON( l l ) .

Does the blowet motor run?

YE S Go to step4,

NO Go o step 17 .


5. Disconnecthe umper wire.

6. Disconnecthe power ransistor4Pconnector.

21-20

8.

7. Check or continuitybetween he No .3 terminalof

th e power ransistor4Pconnectorand body ground.

POWERTRANSISTOR P CONNECTOR

Wire sideol temale erminals

ls therecontinuity?

YES-Go to step8.

NO-Check for an open n th e wire between hepower ransistorand body ground. f the wire is OK,

check or poor groundat G502.I

Connect he No. 1 and No. 3 terminalsof the power

transistor4P connectorwith a umper wire.

POWERRANSISTORPCONNECTOR



Does he blower motor un at high speed?

YES-Go to s tep10.

NO-Repair open n the wire between he power

transistorand he blowermotor.l


Disconnecthe jumper wire.

9 .

1 0 .

1 1 .

2

3 4

BLK

o



1 a

1 3 .

Disconnect eater ontrolpanelconnectorA (14P).

Check or continuitybetween he No. 7 and No. 8

terminalsof heater ontrolpanel

connectorA(14P)

andbodyground nd iv idua l l y .

HEATERONTNOLANEL ONNECTOR{14PI


YES Repairany shortto bod y ground n th e

wire(s)between he heater ontrolpaneland hepower ransistor.I

NO Go o step 14,

Check or continuitybetween he following

terminalsof heater ontrolpanelconnectorA (14P)

an d power ransistor4Pconnector.'l4Pt 4P:

N o . 7 N o . 4N o . 8 N o . 2

HEATERONTROLANEL ONNECTOR(14P)Wire sideot female erminals

I z 3 4 1 5 1 6

T 8 9 rox l I 1 2 l 3 1 4

)8LU/RED

ILU/YELPOWER RANSISTORPCONNECTOR



YES Go o step 15 .

NO Repairany open n the wire(s)between he

heater ontrolpaneland he power ransistor.l

1 4 .

BLU/YEL

15.

l o .

1 7 .

1 8 .

1 9 .

Reconnect eater ontrolpanelconnectorA (14P

Test he power ransistor seepage21-38).

ls thepower transistorOK ?

YE S Check or loosewires or poorconnections

heater ontrolpanelconnectorA (14P) nd at thepower ransistor4Pconnector. f the connections

ar e good,substitute known-goodheater ontrolpanel,and recheck.f the symptom/indication oe


NO Replacehe power ransistor.I

Disconnecthe umper wire.

Disconnecthe blowermotor 2P connector.

Measure he voltagebetween he No, 1 erminalo

the blower motor 2P connectorand body ground.

BLOWERMOTOR PCONNECTOR

BLU/WHT

Wireside f emaleerminals


YES- Replace he blower motor.l

NO Go o step 20.


Remove he blowermotor relay rom the under-

hood use/relay ox, and est t (seepage22-511.

ls the relay OK?

YES Go o step22 .

NO - Replacehe blower motor relay.l

20 .

2 1 .

(cont

21-





22. Measure he voltage between he No. 3 terminalofthe blower motor relay4Psocketand body ground.

BLOWERMOTORRELAY P SOCKET

2 1

4 3

23 .


YES-Go to step23 .

NO Replace he under-hood use/relay ox.t


Measure he voltagebetween he No. 2 terminalofthe blower motor relay4Psocketand body ground,

BLOWERMOTORRELAY P SOCKET


YES-Go o step25 .

NO Repair pen n hewirebetweenhe No.14fuse n he under-dashuse/relayoxand heblowermotor elay.I

21-22

25.

26.

Turn he ignit ionswitchOFF,


the blowe r motor relay4P socketan d body ground.

BLOWERMOTORRELAY PSOCKET

ls therecontinuity?

YES-Repair open n the BLUIr'/HTwire betweenthe blower motor relayan d he blower motor.l

NO Check or an open n the wire between heblower motor relayand body ground. f th e wire isOK, heck or poorground t G301.1

\



DTC 4:An Open n heEvaporatorTemperatureensor i rcuit

1. Remove he evaporator emperature ensorsee

page21-37) .

2. Measure he resistance etween he No. and

No. 2 terminalsof the evaporator emperature

sensor.x Dip he sensor n cewater , ndmeasure

resistance. hen pour ho t wateron the sensor,an d

check or changen res is tance.

EVAPORA

RESISTANCEk 0

TOR EMPERATUREENSOR

t-lll#l

l l , l , l lI UT-TU I--r---T--t ^11c))-l

\9/

50 6810 20

TEMPERATURE

ls the tesistancewithin the specifications hown

on thegraph?

YES-Go to s tep3.

NO Replace he evaporator emperature

sensor . I

3. Disconnect eater ontrol panelconnectorB {22P).

86 'F30 c

Term ina l i de f ma le e rm ina l s

4. Check or continuitybetween he No. 7 terminalofheater ontrolpanelconnectorB (22P) nd heNo. 1 erminalof the evaporalor emperature

sensor Pconnector .

HEATER ONTROL ANELCONNECTOR {22P)Wire ideof emaleerminals

EVAPORATOREMPERATUREENSOR PCONNECTO

Wire id e f emaleerminals


YES Go o step5.

NO Repairopen n the wire between he heater

control paneland he evaporator emperature

sensor . I

5. Disconnect eater ontrolpanelconnectorA (14P

(cont

21-



and Air Gonditioning

\


6. Check or continuitybetween he No. 2 terminalofheatercontrolpanelconnectorA (14P) nd heNo, 2 terminalof the evaporalor emperature

sensor2P connector.

HEATER ONTROL ANEL ONNECTOR{14PIWire ideof emaleerminals

LTGRN

EVAFORATOREMPERATUREENSOR PCONNECTOR


ls therecontinuity?

YES-Check or loosewires or Doorconnections theater ontrolpanelconnectorA ('l4P)and B l22Pland at the evaporator emperature ensor2Pconnector. f the connections regood,substituteknown-goodheater ontrol panel,and recheck.fthe symptom/indication oe saway, replace heoriginalheater ontrolpanel.l

NO Reoairooen n th e wire between he heatercontrolpaneland he evaporator emperaturesensor . I

4.

DTC 5:A Short n heEvaporatorTemperatureensor i rcuit

1. Remove he evaporator emperature ensor seepage21-37) .

2. Test he evaporator emperature ensor se epage

21-37 .

ls the resistance within the specifications shownon the graph?

YE S Go o step 3.

NO Replacehe evaporator emperaturesensor.

Disconnect eater ontrolpanelconnectorB l22Pl.

Check or continuitybetween he No. 7 terminalofheater ontrolpanelconnectorB {22P) nd bodyground.

HEATERONTROL ANEL ONNECTOR(22P)



YES Repairshort o body ground n th e wire

betvveenhe heatercontrolpanelan d heevaporator emperature ensor.

NO-Substitute a known-goodheater ontrolpanel,

and recheck.f the symptom/indication oe saway,replace he originalheater ontrolpanel.I



3.

Recirculation ontrolMotor CircuitTroubleshooting

1. Checkhe No. 14( '10A) fusenthe under -dashfuse/

relaybox.

ls th e f use OK?

YES Go to step2.

NO- Replace he fuse,an d recheck.l

2. Disconnecthe recirculation ontrolmotor 5P

conneclor.


lvleasurehe voltagebetween he No. 5 terminalof

th e recirculation ontrolmotor 5P connectoran d

body ground.

RECIRCULATION ONTROLMOTOR5P CONNECTOR

7 .



YES Go o step5.

NO- Repairopen n th e wire between he No. 14

fuse n the under-dashuse/relay ox and he

recirculation ontrolmotor . l


Testthe recirculation ontrolmotor {seepage21 -

36) ,

ls the recirculation ontrolmotor OK ?

YES Go o step7.

NO- Replacehe recirculation ontrolmotor,or

repa i r he inkage nddoors . I

Disconnect eater ontrolpanelconnectorA (14P).

5 .

6 .

8. Ch eck or continuitybetween he No. 5 and No. 6

terminalsof heater ontrol panelconnectorA (14P

and body ground ndividually.

HEATER ONTROL ANEL ONNECTORI14P)



YES Repairany shortto body ground n th e

wire(s)between he heater ontrolpaneland he

recirculation ontrolmotor.l

NO-Go to step9.

9. Turn he ignit ionswitchON (ll),and check he sam

wires or voltage.

HEATER ONTROLANEL ONNECTORIl4PI

Wire ide f emale erminals

ls therc any voltage?

YES Repa i r nyshonto power n hewi re(s)

between he heater ontrolpaneland he

recirculation ontrolmotor.This shon may also

damage he heater on t ro l ane l .Repa i rhe shon

to power before eplacing he heatercontrolpane l .

NO-Go to s tep10.

{cont

21




Recirculation ontrolMotor CircuitTroubleshootingcont'd!

10. Turn he ignit ionswirchOFF.

11. Check or continuitybetween he following

terminalsof heatercontrolpanel

connectorA(14P)an d he recirculation ontrol motor 5P connector.

' l4Pt5P :

N o . 5 N o .1N o . 6 N o . 2

HEATERONTROLANEL ONNECTOR{14P}Wire ideol emaleerminats

RECIRCULATIONONTROL OTOR PCONNECTORWire ide l emale erminals


YE S Check or loosewires or poor connections theater ontrolpanelconnectorA (14P) nd at therecirculation ontrol motor 5Pconneclor. f th econnections re good,substitute known-goodheater ontrolpanel,and recheck . f the symptom/indicationgoesaway, replace he originalheatercontrol panel,I

NO Repairany open n the wire{s)between heheater ontrolpaneland he recirculation ontrolmotor . l

21-26



HeaterControlPowerandGroundCircuitsTroubleshooting

1. Checkhe No.14 10A) fusen he under -dash

fuse/relay ox.

ls the fuse OK?

YES-Go to step2.

NO-Rep lace he use, nd echeck. l

2. Disconnect eater ontrolpanelconnectorA{'14P).

3. Turn he ignit ionswitchoN (ll).

4. Meas ure he voltagebetween he No. 4terminal

of heater ontrolpanelconnectorA (14P) nd body

grouno.

HEATER ONTROLANEL ONNECTOR{14P}

2 3 4 5 6

7 8 I 1 0 , 11 12 1 4


BLK/YEL


YES-Go to step5.

NO Repairopen n the wire betvveenhe No. 14

fuse n the under-dashuse/relay ox and he

heater ontrolpanel.l


6. Check or continuitybetween he No. 3terminal o

heater ontrolpanelconnectorA (14P) nd bodyg ound .

HEATER ONTRoL ANEL ONNEcToR (1ilP)

1 2 3 4 5 6

I 8 9 r0 , 1 l 12 1 4

BLK

.o

Wire sideof temaleterminals


YES Check or loosewires or poorconnections

healercontrolpanelconnectorA (14P).fthe

connections re good,substitute known-good

heatercontrolpanel,an d recheck.f the symptom

indicationgoesaway,replace he originalheater

controlpanel.l

NO Check or an open n the wire between he

heater ontrolpaneland body ground. f th e wire i

OK, heck or poorground t G501.

21




Condenser anCircuitTroubleshooting

NOTE: f neither he condenser an nor he radiator anwork, go to Radiator nd Condenser an sCommonCircuitTroubleshooting se epage21-29).

1. Check he No. 1 (20A) use n the under-hoodfuse/ re lay ox,and he No. 14 10A) fusen heunder-dashuse/relay ox.

Are the tuses OK?

YES-Go to step 2.

NO Replace he fuse(s), nd recheck.

2. Remove he condenser an relay rom theunder-hood use/relay ox, and es t t(see age22-51) .

ls the relay OK ?

YES Go o step3.

NO- Replacehe condenser an relay.l

3. Measure he voltagebetween he No, 2 terminal ofthe condenser an relay4Psocketan d body ground.

CONDENSER AN RELAY lP SOCKET


YES-Go to step 4.

NO-Replace the under-hood use/relay ox.l

21-28

4. Connecthe No. andNo.2 term ina lso f hecondenser an relay4Psocketwith a umper wire.

CONDENSER AN RELAY tP SOCKET

JUMPERWIRE

Does the condenser lan tun?

YES-Go to step5.

NO Go o step8.

5. Disconnecthe umperwire.


7. Measure he voltagebetween he No, 3 terminalofth e condenser an relay4P socketand bodyground.


YES Replacehe under-hood use/relay ox.t

NO-Repa i ropen n hewi re be tweenhe No.14fuse n the under-dashuse/relay ox and hecondenseran re lay . l

Disconnecthe umper wire.

CONDENSERAN FELAY4PSOCKET

r-,_-l1 2

Flr----1--rl

IELK/YEL

d,I



9.

1 0 .

Disconnecthe condenser an 2P connector,


the condenser an relay4Psocketand he No. 2terminalof the condenser an 2 P connector.

CONDENSERANRELAY PSOCKET

CONDENSER AN 2P CONNECTORWiresideof female erminals

Is there continuity?

YES Go o step 11.

NO- Repairopen n the wire between he

condenseran re lay nd he condenseran, I


the condenseran 2P connector nd bodyground.

CONDENSERAN2PCONNECTOR

1 2

BLK

o



YES- Replace he condenser an motor.I

NO Check or an open n the wire between hecondenser an and body ground. f th e wire is oK,

check or poorgroundat G301.1

'1 1.

Radiator ndCondenser ansCommonCircuitTroubleshooting

NOTE; f both ans and he Ay'C ompressor lutchdo

not work when the Ay'C witch s on , go to Ay'CPressuSwitchCircuitTroubleshootingse epage21-32l,

1. Check he No. 1 {20A}an d No. 4 (20A) uses n the

under-hood use/relay ox, and he No. 14(10A)

fuse n th e under-dashuse/relay ox.

Are the tuses OK?

YES Go o steD2.

NO Replace he fuse(s), nd recheck.l

2. Remove he condenser an relav rom the

under-hood use/relay ox.

3 . Turn he gn i t ion w i t chON ( l l ; .

4. Measure he voltagebetween he No. 3 terminalo

the condenseran relay4Psocketand body groun


YES Go o step5.

NO Repairopen n the wire between he No. 14

fuse n th e under-dashuse/relay ox and he

radiator an relay,and hecondenser an relay.l


6 . Re ins ta l lhecondenseran re lay .

7 . Make ure he VCswi tch s OFF.


(cont

CONDENSERANRELAY PSOCKET

r-,l

1 2 lf---r---

l , l , llar-vver-loI

21-




Radiatorand Condenser ansCommon(cont'dl

CircuitTroubleshooting

9. Usinga Backprobe et ,measure he voltagebetween he No.6 terminalof ECN4onnectorB{24P) nd body groundwith th e EC Mconnectorsconnecteo.

ECMCONNECTOR {24P}


YES UDdate he ECM f it does not have he latestso{tware, r substitute known-goodECM, he nrecheck seepage11-6).f the symptom/indicationgoesaway with a known-goodECM, eplace heor ig ina l CM. I

NO Repairopen n th e wire between he radiator

fan relay, he condenser an relayand he ECM.


21-30

CompressorClutchCircuitTroubleshooting

1. Check he No. 1 (20A) use n the under-hood

fuse/ re lay ox ,and he No.14 10A) fusen heunder-dashuse/relay ox.

Are the tuses OK ?

YES Go o step2.

NO Replacehe fuse(s), nd recheck.I

2. Check he enginecoolant emperature,he throttleposit ionsensor,and he dle speed us e he HondaPGMTesterPGM-Fl ata ist f possible).

ls the coolant temperaturc above nomal, the

throttle position sensor rcading too high, or theidle speed too low?

YES Troubleshoot nd repair he causeof thehigh enginecoolant emperature, igh hrottleposit ionsensor eading, r lo w idle speed.l

NO-Go to step3.

3. Remove he compressor lutch elay rom theunder-hood use/relay ox, and est t (seepage22 -5 1 .

ls the relay OK?

YES Go o step 4.

NO Replacehe compressor lutch elay.I

4. Measure he voltagebetween he No. 2 terminalofth e compressor lutch elay4Psocketand bodyground.

\

COMPfiESSONLUTCH ELAYP SOCKET


YES Go o step 5.

NO Replace he under-hood use/relay ox.I



5. Connect he No. 1 an d No. 2 terminalsof the

compressor lutch elay4Psocketwith a umper

wire.

COMPRESSOR LUTCHRELAY4P SOCKET

JUMPERWIRE

Does the compressor clutch click ?

YES Go o step6.

NO-Go to step14.

6. Disconnecthe umperwire.


8. Measure he voltagebetween he No. 3 terminalof

the compressor lutch relay4P socketand bodyground.

COMPRESSORLUTCH ELAY PSOCKET


YES-Go to step9.

NO Repairopen n th e wire between he No.fuse n the under-dashuse/relay ox and he

compressor lutch elay,

1 4

L Turn he ignit ionswitchOFF.

10. Reinstallthe ompres sor lutch elay.

11. l\4ake ure he Ay'C witch s OFF.

12. Turn he gn i t ion w i t chON { l l ) .

13. Uslng he Backprobe et ,measure he voltage

between he No. 18 ermina!of EC I\4 onnector

E{31P) nd body groundwith the ECMconnector

connected.

ECMCONNECTOR131P}

2 3 t 4 5 6 1 E 9

1 4 1 5 1 6 m 21

22 23 24 26 27 29 31

RED



YES Update he ECM f it does not have he lates


recheck se epage 11-6).f the symptom/indicatiogoesaway with a known-goodECIM,eplace he

or ig ina l CM. I

NO Repairopen n the wire between he

compressor lu tch e lay nd heECM. I

14. D isconnecthe umperwi re .

15. Disconnecthe compressor lutch Pconnector.

{cont

21-




Compressor lutchCircuitTroubleshootingcont'dl

16 . Check or continuitybetween he No. lterminal of

the compressor lutch elav4Psocketan d he No.terminalof the compressor lutch 1Pconneclor.

COMPRESSONLUTCH ELAY PSOCKET

COMPRESSOR LUTCH1P CONNECTORTerminal id eof male erminals


YES-Check he compressor lutchclearance,hethermalprotector, nd he compressor lutch ieldco i l see age21-48) . I

NO-Repair open n the wire between hecompressor lutch elayand he compressorc lu tch . l

A/C Pressure witchCircuitTroubleshooting

'1 .Turn he ignit ionswitchON {ll).

2. Turn he blower switchon, and check or blowermotor operatron.

Does the blower motor run on all speeds?

YE S Go o step 3.

NO Troubleshoothe blower motor circuit seepage21-20).


4. Disconnect eater ontrolpanelconnectorA ('14P).

5 . Turn he gn i t ion wi t chON ( l l ) .

6. Measure he voltagebetween he No ,4 terminalofheater ontrol panelconnectorA {14P) nd bodyground .

HEATER ONTROL ANEL ONNECTOR(I4P}

1 .


YES Go o step7.

NO-Go to s tep9.

Stan heeng ine .

Wiresideof female ermina's



8. Connect he No.4 erminal ofheatercontrolconnectorA (14P)o body groundwith a umper

wire,

HEATER ONTROL ANELCONNECTOR I14P}

BLU

2 3 4 5 6

7 8 I r 0 l x 11 12 l 3 t 4

JUMPER IBE


Does the A/C system come on?

YES Replacehe heater ontrolpanel.!

NO Refer o the multiplexcontrolsystem see

page 2-168) .1

Using he Backprobe et,connect he No. 9

terminalof under-dashuse/relay ox connectorF (12P)o bodygroundwi th a umperwi re .

UNOER.DASHUSE/RELAYOXCONNECTOR{12P}

9.

2 5

6 1 B g r ot l l 2

BLU/WHT

JUMPERWIRE


Does the NC system come on?

YE S Go o step 10 .

NO- Refer o the multiplexcontrolsystem se e

page 2-168) .1

NOTE: heckor mul t ip lex odes n mode1.

Fo l lowthe troubleshootingor any codes ound. f no

codesar e ound, subsititute known-9oodmul t ip lex on t ro l n i tanda ECMoneat a t ime.

Disconnecthe Ay'C ressure witch2Pconnectorand under-dashuse/relay ox connectorF { 12P).

1 0 .

'13.

21-

11 . Check or continuitybetween h e No. 2 terminalof

th e A,/C ressure witch 2Pconnectorand he No.9

terminalof under-dashuse relav box connector

F t12Pt.A/C PRESSURE WITCH PCONNECTOR


UNDER.OASH USE/RELAY OXCONNECTOR (12P)

Wiresideof enale errr inal '

ls therecontinuity?

YES Go o step 12.

NO Repairopen n th e wire between he

under-dash use/relay ox and he A,,/Cressure

switch.I


terminalsof the A,/C ressure witch.1 2 .

A/C PRESSURE WITCH


YES Repairopen n the wire betwee n he heater

controlpaneland he A,/C ressure witch.l

NO Go o s tep13.

check or properAy'C ystempressure.

ls thepressurewithinspecitications?

YES Replace he AilCpressure witch.l

NO Repair he AilCpressureproblem.I




Air MixControlMotorTest

1. Disconnecthe 5P connector rom the air mixcontrolmotor.

2. Connectbatterypowertothe No. terminaloftheair mix control motor,an d ground he No. 2te rm ina l ;hea i r m ix cont ro lmotorshou ld un ,andstop at Max Cool. f it doesn't, everse heconnections;the ir mix controlmotor should run,and stop at Max Hot. f the air mix controlmotordoes not run, remove t. hen check he air mixcontrol inkageand door for smoothmovement.

. lf th e linkageand door move smoothly, eplacethe air mix controlmotor.

. l f he inkage rdoors t ickorb ind , epa i r them sneeded.

. lf the air mi x controlmotor runs smoothly,go to

step3.

AIR MIXCONTROLMOTOR

3.

4 .

Measure he resistance etween he No. 4 andNo. 5 terminals. t should be between2. 1k o3 . 9 Q .

Reconnecthe air mix controlmotor 5Pconnector,then urn he gn i t ion wi tchON { l l ) .

Using he BackprobeSet,measure he voltagebetween he No . 3 and No. 4 terminals.

Ma x Cool about 1V

Max Hot about 4 V

lf either he resistance r voltage eadingsare notas specified, eplace he air mix cotrol motor.

21-34

Air Mix ControlMotor Replacement

1.Remove he under-d ash use/relay ox (seepage

22-491.

Disconnecthe5Pconnector A) rom the air mixcontrolmotor (B).Remove he self-tapping crews

and he air mix controlmotor rom the heaterunit.Removehe rod (C) rom hearm (D)o f he a i rmix

controi motor.

Install he motor n th e reverse rder of removal.After nstallation,makesure he motor runssmoothly.

3.

\'

,.,:l'



Mode ControlMotor Test

Disconnecthe 10P onnector rom the modecontrolmotor.

Connectbatterypower o the No. 1 terminalof themodecontrolmotor,an d ground he No. 2

terminal; he mode controlmotor should un

smoothlyand stop at Defrost. f it doesn't, everse

the connections;he mode controlmotor should

run smoothlyand stop at Vent.When he modecontrolmotor stops unning,disconnect atterypower mmediately.

'1 .

4 .

MODECONTROLMOTOR

3. lfthe mode controlmotor doesnot run n step 2,

remove t, hen check he modecontrol inkagean ddoors or smoothmovement.

. lf the l inkageand doorsmove smoothly. eplace

th e mode controlmotor.. l f he inkage rdoorss t i ck r b ind , epa i r them

as neeoeo.. lfthe mode controlmotor runssmoothly,go to

step 4.

Us ea digitalmultimeterwith an output of 1 mA or

lessat the 20 kQ range.With th e modecontrolmotor runningas n step2, check or continuitybetweenhe No.4 ,5 ,6 ,7 ,8 ,and9 te rm ina ls nd

the No.10 ermina lnd iv idua l l y .here hou ld e

cont inu i t yor a moment t each ermina l s hemotor movespasteachmode position.

lf there s no continuity or a momentat each

terminal. eplace he modecontrolmotor.

Mode ControlMotor Replacemen

2.

3.

1 . R e m o v ehe ECM see age11-4) .

Remove he relaymount bracketbolt,and move

th e relaysout of the way.

Disconnecthe 10P onnector A) ro m the mode

controlmotor (B).Remove he self-tapping crews

and he mode controlmotor ro m th e heaterunit.

lnstallthe motor n th e reverseorder of re moval.

lvlake ure he pin on the linkage s properly

engagedwith the motor. After nstallation.make

sure he motor runs smoothly.

4 .

21-




Recirculation ontrolMotor Test

1. Disconnecthe 5Pconnector rom the recirculationcontrolmotor.

Incorrectly pplyingpoweran d ground oth e recirculation ontrolmotor wil l damge t.Follow he nstructions arefullv.

2. Connectbattervoower o the No. 5 terminaloftherecirculation ontrolmotor, and ground he No. 1and No. 2 terminals; he recirculation ontrolmotorshould run smoothly.To avoiddamaging herecirculation ontrolmotor, do not reversepower

an d ground.Disconnecthe No. 1 or No. 2terminals rom ground; he recirculation ontrolmotor shouldstop at Freshor Recirculate. on'tcycle he recirculation ontrolmotor {or a long ime.

RECIRCULATIONONTROL OTOR

lf the recirculation ontrolmotor does not run nstep 2, remove t, hen check he recirculationcontrol inkageand doors or smooth movement.

. lfthe l inkageand doorsmove smoothly, eplaceth e recirculation ontrolmotor.

. l f he inkageordoorss t i ckor ind , epa i r them

as neeoeo.

21-36

Recirculation ontrolMotor IReplacement

1 . R e m o v eheECM see age11-4) .

Remove he relaymount bracketbolt.and movethe relaysout of the way,

Disconnecthe 5Pconnector A) rom therecirculation ontrolmotor (B),Remove he self-tappingscrewsand he recirculation ontrolmotorfrom the blower unit.

Installthemotor n th e reverse rder of removal.Makesure he pin on the motor s properly

engagedwith the linkage.After nstallation.make

sure he motor runs smoothly.

\



Evaporator emperatureSensorReplacement

1.Remove he driver'sdashboard ower cover see

page20-59) nd he undercover se epage20-60).

Remove he under-dashuse/relay ox (seepage

22-491.

Disconnecthe 2P connector A) rom the

evaporator emperature ensor B) , hen removethe connector l ip (C).Remove he self-tappingscrew,and carefullypull out he evaporatortemperature.

4. Install he sensor n th e reverse rder of removal,

Evaporator emperatureSensorTest

l . Dip he sensor n icewater,an d measure he

resistance etween ts erminals

EVAPORATOREMPERATUREENSOR

2 .

3.

Terminalsideol male erminals

Then pour hot water on th e sensor,an dcheck or achange n resistance.

Compare he resistance eadingswith thespecifications hown n th e graph; he resistance

shouldbewithin the specifications

RESISTANCEk 9

t 0

320

50 68 86 F

10 20 30 'c

TEMPERATURE

21-




\

PowerTransistorTest

1. Disconnecthe 4Pconnector ro m th e power

Iranslslor.

2, Measure he resistance etween he No. 1 andNo. 2 terminalsof the power ransistor. t should be

a b o u t1 . 4

1 . 5 Q .

. lf the resistanceswithln the specifications,o to

step3.. lf the resistances notwithin the specifications,

replace he power ransistor.

POWER RANSISTOB

Carefu l l ye leasehe ock abon he No.4 ermina l(BLUI/EL) A) n the 4Pconnector, hen remove he

term ina l nd nsu la tet rom bodyground.

(T o12V power ource nvehicle)

Reconnecthe 4P connector o the power ransistor.

Supp ly12vo l t s o the No.4 cav i t ywi tha umper

wi re .

Turn he gn i t ion wi tchON ( l l ) , ndcheck ha t he

b lowermotor uns.

. lf the blower motor doesnot run, replace hepower ranstsror.

. l f he b lowermotor uns, the ower t rans is to r i s

oK.

12V power ou rce n veh ic le)

21-38

1 .

HeaterControlPaneland PushSwitch AssemblyRemovalandInstallation

Remove he centerpanel seepage20-62).

Remove he dials(A), hen remove he self-tapping

screwsand he heater ontrolpanel B)from he

centerpanel Cl .Remove he self-tapping crews

and he pushswitchassembly D)from he centerpane l .

lnstall he controlpanelan d pushswitchassemblyin th e reverseorder of removal.After nstallation,

operate he controlpanelcontrols o seewhether t

worKspropeny.

Ru n he self-diagnosisunction o confirm hat

therear e no problems n the system seepage21-

8 ) .

3.

4 .



Dustand PollenFilterReplacement

Th edust and pollen iltersshould be replaced very30,000mi les 48.000m)or 24monthswhichevercomes irst. Replacehe fi ltersmore often f the air f low

is ess hanusua l .

1. Open he glove box. Removebothglove box stops,then let he glove box hang down (seepage20 63).

2 . Removehe i l te r id (A) f rom he b lowerun i t , henpu l lou t he i rs tdustandpo l len i l t e r B) .S l ide hesecond ilter o the left,an d pull t out.

Remove he fi lter{A) rom the housing B),andreplace he fi lter.

4. Install he fi lters n the reverseorder of removal.

BlowerUnit Removal ndlnstallation

For some models:SRScomponents re ocated n this

area.Review he SRScomponent ocations se epage23-13) nd precautions nd procedures se epage23-1

in the SRSsectionbeforeperforming epairsor service

1. Makesureyo u have he anti-theft ode or the radi


buttons.

2. Disconnecthe batterynegative able,and wait 3

minutesbeforebeginningworK.

3. Remove he right kickpanel (seepage20-50),passenger's ashboard ower cover,and he glove

bo x {seepage20-63).

4. Cut he plastic rossbrace n the glove box openinwith diagonalcutters n the areashown.Remove

and discard he plastic rossbrace,

Cut heare.

{cont'd

21-




Blower Unit Removaland Installation cont'd}

Remove he steeringhangerbeam bracket overfrom the right side of the glove box opening, henremove he bolts and he olove box rame.

1 .

8.

9.

Remove he ECM se epage 11-4).

Remove he EPS ontrol unit (seepage17-67).

Disconnect nd remove he PGM-Flmain relaysand bracketassembly, hen remove he ECMbracket.

Disconnecthe connectors A) rom the blowermotor and he power ransistor, hen remove he

wire harness lips (B)and he connectors C).

Remove he self-tapping crewsand he bracket D) .

A

21-40

10. Disconnectthe onnector A) rom the recirculationcontrolmotor, he n remove he wire harness lip

{B).Remove he mountingbolts, h e mounting nuts

and he b lowerun i t C) .

6 x 1 . 0m m I9. 8N.m 1. 0 gt.m,7.2 bt.ftl

6 x 1 . 0 m m9. 8N. m (1.0 gf.m,?.2 tbf.ft)

1 1 .

1 4 .

Ins ta l l l he n i t n he reverse rdero f remova l .Make ure ha t here s no ai r eakage.

Reconnecthe negativebattery erminal.

Do heeng ine ont ro lmodu le ECM)d le earnproceduresee age11-139) .

Enter he anti-theft ode or the radio, he n enterthe customer's adiostationpresets.

\

'13.



BlowerUnit ComponentsReplacement

Nole hese temswhen overhauling he blower unit;

' Th e recirculation ontrolmotor (A), he power ransistor B), he blower motor (C),and he dust and pollen iltefs (D

can be replacedwithout removing he blower unit.. Before eassembly,makesurethatthe recirculation ontrol inkageand doors move smoothly.. After reassembly,makesurethe recirculation ontrolmotorruns smoothly se epage2j-36).

A

21-



ndAir Gonditioning

1 .

EvaporatorCoreReplacement

Recover he refrigerantwith a recovery/recycling/chargingstation se epage21-53).

Remove he bolt, hen disconnect he suction in e(A )and he receiver ine (B)from he evaporatorcore.

6 x 1 0 m m9. 8N. m 1. 0 gt.m, .2lbf.ft)

Remove he blowe r unit (seepage21-39).

Remove he self-tapping crewsand he expansionvalvecover.

5. Carefully ul l out the evaporator ore withoutbending he pipes.

Installthecore n th e reverseorder of removal,and

note hese tems.

. lfyou're install inga new evaporator ore,ad dre f r igeranti l (KElH lN P- ]0) see age21-6) .

. Replace he O-ringswith new onesat each itt ing,

and apply a thin coa tof refrigerant il beforeinstall ing hem. Be sure o use he correctO-ringsfor HFC-134aR- '134a)o avo id eakage.

. lmmedia te lya f te rs ing the i l , e ins ta l l t hecapon the container, nd seal t to avoid moisture

absorotion.. Do not spil l he refrigerant i l on the vehicle; t

may damage he paint. f the refrigerant i lcontacts he paint,wash t off immediately.

. Charge he system se epage21-55).

6 .



HeaterUnit/CoreReplacement

SR Scomponents re ocated n this area.Review heSR Scomponent ocations seepage23'13),an dprecautions nd procedures se epage23-14) n the SRS


1. Makesureyou have he anti-theft ode orthe radio,then write down the freouenciesor the radio's

Dreset uttons.

4 .

Disconnecthe negative able rom the battery,

Disconnecthe suctionan d receiver ines rom theevaporator core (seepage 21-42).

From under he hood,open he cableclamp (A),

then disconnecthe heater alvecable B) rom theheater alve arm (C).Turn he heater alve arm to

the fully openedpositionas shown

When heeng ine s coo l , ra in heeng ine oo lan t

from the radiator se epage10-6).

6. S lide he hoseclamps A)back, hen d sconnectheinlet heaterhose B)an d he outletheaterhose C)

from the heater ore.Engine oolantwill run ou t

when the hosesare disconnected; rain t into acleandrip pan.Be sure not o let coolantspil l onthe electrical artsor the paintedsurfaces. f any

coolantspil ls, inse t of f immediately.

Remove he bolt and he heater alve, hen remove

th e mounting nut rom the heaterunit.Takecarenot to damageor bend he fuel l inesand he brakelines,etc.

7 .

8 x 1.25mm12 N.m (1.2 gf.m,8.7lbf. f t)

(cont'd

21-




HeaterUnit/CoreReplacementcont'd)

8. Remove he dashboard se epage20-66).

9. Disconnectthe onnectors A) rom the blower

motor, he recirculation ontrolmotor, he modecontrolmotor, and he power ransistor, henremove he wire harness lips(B)and he

connector C) .Remove he self-tapping crewsan d

the bracket D) .

Disconnecthe connectors A) rom the evaporator

temperature ensorand he air mix controlmotor,

then remove he wire harness lips(B )and he

connector C) .Remove he self-tapping crewan dth e cover (D).Disconnecthe heater alvecable E).

1 0 ,

7 t ,

21-44

11. Removehe mount ing o l t s , he mount ing u ts ,an d he heaterunit.

Remove he self-tapping crewsand he expansionvalvecover (A).Carefullypull out he evaporatorcore (B)so yo u don't bend he inletand outletpipes.

Remove he grommet (C), hen remove he self-

tappingscrewsand he flangecover D) .Bemovethe self-tapping crewsand he pipecover (E), he ncarefullypull out the heater ore (F)so yo u don't

bend he inletand outlet oioes.

@

5 x 1 . 0m m9. 8N. m11.0 gl m,7.2 tbf.ftl

12 .



13. Installtheheater ore and he evaporator ore n

the reverse rder of removal.

14. Installtheheaterunit n the reverserder ofremoval,and note hese tems:

. Do not nterchangehe nletand outlet heater

hoses,and nstallthe hoseclampssecurely.. Refil l thecoolingsystemwith enginecoolant se e

page10-6).. Adjust he heater alvecable se epage2'l-461.. Makesure hat here s no coolant eakage.. Makesure hat here s no ai r eakage.. Refer o evaporator ore replacement se estep6

on page21-42) .. Do he enginecontrolmodule ECl\4)dle earn

proceduresee age11-139) .

. Enter he anti-theft ode or th e radio, hen enterthe customer's adiostationDresets.

21-




HeaterValveCableAdjustment

1. F romunder the ood, pen he cab le lamp A) ,then disconnect he heater alvecable B) rom the

heater alvearm {C).

t From under he dash,disconnecthe heater alve

cab le ous ingrom hecab le lamp A) , nd

disconnecthe heater alvecable B) rom the air

mix cont ro l inkageC) .

,t .- l

\'r2t' ''' '' ::"'

Set he temperature ontroldial on Max Coolwith

the gnitionswitch ON (ll).

Attach he heater alvecable B) o the air mi x

control inkage C)as shown above, hen snap he

heater a lve ab le ous ingnto he cab le lamp A) .

. ' . - : ' , ,- " l l

.....-

21-46

5, From under he hood, urn the heater alve arm {C)to the fully closedpositionas shown,and hold t.

Attach he heater alvecable B) o the heater alve

arm,andgent l y u l l

on he heater a lve ab lehousing o take up any slack, hen nstall he heater

va lve ab le ous ingnto hecab le lamp A) .

.

\



CompressorReplacement

1. l f he compressors marg ina l l y perab le ,un heengineat idlespeed,and et he air conditioningwork for a fe w minutes, hen shut he engineoff.

2. Makesureyo u have he anti-theft od e or the radio,then write down the frequenciesor the radio'spresetbuttons.

3. Disconnecthe negative able rom the battery.

4. Recoverhe refrigerantwith a recovery/recycling/chargingstation se epage21-53).

5. Remove he alternator se epage4-29).

6. Remove he Ay'C ondenser an assembly seepage1 0 - 1 0 ) .

7. Disconnectthe ompressor lutchconnector A),

remove he bolts, hen disconnect he suction in e(B)and hed ischargeine C) f rom hecompressor .Plugor cap he lines mmediatelyafterdisconnectinghem to avoid moistureand dustcontamination.

6 x '1.0mm9. 8N. m11.0 gt.m,7.2 tbl.ttl

u1/(

o

8. Remove he mounting boltsand he compressor.

8 x 1 .25 m22N. m12.2 gf.m

9. Ins ta l l t he ompressorn he reverse rdero fremoval,and note h ese tems:

. Before nstall ing he new compressor, heck ormeta l r o ther on taminat ionn he ine .Rep lacany contaminated arts.

. lf you're nstall inga newcompressor, ou must

calculate he amount of refrigerant il to beremoved rom it (seepage21-6).

. Replace he O-ringswith new ones at each itt ingand apply a thin coatof refrigerant i l beforeinstall ing hem. Be sure o use he correctO-ringfor HFC-134aR-134a)o avo id eakage,

. Use ef r igerant i l (KElH lN P- '10)or HFC-134

KEIHIN p i ra l ypecompressor n ly .. To avoid contaminatlon, o not return he oilto

th e containeroncedispensed, nd never mix itwith other refrigerant i ls.

. lmmedia te ly f te rus ing heo i l , e ins ta l l t heapon the container, nd seal t to avoid moisture

absorption.. Do not spil l he refrigerant i l on the vehicle; t

may damage he paint. f the refrlgerant ilcontacts he paint,wash it off immediately.

. Charge he system seepage21-55).

. Do he eng ine ont ro lmodu le ECM)d le earnproceduresee age11- '139) .

. Enter he antitheft code or the radio, hen entethe customer's adiostationpresets.

21-




1 .

CompressorClutchCheck

Check he armatureplate or discoloration, eeling,

or otherdamage. f there s damage, eplace he

clutchse t (seepage21-49),

Check he rotorpulleybearingplayand drag byrotating he rotor pulleyby hand.Beplace he

clutchset with a ne w on e f it is nois y or has

excessive lay/drag se epage21-49).

Measure he clearance etween he rotor pulley A)

and he armatureplate B)all he way around. f the

clearances not within specified imits, emove he

armatureplate se epage21-49) nd add or remove

shimsas needed o increase r decrease learance.

Clearance: 0.510.15 mm {0.02010.006n.)

NOTE: hesh imsareava i lab len our h icknesses:0 . 1m m . 0 . 2m m , 0 . 4m m ,a n d0 . 5m m .

21-48

4. Releasehe field coil connector r om the holder,

then disconnect t. Check he thermalprotector or

continuity. f there s no continuity, eplace he

thermalro tec torsee age21-51) .

NOTE:The hermalDrotector il l have no

cont inu i t y bove 52to270"F122 lo132 'C) . hen

the empera tureropsbe low241 o 219 'F 116 o

104'C), he thermalprotectorwill havecontinuity.

Check esistance f the field coil. f resistances not

within specifications,eplace he field coil(see age21-49) .

FieldCoilResistance: 3.05 3.35ohmsat68"F

t20"c)

,\.



Compressor lutchOverhaul

Special Tool RequiredA,/C lutchholder,Robinair10204.Kent-Moore 37872,or HondaTool and EquipmentKMT-J33939,

commerc ia l l yva i lab le

1 . Removehecenter u t A)wh i leho ld ing he

armatureplatewith a commerciallyavailableA,/C

c lu tch o lder B) .

17.6N. m{1.8 gf.m,13 tbt.ft)

Remove he armatureplate A)an d shim(s) B),

takingcare not o lose he shim(s). f theclutchneedsadjustment, ncrease r decreasehenumberand hickness f shims as necessary,he nreinstallthearmatureDlate, nd recheck tsclearance seepage21-481.

NOTE: hesh imsareava i lab len our h icknesses:0 .1mm,0.2mm,0.4mm, and0.5mm.

9-=-g

3. lf you ar e replacing he field coil, remove he snapring (A )with snap ring pliers, hen remove he rotopulley(B).Be carefulnot o damage he rotor pulle

or tne compressor.

4. Remove he bolt and holder A). hen disconnect

the field coil connector B).Loosen he clamp screw(C ) o iree the field coil wire. Remove he snap ring

{D)wi thsnap ingp l ie rs ,hen emove he ie ldco i(E).Be carefulnot o damage he field coil or the

comoressor.

\ot-@

/@h"

.ffi

7. 4N. m(0.75 gf m,5 tbf.ft)----------------

"\)

(cont'd

21-4




CompressorClutchOverhaul cont'd)

5. Reassemblehe clutch n th e reverseorder ofdisassembly, nd note hese tems:

.Ins ta l l t heie ldco i lw i th hewi res ide ac ingdown, and align he bosson the field coil with th eho le n he compressor .

. Clean he rotor pulleyand compressor l iding

surfaceswith contactcleaneror othernon-petroleum olvent.

. Ins ta l l new snap ings, o te he ns ta l la t ion

direction, nd makesure he y ar e ully seated nth e groove.

. Makesure hat he rotor pulley urns smoothly

after t 's reassembled,. Route ndc lamp hewi resproper ly r heycan

be damagedby the rotor pulley.



Compressor hermalProtectorReplacement

1. Remove he bolt, he ground erminal A),and he

holder B) .Disconnecthe field coil connector C).then remove he thermalprotector D).

Replacehe thermalprotector A)with a new one,and apply sil icone ealant B) o the bottom of thethermal Drotector.

A

3. lnstall in th e reverse order of removal.

7. 4N. m(0.75 gf.m,5 rbf.ftl

CompressorReliefValveReplacement

2 .

1 .

4 .

Recover he refrigerantwith a recovery/recycling

chargingstation seepage21-53).

Remove he reliefvalve (A )and he O-ring B).Plug

th e opening o keep oreig n mafter rom entering

the systemand he compressor i l from running

out.

A9, 8N. m(1.0 gf m,7.2lbf. f t)

Clean the mating surfaces.

Installa new O-ringon the reliefvalve,and apply a

thin coat of refrigerant i l to the O-ring.

Remove he plug,an d nstallan d ighten he relief

valve.

Charge he system se epage21-55).

21-5




Gondenser eplacement

1 .

6 x 1 . 0 m m9. 8N. m ('1.0 gf.m,7.2lbf. f t)

Recoverhe refrigerantwith a recovery/recycling/chargingstation seepage21-53).

Remove he front bumper se epage20-85).

Remove he bolts, hen disconnect he discharge

line (A )and he condenser ine (B ) rom the

condenser.Plugor cap he ines mmediatelyafterdisconnectinghem to avoid moistureand dustconlamtnaflon.

, t\

6 x 1 . 0 m m9.8 N.m (1.0 gt.m.7.2lbf. f t)

21-52

4, Remove he mounting bolts, he n remove hecondenser y l ift ing t up . Becarefulno t o damagethe rad ia tor r hecondenserinswhen emovino

the condenser.

6 x '1.0mm9. 8N. m ('1.0 gf.m,7.2 tbl.ftl

5 . l ns t al l t he ondensern he reverse rdero fremoval,an d note hese tems.

. l f you ' re nsta l l i ng newcondenser ,ddre f r igeranti l (KElH lN P- 0) seepage 1 '6) .

. Replacehe O-ringswith new onesat each itt ing,and apply a thin coat of refriger ant i l before

install ing hem. Be sure o us e he correctO-ringsfor HFC-134aR- '134a) tovo id eakage.

. lmmediately fterusing he oil, reinstallthe apon the container, nd seal t to avoid moisture

absorption.. Donot sp i l l t he e f r igeranti l on theveh ic le ; i t

may damage he paint. f the refrigerant i lcontacts he paint,wash it off immediately.

. Be carefulnot o damage he radiatoror thecondenser ins when nstall ing he condenser.

. Charge he system seepage21-55).

t -" ' .

f ,

t-

- l i. : ) -

:.--\ ---- - -'



RefrigerantRecovery

Air conditioning efrigerant r lubricant apor

can rritateyour eyes,nose.or throat.Be carefulwhen connecting erviceequipment.

Do not breathe efrigerant r vapor

Use only serviceequipment hat s U.L.-l isted nd s


removeHFC-134aR-134a)rom hea i rcond i t ion ing

system.


work areabefore esuming ervice

Additionalhealthand safety nformationmay be

obtained rom the refrigerant nd ubricantmanufacturers.

1 ! l r : i t :- :

- ' ' , -

-

(

'=ir

1. Connect R-134a efrigerant ecovery/recycling/

chargingstation A) o the high-pressure erviceport (B )and he low-pressure erviceport (C),as

shown, ollowing he equipmentmanufacturer'sinstructions.

lvleasurehe amountof refrigerant i l removed

from th e Ay'C ystemafter he recoveryprocess s

completed.Be sure o put he sameamount of ne w

refrigerant i l back nto he Ay'C ystembefore

chargrng.

21-




SystemEvacuation

Use only serviceequipment hat s U.L.-l isted nd scertif ied o meet he requirements f SAEJ2210 oremoveHFC-134aR-134a) f romhe a i rcond i t ion inqsystem.

lf accidental ystemdischarge ccurs, entilate hework areabefore esumingservice.

Additionalhealthand safety nformationmay be


1. When an Ay'C ystemha sbeenopened o theatmosphere, uch as during nstallation r repair, tmust be evacuated singa R-134a efrigerantrecovery/recycling/chargingtation lf he systemha s beenopen or severaldays, he receiver/dryershould be replaced, nd he systemshould beevacuatedor severalhours.)

. Air conditioning efrigerant r lubricant apor

can rritateyour eyes,nose,or throat.. Be carefulwhenconnecting erviceequipment.. Do not breathe efrigerant r vapor.

2. Connect R-134a efrigerant ecovery/recycling/chargingstation A)to the high-pressure ervicepo n (B)and he low-pressure erviceport (C),as

shown, ollowing he equipmentmanufacturer'sinstructions. vacuatehe system.

lf the low-pressure oes not reachmore han 93.3kPa 700mmHg,27.6 n .Hg)n 15minutes,here sprobablya leak n the system.Partially harge hesystem,an d check or leaks se estep3 on page21 -56).

-i - r4.t



SystemCharging

Air conditioning efrigerant r lubricant apor

can rritateyour eyes,nose,or throat.Be carefulwhenconnecting erviceequipment.

Do no t breathe efrigerant r vapor,

Useon lyserv ice qu ipmenthat s U.L . ' l i s tednd s


removeHFC-134aR-134a)rom hea i rcond i t ion ing

system.


work areabefore esumingservice

Additionalhealthand safety nformationma y be


1. Connect R-134a efrigerant ecovery/recycling/

charg ing ta t ion A) o the h igh-pressureerv icepo n (B )and he ow-pressure erviceport {C),as

shown, ollowing he equipmentmanufacturer's

instructions.

2 .

3.

4.

Evacuatehe system seepage21'54).

Add the sameamount of new refrigerant i l to the

system hat was removedduring recovery.Us eonly KEIHINSP-10 efrigerant i l.

Charge he systemwith the specified mountof

R-134a efrigerant.Do not overcharge he system;

the compressorwill be damaged.

Select he appropriate nits of measure or your

refrigerant hargingstation.

Refrigerantcapacity:

500 to 550 g

0.50 o 0.55kg

1.10 o 1.21 bs

17.6 o 19.4oz

Check or refrigeranteaks se epage21'56).

Check or systemperformance seepage21-58).

21-5




Refrigerant eakTest

Special Tool RequiredLeakdetector,HondaTool and EquipmentYGK-H-10PMcommerc ia l l v va i lab le

Compressed ir mixedwith R-134aorms acombustible apor.The vapor can burn or explodecausingseriousinjury.Never se ompressedir opressurees tR-134a erv ice qu ipment r veh ic le i rconditioning ystem.

A ir cond i t ion ingef r igerantr lubr i cant aporca n rritateyour eyes,nose,or throat.Be carefulwhen connecting erviceequipment.Do not breathe efrigerant r vapor

Use only serviceequipment hat s U.L.-l isted nd scerti if ied o meet he requirements f SAEJ2210 oremoveHFC-134aR-134a)rom hea i rcond i t ion ingsystem.

lf accidental ystemdischarge ccurs, entilate hework areabefore esumingservice.

R-134a erv ice qu ipment r veh ic le i r cond i t ion ingsystems houldnot be pressure estedor leak estedwith compressed ir .

Additionalhealthan d safety nformationmay beobtained rom th e refrigerant nd ubricantmanufacturers.

21-56

1. Connect R-134a efrigerant ecovery/recycling/chargingstation A) o the high-pressure erviceport (B)and he low-pressure erviceport (C),as

shown, ollowing he equipmentmanufacturer'sanstructions.

Openhe

high pressurealve o charge he systemto the specified apacity,hen close he supply

valve,and remove he chargingsystemcouplers.

Select he appropriate nits of meas ure or yourrefrigerant hargingstation.

Refrigerantcapacity:500 to 550 g

0.50 o 0.55kg1.10 o 1 .21 bs17.6 o 19.4oz

Check he system or leak susing a R-134a

refrigerant eakdetectorwith an accuracy f 14g(0.5oz )per yearor better.

lf you find leaks hat require he system o beopened to repairor replacehoses, itt ings,etc.),recover he system.

Aftercheckingand repairing eaks, vacuate hesystem.

3.



A/C SystemTests

Pressure est

Test results svmotom3 DGaUSe

Dischargehigh)

pressureabnormally igh

After topping ompressor,ressure

drops uickly, nd hencontinueso

Ai r nsystem Recover, vacuateseepage21-54),

and rechargewith specified mount{see aoe 1 55).

Beduced r no air low hroughcondenser

Clogged ondenserr radiatorf insCondenserr radiatoranno t

CleanCheckanvoltage nd pm.Checkan direct ion.

Line o condensers excessivelyot. Restrictedlow of refrigerantn Replaceestrictedines.

Dischargeressure Highand owpressuresrebalancedsoonafter topping ompressor,owside s hioherthan ormal.

. Faulty ompressorischargevalve

. Faultv omoressorea l

Beplacehecompressor.

Outletof expansion alve s notfrosted,ow pressureauge ndicates

Faulty xpansionalveMoisturen system

. Replaceheexpansionalve.

. Recover, vacuateor at east30 minutes,and rechargewithsDecif iedmount.

Suctionlow)pressureabnormallyow

Expansionalve s not rosted, ndlow-pressureine sno tcold.Lo wpressureaugendicatesacuum,

' Frozen xpansionalve(Moisturen system)

. Faulty xpansionalve

Recover, vacuateor at east30minutes, nd echarge ithspecif iedmount.

Beplaceheexpansionalve.Dischargeemperatures ow,and heair low from vents s restricted.

Frozen vaporator Run he fan with compressor ff, thencheckevaooratot emoerature ensor.

Exoansionalve s rosted. eanor reolace,

Receivetdryerut let scool, nd nletiswarm should ewarmduringooeralton),

Clogged eceiver/dryer Replaceeceaver/dryer.

Suction ressureabnormally igh

Lo wpressureose ndcheckointarecoolerhan he emperatureroundevaoorator,

Expansion alve open oo long Bepair r replace.

Suction ressures owered he n. .n r lenser is coo led bv water .

Excessiveefrigerantn system Recover, vacuate, ndrechargewithqnp. i f ie . lamo ' rn r

Highan d ow pressurereequalizedassoonasthecompressorsstopped,an dbothgaugesluctuate hile

Faulty asketFaulty ig hpressurealveForeign anicle tuckn high

Replacehecompressor.

Suction nd

daschargepressuresabnormallv ioh

Reduced ir low hrough ondenser. . Clogged ondenserr radiator

f ins' Condenserr radiatoran no tworkino rooerlv

Clean

Checkoltageand an rpm.

Checkan direct ion.

Suction nddischargeressureabnormallyow

Low-pressureose ndmetalendareas re oolerthan vaoorator,

Clogged r kinkedow-pressurehoseoarts

Repair r replace.

Temperatureround xpansionalveis oo ow compared ith hataround

Cloggedhigh-pressure ine Repair r replace,

Fefrigeranteaks :omoressorlulch sdirtv. :omoressorhaft eal eakinq ReolacehecomDressor,

lomoressor olt(s) redirtv. noaround olt(s) Tiohten olt{s) t reolaceomDresso

;omDressor asket s wet with o i l . ie t no ace hecomoressor.

(con

21-




A/CSystemTests cont'd)

1 .

Performance est

Ai r conditioning efrigerant r lubricant aporcan rritateyour eyes,nose,or throar.

Becarefulwhenconnecting erviceequipment.Do not breathe efrigerant r vapor.

Th e performance est wil l help determine f the ai rconditioner ystem s operatingwithin specifications.

Use only serviceequipment hat s U.L.-l isted nd scenified o meet he requirements f SAEJ2210 oremoveHFC-134aR-134a l f romhe a i rcond i t ion ingsystem.

lf accidental ystemdischarge ccurs, entilate hework area

beforeesuming

service

R-134aerv ice qu ipment r veh ic le i rcond i t ion ingsystemsshould not be pressure estedor leak estedwith compressed ir.

Additionalhealthan d safety nformationmay beobtained rom the refrigerant nd ubricantmanufacturers.

Connect R-134a efrigerant ecover/recycling/chargingstation o the high-pressure erviceportan d he low-pressure erviceport, ollowing heequipmentmanufacturer'snstructions.

Determ inehe re la t i ve umid i t y nda i rIemperaru e.

' Compressed ir mixedwith R-134aorms acombustible apor.

. Thevaporcanburnor exp lode aus ing er iousIn ju ry .

. Neveruse compressed ir o pressure es tR-134a erv ice qu ipment r veh ic le i rcond i t ion ingystems.

4 .

Open he glove box. Removebothglove box stops,then let he glove box hangdown (seepage20-63).

Inserta thermometer A) n the centervent,an dplaceanother hermometer B) near he blower unit.

Testconditions:

. Avoid directsunlight.

. Open he hood.

. Open he front doors.

. Sel he temperature ontroldial on Max Cool, hemodecontroldialon Vent,and he recirculationcontrolswitch on Recircu late.

. Turn he A,/C witchon and he fa n switchon Max.

. Run heeng ine t 750 pm.

.No dr iveror passengersn veh ic le .

Af te r unn ing he a i rcond i t ion ingor I0 minutesunder he above estconditjons, ead he deliverytemperature rom the thermometer n the centervent, he intake emperature ear he blower unit,and he high an d ow systempressure rom the Ay'Cgauges.



7. To complete he charts:

. Mark thede l i very tempera turelong hever t i ca line .

. Mark he intake emperature ambientair emperature) long he bottom ine.. Draw a line straightup from th e air emperature o the humidity.

. Marka po in t10% above nd 10% belowthehumid i t y eve l .

. From eachpoint.drawa horizontal in eacross he delivery emperature.

. The delivervtemperature hould all between hetwo lines

. Complete he ow-sidepressure est and high-side ressure est n the sameway.

. Anv measurements utside he line may ndicate he need or further nspection.

kPa(ksl{cm')Lpsrl

2500[25) _360l

1500{1s},21o)

1000(101:1401

500 -{5)171 l

DELIVERYPRESSURE

80yo

a00/"

HUMIDITYLEVEL

30 9o

30 %

8 0 %

{kgflcm')Lpsil600{6ttssl

2000(2011280

fcl

10 0{ 1 1h4 l

INTAKEPRESSURE

OELIVERYTEMPERATURE

.F

{'cl

I

10 4{40)

95(35)

I86t30)

I77t25l

68t20l

INTAKETEMPEBATURE

21-



\BodyElectrical

Body ElectricalSpec ia lToo lsGeneral roubleshootingntorrnaiion.'......

Relay ndControlUnit Locations ....

ConnectorsndHarnesses

Fuse/Relayoxes . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .

PowerDistr ibut ion... . . . . . . . . . . . . . . . . . . . . . . . . .

Ground istr ibut ion... . . . . . . . . . . . . . . . . . . . . . . .

Under-dashuse/Relayox ..............

Battery ..............

Relays. . . . . . . . . . . . . . .

*lgnitionSwitch ..............

*GaugesComponentocat ionndex . . . . . . . . . .. . . . . . . . . .. .Se l f -d iagnost i crocedure. . . . . . . . . . . . . . . . . . . . . . . . .CircuitDiagramGauge u lbRep lacement. . . . . . . . . . . . . . . . . . . . . . . . .GaugeAssembly eplacementCoolant emperature

Gauge roub leshoot ing. . . . . . . . . . . . . . . . . . . . . .Vehicle peedSignalCircuit

TroubleshootingVS SReplacement

Exterior ightsComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . .C i rcu i t iagramDaytimeRunning ightsControi

Un i t nput es t Canada). . . . . . . . . . . . . . . . . . . . . . .Head l igh td ,us tment. . . . . . . . . . . . . . . . .. . . . .Head l ighrep lacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Combination ightSwitch

Test/ReplacementBu lbRep lacementTa i l l i gh t ep lacement. . . . . . . . . . . . . . . . . . . . . . . . .HighMountBrake ightReplacement.....License late ightReplacement.............S ideMarker igh tRep lacement. . . . . . . . . . . . . . .BrakePedal osit ion witch est ..............SideTurnSignal ightReplacement.......

Turn Signal/HazardFlasher SystemComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . .C i rcu i t i agramTurnSignal/Hazardelay nputTest ........HazardWarningSwitchTest

22,3

22-7

22-13

22-44

22-46

22-4A

22-49

22-50

22-51

22-53

22-5422-5622-5422 6322-64

22-64

22-6522 61

22-6822--71

22-722-7422-79

22-AO22-4122-8222-4222-4322-4322-4422-84

22-8522 A622-8722-88

22-10422-105

22-10622-107

Entry Lightscontrol systemComponent ocationndex .......................2-89Ci rcu i t i agram .. . . . . . . .2 90

lgnit ionKeySwitchTest .....................,......2-9'll gn i t i on ey ight est . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -91Cont ro l n i t nput es t . . . . . . . . . ,. . . . . . . . . .. . . . . . . . . .292

Interior ightsComponent ocationndex .......................2-94CircuitDiagram ......... 2-95Ceiling ighVSpotlights

TesVReplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -96RearCeiling ightTesVReplacemnt ........ 2-96CargoAreaLightTest/Replacemnt ......... 2-97Hatch atchSwitchTest ..,..,.......................2-97

*Audio SystemComponent ocationndex .......................2-98CircuitDiagram ......... 2,99

AudioUnitRemoval/lnstallation..............2-1OOAudioUnitConnector eplacement........ 2-101Speaker eplacement...............................2-102RoofAntennaRep1acement...................-..2-103

Rear Window DefoggerComponent ocationndex ...........C i rcu i t iasram . . . . . . .. . . . .. . . . . .. . : : : : : . : : . : : .Function estDefogger i reRepai r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .No ise ondenserapac i t yTest. . . . . . . . . . . . . . .

MoonroofComponentocat ionndex . . . . . . . . . . . . . . . . . . . . . .2 -1OBCircuitDiagram ......... 2-109MoonroofControlUnit nputTest .............2-' l10Swi tch esVReplacement. . . . . . . , . . . . . , . . . . . . . . . . .2 -1 2MotorTest .................2-112LimitSwilchTest ......22-' l '13Auto-stop witch est ................................2-1 3

PowerMirrorsComponent ocationndex .......................2-114CircuitDiagram ......... 2-115Function est .............2-116PowerMi r ro r w i t ch est . . . . . . . . . . . . . . . . . . . . . . . . .2 - l l 7PowerMirrorActuator est .......................2-117PowerMirrorActuatorReplacement....... 2-11A

* HornsComponent ocationndex .......................2-120CircuitDiagram ......... 2-121Horn esVReplacement. . . . . . . . . . . . . . . . . . . . . . . . . . - .2 -122HornSwitchTest .,....22-122

\



PowerWindowsComponent ocationndex ..........c i rcu i t iagram . . . . . . . . . . . . . . . .. . . . . . . . : . : : : : . : : : : . :

Master w i t chnput est . . . . . . . . . . . . . . . . . . . . . . . . . . .MasterSwitchTestDr iver ' s indowMotor est . . . . . . . . . . . . . . . . . . . . .Passenger's indowSwitch nputTest ...Passenger's indowSwitch est .............Passenger's indowMotorTest ..............lMaster witchReplacement.....................Passenger's indowSwitch

Replacement

Wipers/WashersComponent ocationndex .......................C i rcu i t i agramRearWindowWiper ntermiftent

Cont ro l n i t nput est . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiper/Washer witch

TesVReplacementCont ro l n i t nput est . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WiperMotorTestWasherMotorTestWasher luidLevelSwitchTesV

ReplacementCanada l. . . . . . . . . . . . . . . . . . . . . . . . .WindshieldWiperMotorReplacement.. .RearWindowWiperMotor

ReplacementWasher eservo i rep lacement. . . . . . . . . . . . . . .Washer ubes ep lacement. . . . . . . . . . . . . . . . . . . . .

Accessory Power SocketCircuitDiagram ......... 2-149AccessoryPowerSocket

TesVReplacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 -1 9

Keyless/Power Door Lock SystemComponent ocationndex .......................2-150CircuitDiagram ......... 2-151Keyless eceive r nit nputTest ..............2-153ControlUnit nputTest ...............................2-155Door ockActuatorTest. . . . . . . . , . . . . . . . , . . , . , . . . . .2 -158Hatch ockActuatorTest. . . . . . . . . . . . . . . . . . . . . . . . . .2 -159DoorLockKnobSwitch est ......................2-160DoorLockSwitch est ................................2-160Transmitter est ....... 2-161Transmi t te rrogramming. . . . . . . . . . . . . . . . . . . . . . . .2 -161

MultiplexControlSystemComponent ocationndex ...........c i rcu i tD iagram . . . . .. . . . . . . . . . . . . . . . . . . . . . . : : . : . . : . : : . :

SvstemDescriDtionTroubleshootingMul t io lex on t ro l n i t nDut es t . . . . . . . . . .. .

22 12422-125

22-12622-12822-12922-t3022-13222 13222-133

22-133

22-134

22-138

22-14022-14122-14322-144

22-14422-145

22-14622-14622 147

22,16422-169

22-17'l22 ,11222-175

lmmobilizer ystemcomponent ocationndex ...........

Systemescr ip t ion. . . . . .. . . . . . . . . . . .. : . . : . . : . : . . .

CircuitDiagramTroubleshootinglmmobilizer ontrolUnit

-Rece iverep lacement. . . . . . . . . . . . . . . . . . . . . . . . . .

22-16222-16322-164

22-167



BodyElectrical

SpecialTools

@

Ref.No. ToolNumber Description OtvQ)

o)

o

07wAz-001010AO7 AJ PT3O OA

07TAz-001020A

MPCSServiceConnector 1Test Harness 1

BackProbeAdaotet 1




Tipsand Precautions

Before Troubleshooting

1. Checkapplicable uses n the appropriate use/relayoox.

2. Check he battery or damage.stateof charge,an d

cleanand ight connections.

. Do not quick-charge batteryunless he batterygroundcablehas beendisconnected, therwiseyou will damage he alternator iodes.

. Do no t attempt o crank he enginewith the

batterygroundcable ooselyconnected r yo u

wi l l severe ly amage hewi r ing .

Handling Connectors. Makesure he connectors re cleanand have no

loosewi re ermina ls .. Makesure multiplecavityconnectors re packedwith

dielectric rease exceptwaterti ht connectors).. All connectors avepush-down elease ype locks A) .

Some connectors av ea clip on their side used oattach hem to a mount bracketon the body or on

another omponent . h isc l iphasa pu l l ype ock.

Some mountedconnectors annotbe disconnecteunlessyou first release he lockand remove he

connector rom its mount bracket A) .

Never ry to disconnect onnectors y pull ingon the

wires;pull on the connectorhalves nstead.

Alwavs reinstallDlastic overs,

Beforeconnecting onnectors,makesure he

terminals A) are n placeand not bent.

(cont

22



Testingand Repairs. Do not usewires or harnesses ith broken nsulation.

Replace hem or repair hem by wrapping he break

wi the lec t r i ca l tape.. After nstall ingparts,makesure hat no wires are

o inched nder hem.. When usingelectricaltest quipment, ollowthe

manufacturer'snstructions nd hosedescribed n

th ismanua l .. l f poss ib le ,nser t the robeof he tes ter f romthe i re

side exceptwaterproofconnector).

UsebackDrobe daotor 7TM-0010204.

Refer o the instructionsn the HondaTerminalKit o

identif ication nd reolacement f connector ermina

(cont

22



BodyElectrical


Five-stepTroubleshooting

'1 .VerifyTh e Complaint

Turnon a l l t hecomponentsn he prob lem i rcu i tto verify he customercomplaint.Note hesymptoms.Do not begindisassembly r testinguntil you havenarroweddown the problemarea.

2. AnalyzeThe Schematic

Lookup the schematic or th e problemcircuit.Determine ow the circuit s supposed o work bytracing he currentpaths ro m th e power ee dthrough he circuitcomponents o ground. fseveral ircuits ail at the same ime, he fuse orground s a I i ke ly ause.

Basedon the symptomsan dyour understanding f

the circuitoperation, dentifyone or more possiblecausesof th e problem.

3. lsolateThe ProblemBy TestingThe CircuitMakecircuit ests o check he diagnosis ou madein s tep2. Keep n mind hata og ica l , imp leprocedure s the key o efficient roubleshooting.

Test or the most ikelycauseof failure irst,Tr y tomake estsat points hat are easilyaccessible.

4. Fix The ProblemOnce he specificproblem s identif ied.make herepair.Be sure o use proper oolsand safeproceoures.

5. MakeSureTh e CircuitWorks

Turn on all components n the repaired ircuit n allmodes o makesureyou've ixed he entireproblem. f the problemwa s a blown use,be sureto test all of the circuitson the use. Makesure nonewprob lemsurn up and he or ig ina l rob lem

doesnot recur.

WireColor Codes

The ollowingabbreviations re used o identifywire

colors n the circuitschematics:wHT. . . . . . . . . . . . . . . . . . . . , . , . . . . . . . . . . . . .YEL . . . . . . . . . . . . . . . . . . . . . . , , . . . . . . . , . . . . . .B1K.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BLU . . . , . . . . . . .. . . . . . . . . . .. . . . . . . . . .. . . .GRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .RED.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,oRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PNK. . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . .BRN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .GRY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,PUR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1T81U. . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . .1TGRN. . . . . . . . . . . . . . . . . . . . . . . . . . . , . . .

WhiteYel lowBlackB l u eGreenRedOrangePinkBrownGrayPurpleLightBlueLightGreen

Th ewire insulationhas onecolor or one color withanothercolor stripe.The secondcolor s he stripe.



RelayandControlUnit Locations

EngineCompartment

RADIATOR ANRELAY

BLOWERMOTORRELAY

HORNRELAY

CONDENSER ANRELAY

UNDER-HOODFUSE/RELAYOX

\ . . .

, - :1- ' . . .

ELDUNIT

22



Relayand GontrolUnit Locations

Dashboard

_DAYTIMEUNNING IGHTSEELAYCanada)lWire olorsr ED, ED/YEL,LRED/BLKndRED/8LU I

_LOWEAMCUTRELAYcanada) _lWire olors: EDMHT, ED/BLK,LBEDA/ELndRED/BLU I

KEYLESS ECEIVER NIT

CRUISECONTROL NIT

'

'-.:-':

. . ? ; ,

POWERWINOOW RELAY

TURN SIGNAL/HAZARDRELAY

TAILLIGHTRELAY UNDER.DASHFUSE/RELAY OX; .[:_- -

-l:r --

22-8

MULTIPLEX ONTROL NIT



(cont'

22



RelayandControlUnit Locations

\

Dashboardcont'd)

L

SR SUNIT

EPSCONTROL NITPGM.FIMAINRELAYlWire olors: EUBLK,LWHT/BLK, HT/BLK ndRED/YEL

PGM.FIMAN RELAYfwirecolors: EUBLK, ILYEUGRN,EUBLKand GRN/YEL

AIR/FUEL ATIO ENSOR ELAY[Wire olorsrWHT,WHT/RED, IOBN ndBLK/ORN I



Rearand Roof

MOONROOFPEN ELAY -Wire olors: RNI/EL, RN,

LRED/YEL,LK ndYEL/GRNMOONROOFLOSE ELAY

REARWINDOWWIPERNTERMITTENTCONTBOLNIT

fwirecolors: RN/BLK,RN ,IGRN,AtVHT,LKandYEL/GRN

22-



ndControlUnitLocations

DoorandSeat

Driver'sDoor:

Passenger's eat:

l \ :

] . \

POWERWINDOWMASTERSWITCHlHasbuilt-in ontrol nit)



GonnectorsndHarnesses

a Gonnector ndex

ldentif icat ionumbers av ebeen ssignedo in-l ine onnectors.henumbersprecededy he etter C" fo r connectors,G" fo rgroundterminals r "T " for nongrounderminals.

Hamess LocationEngineCompartment Dashboard Others

Floor,Door,

Trunk.and Roo{l Not€sStarter ubharness C102 ndC103

T1an dT2T101 nd 102

(see ag e 2-15)

Battery round able T3G' lan d -

{see ag e 2-l!)

Engine round able T4 {see ag e 2-14)

Engine ireharness C l0 l h rough 104G 0 1

(see ag e 2 16)

Engine ompartment ireharness{rioht ranchi

G201 ndG202 (see ag e 2 18)

Engine ompartment ireharness(left rench)

G301 (see ag e 2 18)

Engine ompartment ireharness(dashboard) c401

C451andC452C501hroughC503c551c851G402

(see ag e 2-18)

EP S ubharness C 1 5 1 n dC 1 5 2G'151

\seepage22 241

Dashboard ireharnesslleftbranch)

C504hroughC510G501 ndG503

(see ag e 2-26)

Lefts ide urn s ignal ight c506 (see ag e 2-26)

Dashboard ireharness(right ranch)

C50l hroughC503C5 l l h rough 515C852 ndC853G502

(seepage22-26)

Rights ide urn s i9nal ight

sub harnesslseepage22-26)

Dashboard ireharness C40l hrough 40 3

c510G40l

(see ag e 2-30)

EC Mwireharness c101cl52C451hrough 453c 5 1 1G451

{see ag e 2-32}

Floorwire arnessfront ide) C402 ndC403 G551c453C508 ndC509c512C551an.l C55?

(see page 22'34)

Floorwireharnessrear ide) C553 ndC554 (seepage22-34)

Roo{wireharness c507 (see aqe 2-38)Hatch ireharness C553 ndC554 (s6epaqe 22'39)Driver's oo rwireharness C504 ndC505 (see paqe 22-40)Passenqer's oo r wi.e harness 514 ndC515 (seeoaoe 22-41

Te arness )552 (see aq e 2-42i/C wireharness c851 rhrouoh c853 (seepaqe 22.43i

22-1




Gonnectoro Harnessndex

BatteryGroundCable

Connector r Terminal Cavities Location Connectsto NotesT3 Left s ide of enqinecompartment

Left s ide of enginecompartment Body round iabatteryqround ar)le

2 Batterv Bat tervneoative erminal

EngineGroundCable

Connector r Terminal Cavities focation Connec{sto Notesr4 5 Rioht ide f enoine

4 Right ide f engine ompar tm en t Body round iaengine

ENGINEGROUNDCABLE

BATTERYGROUNDCABLE

\ . . . . .

22-14



Connector rTerminal Ret Cavities Location Connoc,tso NotesAlternatorKnock ensorStarter olenoidc102

c103

1 0857

6

4116

1

Right s ide of eng;necompartmentFront of engineMiddle of enginecompartmentFront of enginecompartment

Frontof engane ompartment

Engine ireharnessse epage 2 16)Engine ire harnessse eoaae 2 -16 )

T1r2

24

L€ttsideof enginecompartmentMiddle r enoine omDanment

Underhood use/relayoxStanermotor

T101r102

1I

Under-hooduse/relayoxAlternatorBatterv Batterv osit iveerminal

StarterSubharness

STARTERSUB HARNESS

22-1



Connectors nd Harnesses

EngineWireHarness

Camshaftosit ionCMP) ensorLllr sensorEC[,4 onnectorAECI/l onnectorBEngine oolantemperatureECT)

sensorEngine i l pressurewitchEVAP anister urge alveldleai rcontrol lAC)valve

lgnit ion oilNo .lgnit ion oi lNo .2lgnit ion oilNo .3lgnit ion oilNo .4Iniector o.1Inlector o. 2Iniector o.3Iniector o.4Intake ir emperaturelAT) ensor

TDC ensorThrottleposition TP) ensorVehicle peed ensorVSSI

VT C il control olenoidalveVTEC il pressure witchVTEC olenoidalvec 101

c102

233

242

TransmissionousingLeft ideof engineRight ide fengineUnder loveboxUnder love oxLeftside of engine

Bight ideoI engineLeftside of intakemanifoldLeftsideof intakemanifoldMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompartmentMiddle f engine ompanment

28

1 845672524201 91 2

81 11 02729303

22

123333322222

33

322220

Left ideof ntakemanifoldLeft id eof engineLeftsideof intakemanifoldTransmissionousingRight ideo{ engineRight id eof engineRight ide f engineUnder ight ide f dash

Front f engine ompanment

Front f engine ompartment

EC Mwireharnessse e ag e22-321Starter ubharnessse e ag e22-15)Starter ubharnessse e ag e22 151

Connector o Harness ndex cont'dl

22-16



. . . . -1 0

1 1

1 3

1 4

22-



Connectors ndHarnesses

Connectoro Harness ndex cont'dl

EngineCompartmentWire HarnessRightbranch)

\

Connsctoror Terminal Cavitiss Location Connectso NotesAB Smodulator-controlni t

Bearwasher otorRight rontAB Swheel ensorRight rontairbag €nsorBightfront arkingightRight rontsidemarkerightRight ront urnsignal ightRight eadlightRight ornwash€rf luid evel witchWindshield ashermotor

81 2

11 01 12

7

222222

I22

Bight ideo{ engine ompartment

Behind ight ideof rontbumperRight ideot engine ompartmentBehind ight ideof rontbumperBehind ightheadlightBehind ightside f Jront umperBehind ightheadlightBehind ightheadlightBehindrontbumperBehind ightside f rontbumperBehind ioht ide f ron tbumoer

Canada

G202

G201 6 Behind ightside f rontbumper

Behind ightside f Jront umper

Body round ia€nginecompartment treharnessBody round iaengine.omnerhent wi re harness

22-18



ENGINECOMPARTMENT IREHARNESS

(cont '

22-




EngineCompartmentWire Harness Leftbranch)

AirJuel A,,/F)at io ensorBrakeluid evel witchCondenseran motorCruise ontrol ctuatorELD nitFog ight onnectorLeft rontAB Swheel ensorLeft rontairbag ensorLeft rontparkingightLeft rontsidemarkerightLeft rontturnsignal ightLeft eadlightLefthornRadiatoranmotorRadiatoranswitchSecondaryeated xygen SHO2S)

Test achometeronnectorWindshield ipermotorUnder'hooduse/relayoxconnector {see ag e 2-44)Under-hooduse/relayoxconnector (see ag e 2-44)Underhood use/relayoxconnector (see ag e 2-44)Under ood use/relayoxconnector (see ag e 2 44)Under-hooduse/relayox

Front f engine ompanment

Left ide f engine ompartmentLeft ideof engine ompartmentLeft ideo{ engine ompartmentFront f engine ompartmentUnder ight ide f cowlcoverUnder'hooduse/relayoxLeft ideof engine ompartmentLeft id eof engine ompanmentBehindef t ideof rontbumperBehindef theadlightBehindef tsideof rontbumperEehindef theadlightBehindef theadlightBehindrontbumperLeft ideof engine ompartmentFront f engine ompartmentLeft ide f engine ompartment

Left ide f engine ompanmentL.Jnderef tside f cowlcoverL.Jnderood use/relayox

L.Jnderood use/relayox

L.Jnder'hooduse/relayox

underhood use/relayox

Under-hooduse/relayox

24

222

2519

1 2

1 7

1 3202 123

3

1 17

I

1 0

5

6

l

22243,l

222223l

224

252

5

12

Connector o Harnessndex(cont'dl

\

22-20



l' \ -

ENGINECOMPARTMENTWIREHARNESS

(conr

22-




Connector o Harnessndex(cont'd)

EngineCompartmentWire HarnessDashboard)lcont'dl

Connector r Terminal Cavities Location Connectsto NotesFo gight onnector

Under'dashuse/relayoxconnector(see age 2-45)Underdashuse/relayoxconnector (see age 2-45)Underdashuse/relayoxconnector se e ag e 2'45)Under-dashuse/relayoxconnector(see age 2'45)Under-dashuse/relayoxconnector(see ag e 2-45)c 1 5 1

c401

c451

c452

c501

c502

c502

c503

c851 ' 14

2

3

1

I

9

6

6

5

5

12

1 0

1

1 21 0

3

5

8

2

'10

4

8

5

1 0

1

Undermaddle f dash

Under eftside f dashUnder eftside f dash

Under eft ideof dash

Under ef tside f dash

Under eftsideol dash

Under ight id eof dash

Under ight id eot dash

Under ight ideot dash

Under ight ideoJdash

Under ight id eoI dash

Under ight id eol dash



Undermiddle f dash

Under ight ide f dash

EPS ubharnessse e ag e 2-24)Dashboardir eharness(see ag e 2-30)EC Mwireharnessse e ag e22-321EC Mwireharnessse o ag e22 32)

Dashboard ireharness(see ag e 2-26)Dashboard ireharnesslseepage22-261Dashboard ireharness(seepage22-26)Dashboard ireharness(see ag e 2-26)Floorwire arnessse e ag e22-34l',VCwire harnessseepage22-43\

Oplion

Canada

US A

G402 1'I Eody round iaengine. .mdar lma.t w,rc harncss

22-22



D' -

-.,.i

ifa.: ,, ..j' 1_-1.:,

. - - , ,,

-g'-.t ';.-a

UNDER-DASHUSE/RELAY OX

ENGINECOMPARTMENT IRE

22-




Connectoro Harnessndex(cont'dl

EPSSubharness

Connector r Terminal Cavities Location Connects o NotesEPS ontrol ni tconnectorA

EPS ontrol ni tconnectorEPS ontrol ni tconnectorEP SmotorEP Sorque ensorc 1 5 1

c152

2

,l31

6

4

2

220262

I

Under ightside fdash

Under ight id eof dashUnder ighr id e f dashMiddle f engine ompanmentMiddle f engine ompartmentUnder ight ide f dash


Engine ompartment ireharnessse e ag e 2- 8)ECI\,4ire harness seepage22-321

G151 5 aodyground ia EP S



EP SSU BHARNESS

22-




DashboardWireHarness {Leftbranchl

Connector r Terminal ffiAccessory owersocket

AudioantennaBrakepedalpositionswitchClutch nterlock witchClutch edal oist ion witchCruise ontrol ni tCruisemainswitchDaytime!nning ights ontrol ni tDaytimeunningights elayGauge ssemblyonnectorGauge ssembly onnectorHazard arning witchHeater ontrolpanelconnectorAHeater ontrolpanelconnectorBHVACpushswitchassemblyKeylesseceiver nitLo wbeam ut elayOptional ecurity onnectorPowermirror witch

Under-dashuse/relayoxconnector (see ag e 2-45)Under'dash use/relay ox

L {seepage22-45}Underdashuse/relayoxconnectorM lseepage22'45)Under-dashuse/relayoxconnector (see ag e 2-45)UndeFdashuse/relayoxconnector (see ag e 2-45)UndeFdashuse/relayoxconnectorYse e ag e 2 45)c504

c505

c506c507

c508

c509

c510

22

226

3029628

I8

201 11 81 91 05327

,I 4

1 2

1 1

34

1

24

25

2 Undermiddle f dash

2 Under eftsideof dash4 ] Under eftside f dash2 ] Under eftsrde f dash2 | Under eftside f dash14 I Under eftsideof dash5 Under eftsideof dash14 Under ettsideof dash4 Under ettside f dash22 I Behind auge ssembly22 i Behind auge ssembly10 Behind azard arnning witch22 Behind eater ontrol anel'14 Behind eater ontrol anel10 ] BehindHVAC witch ssembly5 I Undermiddle f dash5 lUnder le f t s i deo f dash16 Under efr ideof dash13 Under eftsideoI dash17 ln heunder-dashuse/relayox

Canada

Canada

l 0 In heunder-dashuse/relayox

In heundeFdashuse/relayox

In he underdashuse/relayox

In he under-dashuse/relayox

In heunder-dashuse/relayox

Under eftsideof dash

Under eftsideot dash

Under eftside f dash


Undermiddle f dash

Undermiddle f dash

Undermiddle l dash

Driver's oo rwireharness(seepage22'40)Driver's oorwireharness(see ag e 2-40)

Left ide urosignal ightsuonarnessRoofwireharnessse e ag e22 3AlFloorwire harnessse e ag e22-341Floorwireharnessse e ag e22 34JDashboardire harness(see aoe 2-30)

12

12

G501

G503

1

21

Under auge ssembly

Under eft ideof dash

Body ground via dashboard

Body ground via dashboard

Left Side Turn Signal Light Sub harness

Connectoro Harnessndex(cont'd)

L

Connector r Terminal Cavities Location Connects o Noles

Left ide urnsignal ightc506 3534 22Behind efts ide urn signal ightUnder eft s ide of dash Dashboard ireharness



DASHBOARDWIREHARNESS

, . /

- 1 9

20

34 I

LEFTSIDETURN SIGNALLIGHTSU BHARNESS

) . \ 'u2s )t

30

(con

22



Connectorsnd Harnesses


DashboardWire Harness (Rightbranch)

Connecloror Terminal Cavities Location Connectso NotesAudio nitconnector

c501

c502

c502

c503

c5 '11

c512

c514

ca52

c853 3

9

2

6

5

5

4

12

8

1 0

20

1 0

4

8

5

8

2

6

21

'l

Eehind udio nit




tJnder ight ideof dash

Undermiddle f dash

Undermiddle f dash

Under ight ideof dash



Undermiddle fdash

Undermiddle f dash

Engine ompartment ireharnessse e ag e 2,18)Engine ompanmentwireharnessse e ag e 2-18)Engine ompartment ir eharnessse e ag e 2-18)Engine ompartment ir eharnessse e ag e 2- 8)ECN4ire harnessse e ag e22-321Floorwire harnessse e ag e22-341Right ide urnsignal ightsuonarnessPassenger'soo rwireharnessse e ag e 2 4l)Passenger'soo rwire

harnessse e ag e 2 4'l)A,/Cwire harness seepage22-43)ly'Cwireharnessse e ag e22-431

US A

Canada

G502 Under ight ide f dash Eody round ia dashboard

RightSideTurn Signal LightSub harness

Connector rTorminal Cavities Location Connectsto Not€sRight ide urnsignal ightc5't3

18

22

Eehind ight ide urnsignalightUnder ioht ideof dash Dashboard ireharness



DASHBOARO IBEHARNESS

'---/... '

T

22



nd Harnesses

Connectoro Harnessndex cont'd)

DashboardWire Harness

Collqctor or Terminal Cavities Locatiol| Connectsto NotesCable

CombinationightswitchDriver's irbagnflatorlgnitionkeyswitchlgnit ion witchlmmobil izerontrol nit eceiverPassenger'sirbagnf atorSRS nitconnectorWiper/washer witchUnder ash use/relayoxconnectorAse epage 2,45)Underdash use/relayboxconnector (see ag e 2-45)Under'dashuse/relayoxconnectorC(seepage22-45)Under-dashuse/relayoxconnector se epage 2-45)Under'dashuse/relayoxconnectorXse e ag e 2 45)

c401

c402

c403

G510

reel 2

11 71 6't9

1 8I

35

6

1

8

1 0

1 2

1 1

1 4

5

4

1141 81 45

6

1 4

2

8

1 0

4

1 2

Insteeringolumn over

In steeringolumn overIn steering olumn overInsteering olumn overInsteeringolumn overInsteering olumn overUndermiddle f dashUndermiddle fdashIn steering olumn overUnder eft sideof dash

Under eft ideofdash


Under ettside f dash



Undermiddle f dash

Undermiddle f dash

Undermiddle ide f dash

Engine ompartment ir eharnessse e age 2-'18)Floorwireharnessse e age22-34JFloorwireharnessse e age22-341Dashboardireharness(see ao e 2-26)

G40 l Under auge ssembly Body round iadashboard



OASHBOARD IREHARNESS

22-





ECMWire Harness

Connector r TerminiF I Re- lcavities L Location Connectsto NotesArr uer /vrl ralo sensor etay

Data ink onnectorEC[/l onnectorEPGM-Fl ain elay1PGM-Fl ain elayUnder-dashuse/relayoxconnector (see ag e 2 45)Underdashuse/relayoxconnectorE seepage22-45)under-dash use/relay oxconnectorR seepage22-45)c10'1

c152

c451

c452

c453

c511

8761

2

3

4

1'I

I

1 0

1 4

1 2

44

6

20

8

4

6

Eehind lovebo x

Undermiddle f dashBehind lovebo xBehind lovebo xBehind lovebo xIn heunder-dashuse/relayox

In he under-dashuse/relayox

In heunder-dashuse/relayox

Under lght id e f dash



Under ight id eot dash

Undermiddle I dash

Undermiddle f dash

Engine ir eharnessse epage 2'16)EP S ubharnessse e ag e22-24)Engine ompanment ir eharnessse e ag e 2-18)Engine ompartment ir e

harnessse eag e

2-18)Floorwire harness seepage22-34)Dashboardir eharness{see aoe 2-26)

G451 Under auge ssembly Body round iaEC Mwireharness

22-32



EC MWIREHARNESS

22-





FloorWireHarnessFrontsidel

Connec-tor r Terminal I Ref uavftres Location connects to Nol6sDriver's eat elt witch

Driver's id eairbagnflatorDriver's ide mpact ensorLeftsideseatbelt buckle ensionerMemory rase ignal MES) onnectorParking rakeswitchPassenger'seatbelt switchPassenger'sid eairbagnflatorPassenger'side mpact ensorRight ide eat eltbuckleensionerSR S ni tconnectorSRS nitconnectorUnder-dashuse/relay oxconnector se e ag e 2-45)Under-dashuse/relayoxconnectorO (seepage22,45)c402

c403

c453

c508

c509

c512

1 1

l 01 31 21 995374

20211 1

'r 8

22

23

2

1 4

1

6

3 I Under r iver's ea t

2 i Under river's eat2 I Leftsideoffloor4 Under r iver's ea t2 Under ash use/relayox1 1Middle ff loor3 Under assenger'seat2 Under assenger'seat2 Right ide ff loor4 Under assenger'seat18 I Undermiddle f dash8 Undermiddle f dash18 Underdashuse/relayox

8

]

Underdash use/relayox

10

I

Undermiddle f dash




6 Undermiddle fdash

8

I

Undermiddle f dash


4 ] Unaermiddle f aasn

Dashboardir eharness{see ag e 230 )

Dashboardir eharness(seepage22-30)EC Mwire harnessse e ag e22-321Dashboardireharness(see ag e 2-26)Dashboard ireharness\seepage 22-26)Dashboardireharness{see ag e 2-26)Engine ompartment ireharnessse e ag e 2 18)OPDS nitharnessse e ag e22-421

G551 I L,nder assenger'sea t Body round ia loorwire



- 10

1 1

FLOORWIREHARNESS

(con

22



GonnectorsndHarnesses

FloorWire Harness{Rearside}(cont'dl

Cargo re a

Driver's oo rswitchEVAP mission ypass olenoid alveEVAP mission ontrol anister entshut alveFuel ump/sendingni tFuelan kpressureensorLeftback-up ightLeft earABS wheelsensorLeft ear idemarkerightLeft ear speakerLeft ear ur nsignal ightLeft ide eat elt ensionerLeft ail l ighVbrakeightNoise ondenserrearwindowdefogger)Noise ondenserrearwindowwiper)Passenger'soor switchRear indowwiper ntermiftent

con t ro lun i tRight ack-upightRight ail l ighvbrakeightRight ear urn signalightBight earAB Swheel ensorRight ear idemarkerightRight ear peakerRight ide eat elt ensioner

c554

Fue l t ank

Fue l t ankFue l t ankLeft ail l ightLeft earoffloorBehindef tsideof rear umperLeftquarter anelLefttail l ightLeftB-pil larLeft ail l ightRight uarter anel

Right uarter anelR igh t p i l l a rRight uarter anel

Right ai ightRight ail l ightRight ail l ightRight id eof cargo rea

side of cargo area

LeftB pil larFueltank

Right uaner anel

6224

I3251

2642A527'1 3

181 01 1

2220211 51 91 21 17

I

2

122

5322222232

232222212

12

21

20

Behind ight ideof rearbumperRight uaner anelRightB-pil larRight uaner anel Hatchwire harness se epage

22 39)Hatchwire harness se epage

rearseal bdcl Bodv ground vt a

Right id eof cargo rea Body round ia loorwire

Connectoro Harnessndex(cont'dl



FLOORWIREHARNESS

22-



Connectorsnd Harnesses


RoofWireHarnsss

Connector r Terminal Cavities tocation Connectsto NotesMoonroofcloseelay

MoonroolcontrolunitMoonroofmotorMoonroot pen elayMoonroof osit ion ensorN4oonroof ositionsensor2MoonroofswitchRear eil ingightSpotlighVceil ingightc507

6

I

7851

21 0

5

525245348

Middle f roof

Middle f roofMiddle f roofMiddle f roofMiddle I roofMiddle f roofFrontof roofN4iddle f roofFrontof roofUnder eftside f dash Dashboardireharness

(see aoe 2-261



HatchWire Harness

Connector r Torminal Cavities Location Connects to NotesHatch atchswitch

Hatchock

actuatorHighmountbrakeightLicense late ightconnectorALicense late ightconnectorBRear indowde{oggeronnector

Bearwindowdetoggeronnector( )Bear indow ipermoto.c553

c554

7

8

I3

1 0

62

l

222221

1

412

2

Middle {hatchMiddle

fhatch

Behind ighmountbrakeightMiddle f hatchMiddle f hatchRightC-pil lar

LeftC-pil lar

Middle f hatchRight uaner anel

Right uaner anel

Floorwireharnessse e ag e22-341Floorwire harnessse e ag e)2-34\

22-




\,onnector o Harnessndex(cont'd)

Driver'sDoorWire Harness

Connector r Terminal ReI Cavities Location Connectsto Notes

Driver'sdoor ockactuator

Driver's oor ock no b witchDriver'sdoor ockswitchDriver's oorspeakerDriver'spowerwindow motorLeftpowermirror actuatorLeft tlveeterPowerwindow masterswitchc504

c505

9

1 01723

85

6

2

332

62

20

't 3

Driver's oo r

Driver's oo rDriver's oo rDriver's ooaDriver's oo rDriver's oorDriver's oorDriver's oorUnder eft ideof dash


Dashboard ire harness\seepage22-261Dashboard ire harness

DRIVER'S OORWIREHABNESS

22-40



Passenger'sDoor Wire Harness

Connector r Terminal Rel Cavities Location Connectsto NotesPassenger'soo r oc k ctuatorPassenger's

oo rspeakerPassenger'sowerwindowmotorPassenger'sowerwindow witchRight owermirroractuatorRighttweeterc514

6

I51432

1

2

225621 3

6

Passenger'soo r

Passenger'soo rPassenger'soo rPassenger'soo rPassenger'soo rPassenger'soo rUnder ight ideof dash


Dashboard ireharness(see ag e 2'26)Dashboard ireharnesslsee oeoe 22-26\

PASSENGER'SOO RWIREHABNESS

22-



Gonnectorsnd Harnesses

Connector o Harnessndex {cont'dl

OPDSUnit Harness

Connoctor rTorminal Cavitios Location Connectsto NotesOPDS nit 2

1I In rontpassenger'sea t

Under rontpassenger'seat Floorware arness

se e ag e22-34)

FLOORWIBEHARNESS

22-42



A/C Wire Harness

Connoctor r Terminal Rel Cavities Location Connec'tsto NotesAir mixcontrolmotorBlowermotorEvaporatoremperatureensorModecontrol motorPowertransistorRecirculat ionontrolmotorc851

c852

c853

I283411

6

5

5221 0

51

21

,]

Undermaddle f dashUnder ight ideof dashUndermiddle f dashUnder ight ideof dashUnder ight id eof dashUnder ight ideof dashUndermiddle l dash

Undermiddle fdash

Undermiddle {dash

Engine ompartment ireharnessse e ag e 2-18)Dashboard ireharness{see ag e 2 26iDashboard ireharnesslsee oaoe 22-261

22-



Under-dash use/Relay ox

Socket Ref Terminal Connects o

BcD

E

F

GH

J

K

M

N

oPPowerwindow relay

oRSStarter ut relayT

Taill ight elayTurn signal/hazardelayU

W (Memory rase igna l MES)

connector)

XY

231

51 99I20

242227

267

61 0251 41 8

1 1l 5

t o

1 7

28

561 4

1 31 21 03

:11'10

1:

.o^

; ;48

2in la l

l t2

Dashboardwire harnessB{see

page22-30)Dashboardwire harnessB {seepage22-30)Dashboardwire harnessB (seepage22-30)ECMwire harness se epage22-32)ECI\4 ire harness se epage22-32)

Engine ompartmentwire harness se epage22-'l8lEngine ompartmentwire harness se page22-181Eng ine ompar tment i re harnesssee age22-18)Engine ompartmentwire harness se page22-18)Engine ompartmentwire harness se epage22-18)Dashboard ire harnessA (seepage22-26)Dashboard ire harnessA (seepage22-26)Dashboardwire harnessA (seepage22-26)Dashboardwire harnessA (seepage22-26)

Dashboardwire harnessA (seepage22-26)Floorwire harness seepage22-34)

Floorwire harness seepage22-34)ECMwire harness se epage22-32)

Dashboardwire harnessB (seepage22-30)

Multiplexcontrol unit service heckconnector

Optional onnectorOptionalconnectorFloorwire harness seepage22-34)

{Plugsdirectly nt o he multiplexcontrol(P luqs i rec t l vn to he mult iD lexont ro l

unat)unrl)

I1 3

t n - - r lI U LI L.]L.Jh - - n -U L ] L ] U L ]

I ] L ] L ] L I L ]

! 3 1 2

22-4



PowerDistribution

Fuse o Components ndex

Under-hood use/Relay ox

FuseNumber

Amps WireColor Component(sl or Circuit(s) Protected

'I 204 BLUI/EL Condenseran motorBLU/RED Ay'C ompressor lutch

15A WHT/GRN Dash ights,Frontparking ights,Frontside marker ights,License late

l iqh t ,Rear idemarker iqh ts , a i l l i qh ts7.5A WHT/BLU Carqo rea iqh t ,Ce i l i nqiqh ts .qn i t ion ev iqh t .Soot l ioh ts204 BLU/BLK Radiator an motor

5 10A WHT/BLK Turn siqnal/hazardelav,Turn siqnal iqhts15A WHT/BLK CK Psensor,ECM, ACvalve, mmobilizer ontrolunit-receiver,njectors,

PGM-FI a in e lav1 and2.TDC ensor7 1 5 A WHT/GRN Brake ights,Brake ignals to ABS modulator-control nit,Cruise ontrol

unit,ECM)BLU/RED i1Orns

8 20A WHT/GRNAB S modulatorcontrolunit

9 10A WHT/RED Audioun i t ,Data inkconnectorDLC) , auge ssembly ,mmobi l i zercontrolunit-receiver,mmobilizer ndicator ight.Keyless eceiverunil,lvlult iDlexontrolunit

1 0 40 A WHT/REDABSmodulator-controlnit1 1 30A BLK/YE Noisecondenser,Rearwindow defoqqer

40 A BLU^^/HT BlowermotorI J 40 A WHT/BLK No. 7 fuse(in he under-dashuse/relav ox),Powerwindow relav1 4 40A WHT/RED No.2 and No.3 fuses in he under-dashuse/relav ox )t 5 1 5 A REDI/EL Daytime unning ightscontrolunit (Canada), aytime unning ights elay

{Canada) , iohbeam nd ica toriqh t . e f thead l iqh t1 6 204 WHT Multiplexcontrolunit1 7 1 5 A RED Davt ime unn inq iqh ts on t ro l n i t Canada) . ioh t ead l ioh t1 8 60A WHTiBLU EP S ontrolunit1 9 80A Batterv.Powerdistribution

20 40A'50A'?

WH T lgnit ionswitch(BAT)

* 1 :U S A" 2. Canada

O: Spare use

t t " | ll l I t t 4 t I

l l - - -- E'l E,l E,l r--r r---r__J ; i6'!/ '

E,l E,l E,l Eol E l f__--lI l ' l r ] n | |I r L__J,a ,..r^{-------l^-,

n[:]$"Lrt " N2, nf - r^l

22-46




Fuse

Number

Amps Wire Color Component(s) or Circuit(s) Protected

1 1 5 A BLKA/VHT l gn i t i on o i l s2 204 WHT/RED Airlfuel atio ensor, CM3 10A RED/BLU Dayt ime unn ing igh ts ont ro l n i t Canada)

10A BLI(ORN Air/fuel atiosensor elay,Alternator,CM Psensor,Cruisecontrolmainswitch,Cruisecontrolunit. ELDunit,Evaporative mission EVAP) ypasssolenoid alve,Evaporative mission EVAP)canister urgevalve,Evaporative mission EVAP) anister ent shut valve,SecondaryH02S,Vehicle peedsensor

5 Not used6 7.5A YEUGRN Moonroofcontrolunit, Moonroofopen and close elay,Powerwindow

re laV7 204 GRN Moonroof motorI 7.5A YEURED Audioun i t

9 10A G R N OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rearwindow wiper ntermittent ontrol unit

1 0 7.54 YEL Back-up ights,Cruise ndicator ight, EPS ontrol unit,Gaugeassembly,Keyless eceiverunit, Multiplexcontrolunit,Security ontrolunitconnector optional)

1 1 7.5A BLIVORN ABS modulator-control ni t12 7.5A YEURED Dayt ime unn ino ioh ts ont ro l n i t Canada)

1 3 10A PNK SRSuni t't 4

10A BLK/YE A,,/Compressor lutch elay,Blower motor relay,Condenser an relay,Heater ontrolpanel,Powermirror actuator,Powermirror defogger(Canada), adiator an relay,Rearwindow defogger elay,Recirculationcontrolmotor

1 E Not usedl o

Notused1 7 15A YEL/BLK ECM, uelpump

BLK/YE >H> Unrr1 8 15A YEUGRN Accessory ower socket1 9 7.5A YEUBLK Turns iqna l /hazarde lav , urns iqna l ioh ts20 30A GRN/BLKMul t ip lex on t ro l n i t ,Windsh ie ld ashermotor .Windsh ie ld ioermotor21 No t used22 204 GRN/BLKPassenqer's indow motor23 20A. GRN,A/VHTDriver'swindow motor24 No t used25 No tused

_ _ ^ :Hr t l_ l

f a t - tat\t I

r^,rl fl

! ! ; r -! 339 , i ; s ! ! sf F n f : | r n I T f

22-4



GroundDistribution

Ground o Componentsndex

Ground Componentor circuitqrounded

Batterv, ransmission ousinq

Eng ine

G1 0 1 EC M PG s BLK; G s BRN/YEL)BLK: AC alve,gnition oils, ehicle peed ensor, TEC olenoid alveBRNA/EL:amshaft ositionCMP)ensor. KP ensor, DC ens or. TEC il pressurewitch

G15 '] EPS ontrol nitG 2 0 1 ELDunit. Multiplexcontrol nspection onnector,Multiplexcontrolunit, Powerwindow relay,Rear

window washermotor, Right ront parking ight, Right ront sidemarker ight, Right r ont turn signal

l ight,Turn signal/hazardelay,Washer luid levelsensor Canada) Windshieldwashermotor,

WindshieldwiDermotor

G202 ABSmodulator-controlni tG301

G401

Blowermotor relay,Brake luid evelswitch,Condensoran motor, Cruise ontrolactuator, eft rontparking ight, Left ront side marker ight, Left ront turn signal ight, Radiator an motor,Radiator an

swrtcn

Combination iqht switch, qnitlonkev srvitch,Wiper/wasfrer r,virch

G402 Leftand riqht airbaqsensors,SR Sunit

G4 51 Data ink connector DLC)G501 Clutch nterlock witchm Clutchpedalposit ionswitch(forcruisecontrol),Cruise ontrolmain switch,

Cruise ontrolunit, Daytime unning ightscontrolunit (Canada), river'sdoor ock knobswitch,

Driver'sdoor lockswitch,Driver'spowerwindow motor, Heater ontrolpanel,Leftpower mirror

defogger Canada),eft side urn signal ight,Moonroofcontrolunit, Monroofopen and close elays,

Moonroofposit ionsensor1,

Moonroof seitch,Powermirror switch,Power ransistor,Powerwindow

masterswitch.SDotliqhts

G502 Accessory owersocket,Gaugeassembly,Keyless eceiver nit, vlult iplex ontrolunit,Rightpower

mi r ro rdefoggerCanada)G503 Audioun i t

G551 Driver'sseatbeltswitch,Fuelgaugesendingunit, Fuelpump, Memory erasesignal IMES)onnector,

OPDSunit.Riohtseatbelt switch

G552 High mount brake ight, License late ights,Rearwindow defogger,Rearwindow defoggernoise

condenser.Rearwindowwioer motor, Hatch atchswitch

Back-up ights,Brake ights,Rearsidemarker ights,Rear urn signal ights,Rearwindow wiper noise

condenser,Rearwindow wiper ntermittent ontrolunit,Tail l ights

22-48




Removaland Installation

SR Scomponents re ocated n this area.Review heSRScomponent ocations seepage23-13) ndprecautions nd procedures se epage23-14) n he SR S

sectionbeforeperforming

epairsor service.

Removal

1. Makesureyou have he anti-theft ode or the radio,then write down the frequenciesor the radio'spresetbuttons.

2. Disconnectthe atterynegative able, hendisconnect he positive able,and wait at leastthree minutes.

3. Remove he driver'sdashboard owercover (seepage20-59).

4. Disconnecthe connectors rom th e fuse sideof theunder-dashuse/relay ox.

5. Remove he mountingbolt, and slide he under-dash use/relay ox (A) down from the bracket B)

6. Disconnecthe backside rom connectors rom thebackof the under-dashuse/relaybox, and removthe fuse/relay ox .

NOTE:The RS onnectors a spr ing- loadedocktype (seepage23-1 ).

lnstallation

1. Installtheunder-dash use/relay ox in the reversorder of removalan dconnectall connectors o theunder-dash use/relay ox .

2 . Ins ta l l t he r i ver ' s ashboardower over .

3. Connectboth he negative ablean d positivecablto the battery.

4. Enter he anti-theft ode or the radio, hen enterthe customer's adiostationpresets.

5. Confirm hat all systemswork properly,

6 . Do he eng ine ont ro lmodu le ECM)d le earnproceduresee age11-139) .

22-



Battery

attery Test

Use eithera JCI or BearARBST ester,an d ollow th e

manufacturer's rocedures.f Vo udon't haveone of

thesecomputerizedesters, ollow this conventionaltest procedure:

1. Be sure he emperatureof the electrolytes

between70'F (21"C) nd 100'F 38'C).

2. Inspect he batterycase or cracksor leaks.

. l f hecase sdamaged,ep lacethe at te ry . l

. lf the case ooksOK ,go to step3.

3. Check he indicatorEYE.

. lf th e EYE ndicatesthebaftery scharged,goto

step 4.. l f he EYE nd ica tesaowcharge, o tos tep7.

4. Apply a 300 amp load or 15 seconds o remove he

surface harge.

5, Wait 15 seconds, hen apply a test oad of 280 ampsfor 15seconds.

6. Recordbatteryvoltage.

. l f vo l tage s above9.6vo l t s , theat te ry sOK. l

. l f vo l tage s be low9.6vo l t s , o tos tepT.

7 . Chargehe bat te ry n High 40amps) n t i l heEYE

shows he battery s charged,plusan additional30minutes. f the batterycharge s very ow, it may benecessaryo bypass he charger'spolarity

protection ircuitry.

. l f heEYE nd ica tes the a t te rys chargedwi th in

3 hours, he battery s OK.l. lf th e EYE ndicatesthebattery s notchargedwithin 3 hours, eplace he battery.l

A batterycan explode f yo u do not follow the

properprocedure, ausingserious njury o anyonenearby.Followal l procedures arefullyand keepsparksand open lames away rom the battery.

22-50



Relays

PowerRelayTest

Use hischan o identifyhe ypeof relay,hendo hetest isted or t.

NOTE: urnsignal/hazardelay nput est se e age 2-87) .

Relay TestA'lC omoressorlutch elav Normal l y -open

type Airlfuel ratio sensor elav

Condenser an relayHead l ioh te lav1Head l iqh te lavHorn e lav

Powerwindow relayRad ia toran re lay

Reverse elavStarter ut relav

Ta i l l i qh t e laVDayt ime unn ing igh ts e lay

{CanadaPGM-FI a in e lavPGM-F lmain e lavBlowermotor relav Normal l y -open

tvpe Bea rwindow defoqoer elavMoonroofclose elay F ive erm ina l

typeoonroofoDen elavLo w beam cut relav Canada)

Normally-openype A:

Check or continuitvbetween he terminals.

. Thereshouldbe continuitybetween he No. 1 andNo,2 erm ina ls henpowerandgroundareconnected o the No. 3 and No. 4 terminals.

. Thereshould be no continuitybetween he No. 1 andNo.2 erm ina ls henpower sd isconnected.

type 1:

type 2:

PGM-FImain relay 1PGM-FImain relay2

type 1:

type 2:

(cont'd

22-5



PowerRelayTest(confdl

Normally-openype B:

Check or continuitybetween he terminals.

. Thereshould be continuitybetween he No. 1 an dNo.3 term ina ls henpowerandgroundare

connectedo the No.2 andNo.4 erm ina ls .' Thereshould be no continuitybetween he No,

'land

No .3 terminalswhen power s disconnected.

Blower motor relay

type 1:

type 2;

tF-grt J 1 l

Rearwindow defonn* *O,

6:)rc*V.r{{n , \( F t )s3.

Five-terminalype

Checkor cont inu i t y e tweenhe erm ina ls .

. There hou ld e cont inu i t y e tweenhe No.1 andNo.2 erm ina ls henpowerandground re

connectedo the No.3 and No.5 term ina ls .. There hou ld e cont inu i t y e tweenhe No. 1 and

No.4 ermina ls henpower s d isconnected.

type 1:

type2:

\



lgnitionSwitch

Test

SRScomponents re ocated n this area.Review heSRS omponentocat ionssee age23-13) ndprecautions nd procedures seepage23-'l4) n the SRS


1, Remove he driver'sdashboard owercover se epage20-59).

2. Disconnecthe 5P connector rom the under-dashfuse/relay ox.

WHT/RED

Wire ide ffemaleermina ls

BLK/WHT BLK/YEL

BLK/RED

Check or continuitybetween he terminals n eachswitchpositionaccording o the table.

\Terminal

p.J,i""-\WHT/RED(ACC)

BLK/WHT YEL(BAT) flGl)

BLK/RE Dtrc2t

BLK/WHT(sr)

o (LocK)| (ACC) o- --o

[ (oN)III (START)

c)- _H

o _H

lf the continuity hecksdo not agreewith the table,replace he steering ockassembly se epage'17-121.

22-5



Gauges

\-ComponentLocation ndex

PARKINGBRAKESWITCHpage19-10

FUELGAUGESENDINGpage 1-156

ENGINEOIL PRESSUREWITCHpage -4

GAUGEASSEMBLYSelJ-diaqnosticrocedure, ag e22-56Gauqedulb Replacement,ag e22 63Rep6cement, ag e22-64Coolant emperatureGaugeTroLrbleshooting,ag e22'64

BRAKE LUIDLEVELSWITCHpage 9-10

VEHICLE PEED ENSORVSS)Troubleshooting, ag e22-65Beplacement, ag e22-67

22-54

\



CONNECTOR(bluel

CONNECTORlgreenJ

SPEEDOMETERVehicle peed ignal ircuitTroubleshooting,ag e 2-65

TACHOMETEB

FUEL AUGETest, ag e 1-156

\7

t----/ \

i . . _ -_ / \

ODO/TRIPMETER

22-



Self-diagnostic rocedure

Th e gaugeassemblyhas a self-diagnosisunction.. TheBeeper r i veCi rcu i t heck. Th e IndicatorDriveCircuitChecL.

The LCDSegmentsCheck. Th e GaugesDriveCircuitCheck Speedometer, achometer, uelgauge,Coolant emperature auge). TheCommunica t ionineCheck the oo lan t tempera tureigna l inebetweenhegauge ndECM)

NOTE: ndicators re also controlled ia the communication ine.

Enteringhe self-diagnosisunction:Beforedoing he self-diagnosisunction,check he No. 9 (10A) us e n the under-hood use/relay ox and No. 10 7.5A)fuse n the under'dash use/relay ox .

1. Pushand hold he trip/resetbutton.2 . Turn he igh t ing wi tchON.3. Turn he gn i t ion wi tchON ( l l ) .

4 . Wi th in5 sec. , u rn he igh t ing wi tchOFF,henON andOFF ga in .

5. Within 5 sec., elease he trip/resetbutton, he n pushan d release he button ou r times reDeatedlv.

NOTE:. While n the self-diagnosismode, he dash ightsbrightness ontrolleroperatesnormally.'Whi le in these l f -d iagnos ismode, the t r ip / rese tbut ton isusedtostar t thebeeperdr i vec i rcu i tcheckandthegauge

drivecicuitcheck.. lf the vehiclespeedexceeds1. 2mp h 12 m/h)orthe ignit ionswitch s tu nedOFF, he self,diag osismodeends.

oN flrllgnit ion

Switch

Lighting

Switch

Trip/Reset

Switch-> Move to selt-diagnosismode.

5 sec. 5 sec.

TheBeeperDriveCircuitCheck:Whenentering he self-diagnosismode, he beeper ou nds ive times

The ndicatorDriveCircuitCheck:When entering he self-diagnosismode, he following ndicators link.Seatbelt ndicator,Door/hatchndicator,Brakesystem,Lowfuel indicator,Maintenance equired ndicator USA),Washer lu id eve l nd ica torCanada) , i l p ressureigh t .

v

OFF



Gauges

CircuitDiagram

'No20ioAlUSA

ECM/PCM

VI-r'r--ll J ,I ii-ciorurnnI 8| coNNECron

Norl l0AlFUSE

UflOEN iOOO USE/8ILAYOX

COOLANITEMPfNAIUFT

SPIEDOMEIEN ACHOMEIIR FUTLGAUGI GAUGE

8L(

-o-



ti) l To mxr I

MAi{IIiIANCEft0unlD[{0tcaTo8LIGH](LEDI

(cont

22-



Gauges

I

No2i l5A lFUSEilnlh.undi hooq DASHllu!./rcl.ybox r LGHTS

Y Yt lt l

CircuitDiagram cont'dl

ls?2I

BLUIYEL

I

JcSutsEm n0L

' - - t

WASHEFItut0I!VEL6t0tc ToRUGHT(tDl

22-60



' - - - t

I DAYTIME I! BUNN|NG ;i LIGHTS II @NTROL

I UNII iL - . - . . I

icmadd

./ ib-n'rnoLtNGniEorL UNIT

PRESSUBEswtTcHlCld.d Eisin.3topp.diopd Ersin.runni.s

(cont

22-



Gauges

\"ircuitDiagram cont'dl

CoME|NAT|ON tMf,tOBtUZEn

LtctlTswtTclt @l\tTRoLUN|I ftCtIVER

GRNIfiED

I\""'7

VLEFTTUNSIGI'IALII'{DICATOR

GAUGIASSEi|BLY LTCHTS

\,IGHSEAM -|. IMMOBITIZER

ltDtcATon r/: \ tilucaToB

f,il vll9i,]



GaugeBulb Replacement

CRUISEHIGHBEAM NOICATORIGHT 1.4W)

ITOR IGHTI. 4W)LEFTTURNSIGNAL NDICATOR IGHT 1.il wl

GAUG€ IGHT1. 4WI

IMMOBILIZENNDICATORLTGHT1. 4Wl

GAUGELIGHT 1. 4W}

RIGHTTURN IGNAL NDICATORIGHT 1. 4WI

22-



2.

3 .

GaugeAssemblyReplacement

1.Remove he instrumentpanel seepage20-59),then emove he upper o lumn over see age17-

Place c lean hop owel A)under hegauge

assembly o preventscratchinghe steeringco lum or dashpane l .

Remove he screws rom th e gaugeassembly B) .

Disconnecthe connectors C) ,and remove hegauge ssemDry.

Ins ta l l t he auge ssemblyn he reverse rdero fremova l .

Coolant emperature augeTroubleshooting

Before esting, heck he No. {10A) use n the under-

hood use/relay ox and he No.10

(7.5A) use n th eunder dash use/relay ox .

1. Start he engine,and check he malfunc tionind ica toramp MlL) .

Does he MIL comeon ?

YES- Troubleshoothe causeof the ECMDT C se epage11-57) , nd echeck.

NO-Go to step 2.

2. Check or a multiplexcontrolunit DTC se epage

22,168).

ls a DTC ind cated?

YES Troubleshootinghe causeof the multiplexcontrolunit DTC se epage22-168), nd recheck.NO Go o step3.

3 . Do hecommunica t ionine heckwi th hese l f -diagnosisprocedure seepage22-56).

ls the word "Error" indicatedon the odo/tt ipd splay?

YE S Th e gaugecannot eceive he signal ro m th emultiplexcontrolunit and he ECI\,4.heck or anopen n the WHT/GRNwire (gauge onnectorte rm ina lB13) . f no open s ound, o o s tep5.NO Go o step4.

4. Do he gaugedrive circuitcheckwith the self-d iagnos is roceduresee age 2-56) .

Does he temperature augeneedlesweep romthe minimum position to the maximum, then tetutnto the minimumposition?

YES Go o step 5.

NO Rep lacehegauge ssembly . l

5. Substitute known-goodECMand recheck.

Did the symptom/ nd cation go away?

YES Replacehe ECM.NO Substitute known good gaugeassembly. fthe symptom/indication oe saway, replace hegauge ssembly . l

4.



VehicleSpeedSignalCircuitTroubleshooting

SpecialTools Required:Test Harness 7LAJ-PT3020A

Before esting, nspect he No. 4 (10A)and No. 10 7.5A)fuses n the under-dashuse/relay ox .

1. Disconnecthe 3P connector rom th e vehicle

speedsensor VSS) A) .

Connect he test harness nly to the enginewire

harness.

Connect he RED est harness li p (B ) o the positiveprobeof an ohmmeter.Cover he white (C)an dgreen D) es t harness eadswith protective ap e (E).

Check or continuitybetween he RED est harnessc l ipand bodyground,


YES Go o step5.

NO Repa i r pen n he BLKwi re be tweenheVSS

a n dG1 0 1 . I

3.

4.

5. Connect he WHT est harness li D B) o thepositiveprobeof a voltmeter,and connect he REtest harness li p (C ) o the negativeprobe.


l e t h a r a h 2 l t a r v v ^ l t a d a ?

YES-Go to s tep7.

NO Repairopen n th e BLK,/YEL ire between hVSS and he under-dashuse/relay ox.l

Disconnecthe WH T es t harness lip (B).

Connecthe GRN estharness l i p D) o thepositiveprobe

of a voltmeter.

Is there5 V or more?

YES- Go o step9.

NO Repair hort or open n th e BLUMHT or WHTGR Nwire between he VSS and he cruisecontrol

un i t , r heECM. I

(cont

7 .

8 .

22-



9.

10 .

VehicleSpeedSignalCircuitTroubleshootingcont'dl


Connect he other est harness onnector A) o the

VSS B) ,

1 1 .Raise he front of the vehicle,and makesure t issecurely upported.

Put he vehicle n neutralwith th e ignit ionswitchoN | | ,

Slowly rotateone wheel with the otherwheelblocked.

Does voltage pulse ttom 0 to about 5 V ot morc?

YES Go o step 14.

NO Replace he VSS.I

' t2 .

t 5 .

14. Disconnecthe 22Pconnector 8" from th e gauge

assemDry.

GAUGE SSEMBLYONNECTOR(22P)

Wire side ot female erminals

'15.Connect he positiveprobeof a voltmeter o theBLU/WHTwire and he negativeprobe o ground.

'16.Slowly rotateone wheel with the other wheelblocked.

Does voltage pulse f rom 0 to about 5 V or more?

YES Replacehe speedometer ssembly.I

NO Repairopen n the BLUMHTwiTe betweenthe VSS and he speedometer.l



J VSS Replacement

1. Remove he ntake esonator.

2. Disconnecthe 3Pconnector rom th e vehicle

speedsensor VSS) A).

4 .

Remove he mountingbolt, hen remove he VSS.

lnstalltheVSS n the reverse rder of removal.

22-



GomponentLocation ndex

UNDER.HOODFUSE/RELAYOX

\ /

HEADLIGHTSReplacement,ag e22 79Adjustment. ag e22-78Eulb Replacement,ag e22-81

HEADLIGHT ELAYTest,page22-51

HEADLIGHT ELAYTest,page22-5'l

0 /

FRONTSIDEMARKER IGHTBulbReplacement, ag e22 83

BRAKEPEDALPOSITIONswtTcHTest,page22-84Adjustment, ag e 9'6

SIDETURN SIGNAL LIGHTReplacement,ag e22-84

FRONT URNSIGNALLIGHTBu lbBep lacem en t ,age 2 81

PARKING IGHTBu lbRep lacem en t ,age 2 -81



-a-.,_z

REARSIDEMARKER IGHTReplacement,ag e 2-83

HIGHMOUNTBRAKE IGHTReplacement,ag e 2-82

LICENSELATE IGHTSReplacement,ag e 2-83

BACK.UPLIGHTReplacement,ag e22-82

TAILLIGHTS nd BRAKELIGHTSReplacement,ag e22-82REAR URNSIGNAL IGHTBeplacement, ag e22-82

(cont'

22-



Exterior ights

ComponentLocation ndex cont'dl !

DAYTIME UNNING IGHTS ELAYCanadal[Wire olors: ED, EDryEL,

LRED/BLKndRED/BLU ITest,page22-51

_LOWEAMCUTRELAYCanadal_Wire olors r EDMHT, ED/BLK,

LREDryELndRED/BLU ITest,page22-51

DASH LIGHTSBRIGHTNESSCONTROLLER

/

COMBINATIONIGHT WITCHTesVReplacement,ag e 2-80

oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada)InputTest,page22-76

DRL NDICATORIGHT Canadal

HIGH BEAM INDICATOR IGHTBulb Replacement,ag e22-63

UNDER.DASHUSE/RELAY OX

:' --,': -'

' i,-'-'l

. . i \

I t - -

22-70



I ucEr\6EI PI.ATE

|fiIliI

8L.l(

_o

IETTNEANSIDEMAircNIIGHT

f,IGHTTSONTs]0EMANXtFIJGIIT

LET]FBOIIISIDEMAiKEEL.IGHT

22-



ights

tircuitDiagram Canada

t

cl.1G501

G301

UNOEN OOOUSE/8ELAYOX

No 9 l80Al

J

) to.o- i50Al

No.1'lloa)

No.!0(7Alr

VI'l'I

usE /',d.3hl I EAr

\

BU1

IT WHT

t-\\ rc|'/moN

. rcz/swfrcH

vI G2Hor n0N ll )

IBED

ED RED,I

I'2I

*01

Ififili{*1l,.H'

II

tU RED/

, l

- _ l-- ,'orrro". ) INDICAIOF

-/ l'lcli;

BLU

l

RE=.|A DNL

) No12

i l7.5Al DAYTIMEBUNNINCLIGHTSEfLAY

y

II

HT/BI

I n

TIGHTluDl

12

RE

t0 t1

--t

lT,{ oorr,",rr.,ro { r-

I I

uctrrscournoLu,'r"

J l

SLU/BID8

SYSIIM GHI

VYI

GNfl/FEO GRI\

(

!3

/NED

III

f'\ 88A(E

I FiUrD2 , LTVEL

[./ SWITCH

I

'nddoM

I

i

||MoS|UZEnCONTNOLUNIT RECEIVEB

17YI

3

BI( BI BI G8N

F\ PANKNG; } BNAXE+./ swrTcH

i

,



JDASHLIGHTS

COMEINATIONIGHTWIqI

I LICENSEI PLAIII LIGNTS

|(twr2l

8LI

IIG552

NEHIIAILUOHI

RIGHTRIAF IDII/IAFrc8

UCHT

LEFTBEAF IDE

LJGHT

LEFTTAII LGlT

FIGIITFBONTSIDE

MAfircFLJGHTl5w)

BIGHTPANKNGLIGIIT

TTFTTRONT3r0E

MABKERLIG}IT

LEFTPAfiX*'IGLIG}IT

BLI( BL](

t l! l ! I

G301 G301

22-



ights

\CircuitDiagram BrakeLights

UiDENHOODFUSE/NEUYBOX

SATIISYI

r!o7l15A)|

\ ,r-T-v--rrn i 'c i tr

4



CircuitDiagram Back-upLights

UiDEN H@DFUSI/8EIAY0)(

22-



ights

DaytimeRunning ightsControlUnit InputTest Canada

TheDRL nd ica torigh t n hegauge ssembly i l l comeon whenyou urn he gn i t ion w i t ch o ON ( l l )w i th he

headlight witchoff and he parkingbrakese1.t shouldgo of f when yo u turn on the headlight witchan d release he

parkingbrake. f it comeson at any other ime, do the controlunit nput est.

NOTE:When hedayt ime unn ing igh ts reon, he h ighbeam ndica tor i l l g lowat ha l f t snormal n tens i t y .

1. Remove he driver'sdashboard ower cover (seepage20-60).

2 , D isconnect the4Pconnector (A)rom hedayt ime unn ing igh tscont ro l ni t (B) .

RED/BLUGNN/BLK

RED/BLU GRN/BLKGRN/ORN

BLU/RED RED/YEL YEL/RED

Inspect he connectoran d socket erminals o be sure hey are all makinggood contact.

. lf the erminalsare bent, ooseorcorroded, epairthemas necessary, nd recheckthe ystem.' lf the terminals ook OK,go to step4.

\

22-76



4. Make hese nput estsat the connector,

. l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m .

. lf all he input estsproveOK, he controlunit must be aulty.Replace t.

Cavity Wire Test condition Test:Desired esult Possibleause f result s not obtained2 RED/BLU Under l l

condi t ionsCheck or voltage o ground:

Thereshould be batteryvoltage.Blown No. 14 (40A) us e n theunder-hood use/relay oxBlownNo.3 {10A) fusen heunder-dashuse/relay oxAn open n hewi re

12 YEL/RED lgnit ionswitchoN r)


Thereshould be batteryvoltage.BlownNo. 2 (7 .5A) fusen heunder-dashuse/relay oxAn open n the wire

BLK Under l lconditions

Checkor cont inu i t yo ground:

There hou ld econt inu i t v .

. Poor round G50 '1)

. An oDen n the wire7 BLK Under l l

conditions

Check or continuity o ground:

Thereshould be continuitv.

. Poorground G501)

' An open n hewi re1 0 REDI/EL Combinat ion

light switchON/ =f\\


Thereshouldbe batteryvoltage.BlownNo. 15 15A)use n heunder-hood use/relay oxFaultyheadlight elay2Faultycombination ight switchAn open n th e wire

1 RED/BU Combinat ionlightswitchON

{iD), an ddimmer switch

i n H I G H

Connect umper wire betweenNo.3 andNo.1 ermina ls .Bothhead l igh tsHIGH) ndh ghbeam nd ica torigh tshou ld omeon.

Blownbu lbFaulty ow beam cut relayFaultycombination ight switchPoorground (G50'l

An open n the wire'11

3

RED/BLK

GRN/BLK

Combinat ionlightswitchON(iD), an d

dimmer switchi n H I G HCom ina t ionlightswitchON(iD), an ddimmerswitchi n H I G H

Connect umper wire betweenNo.5 andNo.11 ermina ls .R igh t ead l igh tHIGH)

hou ldcomeon.

Checkor cont inu l t yo ground

There hou ld econt inu i t y .

. B lownbu lb

. Faultycombination ight switch

.Poor

ground (G50'1. An open n hewi re

. Faultycombination ight switch

. Poorgrou d {G501)

. An open n hewi re

5

6 GRN/ORNParking rakelever u l led

Checkor cont inu i t yo ground:

Thereshould be continuitv.

FaultyparkingbrakeswitchAn open n hewi re

8 BLU/REDCombinat ionl igh t w i t chOFF


Thereshouldbe batteryvoltage.Fau l t y ead l igh te laysShort o ground

An ooen n hewi reWHT/BLU lgnit ionswitch

oN0r)

Attach o ground:

TheDRL nd ica torigh tshou ldcomeon.

. B lownNo. 10 7.5A)use n he

under-dashuse/relay ox. FaultyDRL ndicator. An ooen n hewi re

t 5 GRN/RED lgn i tionswitchoN | | )

Attach o ground:

Thebrake ys tem igh t hou ldcomeon.

Faultybrakesystem ndicatorAn open n hewi re

22-7



Exterior ights

HeadlightAdjustment

Before diusting he headlights:. Parkhevehicle na level urface.. Make ure he irepressuresrecorrect.. Thedriveror someone howeighs hesame hould

sit n hedriver's eat.

'1 .Clean he outer ensso hatyou can see he center

of the headlights A).

Headlights ecomevery hot during use;do no t

touch hem or any attaching ardware mmediatelyafter hey havebeen urned off.

22-78

7.5m {25 tl

\

2. Park he vehicle7. 5m (25 t) away ro m a wall or a

screen A).

3 . Open he hood.



5

Turn he ow beams n.

Determine fthe headlights re aimed properly.

Verticaladjustment:

Measure he heightofthe headlights A).The ightsshould eflect52 mm (2.'1n.)below headljght

he igh t B) .

6. lf necessary, djust he headlightso localrequirements y turning he verticaladjuster.

i

HeadlightReplacement

Remove he front bumper (seepage20-85).

Disconnecthe connectors A) ro m th e headlight( B ) .

Remove he five mountingbolts, hen remove hecorner upperbeam (C )and headlightassembly.

Install n the reverse rder of removal.

After replacement, djust he headlights o localrequirements.

'1 .

2 .

5 .

22-



Exterior ights

4.

5 .

CombinationLight Switch Test/Replacement

1. Remove he driver'sdashboard ower cover (seepage20-60).

2. Remove he steering olumncovers se epage17-9).

3 , D isconnect the6Pconnector (A) om hecombinat ionigh t w i t ch B) .

Remove he tlvo screws, he n slideou t the combination ight switch.

Inspect he connector erminals o be sure he y are all makinggood contact.

. lf the terminalsare bent, ooseor co roded, epa r them as necessay, and recheck he system.

. l f t h e t e r m i n a l s l o o k O K , c h e c k f o r c o n t i n u i t y b e t w e e n t h e t e r m i n a l s i n e a c h s w i t c h p o s i t i o n a c c o r d i n g t o t h e

tables.- lf th e continuity s not as specified, eplace he switch.

Light switch:

\ Telmint

Position4 5 1 2 1 3

Headlight switch

OFF

LOW o--

HIGH o--

Passingswitch

OF F

ON o-

Turn signalswitch:

\ TerminalPosition

2 1 0 1 1

LEFT ----o

NEUTRAL

RIGHT o--

22-80



Bulb Replacement

Headlight:

1. Disconnecthe 3P connector A) rom the headlight.

Headlight high/low): 60/55W

f - r I-'-+l

A - ) /

Remove he rubbercover B).

Pull he retaining pring (C )away rom the bulb (D),

then remove he bulb.

Installa new bulb n the reverse rder of removal.Makesure he notches n the bulb align with thetabs n hehead l igh t .

2.

FrontTurnSignalLight:Parking ight:

1. Removehe nner ender see age 0-102) .

2. Disconnectthe onnectors A) ro m the lights.

21W5 W

4 .

Front urnsignal ight:Parkingight:

Turn he bulb sockets B)45'counterclockwiseo

remove hem from th e headlighthousing.

Installthenew bulb(s) n th e reverseorder ofremovat .

22-8



Exterior ights

1 .

2.

Taill ightReplacement

Removehe rearbumper see age 0-86).

Open he ailgate, nddisconnectheconnectors(A ) rom he aillight B) .

Brako/Taillight; 2115WTurnSignal ight: 21WBack-up ight: 21W

Remove he mountingnuts and bolts, hen remove

the a i l l i gh t .

Turn he bulb socket45' counterclockwiseo

remove he bulb socket.

When nstall ing he tail l ight. heck he gasket; f it is

distortedor stayscompressed, eplace t.

After nstall ing he tail l ight. un water over he

tail l ight o makesure t doesnot eak.

= \ \

i l i - - - _ \ \r B , \ .\r

---'a t\

22-82

HighMount Brake ightReplacement

1. Open he hatch.

2. Remove he plastic rim.

3. Disconnectthe Pconnectors A)from the highmountbrake igh t B) .

High Mounl BrakeLight: 5 W x 5

Carefully emove he high mount brake ight.

lnstall he ight n the reverseorder of removal..

'



LicensePlateLight Replacement

1.Remove he hatch ower rim panel se epage20 -

Pu l l the i cense la le igh tassembly u t .anddisconnecthe 2P connector A) rom the light.

LicensePlateLight: 5Wx2

3.

4.

'[-J^,^f, t lo \

+tiP'-t \-J' f l ^

"/\==-^

Separa tehe ens B)and hous ing C) , hen emove

the bu lb .

lns ta l l t heigh t n he reverse rdero f remova l .

SideMarkerLightReplacement

1. Carefully ry he ight A)outofthe rearbumper,anddisconnecthe2PconnectorB) rom he ighBecareful ot o damagehe rearbumper.

Side Marker Light: 5 W

2. Removehe bulbsocketA)by urning t 45'counterclockwise.hen eolacehe bulb.

22-



Lights

BrakePedalPositionSwitch Test

1. Disconnectthe Pconnector A) rom the brakepedalposit ionswitch{B).


te rmtna ls .

. There hou ld econt inu i t y hen he brake eda l

rs presseo.. Thereshould be no continuitywhen the brake

pedal s released.

Check or continuitybetween he No .3 and No. 4terminals withcruisecontrol).

There hou ld e no cont inu i t y hen he brakepedal s pressed.

There hou ld econt inu i t y hen he brake eda l

i s re leased.

lf necessary, djustor r eplace he switch,or adjust

the peda l e igh t see age19-6) .

SideTurnSignalLightReplacement

NOTE:Becarefulno l to damage he fender.

1 . Push he re ta in ing pr ing A) . nd emove hes ideturns igna l igh t B) ,

SideTurn SignalLight: 5 W

2. Disconnecthe 2Pconnector C) rom the light.



TurnSignal/Hazardlasher


COMBINATIONIGHT/TURNIGNAL WITCHTest, ag e 2-80Beplacement,ag e 2-80

TURNSIGNALNDICATORIGHTS(l n hegauge ssembly)BulbReplacement,ag e 2'63

HAZARDWARNINGSWITCHTest, age 2-88Replacement,ag e 2-88

TURNSIGNAL/HAZARD ELAYInput est, ag e 2-87

UNDER.DASHUSE/RELAYOX

22-



TurnSignal/Hazardlasher

UNDff HOODUSUftIIY OX

CircuitDiagram \

'No20lr0AUSA

Ut\toEBASH No.2{50A)Cmada

TUSVRILAYOX

INDICATONIIGHT11.1W)

fiIGHT

FBONT

22-86

!



TurnSignal/Hazardelay nputTest

1. Removetheturn igna l /hazarde lay A) rom he under -dashuse/ re lay ox (B) .

Inspect he relayand use/relay ox socket erminals o be sure hey are all makinggood contact

. lf the terminalsare bent. oose,or corroded, epairthem as necessary, nd recheckthe ystem.

. lf the terminals ook OK,go to step 3.

Make hese nput estsat the fuse/relay ox.

. l f anvtes t ind ica tesaprob lem, f indandcor rec t thecause, thenrecheckthesystem.

. l f a l l he nput tes ts roveOK, the turn igna l /hazarde laymustbefau l t y .Rep lacet

000i!100000u!u0

Cavitv Tesl condition Test: Desiredresult Possible ausel result s not obtained

1 Under l lcond i t ions Check or continuity o ground:

Thereshouldbe continuiw.

. Poor roundG201)

. An ooen n hewire

3 lgnit ionswitchON ( l)

Hazardwarning switch

OFF


Thereshould be batteryvoltage.

' Blown No. 19 (7.5A) use n the

under-dashuse/relay ox. Faultyhazardwarning switch. An ooen n hewi re

Hazard arning witchO Nlgnition witchOF F


Thereshouldbe batteryvoltage.

. Blown No. 5 {10A) us e n th e

under-hood use/relay ox. Faultyhazardwarning switch. An ooen n the wire

2 l gn i t i on w i t chON ( l )

and urn signalswitch

in Rightor Leftposit ion

Connect o .2 te rm ina l toNo.3

term ina l :

R igh t r le f t u rns igna l igh tsshou ld omeon.

. Poorground G201, 301,G501,

G502,G553)

. Faulty urn signalswitch

. An oDen n he w i re

lgnit ionswitchOFFHazardwarningswitch

O N

Connect o .2 erm ina lo No.3

termrna l :Hazard a n ing igh ts hou ld

comeon.

. Poorground G201, 301,G501,

G502,G553). Faultyhazardwarning switch. An open n he wire

22-



Signal/Hazardlasher

1 .

2.

HazardWarningSwitch Test

Remove he centerpanel se epage20-62).

Disconnecthe 10 P onnector A) rom the hazard

warn ing w i t ch B) .

4 .

Pushout the hazardwarningswitch rom behindthecenter ane l C) .


lf the continuity s not as specified, eplacehe bulb(D)or the hazard arn ing wi tch .

\ Termin6l

;;;-_-\1 2 4 7 1 0

OF F

ON @

3.



EntryLight ControlSystem


IGNITIONKEYLIGHTTest, ag e 2-91

IGNITIONKEY SWITCHlest, page22-91

DRIVER'SDOORSWITCH

CEILING IGHT/SPOTLIGHTSTest,page22-96Replacement,ag e22-96

REAR EILINGIGHTTest, ag e 2-96Replacement,ag e 2-96

FRONTPASSENGER'SDOORSWITCH

HATCHLATCHSWITCHTest,page22-97

CARGOREA IGHTTest, ag e 2-97Replacement,ag e 297

22-



LightControlSystem

'No.20({0A)US A

CircuitDiagram

CEILINGUGHT

YII

GNIlx)NKEYSWtTCH

PASSTNGERSDOOBSWITCH

i9r"..d l

ORIVEBSDOORSWITCH

DtrVTN'SDOORLocx(NOBs!t/tTc8

l'U

IG()t

lGlHoTin N lllnd STAnTD

EiIIpNSMTqI

UiIOTf,HOODUSE/8ELAYOX



lgnitionKeySwitchTest

NOTE:For more key-inbeeper nformation, efer o th e

circuitdiagram se epage22-90) nd nput est (see

page 22-921.

When he gnitionkey s n the gnitionswitch he

multiplexcontrolunit sensesground hrough he

closed gnitionkey switch.When you open he driver's

door, he multiplexcontrolunit senses round hrough

the closeddoor switchan d sounds he beeper.

1. Remove he steering olumnupperand ower

covers see age '17-9) .

2. Disconnecthe 6P connector.

3 . Check or continuitybetween he No. 1 and No. 2

termrnars .

. Thereshouldbe continuitywith the key n the

ignit ionswitch.. Thereshouldbe no continuitywith the ke y

removed rom the ignit ionswitch.

lf th e continuity s not as specfied, eplace he

ignit ionswitch.

lgnition KeyLight Test

1 . Remove he steering olumn upperand ower

covers se epage17-9).

Disconnecthe 6P connector,

Th e LE Dshouldcome on when power s connecte

to the No. 6 terminalan d ground s connected o

No.5 term ina l .

lf the LEDdoesnot come on, replace he ignit ion

swrtch.

i '/ . '

22-



5. With heconnectorst i l ldisconnected,ake hese nput ests t heconnector'

. l f anv est ndicates problem,ind and orrecthecause,he n echeckhesystem

. lf all he npul ests roveOK , o o step6.

6. Reconnectheconnectorso he under ash use/relaVox ,an dmake hese nput ests t he appropriateonnectorsn he under-dash

fuse/relayox .. l f any t es t i nd i ca tesap rob lem , f i ndandco r rec t t hecause , t hen recheck thesys t em .. l f a l l t he inpu t t es tsp roveOK, t hemu l t i p lexcon t ro lun i t mus t be f au l t y . Rep lace t heunder 'dash fuse / re laYboxasse

Cavitv Wire Testcondition Test:Desired esult Possible quse l result s not obtained

K2 8LU/ORN lJnder llcondit ions Checkor continuity etweenhe K2terminal nd hekeylesseceiverunit5P onnector o.2 erminal:There hould econtinuitv.

An open n the wire

o7 GRN/RED Cejl ing ight switch n

middle posit ion.Attacho ground:Ceil ingight(s)shouldom eon .

BlownNo .3 (7.5A)use n he underhood

Blown ulbFaulty eil ingightAn ooen n hewire

X8 WHT/BLK Under l l cond i t i ons Attach o ground:lgnit ion ey ight hould omeon .

ElownNo.3 (7.5A)fusen he underhoodfuse/relayoxFaultygnit ion ey ight LED)

An ooen n hewire

Cavitv Wire Testcondition Test:Desired esult Posq!!!c sq!!ej1!.9!!!!j €d

P 1 8 RED Hatchopen Check or voltage o ground:

There should be 1 V or less.

Poor round G552)

Fauhy atchatch witchAn open nthewire

Hatchclosed Checkor voltageo ground:There hould e5 v or more.

Faultyhatch atchswitchShorttooround

Q3 GRN Driver's ooropen Check or voltage o ground:


Faulty r lver's oorswitchAn oDenn hewire

Driver's oor losed Checkor voltageo ground:Thar.shoul. l e 5 V or more.

Faulty r iver's oo rswitch

o4 LTGRN/BED

RED^vHT

Passenger'soo r Checkor voltageo ground:There hould e 1 V or ess.

' Faulty assenger'soo rswitch' An onen nthewire

Passenger'soo r

croseo

Checkfor oltageo ground:

There hould e5 Vor more.

. Faulty assenger'soo rswitch

. Shor o oroundX5 lgnitionkey nserted

into he gnit ionCheckor voltageo ground:There hould e 1V or less.

Poor round G401)

Faultygnit ion ey witchAn ooen n hewire

lgn it ion key removed

from the gnit ion


Thereshould be 5 V or more.

Faulty gnit ionkey switch

Short o ground

Y8 YEURED Driver's oor ockknob switch ocked

Checkor voltageo ground:There hould e 1V or ess.

Poor round G501)Faulty r iver's oor ock nob witchAn ooen n hewire

Driver's oor ockkn6h cwi rch In l6cke. l

Checkor voltageo ground:There hould e 5 V or more.

Faulty r iver's oor ock nob witchShort o oround

22-



Lights

uomponentLocation ndex

CEILINGIGHT/SPOTLIGHTSTest, ag e 2-96Replacement,ag e 2-96

REAR EILINGIGHTTest, ag e 2-96Replacement,ag e 2-96

v

HATCHLATCHSWITCHTest,page22-97

CARGO REALIGHTfesl, page 22-97Replacement,ag e22-97

$



CircuitDiagram

STABctu[GLIGHT

MUITIPLEXc0NTlotUIIIT

J

HATCHLATClIswtTcH

22-



InteriorLights

CeilingLight/SpotlightsTest/Replacement

Turn he ceil ing ighvspotlights witchesOFF.

Carefullypr y off the lens A) wilh a smallscrewdnver,

CeilingLight: 5WSpot l igh t : 5Wx2

1 .

2 .

x 1-0mm

3. Remove he two screwsand he housing B) .

4 . D isconnecthe 4PconnectorC) romthehous ing .

5. Check or continuitybetween he terminals n eachswitchpositionaccording o the table.

\ A

\ Terminal

P."lil;------_l il

celL,"ca,c",oFF

isoottiohts\ MIDDLE' u i r

oN

re -oa}-+4 -o

SPOTLIGHTS

I Ce i l i nqioh tr o F F - - i

RON o (.F.O

OF F

LON G-

OF F

lf the continuity s not as specified, heck he bulb.l f he bu lb s OK, ep lacehece i l i ng ighvspot l igts .

1 .

2.

3.

4.

RearCeilingLight Test/Replacement

Turn he ightswitchOFF.

Carefully ry offthe lens A) with a smallscrewdriver.

Ceil ingLight: 8 W

5 x 1 . 0 m m

A .

Remove he two mountingscrews.

Disconnecthe 3P connector B) rom the housing{c).


Terminal

Position1 2 3

OFF

MIDDLE

oON G -@- O

lf the continuity s not as specified, heck he bulb.l f hebu lb s OK, ep lacehe rear e i l i ng igh t .



CargoAreaLightTest/Replacement

1 . Open he hatch.

Carefully ry out the cargo area ight (A).

CargoArea Light: 5W

Disconnecthe 2Pconnector B) rom the ight.

Check or continuitybetween he No. 1 (+ ) an d

No.2 ( ) te rm ina ls . here hou ld econt inu i t y .

lf there s no continuitv, heck he bulb. f the bulb

is OK, replace he cargoarea ight.

'1 .

Hatch Latch Switch Test

Open he hatch.

Remove he hatch ower rim panel seepage20 -

s3).

Disconnecthe 2Pconnector A) rom the hatch

4 . Check or continuitybetween he No. 1 and No. 2

te rm ina ls .

. Thereshouldbe continuitywith the hatchopen. Thereshouldbe no continuitywith the hatch

ctoseo.

lf the continuity s not as specified, eplace he

hatch atch.

la tch B) ,

22-



System


AUOIO NITRemoval/fstallation,aoe 2-100Connectorerminals,a-ge2-101

RIGHT OOB WEETERReplacement,ag e 2-102

ANTENNASUB LEAD

DRIVER'SDOORSPEAKERReplacement,ag e 210 2

ROOFANTENNAReplacement,ag e22-'13

RIGHT EAR PEAKERReplacement,ag e 2-102

LEFTREAR PEAKERReplacement,ag e 2-102

ANTENNALEAD



t CircuitDiagram

'No.20ioA)USA

/ 8AT \--------F f!t- WHT/FED

\ ACC/

ACC oTinACCllmd0N lll

AUDIOflIT

t - r a - r : - r a O e ? a

DRIVER'SDOORSPEArcF

IEFITWEETER PASSE!{GIF'S SIGIITTWEETEBDOOBPEAKES

LEFTFEAB NrcBTREAFSPEA(I8 SPEAKEF

22-



System

AudioUnit Removal/lnstal lation

NOTE:. Puton gloves o protectyour hands.. Takecareno t o scratch he dashboard nd related

pa ts.

1. Makesureyou have he anti-theft ode or the radio,then write down the frequenciesor the radio'spresetbuttons.


3. Remove he two mountingbolts, hen pull out thecenterpanel A) .

4. Disconnecthe audio connector B)and antennalead C) ,heater ontrol panelconnectors D)an dHAVCpushswitch assembly E) , hen remove hecenterpanel.

! \

7 .

Remove he heater ontrolpanel se epage21 38).

Removehe our mount ing o l t s nd heaud ioun i t

from the radio brackets.

Ins ta l l t he ud ioun i t n he reverse rdero fremoval,and note hese tems:

. Makesure he audio unit an dA/Cconnectors replugged n properly,an d he antenna ead s

connected roperly.. Enter he anti-theft ode or the radio, hen enterthe customer's adiostationpresets.

\ v



AudioUnit Connector eplacement

Cavity Wire Connectso1 YEUGRN Roofantenna

2 YEURED ACC Power)

3 Not used4 No t used5 PNK Rioht ear Deaker+ I

6 BLU^/vHT Left ear Deaker+)

7 GRN/YEL Frontoassenqer's oor sDeaker+)/Riqht weeter +)

8 GRN/BLK Driver'sdoor speaker + )/Left weeter + )

9 RED/BLK Liqhts on siqnal1 0 WHT/RED Constant ower

1 1 Not used

12 Not usedNot used

1 4 No tusedt a BLU/YE Rioht ear oeaker-

t o BLU/BLK Left earsDeaker1 1 GRY/RED Frontpassenqer's oor speaker )/Riqhttweeter1 8 LT GRN Driver'sdoor sDeaker )/Left weetr ( -

1 9 RED Dash iqhtsbriqhtness ontroller

20 BLK G ound G503)

AUDIOUNIT2O PCONNECTOR

22-1



System

SpeakerReplacement

DoorSpeaker:

1. Removehe doorpane l seepage20-4) .

2. Pull he top of the speaker A)straightout, us t

enough o release he upperclip. f yo u pull hespeakerout too far, you will damage he lowerclips(C).Then if i the speaker traightup to rele asehelowerclips.

3. Disconnecthe 2P connector B),and remove hespeaKer.

Tweeter:

Carefullypr y the tweeter A) out of the mirror mountcover, he n disconnect he 2Pconnector B) ro m th etweeter.

'-----d

Rear:

1 . Remove he speaker over (A).

Remove he threescrews, hen dis connect he 2Pconnector B) ro m the speaker C).

2.



RoofAntennaReplacement

1. Re move he rearpartof headliner se epage20-54).

2, Disconnecthe antenna eadconnector A) an d 1Pconnector B) rom the roof antenna C) .

3. Remove he mounting nut and he antenna.

22-1



RearWindow Defogger


*:Rearwindow defogger witch s built nto he heater ontrolpanel.


REARWINDOWDEFOGGERWITCH+

t

REARWINDOWDEFOGGER ELAYTest, ag e 2-51

u

NOISE ONDENSERCapacityTest,age 2 10 7

REARWINDOWDEFOGGEBFunctionest, ag e 2 106DefoggerWire Repair, ag e22 106



J CircuitDiagram

J

;Hl}lj.'fl,1fl1fi" BEATERcoNrf,oLpANrLT f,rAiwrxDow

,74 DEfOGGES( \/ I SWrcfl\iP INDIATOR

L ILEDI

22-10



WindowDefogger

Function est

NOTE:. Be carefulno t o scratchor damage he defogger

wires with the testerprobe.. Before esting,check he No. 11 30A) use n th e

under-hood use/relay ox and No. 14('10A)use nth e under-dashuse/relay ox .

1. Check or voltagebetween he ve tica dividersand

body groundwith the ignit ionswitch and defoggerswitchON .Thereshould bevoltageas shown.

. lf there s no voltage. heckfor:- faulty defogger elay.- an open n the BLK,BLK,/YEL,r YEL/BLK ire.- taulty heatercontrolpanel.

. lf there s batteryvoltage,goto step2.

6V

Check or continuitybetween he negative erminal(B)and bodyground.

lf there s no continuity, heck or:. an open n he BLKwi re .. Poorbody groundat the window antenna oil

mounting bolt.

Touch he voltmeterposit iveprobe o the halfwaypointof eachdefoggerwire. and he negativeprobe o the negative erminal,Thereshould be about 6 V with th e ignit ionswitchan d he defogger witch ON.

. l f hevo l tages asspec i f ied ,he defoggerwl resoK.

. lf the voltage s not as specified, epair hedefoggerwire.- l f t s more han6 V, here s a break n he

negat i ve a l fo f hewi re .- lf it is less han 6 V, here s a break n th e

positivehalf of the wire.

2 .

2.

DefoggerWire Repair

NOTE:To makean effective epair, he brokensectionmustbe no onger hanone nch.

1. Lightly ub he areaaround he brokensection A)

with f ine steelwool, hen clean t with alcohol.

Carefullymaskaboveand below he brokenportion

of the defoggerwire (B)with transpare nt ape{C).

Mi x the silverconductivepaint horoughly.Usingasmall brush,apply a heavycoatof paintextendingabout 1/8 nchon b oth sidesof the break.Allow 30minutes o dry.

Check or continuity n the repairedwire.

Apply a secondcoat of paint n the sameway. Let tdry 3 hours before emoving he tape.

5 .



NoiseGondenser apacityTest

1 .Remove he right rearside ri m panel se epage20 -66).

Disconnecthe 2P connector A) rom the noise

condenser.

Noise condenser capacity:

0.47 a 0.09 microfarads


4.

Use a commerciallyavailable ondenser ester.Connect he condenser esterprobes,and hemeasure ondenser apacity.

lf it is not within the specification,eplace he noise

condenser.

22-1



Moonroof


MOONROOF ONTROL NIT

Input est, ag e 2-'l10

MOONROOFWITCHf e$,page 2-112Replacement ,age 2-1 2

Test . age22-112Replacement,ag e 0-41

MOONROOFLIMITSWITCHTest,page22-113

\|.

MOONROOFAUTO-STOPSWITCHTest,page22'113

MOONROOF PENRELAYlwirecolors: RN/YEL,RN , ILRED/YEL,LK ndYEUGRNTest, ag e 2-51MOONROOFLOSE ELAYlwirecolorsr RN/BLK,RN ,LGRN/WHT,LKand YEL/GRNTest, ag e 2-51

22-108



CircuitDiagram

-No.20lOAl USNo.20150 :Canda

A Clos.d om lh€ ruto nop poshio. to h€ doed porhion

B Clo!.d in th€ ilt or do3.d poilion

C : Clo!.d in anyop.n (io! riltl posirion

D Clos.d n th€ ilt po6iiion

UNDIR OAS8 USE/NILAYX

BL|(

+G50t

8LI

IG5{1

22-10



Moonroof

MoonroofControlUnit Input Test

Removeheheadl inersee age 0-54) .

Disconnecthe5PconnectorA) rom hecontrol nit B) .

Wire sideoff em a le e rm ina l s

Inspect he connectorand socket erminals o be sure hey are all makinggoodcontact.

. lf the terminalsare bent, ooseor corroded, epairthemasnecessary. nd recheckthe ystem.

. lf the terminals ookOK ,go to step4.

I1 .

2 .

b

GRN/WHT LTGRN

1 2 3 4 5

RED/YEL BLK

22-110

$



4- Reconnecthemoonrool ontrol nit5Pconnector,ndmakethesenputtests ttheconnector.

. l f any t es t i nd i ca tesap rob lem , f i ndandco r rec t t hecause , t hen recheck thesys t em .

. lf all he nput ests roveOK, o o step5.

Caviiy Wire Testcondition Test:Desired esuh Possible aus6 f result s not obtained

5 BLK Under l lcondit ions Checkorcontinuityo ground:There hould econtinuity.

Poor round G501)An open n hewire

,l YEUGRN lgnit ion witchON ll ) Check or voltage o ground:

There should be baftery voltage.BlownNo .6 (7.54)tusen he underdash use/relay oxAn open n hewire

LT GRN l gn iti on witchON ll)Moonroofclosed


Thereshould be 1V or less.Poor round G501)Faultymoonroofauto-stop witchAn open nthewire

Moonroof open Checkor voltageo ground:Thereshouldbe batteryvoltage.

ShorttogroundFaultymoonroof uto-stopwitch

Disconnecttheoonroof ontrol nit5Pconnector,ndmake hese;nputtestst heconnector

' l f any t es t i nd i ca t esap rob lem , f i ndandco r rec t t hecause ,t hen recheck t hesys t em .. lf all he nputtests roveOK, hecontrol ni tmustbefaultv. eplacet.

Cavity Wire Testcondition Test:Desired osult Possible ause f result s not obtained

3 RED//EL lgnit ion witchON ll ) Connect umperwire between o,3 andNo .5 erminals.Moonroofmotor hould un(opened).

PoorgroundG501)BlownNo .6 (7.5Aifusen he under'dash use/relay oxBlownNo.7120Alfusentheunderdash use/relayoxFaultymoonroof pen elayFaultymoonroof lose elayFaultymoonrooJ otorAnopen ; nhew i re

2 cRN,4/VHTgnit ion switch ON ( l l ) Connect umperwirebetween o.2 andNo .5 erminals.I \ ,4oonroofotor hould un closed).

Poor round G501)BlownNo .6 (7.5Aifusen he underdash use/relayoxElownNo .7 (20A)fusen he underdash use/relay oxFaultymoonroof pe n elayFaultymoonrool lose elayFaultymoonroofmotorAn open n hewire

22-11



Moonroof

SwitchTest/Replacement

'1. Carefullypr y he moonroofswitch(A )out of the

head l in r .

2. Disconnectthe P connector Blfrom the moonroof

swtrcn.

3. Check or continuitybetween he terminals n each

switchpositionaccording o the table.

\ Terminal

Pi.iti..--\ 1 4 5

CLOSE FO

TILT

OPEN -o

l f the continuity s not as specified. eplace he

moonroofswitch.4 .

22-112

Motor Test

1. Removehe head l inersee age20-54) .

2. Disconnecthe 2Pconnector rom the moonroof

motor.

3. Check he motor by connectingpowerand ground

accordino o the table.

\ Terminal

pl.iri""---\

OPEN \7 oCLOSE (,

lf th e motor doesnot run. replace t,

NOTE:Seeclosing orce check seepage20-48)for

motor clutch est.

\



l .

2.

Limit Switch Test

Remove he headliner se epage20-54).

Disconnecthe 4Pconnector rom the moonrooflimit switch.

Check or continuilybetween he terminals n eachswitchpositionaccording o the table.

NOTE: urn he motor by handwith the wrench.

\ Terminal

Position1 3 4

TILT o- o-OPEN

CLOSE

lf the continuity s not as specified, eplace hemoonroof imit switch.

1 .

2 .

Auto-stopSwitch Test

Remove he headliner seepage20-54).

Disconnecthe 2Pconnector rom the moonroof

auto-stop witch.


NOTE:. Turn he motor by handwith th e wrench,. Th e auto-stop osition s about 145mm (5.75 n.

from fully closed.

Position

Terminal1 2

BotwoenAUTO-STOPandCLOSE

Between OPEN andAUTO.STOP

l f the continuity s not as specified, epairor replacthe auto-stop witch.

22-11



Mirrors


POWERMIRRORSFunction est,page22-116Replacement,ag e20-15ActuatorTest,page22-117ActuatorReplacemenl, ag e22-1 8

POWERMIRROR ndMIRRORDEFOGGER WITCHlesl, page22-111Replacement,ag e22-1 7

---\,--,-'/ -:,)

j-' ',i.it .i/3:.[

'\ \, -,''

-lo' '-ot:,.'7

$



CircuitDiagram

UiIDTS cODR]SE/R€LAYOX rcilmoN1/vtTcH

'1ih.a i|0At Usa

UiD$ DASHN'SUnIIAY OX

J

22-11



PowerMirrors

FunctionTest

1. Remove he driver'spocket se epage20-60).

2. Reach hrough he pocketopening,an d pushou t

th e powermirror switch(A).

, \

RED B

Wires ideoft em a le e rm ina l s

WHT/RED

RED/YEL

3. D isconnect the '13PonnectorB) rom heswi tch .

4. Choose he appropriate est basedon thesymptom:. Both mirrorsdon't work, go to s tep 5.. Left mirror doesn'twork, go to step7.. Rightmirror doesn'twork,go to step8.. Defogger oesn'twork (Canada), o to step9.

Both mirrors

5. Check or voltagebetween he No. 2 terminal and

bodygroundwi th he gn i t lon wi tchON ( l l ) .

Thereshouldbe batteryvoltage.. lf there s no batteryvoltage,check or :

- b lownNo.14 10A) use n he under 'dashfuse/relay ox.

- an open n he BLKryEL i re .. lf there s batteryvoltage,goto step6.

6. Check or continuitybetween he No. 6 terminalandbodyground.

There hou ld e cont inu i t y .. lf there s no continuity, heck or :

- an open n he BLKwi re .- poorground G501) .

. lf there s continuity, heckboth mirrorsind iv idua l l y sdescr ibedn he nextco lumn.

RED/BLK

22-116

Left mirror

7 . Connecthe No.2 term ina lo theNo. l0 te rm ina l ,

and he No.5(or

No. 12) erm ina lo the No.6term ina l i th umperwi res .The e f tm i r ro rshou ldt i l tdown orswing e f t )w i th he gn i t ion w i t chON

f l ) .. l f he m i r ro rdoes o t t i l t down ordoesnotswing

left), heck or an open n the GRN/WHT or BLU/

Wl-lT)wirebetween he left mirror and he 13P

conneclor, f th e wire is OK ,check he left m rror

actualor.. lf the mirror neitherti ltsdown no r swings eft.

repa i r he BLU/BLK i re .. l f hemi r ro rworks roper ly , heckthemi r ro r

SWIICN,

Right mirror

8 . Connecthe No.2 te rm ina l to he No.11 erm ina l ,

and he No.5 {orNo.13) e rm ina l o the No.6

term ina lw i th umperwi res . he igh tm i r ro r hou ld

ti lt down (o rswing eft)with he ignit ionswitchON( ) .. lf th e mirror does not i lt down (o r doesno t swing

left),check or an open n the GRN/WHT or WHT/

RED)wi re e tweenhe r igh tm i r ro rand he 13P

connector.lf the wire is OK ,check he right mirror actuator.

. l f he mi r ro rne i ther t i l t sdownorswings ef t ,

repalr he RED|YEL ire.

' l f hemi r ro rworks roper ly . heckthemi r ro r

swrrcn.

Defogger Canada)

9 . Connecthe No.1 andNo. te rm ina ls i t h ajumper wire, and check or voltagebetween he

No.2 erm ina l f he mi r ro r onnector ndbodyground.Thereshould be batteryvoltageand both

mi r ro rs hou ldwarm up wi th he gn i t ion w i t ch

oN t ) .. l f here s novo l tage rne i therwarms p ,check

for:-

an open n he BLKI /EL r oRN wi re .- b lownNo.14 ' l0A) fusen he under -dashfuse/relaybox.

. l f on lyone a i l s o warm up,check:- it s defogger.- poorground G501, 502)

. l f bo thwarm up,checkthedefoggerswi t ch .



1 .

2 .

3.

PowerMirrorSwitch Test

Remove he driver'spocket se epage20-60).

Reach hrough he pocketopening,an d pushou t

th epower

mirror switch(A).

Disconnecthe 13P onnector B) rom the switch.


Mirror Switch:

\.f9.-'"1LPosition

2 5 6 1 0 1 1 1 2 13

UPCF --o

o- o

o-G -c)

o

o-o-

-o

!

RIGHT-o

o -o

UP

"[T

RIGHT

DefoggerSwitch (Canadal:

\ Te.minal

il;;;tlf I 8

ON o oOFF

lf the continuity s not as specified, eplace hepower mirror switch.

5 .

22-11

1 ,

2 .

PowerMirror ActuatorTest

Remove he door panel se epage20-4).

Disconnecthe 6P connector A) ro m th e power

mi r ro rac tua torB) .

Checkactuatoroperationby connectingpoweran dgroundaccording o the able.

\ Terminal

Posit ion6 4

TILT UP o oTILT DOWN oSWINGLEFT o @SWING RIGHT @

4. lf the mirror ails o work properly, eplace hemtrror actuator.

DefoggerTest {Canada);

5 . Checkor cont inu i t y e tweenhe No.1and No.2terminalsof the 6P connector. hereshould becontinuity. f there s no continuity, heck or anopen circuit.



PowerMirrors

PowerMirror ActuatorReplacement

Remove he power mirror (seepage20-15).

Carefully emove he mirror holder rom the mirror

hous ing . en t l yu l l

t ou t by handsee age

20-15) .

Disconnecthe connector.

Remove he cover, hen remove he two Torx

screws rom the mirror connector.

Record he erminal ocations nd wire colors.

Cut he wire harnesswith the wire cutter.

7. Remove he threescrews,and separate he mirror

housinq rom the mirror base.

'1 .

2 .

3 .

4.

5 .

6 .

22-118

\

8. Remove he threeTorx screws,and separateheactuator A) rom the mirror housing B).

Route he wire harness A) ofthe new actuatorth rough he ho le n he bracketB) .

9 .

\



10. lnsert he terminals nt o he connector n the

or ig ina l r rangementsshownbe low.

LEFTMIRROR ONNECTORRIGHTMIRROR ONNECTOR

Wire ide f emaleerminals*:Canada

'l '1.Reassemblen he reverse rder of disassembly.

Be carefulnot o break he mirror holderwhen

reinstall ingt to the actuator.

Re ins ta l l t he i r ro rassembly n hedoor .

Operate he power mirror o ensuresmooth

operation.

1 2 .

t J .

22-1



\ComponentLocation ndex

HORNRELAYTest, ag e 2-51

HORNSTest,page22 122Bep lacem en t ,age 2 122

UNDER-HOODUSE/RELAYOX

. -: . . " '

HORNSWITCHfesl, page22-122

CABLEREELReplacement,ag e23,1 9

*



J GircuitDiagram

J

22-1



1 .

3.

HornTest/Replacement

Remove he front bumper {seepage20-85).

Disconnecthe 1Pconnector B),and remove he

horn (A).

Test he horn by connectingbatterypower o theterminal (A )an d ground o the bracket B) .Th e hornshou ld ound.

4. lf it fails o sound, eplace t.

1 .

HornSwitch Test

Remove he steering olumncovers se epage 17 -

9 ) .

Disconneclhe dashboardwire harnessB 5Pconnector A) rom the cable eel B).

Usinga umper wire . connect he dashboardwireharnessB 5P connector A) No. 2 terminal o bodyground

. lf the hornssound,goto step 4.

. l f he horns o notsound, heckthesetems:- Horn relay- No.7 (15A) fusen he under -hooduse/ re lay

bo x- Horns (see page22-122).- An open n the wire

| ../... . . . : . . . . ,



4. Reconnecthedashboard ireharness 5PconnectorA) , nddisconnecthe hornswitchpositive P onnectorB) .

Using a umperwire, connectthehorn switchpositive1Pconnector B) o ground

. lf the hornssound,go to step6.

. l f he horns o no tsound, ep lacethecab leee l .

Reconnecthe horn switchpositive1Pconector B) .6 ,

22-1

1 . Using umperwire, onnenthesteering heel obody round.

Closehecontacts etweenhe hornplate nd hecontact late.

. lf he horns ound, eplacetheteering olumn.

. l f hehornsdo otsound,eplacetheorn ndcontact late.

8.



PowerWindows

IomponentLocation ndex

DRIVER'SWINDOWMOTORTest, ag e 2-129

UNDER.DASHFUSE/RELAYOX

POWERWINDOWRELAYIest,page 2-51

FRONT ASSENGER'SWINDOWMOTORTest, ag e 2-132

t

POWERWINDOW MASIER SWITCHInputTest.Daqe 2.126Test,page22--128Replacement,ag e22-133

FRONTPASSENGER'SWINDOW SWITCHI nDu t es l , aqe 2 -130

f est, page 22-132Beplacement, ag e22-133

al.l ' -f..--.--

L - . : :

\



CircuitDiagram

tGt'Ttoit wtTcfi

'No.20il0A):USA

UNOERHMO FUSI/8tLAY OI

--+r o'F BTTYEL

U/lGl HOTn 0N{ll)tnd STABTllll

WHT/BU

22-1



Windows

MasterSwitch InputTest

NOTE: hepowerwindow ontrol nit s built nto he powerwindowmaster witch, nd t onlycontrolshedriver'swindowoperations.

1. Removehewindowmaster witch A) see ag e 2-133).

2. Disconnecthe 14P onnectorB) rom hemaster witch.

GRN/WHT

3. Inspect he connectorand socket erminals o be sure hey are all makinggood contact.

. lf theterminals are bent, ooseorcorroded, epairthemas necessary, nd recheckthe ystem.

. lf the terminals ook OK,go to step4.



4. Withthe connector ti l l disconnected, akethese nputtestsattheconnector.

. l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e . t h e n r e c h e c k t h e s y s t e m .

. l f a l l t he nput tes ts roveOK,goto step5.

5. Reconnecthe 14P onnector o the switch,an d perform he following nput ests.

. l f a n y t e s t i n d i c a t e s a p r o b l e m , f i n d a n d c o r r e c t t h e c a u s e , t h e n r e c h e c k t h e s y s t e m .

. lf all he input estsproveOK, he controlunit must be aulty. Replacehe powerwindow masterswitch.

Cavity Wire Test condition Test:Desired esult Possible ause f result s notobtained

1 0 BLK Under l lcond i t ions Check or continuity ogrouno:

Thereshould be continuity.

. Poor roundG50'1)

. An open n hewire1 4

11 GRN^,^/HT lgn i t ion wi tchON ( l l ) Check or voltage oground:


voltage.

BlownNo.6 (7 .5A)use n

the under-dashuse/relay

box

Blown No. 22,23 l2OA)us e

in th e under-dashuse/relayDo x

Faultypowerwindow relay

Poorground G201)

An open n the wire

2 GRN/BLK

1 RED/YEL Connecthe No.l ' 1

and

No.7 te rm ina ls , nd he

No,4 andNo.14 erm ina ls ,

and urn the gnitionswitch

oN lr).

Check or driver'swindow

molor operaflon:I t shou ld un the r i ver ' sw indowmovesdown) .

. Faultydriver'swindow

motor. An open n the wireED/B K

3 BLU/REDConnect he No. 2 and No. 1

te rm ina ls , nd he No.3and No.10 erm ina ls , ndturn he gn i t ion w i tchON

f i ) ,

Check or passenger's

window motor operation:I t shou ld un ( the

passenger's indow moves

oown).

Faultypassenger's indow

motorFaultypassenger's indow

swatchAn open n the wire

BLU/WHT

Cavity Wire Test condition Test: Desiredresult Possible cause f result is notobtained

1 3 ORN Connecthe No.11andNo.7 te rmina ls , nd he

No.4 andNo.14 erm ina ls ,and urn the gnitionswitchoN0r) .

Check or voltagebetweenthe No. 13andNo.14

termtna ls :A b o u t 6 V s h o u l d b eindicatedwith the driver'swindow motor running.

. Faultydriver'swindowmolor

. An open n hewi re

22-1



Driver'sWindow Motor Test

Motor Test:

Remove he door panel seepage20-4).

Disconnecthe 4P connector A) rom the driver's

window motor.

1 .

4.

Test he motor n eachdirectionby connectingbatterypoweran d groundaccording o the able.

When he motorstops unning,disconnect nelead mmediatelv.

\Terminal

il;;'-\2

UP e oDOWN @ e

l f the motor doesnot run or fails o run smoothly,

replace L

1 .

Pulser est:

Reconnecthe 4P connector o the driver'swindow

motor,and reconnecthe 20Pconnector o thepowerwindow masterswitch.

Connect he test eadsof a voltmeter o the No, 3

and No.4 terminalsof the driver'swindow motor

4P connector.

Run he motor using he masterswitch.Th e

voltmetershould readabout 6 V.

lf the voltage s not as specified, heck or an openin th e wires. f th e wires are OK, replace he drive

window motor.

22-1



PowerWindows

1 .

2.

Passenger'sWindow Switch InputTest

Remove he switchpanel se epage20-4).

Disconnecthe 5P connector A) rom the switch (B).

o'' "'"1.

4 .


BLU/WHT GRN/BLK

Input he connectorand socket erminals o be sure hey areal l makinggood contact.

. lf theterminals are bent, ooseor corroded, epairthem as necessary, nd recheckthe ystem.

. lf the terminals o ok OK,go to step4.

Reconnecthe connector, nd using a backprobe,make hese nput estsat the connector. f any est ndicatesproblem, ind and correct he cause, hen recheck he svstem,

Cavitv Wire Test condition Test:Desired esult Possibleause f result s not obtained3 GRN/BLK lgnit ionswitchON

{ l )Check or voltage ogrouno:


BlownNo.6 (7 ,5A) fusen heunder-dashuse/relay ox

BlownNo.22 20A) fusen heunder-dashuse/relay oxFaultypowerwindow relayAn open n the wirePoor round G201)

2 BLD,A/VHT lgnit ionswitchON( )At th e masterwindow switch,pressand holddown th epassenger's witch

Check or voltage oground:


Faultymasterwindow switchAn open n th e wire

BLU/RED lgnit ionswitchON( | | )

At the masterwindow switch,pu l lup and ho ldth e passenger's

switch

Check or voltage ogrouno:


Faultymasterwindow switchAn open n the wire



5. Disconnecthe5Pconnector,ndmake hese nput ests.

6. lf allthe testsproveOK, he switch must be aulty. Replacet.

Cavitv Wire Test condition Test: Desired result Possible ause l result s not obtaine

1 RED Connect he No. 2te rm ina lo the No.1 ermina l , nd heNo.4 erm ina l o

the No.5 te rm ina l ,and urn heignitionswitchON

{ll),and press hedown bu tton on

th e powerwindowmasterswitch orth e passenger's

window.

Check or passenger'swindow motor operation: f

should un (thepassenger's

window moves down),


voltage.

Faultymaster'swindow switchAn open n the wireFaultypassenger's indowmoror.

RED/BLU

22-1



PowerWindows

1 .

Passenger'sWindow Switch Test

Remove he switchpanel seepage20-4).

Remove he powerwindow switch(A ) ro m th e

doorpane l .

Disconnecthe 5Pconnector B) rom thepassenger's owerwindow switch.


lf the continuity s not as specified, eplace heswtlcn.

tfiTtTtT;Etll' '-r--r-,Jl

\TorminalPoiition\

1 2 4

UP

OF F

DOWN

Passenger'sWindow Motor Test

1.Remove he passenger's oor panel se epage20 -4) .

Disconnecthe 2P connector A) rom th epassenger's owerwindow motor.

Terminal ideofm a le e rm ina l s

Test he motor in eachdirectionby connectingbatterypower an dgroundaccording o the table.When he motor stops unning,disconnect nelead mmedia te ly .

\ Terminal

Dl*;;;__\1

UP

Io oDOWN o

lf the motor does not run or fails o ru n smooth y,reptace t.



'1 .

2 .

MasterSwitchReplacement

Remove he door grip (seepage20-4).

Remove he powerwindow masterswitch(A ) ro m

the doorpane l .

Disconnecthe 14Pconnector B) rom the switch.

Remove he three screwsand he switch rom theswitchpanel.

3.

22-1

Passenger'sWindow SwitchReplacement

Remove he door grip {seepage20-4).

Remove he powerwindow switch(A ) rom th eooorpaner .

Disconnecthe 5P connector B) rom the switch.

Remove he two screwsand he switch rom th eswitchpanel.

1 .

2 .

3.

4 .



Wipers/Washers


WINDSHIELD IPERMOTORTest,page22-'143Replacement,ag e22-145

WINDSHIELD IPER RMSand LINKAGEReplacement,ag e22-'145

WIPER/WASHER WITCHTest,page22-140Replacement,page2 140

UNDER.DASH

FUSE/RELAYOX

INTERMITTENT IPERCIRCUITl ln hemul t ip lexont ro ln i t )Input est, ag e 2-138



REARWINOOWWASHERMOTORTest, ag e 2-144Replacement,age 2 146

WINDSHIELDWASHERMOTORfesl, page 214 4Beplacement,ag e 2-146

WASHERUBESReplacement,ag e 2-147

CONDENSERCapacityTest, ag e22 10 7

BEARWINDOWWIPERARMReplacement,age 2 146

WASHERESERVOIBReplacement,ag e 2'146

WASHERFLUIDLEVELSWITCH Canada)TesI,page22-144Replacement,ag e22-144

REARWINDOWWIPER NTERMITTENTCONTROLNITInput est, ag e 2'138

REARWINDOWWIPERMOTORf e$, page22-143Replacement,ag e 214 6

22-1



CircuitDiagram Windshield

UNOEN OODL]SE/8ELAYOX IGNITIONSWITCN

'7{F;^--il I 6\U-I^-- -':-;--u,Hr- o,f-''*""

\

L \

MULTIPIIXcoiln0LUNIT

\,!



CircuitDiagram RearWindow

UI\IOIF H@OFUSE/RELAYX GNMOIIISW|ICH

-No2olaoAlUSA

BATTERY---------------;i

l No'g,soA,ro2o. | /,^1\(-;1_=l----_--_fww{"-' l

\+yl E r H o r b 0 N i | | l

Iandsra8r

ffAn w$tDow tPEEINTE$'ITTEI'IT{)NNOLI'/IT

f--------------- li

22-13



1 .

2 .

RearWindowWiper ntermittentGontrolUnit nputTest

Removehe right ear ide rimpanel see ag e 0-51).

Disconnecthe20P onnectorA) rom he rearwindow.wiDerntermittentontrol nit B) .

Inspectheconnector ndsocketerminalso besure heyareal lmaking ood ontact.

. lf he erminals rebent, oose rcorroded,epairthem snecessary,nd echecktheystem.

. lf he erminalsoo kOK,go o step4.


LTGRN/REO WHT/RED LT GRNHT/RED

LT GRN/BLK



4. With the connector ti l l disconnected, akethese nput estsat the connecrors.

. l f anytes t ind ica tesaprob lem, f indandcor rec t thecause, thenrecheckthesystem.' lf all the input

estsprove

OK, he controlunit must be aultv.Replacet.

Cavitv Wire Tesl condition Test: Desired result Possibleause f result s not obtainedGRN lgnit ionswitchON

f l r )Check or voltage o ground:

Thereshouldbe batteryvoltaqe.

. B lown o.9 10A) fusen heunder-dashuse/relayox

. An open n hewire1 0 BLK Under l l

conditionsCheckor continuityogrouno:There hould econtinuitv.

Poorground (G553)

An open n hewi re

6 WHT/RED lgnit ionswitchON( l l )and earwindow washer

switchON


Thereshould be batteryvortage.

BlownNo.9 (10A)use n heunder-dash use/relay oxFaulty earwlndow wiper/washerswitchAn open n hewi reLT GRN/

R E D

lgnit ionswitchON

( l l )and earwindow wiperswitchON

Attach o groundl

Th e rearwindow wiper motorshou ld un .

LT GRN lgnit ionswitch ON

flr)Attach o ground:

Th e rearwindow wiper motorshou ld un .

B lownNo.9 (10A) fusen heunder-dashuse/relay oxFaulty ea rwindow wiper motorAn open n the wire

20 LT GRN/BLK

lgnit ionswitchON( l l )



BlownNo.9 (10A)use n heunder-dash use/relay oxFaulty earwindow wiper motorAn oDen n hewi re

22-13



1 .

Wiper/WasherSwitchTest/Replacement

Removehedriver's ashboardower over se e age 0-60).

Removehesteering olumn oversse e age17-9).

Disconneclhe 14P onnectorA) rom hewiper/washerwitch B)

Remove he two screws, he n pull out the wiper/washer witch.

Inspect he connector erminals o be sure hey are all makinggoodcontact.

. lf the terminalsare bent, ooseor corroded, epairthem as necessary, nd recheck he system.

. l f t he term ina ls lookOK,checkforcont inu i t ybetweentheterm ina ls ineachswi tchpos i t lonaccord ing to the

tables,- lf th e continuity s not as specii ied, eplace he switch.

Terminal

Position 6 4 1 4 l 2 12 1 1

OFF o- -{

tN l o-LO o-HI

Mist switchON rWashor 3witch ON



ControlUnit nputTest

l . Befor e esting, roubleshoothe multiplexcontrolsystem see page22-jj2).

Remove he dashboard owercover,

Disconnecthe under-dashuse/relay ox connectorsB, G, J, X andy

NOTE:Al l connectors rewire sideof female erminals.

UNDER-DASH USE/RELAYOXCONNECTORI6PI

UNDER.DASHUSE/RELAYOXCONNECTOR{1OP)

2 .

3 .

UNDER-DASH USE/RELAY OXCONNECTOR{8PI

l-,1- llTtlF_j-JF-#1 4 1 5 1 6l 8 l

WHT/BLU

\

l-,1 - l-rl€ l l

l s l r l z l o l\

BLU/RED

UNDER.DASHUSE/RELAYOXCONNECTORI8PI

4. Inspect he connector nd socket erminals o be sure hey are all makinggood contact.

. lf the terminalsare bent, ooseor corroded, epairthemas necessary, nd recheckthe ystem.

. l f he erm ina ls reOK,goto step5.

(cont'

BLU/WHT

BLU/BLK

22-1



Wipers/Washers

ControlUnit Input Test(cont'dl

5. Reconnecthe connectors, nd make hese nput estsat the connector.

. l f anytes t ind ica tesaprob lem, f indandcor rec t thecause, thenrecheckthesystem.

. l f a l l t he input tes tsproveOK, themul t ip lexcont ro ln i tmustbe au l t y .Rep lacehe under -dashuse/ re lay ox

assembly.

Cavity Wire Test condition Test:Desired esult Possibleausef result s not obtained

J 4 BLK Underal l

conditlons

Checkor vo l tageo ground: . Poorground G501)

T h e r e h o u l d e 1 V o r e s s . . A n o D e n i n t h e w i r e

Y6 BLK Underal l

cond i t ions

Check or voltage o ground: . Poorground (G502)

There hou ld e 1 V or ess. . An oDen n hewi re

B I WHTiBLU lgnit ionswitch ON

{ l l )andwasher

switchON


Thereshould be batteryvortage.

Blown No. 20 (20A) use n the

under-dashuse/relay oxFaultywiper/washer witch

An open n the wire

E'0 BLU/RED lgnit ionswitchON( l l )andwiper

switch OFF wipermotor stopped)


Thereshouldbe battery

voltage.

Blown No. 20 (20A) use n the

under-dashuse/relay ox

Faultywiper/washer witchFau l t y indsh ie ld ipermotor

An open n the wire

G7 BLUA/VHT lgnit ionswitchON( l l )andwipers nparkpos i t ion



BlownNo.20 20A) fusen he

under-dashuse/relay ox

Fau l t y indsh ie ld ipermotor

An ooen n the wire

x1 BLU/BLK l gn i t i on w i t chON( l l )andwiper

switch n INT



BlownNo.20 20A) fusen he

under-dashuse/relay oxFaultywiper/washer witch

An oDen n th ewire

\

\

L

22-142



Wiper Motor Test

Windshield:

1. Open he hood,an dcarefully emove he cap nutsand he wiper arms. Makesure hey do not ouchthe hood.

2, Remove he hood sealandcowl cover.

3 . D isconnect thePconnectorA) f rom he motor B) .

Test he motor by connecting atterypoweran dgroundaccording o the table. f the motor doesno trun or fails o run smoothly, eplace t.

P-"-,tion

Terminal1 2 4

LOWSPEED O OHIGHSPEED o o

5. Test he wiper motor parkswitch by connecting nana log o l tmeter e tweenhe No,5 (+) te rm ina l

andground, nd un he motora t ow or h ighspeed.Thevo l tmeter hou ld nd ica te 2V and4 V or lessalternately.f it does not, replace he motor.

lJ22-1

RearWindow:

1. Open he hatch,and remove he hatch rim panel(seepage20-53).

2. Disconnectthe Pconnector A) ro m the motor {B

Test he motor by connectingbatterypower an dgroundaccording o the table. f the motor does norun or fails o ru n smoothly, eplace t.

Telminal

Battery

Connected @ o

Test he wiper motor parkswitch by connecting nana log o l tmeter e tweenhe No.4 (+) te rm ina l

an d ground,an d ru n he motor.The voltmetershould ndicate12V and 4 V or lessalternatelv.f idoes not, reolace he motor.

4 .



WasherMotorTest

1. Partially emove he right nner ender se epage

20-'t021.

2. Disconnecthe 2Pconnectors A) rom the washer

motors(B).

Test he washer motor by connectingbattery

poweran d groundaccording o the able.

Terminal

Battery1 2

Connected @ o

4. lf th e motor doesnot run, replace t,

WasherFluidLevelSwitchTest/ReplacementCanada

1 .

3.

4.

Partially emove he right nner ender seepage

20-102).

Disconnecthe 2P connector A) rom the washer

levelswitch.

Remove he washer luid evelswitch r om the

reservoir.

NOTE: lu idmay lowout heopen ing .

Check or continuitybetween he terminals n each

float (B) positionaccording o the table.

Terminal

Position2

FLOATUP

FLOATDOWN o- ---o

l f the continuity s not as specified. eplace he

swtTcn.



WindshieldWiperMotor Replacement

1 . Open he hood.Remove he nuts(A )and hewindsh ie ld iperarms B) .

Remove he hood sealan d cowl cover.

Djsconnecthe 5Pconnector A) ro m the wipermotor (B).

9. 8N. m (1.0

Removehe bo l t s C) ,movewindsh ie ld iperl inkage ssemblyD) towardhe passenger ' sideof the vehicleuntil t slidesoff of the pin (E), he nremove he assembly.

5 . Scr ibe ine A)acrosshe inkandwlndsh ie ldwiper linkage o show he originaladjustment.Separa tehewindsh ie ld iper inkage B) rom h

wipermotorC) .

N. m(3.2 sf.m,23 bt.ft)

Install n the reverseorderof removal,and notelhese tems.

Apply multipurpose rease o the moving partsBefore einstall inghe wiper arms, urn the wipeswitch ON, hen OFF o return he wipershafts oth e oark oosit ion.lf necessary,eplaceany damagedclips,Check he wioer motor oDeration.

22-1



RearWindow WiperMotorReplacement

1 .

B

Open he hatch,and remove he hatch ri m panel

(seepage20-53).

Remove he mountingnu t (A), he wiper arm (B)

and he specialnut (C).

A9.8N. m 1. 0 gf.m,7.2 bf.ftl

B

8 N.m10.8gt.m,6.0 bf.ft)

Disconnecthe4PconnectorA), emovehe hreemounting olts B), hen emovehe earwindowwiDermotor C) .

9.8 N.m{1.0 gt.m,7.2lbftl

4 , Install n the reverse rder oI removal,and note

these tems.

Apply multipurpose rease o the moving parts.

Before einstall ing he wiper arm, urn the wiper

switchON, hen urn OFF o return he wiper

shaft o the Darkoositon.lf neces sary, eplaceany damagedclips.

Check he wiDermotor operation.

WasherReservoirReplacement

1 . Partially emove he right nner ender.

Disconnecthe 2P connectors A) rom the washer

motors(B )and evelswitch(Canada).

3. Disconneclhe tubes(C ) rom the washermotors.

Remove he threebolts A) and he washer

reservoir B) .

A9. 8N. m(1.0 gt.m,7.2 tbf.tt)



WasherTubesReplacement

Removehe right n ner ender see age 0-102).

Removehewasher ozzlesndclips, hen emovehe ubes.

1 .

2 .

<=>

r"-----------='

--==':?-L-!

(cont'

22-1



WasherTubesReplacementcont'dl

3. Ins ta l ln the reverseordero femova l . ake arenot to p lnchthewasher tubes.heckhewasher pe at ion .



Accessory owerSocket

CircuitDiagram

22-1

AccessoryPowerSocketTest/Replacement

1 .

4.

Carefullypry the accessory owersocket A)ou t

from the center owercover.

Disconnecthe 2Pconnector B) rom the socket.

Inspect he connector erminals o be sure hey areal l makinggood contact.

. lf the terminalsare bent, ooseorcorroded,repairthem as necessary, nd recheckhesystem.

. lf the terminals ook OK,go to s tep 4.

Turn he gnitionswitchACC l) ,and check orvoltagebetween he No . l

and No. 2 terminals.

. Thereshould be batteryvoltage.

. lf there s no baneryvoltage,checkfor:- poorground G502) .- an open n the wire.- b lownNo.18 15A) fusen he under -dash

fuse/relay ox .



oorLockSystem


MUTIPLEXCONTROL NITInput est, ag e 2-155

DRIVER'S OORLOCKSWITCHTest, ag e 2-160

Test,page22-161Prog ram m ing ,age 2 -161

PASSENGER'SOOR OCK CTUATORTest, age 2 158

RECEIVER NITlnputTest,page22-153

IGNITIONKEYSWITCHTest,page22-91

DRIVER'SDOORSWITCH HATCHLATCHSWITCHTest,page22-97HATCHLOOKACTUATORTest,page22 159

DRIVER'S OOR OCK

ACTUATOR/KNOBWTICHActuator est, ag e 2-158KnobSwitch est, age 2 160 PASSENGER'S OORSWITCH



J CircuitDiagram

UNOEEASHfUSE/SELAYBOXiDENHooD USE/RETIYOX

UI'IDE8 ASHUSE/RETAY0X

/ 8Ar \-) cl-

\ lG1 /

lG1 oTn0N lllaidSTAfft(llll

J

000RLoc(KNOE

tlxtY

\"2

t'-F>Li___J-

(cont'

22-1

l 3

IT

IBLK

IG502

MULTIPUXONTNo!flfi

PASSTNGtrS0008100(ACTUATOi

DBt!'t8'S000R 00(ACTUATOB

t



oor LockSystem

UNDEN OODU8E/BELAYX

l\b t15a)USE

CircuitDiagram cont'dl \

t"-ORN

SWTCH

UNDEN AS}IUSE/8ELAYOX

t

Y,,,

Df,IVEB'S0008swtrcHplo'.d l

DFIVES'SDOOBTOCK6WTCH

tG tltot\tIGYstvrTcH

mMErNAlloflLIGHISWITCH

HATCHLATCHswlrol

\



KeylessReceiverUnit InputTest


2 . Removehe aud ioun i t see age22-100) .

3. Disconnecthe 5Pconnector A)from the keyless eceiverunit (B).

WHT/RED


4. Inspect theconnectorandsocket te rm ina ls tobesure theyarea l la inggoodcontact .

. lf the terminalsare bent. ooseorcorroded, epairthem as necessary, nd recheckthe ystem.

. lf the terminalsare OK,go to step 5.

(cont'

t

22-1



Keyless/Power oorLockSystem

KeylessReceiverUnit Input Test (cont'dl

With the connector t i l l disconnecled,make he input est at the connector.

. l f t es t ind ica tesaprob lem, f indandcor rec t thecause, thenrecheckthesystem.

. lf th e nputtest provesOK ,goto step6.

Reconnecthe 5Pconnector, nd make hese nput estsat the connector.

. l f anytes t ind ica lesaprob lem, f indandcor rec t thecause, thenrecheckthesystem.

. lf all the inputtestsproveOK, replacethekeyless eceiverunit.

Cavity Wire Test condition Test:Desired esult Possibleausel result s not obtained2 BLU/ORN Under l l

conditionsCheck or continuitybetween

the No.2 erm ina l nd heNo.2 te rm ina l f the

under-dash use/relay oxconnectorK {17P).Thereshouldbe continuitv.

An open n the wire

Cavitv Wire Test condition Test:Desired esult Possibleause f result s not obtained1 BLK Undera l l

conditionsCheck or voltage o ground:

Thereshouldbe 1 V or less.

. Poorground (G502)

. An oDen n the wireYEL lgnit ionswitch

oN | | )Check or voltage o ground:

Thereshould be batteryvoltaqe.

Blown No. 10 7.5A) use n heunder-dashuse/relay oxAn ooen n th ewire

WHT/REDUnd er l lconditions


Thereshouldbe batteryvoltaqe.

' B lownNo.9 (10A)use n heunder-hood use/relay ox

. An ooen n hewi re

22-154



ControlUnit Input Test

1. Before esting, roubleshoot he m u tiplexcontro system seepage22-172).

2, Remove he dashboard ower cover.

3. Disconnecthe under-dashuse/relay ox connectors.

NOTE:All connectors rewire side of female erminals.

UNDER.DASHUSE/RELAYOXCONNECTOR{1itPl

UNDER.DASHUSE/RELAYOXCONNECTOR12P)

UNDER.DASHUSE/RELAYOXCONNECTORIl2PI

UNDER-OASH USE/RELAY OXCONNECTOR{8PI

UNDER.OASHUSE/RELAYOXCONNECTOR18PI

UNDER.DASHUSE/RELAYOXCONNECTOR{17PI

BLU/ORN

UNDER.DASHUSE/RELAYOXCONNECTOR(8P)

YEL/BLKYEL/BLK YEL YEL

UNDER-DAsHUsE/neLeYbxCONNECTOR(8P)

YEL YEL/BLK

UNDER.DASHUSE/RELAYOXCONNECTOR{13P)

,/1,/ 3 4 5 6 8

LT GRN/RED WHT/BLKYEL/REDWHT/GRNWHT/B

4. Inspect he connector nd socket erminals o be sure hey are all makinggood contact.

. lf the terminalsare bent, ooseorcorroded, epairthemas necessary, nd recheckthe ystem.. lf the terminals ook OK,go to step 5.

(cont

GR N

BLU/REDLU

RED/WHT

22-1



oor LockSystem

ControlUnit Input Test(cont'dl

5. Reconnectl lconnectionso he underdashuse/relayox ,an dmake hese nput ests t heappropriateonnectorsn he under-dashfuse/relayox.

' l f any t es t i nd i ca tesap rob lem , f i ndandco r rec t t hecause , t hen recheck thesys t em .

. l fall he nputtests roveOK,goto step .

Cavitv Wire Test condition Test:Desired esult Possiblea sef results notobtainedc1 ' l 8LU Under l lcondit ions Aftach o ground:

Parking,id emarker,icenseplate ights, nd ajl l ights houldcomeon .

B lown o . 2 15A) fusen heunderhood use/relay oxFaultyail l ightelayFaulty nder-dashuse/relayoxAn onen i n rhc wi re

BLU/BEO Under l lcondit ions Attacho ground:Headlightshould omeon .

B lown o .15 r 17 15A) f usen heunderhood use/relayoxFaulty eadlightelay1or 2An ooen in the wi re

J2 WHT/RED Under l lcondit ions Checkor voltageo ground:There hould ebattery oltage.

B lown o. 9 15A) fusen heunder -hood use/relayoxAn oncn in thc wi rc

BLK Under l lconditaons Checkor voltageo ground:Thcre houln c 1 V or pqs

Poor round G501)An ooen n hewire

J6 OBN Under a l lcondi t ions Attach o ground:

The horns should sound.

BlownNo .7 (15A)fusen he underhood use/relayoxFaulty orn elayFaulty ornsAn 6nen in rhe wi re

J7 Under a l l condit ions Checkor voltageo ground:There hould e battery oltage.

ElownNo .16 20A)fusen he underhood use/relay oxAn oocn in ihc wi .c

P18 BED Hatchopen Checkor voltageo ground:There hould e1 V or ess.

Poor round G552)Faultyhatch atchswitchAn oncn in rhc wi rF

Hatchclosed Checkor voltageo groundlThere houl. l e 5 V or more

Faulty hatch latch switch

GBN Driver's ooropen Check or voltage o g.ound:

There should be 1 V or less

. Faulty river's oorswitch

. An ooen n hewireDriver's oorclosed Check or voltage o ground:

There should be 5 V or more.Faulty r iver's oorswitchShort o oround

o4 LT GRN

/RED

Passenger'soo ropen Checkor voltageo ground:

There hould e 1 V or ess.

Faulty assenger'soorswitch

An ooen nthewirePassenger'soo rclosed Check or voltage o groundl

There should be sVor more

. Faulty assenger'soo rswitch

. Short o oroundX5 REDAVHT lgnition key inserted into

the ignit ion swhchCheck or voltage o ground:

There should be 1 V or less.Poor round G401)Faultygnit ion ey witchAn ooen nthewire

lgnit ion ey emovedro mrhe onit ion witch


There should be 5 V or more.Faultygnit ion eyswitchShort o oround

Y1 WHT/BLK Driver's oor ock nobswitch nlocked

Check or voltage o groundl

There should be 1 V or less.PoorgroundG50'l)Faulty r iver's oor ock n ob witchAn open n hewire

Driver's oor ock nob Check or voltage o groundl

Ihere should be 5 V or mor e.Faulty river's oor ock nob witchShort o oround

Y8 YEURED Driver's oor ock nobswitch ocked

Check or voltage o groundl


PoorgroundG50'l)Faulty r iver's oor ock nob witchAn oncn in ihewi re

Driver's oor oc k no bswitch unlocked


There should be 5Vor more

' Faulty river's oor ock nob w;tch. Shorr o oround

Y10 WHT/GRN Drtver's door lock switchunlocked

Check or voltage o groundlThere should be 1 V or less. PoorgroundG501iFaulty river's oor ock witch

An ooen n hewireDriver's oor oc k witch n Check or voltage o ground:

Therc shorl. l be 5V or m6rpFaulty river's oor oc k witchShort o o olrnd

Y1 2 WHT/BLU Driver's oor ock witchlocked


There should be'l

V or less.Poor round G501)Faulty r iver's oor ock witchAn oDen n hewire

Driver's oor oc k witch n Check or voltage o ground:

There should be 5Vor moreFaultydriver 's door lock switch



6. DisconnectheM, P,K and connectorsro m he underdashuse/relayox ,an dmake hese nput ests t heconnectors.

. l f any t es t i nd i ca t esap rob lem , f i ndandco r rec t t hecause , t hen recheckt hesys t em .

. l f a l l t he inpu t t est sp roveOK, t hemu l t i p lexcon t ro lun i tm us t be f au l t y .Rep lace t heunder -dash f use / re layboxasse

Cavitv Wire Testcondition Test:Desired esult Pdsiblo c6use f result s not obtain€d

K2 BLU/ORN Under l lconditions Checkor continuitybetweenth eK2 erminal nd hekeylessreceiver nit5P onnectordisconnected:There hould econtinuitv.

An open n hewire

M7 YEUBLK Connect 7 erminalo [ ,47lMgl terminal, ndMglMTl terminalto 4

Check ctuator perat ion:Th edriver's oor ock ctuatorshould ock lunlockl

Faulty r iver's oor oc k ctuatorAn open n hewire9 YEL

M6 YEUBLK Connect 7 erminalo M6lMSl terminal, ndM8lM6l terminalto 4

Check ctuator peration:Th epassenger'soor ockactuatorhould ock iunlockl

Faulty assenger'soo r oc k ctuatorAn open n hewire8 YEL

P16 YEL Connect7 erminalo P17lP16l terminal, ndP1 6lP17 l t e rm ina l t o4

Check ctuator perat ion:Th ehatch ock ctuator houldlock lunlockl

. Faultyhatch ockactuator

. An open n hewire17 YEUBLK

-

22-1



oorLockSystem

Door LockActuatorTest

Driver's oor:

1. Removehe dr i ver ' s oorpane l seepage20-4) .

2. Disconnecthe 2P connector rom the actuator.

Checkactuatoroperationby connectingpoweran dgroundaccording o the table.To preventdamageto the actuator, pply batteryvoltageonlymomenlanry .

\Terminal

ilil;lll'l 2

LOCK

e eUNLOCK e el f the actuatordoes not operateas specified,reprace r.

4 .

Passenger'soor:

1. Removehe passenger ' soorpane l seepage20-

4) .

2. Disconnecthe 2Pconnector rom the actuator,

Checkactuatoroperationby connectingpoweran dgroundaccording o the table.To preventdamageto the actuator, pply batteryvoltageonlymomenlanty .

\Terminal

P."I,l.;--\2

LOCK e eUNLOCK e o

lf the actuatordoesnot operateas specified,reprace ,



J

Hatch Lock Actuator Test

1. Open h e hatch.

2. Remove he hatch ower ri m panel se epage20 -

53).

3. Disconnecthe 2Pconnector ro m the hatch ock

actualor.

4. Checkactuator perationby connectingpoweran dgroundaccording o the table.To preventdamageto the actuator, pply battery oltageonly

momentaflty.

\TerminalPo.irion\

1

LOCK @

UNLOCK o

Terminalsideofm a le e rm ina l s

22-1



LockSystem

1 .

Door LockKnob Switch Test

Removehedriver's oorpanel see age 0-4).

Disconnecthe3Pconnectorrom heactuator.


terman as.

. Thereshould be continuitywhen the door oc k

knob switch s n th e LOCKED osition.. Thereshould be no continuitywhen the door ock

knob switch s n the UNLOCKED osition.

Check or continuitybetween he No. 2 and No. 3termtna ls .

.Thereshouldbe continuitywhen the door ockknobswitch s in the UNLOCKED osition.

. Thereshouldbe no continuitywhen the door ockknob switch s in the LOCKED osition.

lf the continuity s not as specified, eplace he doorlocl(actuator.

5.

'1 .

Door LockSwitch Test

Remove he driver'sdoor panel se epage20-4).

Remove he two mountingscrewsand he door

lockswitch.

Check or continuitybetween he terminals.

. Thereshould be continuitybetween he No. 1

and No. 2 terminalswhen the door ock switch s

in the LOCKED osition.. Thereshould be continuitybetween he No. 2

and No. 3 terminalswhen the door ockswitch s

in the UNLOCKED osition.

lf the continuity s not as specified. eplace he door

lockswitch.



Transmitter est

NOTE:. l f he doorsun lockor lockwi th the t ransmi t te r ,u t

the LE Don the ransmitterdoes not come on, he LED

is faulty.Replacehe ransmitter,. l f anydoor sopen, oucannot lock thedoorwi th the

transmrtter.. lf you unlocked he doorswith the transmitter,but do

no t open any of the doorswithin 30 seconds, hedoors relockautomatically.

. The doorsdo not ockor unlockwith the transmitter fthe gnitionkey s nserted n the gnitionswitch.

1. Press he lockor unlockbutton ive or six t imes oreset he transmitter.

. lf the lockswork, he ransmitter s OK .

. lf the locksdon't work, go to step 2.

2. Open he transmitterand check or water damage.

. lf you find any water damage, eplace hetransmrtter.

. lf there s no waterdamage,go to step3.

3. Replacehe transmitterbattery A)with a ne w one,an d ry to lockand unlock he doorswith th etransmitterby pressing he ockor unlockbuttonfive or six imes.

. lf the doors ockand unlock, he transmifter s OK.

.lf the doors don't lockand unlock,go to s tep 4.

Reprogram he ransmitter, hen ry to lockan dun lock hedoors .

. l f hedoors ockand n lock. the t ransmi t te rs OK.

. l f he doorsdon ' t lockand n lock,ep lacethetransmitter.

4 .

Transmitter rogramming

Storing ransmitter odes:The codesof up to three ransmitters an be stored nthe keyless eceiverunit memory. (l f a fourthcode s

stored. he codewhich was input irst wil l be erased.)NOTE: t is important o maintain he time limitsbetween he steps.Makesure he doors and he hatchar e closed.

1 . Turn he gn i t ion wi tchON ( l l i .

2. Within 1 o 4 sec.,push he transmitter ockorunlockbuttonwith the transmitteraimed at thereceiver n the multiplexcontrol unit behind hedr iver ' s ideof he dash.

3. Within 1 o 4 sec., urn the ignit ionswitchOFF.

4. Within 1 o 4 sec., urnth e ignit ionswitchON (ll).

5. Within'l

to 4 sec.,push he transmitter ockorunlockbuttonwith the ransmitteraimed at thereceiver n th e multiplexcontrolunit behind hedr iver ' s ideof hedash.

6. Within 1 to 4 sec., urn the ignit ionswitch OFF.

7 . Wi th in4 sec. ,u rn he gn i t ion wi tchON ( l l ) .

8. Within 1 o 4 sec.,push he transmitter ockorunlockbuttonwith the ransmifteraimedat thereceiver n the mupltiplexcontrolunit behind he

driver'sside of the dash.

9. Within 1 o 4 sec., urn the ignit ionswitchOFF,

'10 .Wi th in4 sec. ,u rn he gn i t ion wi tchON ( l l ) .

11 . Wi th in1 o 4 sec. , ush he ransmi t te rockorunlockbuttonwith the ransmitteraimed at therece ivern he mul t ip lex on t ro l n i tbeh ind hedriver'ssideof the dash.

12. Conf i rm oucanhear the ound f the door ockactuators.Within 1 to 4 sec.,push he transmitterlockor unlockbuttonagain,

13, Within 10sec.,aim the ransmitters up o twoadditionalones)whose codesyou want to storeatth e receiver, nd press he transmitter ockorunlockbuttons.Confirm hatyou ca nhear he soundof the doorlockactuators ftereach ransmitter ode s stored

14. Turn he gn i t ion wi tchOFF, ndpu l lou t he key.

'15.Confirmproperoperationofthe transmitter.

22-1




INOICATORIGHTBulb Replacement,ag e22 63

EC MReplacement,ag e11-4

Substitute nown-good or test ing,page 1-5

IMMOBILIZER ONTROL NIT.RECEIVERTroubleshooting,ag e 2-165Replacement,ag e 2-167

TRANSPONDER(8uilt nto he gnition ey)



SystemDescription

The vehicle s equippedwith an immobilizer ystem ha twill disable he vehicleunless he proper gnitionkey s usedThissystemconsists f a transponder ocated n th e ignit ionkey,an mmobilizer ontrolunit-receiver, n indicatorl i gh t , nd he ECM.

When he key s nserted n th e gnitionswitchand urned o the ON {ll) posit ion, he immobilizer ontrolunit-receivesendspower o the ransponder n the ignit ionkey.Th e ransponder hen sendsa codedsignalback o th e immobilizcontrolunit-receiver hich hen sendsa codedsignal o the ECI\4.

iEl'JUiliii'tlun"oona"|.r EYCYLTNDER

l f the properkey hasbeen used, he immobilizer ndicator ight wil l come on for about 2 seconds, hengo off.lf the wrong key hasbeen usedor the codewa s not received r recognized y the unit, he indicator ight wil l comeon for about2 seconds,hen t wil l blink until he ignit ionswitch s turnedOFF.lf the gnitionswitch s turnedOFF, he indicatorwill blink or about 5 seconds o signal hat the unit has resetcorrectly, hen he ndicatorwill go off.lf the customerhas ost his key,and cannotstart he engine, ontactHondaCustomerRelations.

IMMOBILIZERNDICATORIGHT LINKING ATTERN:

IGNITIONSWITCH ON

OFF

PROPER EYINSERTED

INDICATORLIGHT

ON

WRONGKEYINSERTED

INDICATORLIGHT

ON

OF F

i .,

IMMOBILIZER ONTROL NIT.RECEIVER

)22-1



System

UNDTRcODFUSE/RELAYOX

rGNtTt0i/swlrcH

lct HoTn0N ll).ndSIAnT|l)

0R8 itAWStY tct tGPl tGPz LG3 |M0CD

EC

LGI LG2

t

'No20(LAl r USA

CircuitDiagram

F G N8ELAY1

YEUBIJ(

t

DATA . PA8(II'IGLIN( SMIGCONNECIOR SWITCH{0Lcl .8nA{E

FTUIDI!VELSWTfi

\



Troubleshooting

Before roubleshootinghe immobilizer ystem,troubleshoot ny EClvlDiagnostic roubleCodes DTCS)(see age11-3) , ndmake ure heECMhasno

malfunction.

Note hese temsbefore roubleshooting:

. Due o the actionof the mmobilizer ystem, heengine akesslightlymore ime o start han on avehiclewithout an mmobilizer ystem.

. When he system s normal,an d he properkey sinserted,he indicator ight comeson for 2 seconds,then t wil l go off.

. If the ndicatorstartstoblink after2 seconds, r if th eenginedoes not start. emoveany other mmobilizerkeysor largekey obs on the key ring, hen repeat hestartingprocedure.

lf the enginestil l doesnot start,continuewith thisprocedure.

1. Turn he ignit ionswitchON {ll)with properkey.

2. Check o see f the mmobilizer ndicator ightcomes n .

Does the indicator light blink?

YE S Disconnecthe 7Pconnector rom theimmobilizer ontrolunit-receiver,he n go to step9.

NO Check or theseproblems, he n go to step3.

. Blown No.9 (10A)fuse n the under-hoodfuse/relay ox.I

. An open n the wire between he gaugeassemblyand he mmobi l i zeront ro l n i t - rece iver . l

. A fau l t y mmobi l i zernd ica torigh t , I

. An open n the wire between he gaugeassemblyand he under-hood use/relay ox.l

Remove he driver'sdashboard owercover (see

page20-59).

Remove he steering olumn ower cover (seepage

11-9).

22-16

5. Disconnecthe 7Pconnector A)from th eimmobi l i zeront ro l n i t - rece iverB) ,

Check or voltagebetween he mmobilizer ontrolunit-receiver P connectorNo. 7 terminal and bodyground.


YES-Go to step7.

NO Check or theseproblems;

. B lownNo.9 {10A) fusen he under -hooduse/relaybox.l

. An open n the WHT/RED ire.l

Check or voltagebetween he immobilizer ontrolunit-receiver PconnectorNo. 6 terminaland bodygroundwith th e ignit ionswitchON {ll).


YES- Go o step8.

NO Check or theseproblems:

. B lownNo.6 (15A) fusen he under -hoodfuse/relay ox,I

. Fau l t y GM-F lmain e lay1, t

. An open n he YEUBLK i re . l

1 .

(cont'd



System

Troubleshootingcont'dl

8. Check or voltagebetvveenhe immobilizer ontrolunit-receiver P connectorNo. 6 terminaland No. 1

rerm lnat .


YES Go o step 12.

NO Check or theseproblems,

. Open on the BRNI/ELwire.l

. Fau l t y CM. I

9. Remove he driver'sdashboard owercover se e

page20-59).

10. Remove he steering olumn ower cover (seepage

17-9) .

11. Disconnecthe 7P connector A) rom the

immobilizer ontrolunit-receiverB) .

Check or continuitybetween he mmobilizer

controlunit-receiver PconnectorNo. 2 terminal

andECM ermina l 27 .

ls therecontinuity?

YES-Go to s tep13.

NO- Repa i rhe open n he RED/BLU i re . I

Reconnecthe 7Pconnector o the mmobilizer

controlunit-receiver.

Check or voltagebetween he immobilizer ontrol

unit-receiver PconnectorNo. 4 terminaland bodygroundwith the parkingbrake everpulled, he n

released.

ls there 1 V or less, hen5 V or more?

YES Replace he immobilizer ontrolunit-receiver.

After replacing he immobillzer ontrolunit-

receiver, ewrite he unitwith a HondaPG M

Tester.l

NO Check or theseproblems:

. Faultyparkingbrakeswitchor a poor bodygroundof the parkingbrakeswitch.l

. Repa i r hor to r open n he GRN/ORN i re .

1 3 .

1 4 .



2 .

3 .

lmmobilizerControlUnit-Receiver eplacement

'LRemove he driver'sdashboard owercover (seepage20-59).

Remove he steering olumncovers se epage17 -

Disconnecthe 7P connector A) rom th eimmobilizer ontrolunit-receiverB).

5 .

Remove he two screwsand he mmobilizercontrolunit-receiverrom the gnitionkey cylinder(c).

Install he mmobilizer ontrolunit-receivern th ereverse rderof removal.

After replacement,ewrite he unit with a Honda

PGMTester, hen check he immobilizer ystem.

J

6.

22-16



ControlSystem


IGNITION EYLIGHTTest,page22'91

lr,

REARCEILING IGHTTest, ag e 2'96

LIGHT/SPOTLIGHTSTest,page22-96

GAUGE SSEMBLY

ECM

MULTIPLEX ONTROL NI T{Built nto the under-dashfus6/relav boxlTroubleshooting, ag e22'172InputTest,page22-175



CircuitDiagram

'I'10.20a0AJusAib.a)l50A)C.nd.

IGNITiONWITCH

/ BAI \--_to oJ- BLI,'YEL

\ tcl ./

J

G201

HAICIILATCHSWITCH

{cont'd

UiIDM HOODUSE/NEUYOX

MULTIPLEXc0NT80rtNsPECTror!CONNECIOF

UNDEf, ASHFUSE/NEUYBOX

22-16



MultiplexControlSystem

CircuitDiagram cont'd)

l'1o.37.5AJUStlln$.uidt hoodritutefd4bor I

VIwHTPLU

l 0t--t---

l r f l |lE nv*-| > | ucHT

lA ' * 't Y l

I '

CIILINGIGHT

I.l|MOBItEER@NTIOL IIITRECEIVEE

VI

I

22-170



SystemDescriptions

Th e MultiplexControlSystemhas our internalfunctions:. Mu l t ip lex ingsendmul t ip le igna ls vershared

wt res). Wakeup/sleep runsat full poweronly on demand o

reducebatterydraw). Fail-safefixesor ignores aultysignals). Self-diagnosisMode1 or the system,Mode2 for

input ines)

The systemcontrols he functionof thesecircuits:. Ent ry igh tcont ro l ign i t ion ey igh tandce i t ingigh t ). Wiper/washerntermittentwipe an d park unctions. Keyless/power oor ock. Meterassembly, emperature auge,and ndicator

lights. HVAC compressor nd an control)

. Key- in eminder. Head l igh teminder

. Seatbelt eminder

J

22-17

MultiplexCommunication

To reduce he numberof wire harnesses, igitalsigna

aresent ia sharedmul t ip lex ommunica t ioninesra therhansend ing ormal lec t r i ca ligna lshroughind iv idua l i res .. The nputsignals rom eachswitch areconverted o

digitalsignalsat he centralprocessing ni t (CpU).. Thed ig i ta l i gna lsaresent f romthet ransmi t t ingn i

to the rece iv ing ni tasser ia l igna ls .. Th e ransmittedsignal s converted o a switchsigna

at th e receivingunit,and t operates he relatedcomponentor monitorsa swltch.

. Thereare exclusive ommunicalion inesbetweenthe ECM, he gaugeassembly, nd he under,dashfuse/relay ox.

Wake-up nd Sleep

The multiplexcontrolsystemha s"wake-up"an d

"sleep" functions o decrease arasit ic raw on thebatterywhen the ignit ionswitch s OFF.. ln the sleepmode, he multiplexcontrolunit stops

functioning communication nd CP Ucontrol)when is not necessaryor the system o operate.

. As soon as any operation s requested fo rexample,adoor is unlocked),he related ontrolunit n the sleepmode immediatelywakesup and begins o function.

. When he gnitionswitch s turnedOFF,and hedriver'sor front passenger's oor is opened, henclosed, here s abouta 10seconddelay before hecontrolunit goes ro m the wake-upmode o the sleemode.

. lf any door s open, he sleepmode will not function.

. l f a key s n he gn i t ion wi tch , he s leepmodewi l lnot function.

. When in sleepmode, he draw is reduced ro m70 80 mA to less han 10 mA.

Fail-safe

To prevent mproperoperation, he multiplexcontrolsystemhas a fail-safe unction. n the fail-safemode,th e output signal s fixedwhen any partof the system

malfunctionsfo r

examplea faultycontrolunit orcommunica t ionine) .Each ontrolunit hasa hardware ail-safe unction ha tfixes he output signalwhen there s any CP Umalfunction, nd a software ail-safeunction ha tignoreshe s igna l rom he mal funct ion ingont ro l n i tand allows he system o operatenormally.



ControlSystem

Troubleshooting

Mode 1 Tset

1. Remove he driver'sdashboard owercover seepage

20-59).

2. Check he No. 9 (10A) use n the under-hood use/

relaybox and he No. 10 (7.5A) use n the under-

dash use/relay ox.

Ar e the fuses OK?

YES-Go to step2.

NO-F ind and epa i r the ause f the b lown use. !

3 . Turn he gn i t ion w i t chON ( l l ) . l fhe dr i ver ' s

seatbelt s unbuckled he seatbelt reminderwill

ch ime6 t imes.

4. Set he ceil ing ight o the centerposit ionand close

a l l thedoors .

5. Connect he specialtoolto he multiplex nspection

conneclor.

6. After about 5 sec onds he spotlightan d ceil ing ight

shouldcome on for 2 seconds, o out, hen blinkon

for 0.2 second o show he system s now in mode

1 .

Did the spotlight and ceiling light indicate mode

1 ?

YES-Go to step8.

NO Go o step7.

7. Check or continuitybetween erminal4ofthe

under-dashuse/relay ox connector and bodyground.

ls therecontinuity?

YES Replace he under-dashuse/relay ox.l

NO Repa i rhe open n hewi re . l f he w i re s ok ,

repa i rG301.1

8. lf ther are any DTCS resent, he spotlightan d

ceil ing ightwill blink o indicate he DTC(S).f more

than one DTC s present,he DTCS il l be displayed

in ascending rder, f thereare no DTCShe

spot l igh t ndce i l i ng igh tw i l l no tb l inkaga in f te r

the mode1 nd ica t ion .

Are therean y DTCg?

YES Go o step9.

NO Go o the Mode 2 test.

9. Troubleshoothe DTC(S)n the order ndicated

us ing he o l lowing har ts .

lf a faultycontrolunit s suspected, ubstitute t

with a known ood partan d recheck or DTCS,

. lf the DTC(s)ssti l l present. o to the next step

listed or the DTC.. lf the DTC(S)s no ongerpresent eplace he

or ig ina l a r t .



Individual

MultiplexDTC

ProbableCause

Th e multiplexcontrolunit cannotreceive ignals ro m th e gaugeassemDty.'l

Faulty oweror groundo hegauge ssembly

2 . Faultygaugeassemblv3 . Faultyunder-dashuse/relay

bo xTh e multiplexcontrolunit cannotreceive ignals rom the ECM1 Faultypoweror ground o the

ECM

2. Fau l t y CM? Faulty nder-dashuse/relay

bo xJ Internal ailureof the multiplex

controlunit1 Faulty nder-dashuse/relay

box5 The gaugeassembly annot eceive

signals ro m the multiplexcontrolun i tand heECM

Faultypoweror ground o thegauge ssembtvFau l t y auge ssemblv

6 The ECMcannot eceive ignalsfrom multiplexcontrolunit and hegaugeassembty

1 Faultypoweror ground o th eECMFaul t y CM'

'Beforereplacing FaultyECM/PCMmakesure t

ha s he atest oftware evision.UDdate fnecessary eforeswappingor replacing.

DTCsMult iplex

DTCProbableCause

1 , 2a n d&ECMDTC

P0600Simul tane

ously

Short o ground on one of thecommunicationwires.Short o ground on the YELwirbetween he PCM erminalE24and he under-dashuse/relaybox erm ina l 10

2 . Short o groundon the WHT/GR Nwire between he Gaugeassembly erminalA2 an dunder-dashuse/relay oxterm ina l 10

1 a n d 6

Simul tane

ous y

Open n the communicationwireI Open n WHT/GRNwire

between he under-dashuse/

relaybox erminalK10and heGauqeassemblVerminal42

2 a n d 5Simul tane

ous ly

Open n hecommunica t ion i re1 Open n the YELwire between

the under-dashuse/relay oxterm ina l 10 ndECM ermina

(cont'd

22-17



MultiplexControlUnit Input Test

Remove he driver'sdashboard owercover(seepage20-59).

Disconnecthe under-dashuse/relay ox connectorsC, E, F,J, K,O, p, O, X and y.

NOTE:Al l connectors re wire sideof female erminals.

CONNECTOR{14P} CONNECTORI13P)

1 .

2 .

CONNECTOR{12P}

GRN/REDUSAIGRN/ORNCanada)

coNNECTOR 18P)

CONNECTOR{8PI

WHT/RED

1 2 3

4 5 6 1

BLK

{cont'd

GRN/ORN BL U

CONNECTOR{17P) CONNECTOR12P)

CONNECTOR {8P)ONNECTOR(8P}

LTGRN/RED GRN/ORN

CONNECTOR {13P)

BRN/YEL

BLU/RED BLU/RED

3 4 5

6 7 E 10) . / 12

YEL GRN/RED

1 2 4 5 7

8 10 /V ,/ l,/

WHT/GBN

3 5 6 7 I

,/1,/l,/ 12 15 1 7

REDRN/RED

WHT/BLK

RED/WHT

2 3 ,/1,/6 1 8 r0 12

BLK

22-17



ControlSystem

MultiplexControlUnit lnputTest(cont'd)

3. Inspectheconnectorndsocketerminalso be sure he yar eal lmaking oo d ontact

. l f t he t e rm inal sa reben t , l ooseo rco r roded , repa i r t hemasnecessa ry , and recheck t hesyst em

. llthe erminalsoo kOK , o o step4.

4. Reconnecttheonnectorstothenderdash userelay ox,an dmake urethesenputtests t theappropriateonnectorsn he under-

dash use/relavox .

. lf an y es t ndicatesproblem,in dan d orrecthecause,he n echeckhesystem

. lf allthe nput ests roveOK, hemult iplex ontrol nitmustbe aulty.Replacehe under_dashuse/relayoxassembly

Cavitv Wire Test condition Test:Desired esult r Possibleausef resullEqS!q!!e!!edJ 4 BLK [Jnder a l l condit ions Checkor voltage oground:

Therc sho l l . l he 1V or less

Poor round G20'l)An ooen n hewire

Y6 BLK lJnderal l condit ions Check or voltage o ground:

There should bc 1 V or less.Poor round G501)An ooen n hewire

Y1 BFNryEL Parking rakeeverdown, urn heigntion witchON ll )

Checkor voltageo ground:There hould ebattery oltagewhile he Brake ystemndicatorson orthe buld heck.

An open n hewireShorttogroundFaulty BSmodulatorcontrolni t

Checkor voltageo ground:There hould e 1V or es swhen he

J 2 WHT/RED Under l l cond i t i ons Checkor voltageo groundiThere hould e baftery oltage.

BlownNo.9 10A)fusen he under'hoodfuse/relayoxAn oncn n hcwire

Cavitv Testcondition Tesi:Oesired esult Possibleausefresultsnotobtained

o3 GRN Driver's oo ropen Check or voltage o ground:

There should be 1 V or less-

Faulty r iver's oorswitchAn ooen n hewire

Driver's oorclosed Check or voltage o ground:

There should be 5 V or more.

Faulty r iver's oo rswitchShort o qround

O4 LT GRN/RED Passenger'soo r Check fo rvoltage10 ground:


Faulty assenger'soo rswitchAn ooen nthewire

Passenger'soor Checkor voltageo ground:There hould e5 V or more.

Faulty assenger'soo rswitchShort o oround

os I ] l. l

4.,

F 1

F8

GRN/ORN

GRN/ORN

GRN/RED(USA)

GRN/ORN(Canada)

Parking rakeever Check or voltage o groLrnd:

Thereshorl. l be 1 V or less.

Faultyparkingbrakeswitch. An ooen n thewire


There should be 5 V or more.

. Faulty arking rake witchShorttoground

o5 BLU/RED lgnit ion witchON ll),

driver's eat elt sCheck or voltage o ground:

There should be 1V or less.

Faulty r iver's eat elt witchPoorg roundG551)An oDenn hewire

Q6 BLU/RED lgnit ion witchON ll)

driver's eat elt sbuckled.

Checkor voltageo ground:There hould e6 V or more.

Faulty r iver's eat elt witchShorttoground

P18 RED

H",=heckor voltageo ground:

There ho0ld e 1V or ess-

f-9*:li:'^:**:':s*:*

Faulty atch atch wrtchPoor round G552)An open n hewireFaultyhatch atchswitch

X5 lgn ir ionkey n the Check or vol iage o gtound:

ignit on switch Thpre should be I V or lcss

lgnrtron ev ou r o{ he Check or vol lage o ground:

. Faulty gnit ion key switch

. Poorground (G401)

. An open n he wire

I : [11y.'::i':::1"'*6

\

22-176



J

J

J

Cavitv Wire Testcondition Test:Desired esult Possibleausef resuksnotobtainedX8 WHT/BLK Under llcondit ions Attach o ground:Thegnit ion ey

light hould ome n.BlownNo.3 7.5A)fusen he under,hood

Blown EDAn ooen n hewire

o7 GRN/RED Cei li ngight witch nth emiddle osit ion,al ldoors losed

Attach o ground:The ceil ing ight,spotl ightsshould come on.

ElownNo .3 (7.54)fusen he undeFhood

Faulty eil ingightAn oDenn hewire

c ] 1 BL U Under ll condi ti ons A tt acho ground:Dash ights hould BlownNo .2 (15Aifusen he under-hoodfuse/relay oxFaultyail l ightelayAn ooen n hewire

F8 GRN/RED Brakeluid eservoirfloat n downposit ionbrakeluid


There should be less ha n I V.Faulty rakeluid evel witchAn open n hewire

Brakeluid eservoirf loat n upposit ion(brakeluidat ul llevel)

Checkor voltageo ground:There hould e5 V or more.

Faulty rakeluid evel witchShorttoground

E 1 0 YEL Under l lcondit ions Check or voltage o ground:

There should be batteryvoltage nthe s leepmode and 3 Tvoltswhen

. An openor short n hewire

K10 WHT/GRN Under llcondi ti ons Checkor voltageo ground:There hould ebattery oltagenth esleepmodean d3 Tvoltswhen

An openor short n hewire

22-1



Restraints

RestraintsSpecial ools .. . . . . . . . . . . .3-2

SeatBeltsComponentocationndex .. . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .. . .3-3FrontSeatBeltReplacement.. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . .3-4Rear eatBeltReplacement.. . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . .3-6Inspection .. . . . . . . . . . . . . . . . .3-8Chi ldSeat ether nchorRemoval/ lnstal lat ion.. . . . . . 3-9

SRS Supplemental estraintSystemlComponentocationndex . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . .. .3-13PrecautionsndProcedures ,, . , . . . . . . . . .3-14General roubleshootingnformation .. . . . . . . . . . . . . . . . . . . . .3-23DTC roubleshootingndex .. . . . . . . . . . . . .3-28Symptom roubleshootingndex . . . . . . . . . . . . .. . . . . . . . . . . . . .. . .3-30System escript ion.. . . . . . . . . . . . . . . . . . . . . . . . . .3-31Circuit iagram ... . . . . . . 3-34DTC roubleshooting.. . . . . . . . . . . . . . . . . . . . . . .3-36

SRS ndicator ircuit roubleshooting.. . . . . . . . . . . . . . . . . . . . .3-105Component eplacemen(/ln pecton AfterDeployment .. . . . . . . . . . . . .23-112

Driver 's i rbagReplacement .. . . . . . . . . . .3-113FrontPassenger'sirbagReplacement.. . . . . . . . . . . . . . . . . . .3-1 4SideAirbagReplacement .. . . . . . . . . . . . . . . . .3-115Ai rbag isposa l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 -116Cable eel ep lacement . . . . . . . . . . . . . . . . . . . .3 -119SRSUnitRepfacement .. . . . . . . . . . . . . . . . . . . . . .3-122Side mpact ensor eplacement.. . . . . . . . , . . . . . . . . . . . . . . . . . . . .3-123OPDS nitReplacement .. . . . . . . . . . . . . . . . . . .3-124Front mpact ensor eplacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . .3-125



Restraints

\SpecialTools

@

*1 : Inc ludedn SRSToolSet07MM'SM50008*2 : Us ewith the stackingpatchcords rom T/N 07SAZ-0010004, ackprobe et.

o o

ro

\

Gl

' 07HAZ-SG00500 DeploymentTool

SCSServiceConnector

SRS nf la to r imu atorSRSSimula tor eadCBackprobe dapter , 7mm

SRSSimula tor eadE

SRSSimula tor eadF

8t oTPM-oo101oo

€ oTsM-TB4o114O oTTM-sz5o114o- ' 07TM-0010204@ o7xAz-s140200-1

07xAz-s230100SRSSimula tor eadH

23-2

L



SeatBelts


CHILDSEATTETHERANCHORSRemoval/ lnstallat ion,page23-11

REAR ENTER ELT ndREARSEATBELTBUCKLESstep1onpage 3- 8

Inspection,ag e 3 9

SHOULDERANCHOR DJUSTERstep onpage 3- 4

FRONT EATBELTReplacement,ag e 3- 4Inspection,ag e 39

REAR EATBELTBeplacement,ag e 3. 7Inspection,ag e 3- 9

FRONT EATBELT UCKLESstep onpage 3' 6

23



Belts

FrontSeatBelt Replacement

SRScomDonents re ocated n this area.Review he

SRScomponent ocations se epage23-13) nd heprecautions nd procedures se epage23-14) n the SRS

sectionbeforeperforming epairsor service,

NOTE:Check he front seatbelts or damage,an d

replace he m if necessary. e carefulnot o damage

them during removalan d nstallation.

FrontSeatBelt

Makesureyou have he anti-theft ode or the radio,


buttons.

Disconnecthe negative able rom the battery, nd

wait at least3 minutesbeforebeginningwork.

Slide he front seat orward ully.

Remove he lower anchorca p (A),and remove he

lower anchorbolt (B).

3.

1 .

5 . Removehe rear ide r im pane l seepage20-51) .

B

7/16-20 NF32N m (3.3 gf.m,24lbt.ft)

7. Disconnecthe seatbelt ensioner onnector A) .

Remove he retractormountingself-tapping T

screw B),and he retractor olt (C), hen remove

the front seatbelt (D)and retractor E) .

6 x 1 . 0 m m3. 4N m {0.35 gf.m,2.5bf.ft)

6. Remove he upperanchorcover A),and remove

the upper nchor o l t B) .

7/16-20 NF32N. m 3. 3 gf m,2ir bf.ft)

8. lf necessary,emove he(F) .

front seatbelt protecto



9.

1 0 .

Removehe B-pillar pper rim{see age 0-50)

Removeheshoulder nchor djuster{A).

22N. m 2. 2 gf.m, 6lbf.ft l

Installtheseatbelt n the reverse rder of removal,

and note hese tems:

. lf thethreadson the retractormountingself-

tappingETscrewar eworn out, use an oversized

self-tapping Tscrew P/N90133-SZ4-0030)

made specificallyor this application.. Check hat he retractor ockingmechanism

functions se epage23-9).

. Assemblehewashers , o l la rs , nd bush ing nthe upperand ower anchorboltsas shown.

. lf th e seatbelt ensionerhas beendeployed

replace he front seatbeltprotectorwith a ne w

one.. App ly iqu id hread ock o the anchor o l t s

before einstallation.. Before nstall ing he anchorbolts,makesure

therear e no twists or kinks n the front seatbelt.. Makesure he seatbelt ensioner onnector s

plugged n properly.. Reconnecthe negative able o the battery.. Enter he anti-theft ode or the radio, hen enter


. Reset he clock.

. Do he ECM/PCMdle earnprocedure seepage

1 1 , 1 3 9 ) .

1 1 .

8 x 1.25mm

UPPER NCHORBOLT

BUSHING

Upper nchor oltconstruction:

UPPER NCHOR

Lower anchor bolt construction:

COLLAR

TOOTHEDLOCKWASHER

LOWERANCHORBOLT TOOTHEDOCKWASH

{con

WASHER

2



Belts

FrontSeatBeltReplacementcont'd)

SeatBeltBuckle

1. Makesureyou have he anti-theft od e or the radio,

then write down th e frequenciesor th e presetbuttons.

2. Disconnecthe negative able rom the batteryan dwait at east3 minutesbeforebeginningwork.

3. Remove he front seat se epage20-7'1).

4. Detach he seatbelt switchconnector l ip (A),seatbelt buckle ensioner onnector li p (B),an dharness l ip C) .

5. Remove he centeranchorbolt(A),

and remove heseatbelt buckle B).

7/16-20 NF32N m {3.3 gf m,24lbf.ft)

6. Pullthe seatbeltswitch/tensioner arness C)outthrough he holeon the seat rack.

. .. .a--

7. Installthebuckle n the reverse rder of removal,and note hese tems:

. Assemble he washerson the centeranchorboltas shown.

. Apply l iquid hread ock o the centeranchorboltbefore einstallation.

. lf the seatbelt ensionerha sbeendeployed,replace he front seatbelt protectorwith a newone.

. Apply l iquid hread ock o the seatmountingboltsbefore einstallation

. Reconnecthe negative able o the battery.

. Enter he anti-theft ode or th e radio, hen enterth e customer's adiostationpresets.

. Reset he clock.

. Do he ECMiPCMdl e earnprocedure seepage11 _ 1 3 9 ) .

COLLAR



RearSeatBelt Replacement

NOTE:Check he rearseatbelts or damage,an d

replace hem if necessary. e carefulnot to damage

themdur ing emova l nd ns ta l la t ion .

RearSeatBelt

1. Removehe rear ea t ush ion see age20 80) .

2. Remove he lower anchorbolt {A}.

l . \ J ,

Removehe rear ide r im pane l see age20-51) .

Remove he retractormountingself-tappingET

screw A) ,an d he retractor olt (B), he n remove

the rearseatbelt (C )an d retractor D) .

B

7/16-20 NF

3 ,

4.

A6 x 1 . 0 m m3.4 N. m {0.35 gl m,2.5 bf. f t l

A7/16-20UN F32 N.m (3.3 gf.m,24 tbf.ftl

N m {3.3 gf.m,2ir bf. f t)

5. Installtheseat belt n the reverseorder of remova

and note hese tems:

. lf the threadson the retractormountingself-tappingETscreware worn out, usean oversize

self-tapping Tscrew P/N90133-524-0030)

madespec i f i ca l l yor hisapp l i ca t ion .. Apply liquid hread ock o the anchorbolt befor

re ins ta l la t ion .' Check hat he retractor ockingmechanism

functions seepage23-9).. Before nstall ing he anchorbolt,makesure her

ar e no twists or kinks n th e rear seatbelt.

(cont

23



Belts

RearSeat Belt Replacementcont'd)

CenterBelt and Seat Belt Buckles

1. Remove he seatcushion se epage20-80).

2. Remove he centeranchorbolts A),and removeth e seat belt buckles B)and centerbe h (C).

A7/16-20 NF32N. m13.3gf.m,24 bt.ft)

'.;r-1-..i, ,

<i..'"

-"':''"' :

3. Remove he rightseat-back se epage20-80).

4. Remove he seat-back over (seepage20-82).

5, Remove he seat-back ad ro m the seat-backframe (seestep3 on page20-81).

6. Remove he screw,and release he hooksA),

he nremove he retractor o ver (B).

Fastener ocation B

t .

7. Remove he seat beltguide(A ) rom th e pi n (B),

an d releasehe centerbelt (C ) ro m the seatbeltgu de.

Remove he retractormountingbolt (A),and heretractor olt (B), hen remove he centerbelt (C )

and retractor D) rom the seat-backrame (E).

A6 x 1 . 0 m m9. 8N. m (1.0 gf m,7.2 tbl.ttl

7/16-20 NF32N. m 3. 3 gf m,24 bf.ftl

.:.',



9. lnstalltheseatbeltand buckles n the reverse rder

of removal,an d note hese tems:

. Check hat he retractor ockingmechanismfunctions se estep 1 on page23-10).

. Assemble he washerson the centeranchorbolt

as shown(except entershoulderbelt).. Apply liquid hread ock o the anchorbolts

before einstallation.. Before nstall ing he centeranchorbolt, make

sure hereare no twlsts or kinks n th e centerbelt,

Canler anchor bolt construction:

WASHER

Inspec'tion

For rontseatbelt etractors ith seat elt ensionersreviewthe RS omponentocationssee ag e 3-13and heprecautionsndproceduressee sge23-14)

the SRS ection efore erformingepairs r service

Retractor,Front andRear

1. Before nstall ing he retractor, he ck hat he seat

beltcan be pulledou t freely.

2. l\4ake ure hat he seatbeltdoes not ockwhen th

retractor A) s eanedslowly up to 15'from the

mountedposition.The seatbeltshould ockwhen

the retractor s eanedover 40'. Do not attemDt o

disassemblehe retractor.

Front:

Rear:

Forward

Forward

lnside

Inside

Replacehe seat beltwith a new assembly f there

is any abnormality.Do not disassemble ny pa n o

th e seatbelt or any reason,

(cont

23



Belts

Inspection cont'd)

RetraEtor,RearCenter

1. Before nstall ing he retractor, heck hat the seat

beltcan be pulledout freely.

2, Makesure hat he seatbelt does not ockwhen the

retractor A) s leanedslowly up to 15' from th e

mountedposition.

lnside Forward

3,

4.

Lean he retractor ver 40', and makesure hat he

seat beltdoes not ockwhen pulledout over 900

mm (35.4 n.).Do not aftempt o disassembleheretractor.

Replacehe seatbeltwith a new assembly f there

is any abnormality.Do no t disassemble ny partofthe seatbelt or any reason.

\ ,

In-vehicle

1. Check hat he seatbelt s not twistedor caughton

anything.

2. After nstall ing he anchors. heck or freemovementon the anchorbolts. f necessary,

remove he anchorboltsand check hat he

washersand otherpartsar e no t damagedorimproper lynsta l led .

3. Check he seatbelts or damageor discoloration.

Cleanwith a shop owel if necessary. seonlysoapand water o clean.

NOTE:Dirt build-up n the loopsof the upperanchors an cause he seatbelts o retract lowly.Wipe th e nsideof the oopswith a cleancloth

dampenedn sopropy l l coho l .

Check hat he seatbelt doesnot ockwhen pulled

out slowly.The seatbelt s designed o lockonly

during a suddenstop or impac t.

For rearcentershoulderbelt,check hat he seat

be l t ockswhenpu l led utover400mm (15.7n. )with the seat-backoldeddown.

Makesure hat he seatbeltwil l retract

automaticallywhen released.

Fo reachpassenger's ea tbelt,check he seatbeltretractor ockingmechanismALR (automatic

locking etractor). his unction s or securing hild

seats.

-1 Pu l l the ea tbe l ta l l t heway out to engage he

ALR.The seatbelt should etractwith a

ratcheting ound,bu t no t extend.This s

normal .

-2 To disengage he ALR, elease he seatbelt and

a l low t to fu l l y e t rac t ,henpu l l theseatbe l tou t part-way. he seatbelt should etractand

extendnormally.

Replace he seatbeltwith a new assembly f there

is any abnormality.Do not disassemble n y partofthe seatbelt or any reason.

7 .

8 .



ChildSeatTetherAnchorRemovaUlnstallation

Middle

1. Remove he child seat etheranchorcover (A ) n

the rear r im pane l B) .

8 x 1.25mm22 N m {2.2 sf.m, 16lbf. f t)

,tltl

v\2 .

3.

Removeheanchor o l t C) , hen emove hech i ld

seat etheranchor D) .Do not remove he toothed

washer E) rom the etheranchor.

Ins ta l l t he nchor n he reverse rdero f remova l .

J

23-

Side

1. Remove he rearbulkhead overs rom both sides

(see age 0-51) .

2. Remove he anchorbolt (A), he n remove he child

seat etheranchor B) rom behind he seat-back

eachsideofthe cargocompartment.Do not

remove he toothedwasher C) rom the tether

anchor .

A I 1

8 x 1 .25mm22 N.m {2.2 gt m. 16lbff t)

l ns ta l l t he nchorsn he reverse rdero f remova

f-..- t". i . . ] . -



Rs

Precautions nd Procedures

General recautions

Please ea d he following precautions arefullybefore

performingairbagsystemservice.Observe heinstructions escribed n this manual.or the airbagscould accidentally eployand causedamageor injuries.

. Exceptwhen performingelectrical nspections.always urn the ignit ionswitchOFF,disconnect henegative able rom the battery, nd wait at least3minutesbeforebeginningwork.NOTE:Th e memory s not erasedeven f the gnitionswitch s turnedOF For the batterycablesar edisconnectedro m the battery.

. Use replacement an swhich are manufacturedo thesamestandards nd qualityas he originalparts.Donot nstallusedSRSparts rom anothervehicle.Us eonly new pans when makingSRS epairs.

. Carefully nspectany SRSpartbeforeyo u install t.Do not nstallan y part hat showssignsof beingdroppedor improperlyhandled, uch as dents,cracks,or deformation.

. Before emovingany SRSparts including hedisconnection f connectors), lwaysdisconnect heSRSconnector.

. Us eonly a digitalmultimeter o check he system. f itis not a Hondamultimeter,makesure ts outout s 10mA (0.01A) r lesswhen switched o the lowestvaluein the ohmmeter ange.A testerwith a higheroutputcouldcauseaccidental eploymentan d possible

injury.. Do not pu t objectson the front passenger's irbag.. Th e original adio has a coded heft protection ircuit.

Be sure o ge t he customer's adiocodeand writedown the frequenciesor the radio'spresetstationsbeforedisconnectinghe battery able.

. Before eturning he vehicle o the customer,enterthe radiocode. hen enter he customer's adiostationpresets, nd set he clock.Do he enginecontrolmodule(ECM) dl e earnprocedure seepage1 1 - 1 3 9 ) .

\ r

Steering-relatedlecautions

CableReelAlignment

. M isa l ignmentf thecab le ee l ou ld ause n open nthewi r ing ,mak ing heSRS ystem nd he hornsinoperative. enter he cable eelwhenever hefollowing s performed se estep 6 on page23-121).

- Installation f the steeringwheel- Installation f the cable eel- Ins ta l la t ionf the s teer ing o lumn- Othersteering-relateddjustment r installation

. Do not disassemblehe cable eel.

. Do not applygrease o the cable eel.

. lf the cable eel showsany signsof damageorcontamination. eplace t with a new one. Forexample, t does not rotatesmoothly.



AirbagHandling ndStorage

Do not disassemble n airbag, t has no serviceable

parts.Oncean airbaghas beendeployed, t cannotberepairedor reused.

For emporarystorageof an airbagduring service,

observe he followingprecautions.

. Store he removedairbagwith the pa dsurfaceup .

Neverpu t anythingon the airbag.

To preventdamage o the airbag,keep t free rom

any oil, grease, etergent, r water,

23-

. Store heremoved irbag n a secure,la tsurfaceaway romanyhighheat ourceexceeding00'Fi

Neverperformelectricalnspectionso the airbags,

such as measuring esistance.

Do no t posit ionyourself n front of the airbagduring

removal, nspection, r replacement.

Refer o the scrappingproceduresor disposalof a

damaged i rbag.

(cont



sRs

Precautions nd Procedurescont'dl

SRSUnit,Front mpactSensors, ndSidelmpactSensors

. Becarefulnot o bump or impact he SRSunit, rontimpactsensors, r side mpactsensorswhenever heignit ionswitch s ON (ll),or for at least3 minulesafterth e gnitionswitch s urned OFF.

. During nstallation rreplacement,be carefulnottobump (b y mpactwrench,hammer,etc.) he areaaround he SRSunit, ront impactsensors, nd sjdeimpactsensor.The airbagscould accidentally eployand causedamageor injury.

Aftera coll ision n whic h anyairbagsor seatbelttensionerswere deployed. eplac e he SRSunit, rontimpactsensors, nd other relatedcomponents se epage23-112). fter a coll ision n which a side airbagwa s deployed. eplace he side mpactsensoron the

deployedsideand he SRSunit.Aftera coll ision nwhich he airbagsor the side airbagsdid not deploy,inspect or any damageor any deformationon theSR Sunit, ront impactsensors, nd he side mpactsensors .f here s any damage, ep laceheSRSuni tand/or he sensors.

23-16

. Do not disassemblehe SRSunit, ront mpactsensors,or side mpactsensors.

. Turn he gnitionswitchOFF,disconnect he batterynegative able,and wait at least3 minulesbeforebeginning nstallation r replacement f the SBS unit,or disconnectinghe connectors rom the SRSunit.

. Be sure he SRSunit, ront impactsensors, nd sideimpactsensorsare nstalled ecurely.with th emountingbolts orqued o 9.8 N.m(1.0kgf.m,7.2 bf.ft)

. Do not spil l wateroroil on the SRSunit, ront impactsensors, r the side mpactsensors, nd keep hemaway rom dust.

. Store he SRSunit, ront imDact ensorsand sideimpactsensors n a cool (less ha n 104"F/40'C) nddr y (less han 80% relativehumidity,no moisture)area.



J

WiringPrecautions

Some of the SR Swiring can be dentif iedby a special

yellow outercovering,and he SRSconnectors an beidentif ied y their yellow color.

Observe he instructions escribed n this section.

. Neverattempt o modify. splice,or repairSRSwiring.

l f here s an openor damage n SRSwi r ing , ep lace

th e harness.

Be sure o install he harnesswires so they do not ge t

Dinched r interferewith otherDarts.

Make urea l lSRSground ocat ions rec lean, nd

groundsare securely astened or optimum metal-to-metalcontact.Poorgroundingcan cause ntermittentproblems hat arediff icult o diagnose.

Precautionsor Electricalnspections

. When using electricaltest quipment, nsertthe

probeof the tester nto he wire sideof the connectDo not insert he probeof the tester nt o he termina

side of the connector, nd do not amperwith th e

connector.

Us ea U-shaped robe.Do not nsert he probe

forcibly.

Use specified ervice onnectors n tr oubleshootin

Us ing mproper oo ls ou d cause ner ror n

inspection ue o poor metal-to-metal ontact.

(con

23



Rs


Spring-loadedockConnector

Some SRSsystemconnectors avea spring-loaded

lock.

Front Airbag Connectors:

Disconnecting

To release he lock.pullthe spring-loaded leeve A)

toward he stop (B )while holding he oppositehalfofthe connector. henpullthe connectorhalvesapart,Besure o pull on the sleeveand not on he connector.

Connecting1. To reconnect, old he pawl-side onnector, nd

presson the backof the sleeve-side onnector nthe directionshown.As the two connectorhalvesar e pressed ogether, he sleeve A) s pushedbackby the pawl (C).Do not ouch he sleeve.

When he connectorhalvesare completelVconnected,he pawl s released, nd he spring-

loadedsleeve ocks he connector.

\

SideAirbagConnector:

Disconnecting

To re leasehe ock, u l l t hespr ing- loadedleeve A)and he s l ider B)wh i leho ld ing heoppos i te a l fo f heconnector. henpullthe connectorhalvesapart.Besure o pull on the sleeveand not on the connectorhalf.

Connecting

Hold bothconnectorhalves, nd press hem firmly

togetheruntil he projection C)of the sleevesideconnector licks.



Backprobing pring-loadedockConnectors

When checking oltageor resistance n this type of

connector he first ime,you must remove he retainerto insert he esterorobe ro m the wire side.

NOTE: t is not necessaryo reinstall he removed

retainer;the erminalswill stay ocked n the connector

housrno.

A

To remove he retainer A) , nserta flat-t ipscrewdriver(B )between he connectorbody and he retainer, he ncarefullypr y out the retainer. akecarenot o break he

connector.

Seatswith SideAirbags

Seatswith sideairbagshavea"SIDEAIRBAG" abelo

the seat-back. ecausehe componentpans (seat-bacover,cushion,etc.)of seatswith andwithout airbagsare different,makesureyo u installonly the correctreplacement arts.

Whenc lean ing , o no tsa tura te the eatwi th iqu id ,

and do not sDrav teamon the seal

Do not reoalra torn or fravedseat-back over.

ReDlacehe seat-back over.

Af te ra co l l i s ionn wh ich he s idea i rbagwas

deployed, eplace he side airbagwith new parts. f

th e seat-back ushion s split, t must be replaced.f

th e seat-backrame s deformed, t must be replace

Neverpu t aftermarket ccessories n the seat covepads,seatheaters, ights,etc.).

(cont

23-



sRs


DisconnectingSystemConnectors

Before emovinga front airbag.sideairbag,or otherSRS elateddevices th eSRS unit, he cable eel, he front impact

sensors, he side mpactsensors, he seatbelt buckle ensioners, nd he seatbelt ensioner onnector), isconnectingconnectors rom relateddevices, r removing he dashboard r the steering olumn,disconnecthe airbagconnectorsor the sideairbagconnectors o preventaccidental eploVment.Turn he ignitionswitchOFF,disconnecthe negative able rom the battery,and wait at east3 minutesbeforebeginning he followingprocedures.'Befored isconnect ingSRSuni t connectorA(1) f romtheSRSuni t ,d isconnect thedr iver ' sa i rbag4Pconnector (3) .

th e front passenger's irbag4Pconnector 4) , he driver'sseatbelt ensioner2Pconnector 6),and he frontpassenger's ea tbelt ensioner2P connector 7) .

. Beforedisconnecting RSunit connectorB (8) ro m the SRSunit,disconnect oth side airbag2Pconnectors 11 . 12),

and both seat belt buckle ensioner4P connectors 9, 10).. Beforedisconnectinghe cable eel4P connector 2),disconnect he driver'sairbag4Pconnector 3) .'Be fored isconnect ing the f loorwi reharness4Pconnector (5) ,d isconnectbothseatbe l t tens ioner2Pconnectors

( 6 . 7 ) .

\ .



1. Disconnecthe batterynegative able,an dwait atleast3 minutes.

Driver's Airbag

2. Remove he access anel A) ro m the steeringwheel, h en disconnecl he driver'sairbag4Pconnector B)from the cable eer.

Front Passenger'sAirbag

3. Disconnecthe front passenger's irbag4Pconnector A)from dashboardwire harnessB.

Side Airbag

4. Disconnect oth side airbag2Pconnectors Alfrom

the floor wire harness.

(cont'

23-



sRs

Precautions nd Procedurescont'd)

SeatBeltTensioner

5. Disconnectot hseatbelt ensioner Pconnectors(A )

rom he loorwireharness

Seat Belt BuckleTensioner

6. Disconnect oth seatbelt buckle ensioner4P

connectors A) .

23-22

\

SRS Unit

7. Disconnect RSunit connectorA, SRSunit

connectorB, and/orSRS unit connectorC rom th e

SRSuni t .




DTC Diagnostic roubleCodesl

Th eself-diagnosticunctionof the SRSsystemallows tto locate he causes f systemproblemsand hen storethis information n memory.For easier roubleshooting,this datacan be retrieved ia a data inkcircuit.

. Whenyou urn he gn i t ion w i t chON ( l l ) , he SRSindicatorwill come on. f it goesof f after6 seconds,th e system s normal.

. lf there s an abnormality, he svstem ocates nddefines he problem,stores his nformation nmemory, and urns he SRS ndicatoron. Thedatawi l l remain n he memoryevenwhen he gn i t ionswitch s urnedoff or if the battery s disconnected.

. Whenyo u connect he HondaPG MTester o the 16Pdata inkconnectorDLC) to hor t heSCS ermina l ,

and urn he gn i t ion wi tchON ( l l ) . heSRS ndica torwill indicate he diagnostic roublecode (DTC) y thenumber f b l inks .

. When yo u connect he HondaPGM Tester o the 16Pdata in k Connector DLC), ou can retrieve he DTC ntheHondaSystems SRS"menu.

. After readingand recording he DTC,proceedwiththe roubleshooting rocedure or th s code.

Precautions. Useon lya d ig i ta lmu l t imetero check hesystem.f

it 's not a Hondamultimeter,makesure ts output s10mA (0.01A) r esswhenswi tchedo the smal les tva lue n heohmmeter ange, tes terw i th a h igher

output ou lddamage hea i rbag i rcu i t r causeacc identa li rbag ep loyment ndposs ib len ju ry .

. Whenever he gnitionswitch s ON (ll),or ha s beenturned OFF or less han 3 minutes,be carefulnot obump heSRSuniU hea i rbags ou ldacc identa l l ydep loy ndcause amage r n ju r ies .

. Before ou remove he SRSharness, isconnect hedriver'sairbagconnector. he front passenger's

airbagconnector, oth side airbagconnectors, othseatbelt buckle ensioner onnectors, nd both seatbe l t ens ioner onnectors .

. Makesure he battery s sufficiently harged. f thebattery s deador low, measuring alueswon't becorrect.

. Do not ouch a testerprobe o the terminals n th eSRSunit or harness onnectors, nd do not connectthe ermina ls i t h a umperwi re .Useon ly hebackprobe et and he HondaPGMTester.Backprobespring oaded ock ype connectors orrectly.

Readinghe DTC

When he SRS ndicator s on , read he DTCusingeith

of the following methods:

PGM Tester "SRS" Menu Method:Connect he HondaPG MTester A) o the 16Pdata inconnector DLC)(B), nd ollow the Tester'sDromptsthe

"SRS"menu.

lf the Tester ndicates o DTC,no communication.DT3-6 o 3-'10, TC4- 6 o 4-10,DTC9-1,or DTC9-2,double-check y using he "SCS" menu method.

(cont

23-



Rs

GeneralTroubleshootingnformation cont'd)

PGM Tester "SCS" Menu Method {retrieving the flash

codes):

The SRS ndicator A) ndicates he DTCby he number

of blinkswhen the HondaPGMTester B) s connectedto the DLC data in kconnector) 16P) 1) .

'1 .Makesure he onitionswitch s OFF.

2. Connect he HondaPGN4 ester B) o the DLC C) ,

and ollow the Tester'soromDts n the "SCS" menu

to ground he SCS in e (see he HondaPGMTester

ODerator'sManual).

Makesure he SCS ine s grounded, he n ur n th eignit ionswitch ON (ll).Th e SR S ndicator omes on

for about6 seconds, nd hen goesoff. Then t wil l

blink o indicate he DTC se e he table below).

Read he DTC.

Turn he ignit ionswitchOFF,and wait for 10

seconds.

3.

4.

5.

6, Disconnecthe HondaPG MTester rom the DLC.

7. Do he troubleshooting rocedure or the DTC.

Patteins of DTC ndications:

The DTCconsistsof a main code and subcode.

S: Second

2 5 3 5S

o N[ l t l | [

o F F l I l - - - - - - L l - - - l I

First emitting Main code Subcode

23-24

\

Reading he main code:

I ncase f 1 - 10Count henumber f blinks.

Examplo:1 . 2 r . 2S 1 . 2 1 . 2 1 . 2

*t**t*l*l

""_f]_flflMaincodo= 1 + 1 + 1 =3

In case t 11.. '15Four astblinks ount s 10.Ad dany unherblinksogether sshown.

Example:

0 . 1

,A/// t\\\

/ / l i i \ \ 1 . rs r .2s r .2s 1.2s_ | * t * - L' - - * l

Main code= 10 I

ln caseof 20 or more

Tw o setsof four fast b l inkscount as 20.Ad d any unher b l inks ogetheras shown.

Examplo:

0 . 1 0 . 1 s

,y'fl\,,. /[N 12s 2s

= 1 2

L

""ffi

*FtftffN*+fH-t-ff l-

Main code= 10 + 10

Reading he subcode:

Counthenumber fblinks.

Example:

0.3 0.3 0.3 0.3 0.3 0.3 0.3

l**t**t*t*t*l

""ffiS u b c o d e = 1 + 1 + 1 r ' 1 = 4

lf the main code s3' ,

and he subcode s 4' , recorda

DTC 3 4.



Including he most recentproblem,up to three differentDTCS an be ndicated se eexample1 below).ln caseof a continuous ailure, he DTCwill be indicated epeatedly se eexample1 below).In caseof an ntermittent ailure, he SRS nd icatorwill indicate he DTCS ne ime, hen t wil l stayon (seeexampl2 below).lf both a continuousand an ntermittent ailureoccur,both DTCS il l be ndicated s continuous ailures.When he system s normal(n o DTCS),he SRS ndicatorwill stayon (seeexample3) .lf the SRS ndicator omeson continuouslywithout a DTC, heremav be a problemwith the svstem.lf the SR S ndicatordoes notcome on as indicated bove,alwayscheck or an open or a short o ground n the SC Scircuitbefore roubleshootinghe system.

Exampleof DTC ndications:

1.Continuousailure,SRS ndic6tor link$ ike his:

1 .2S 1, 2SS: Second

0.3s 0.3s

ON

OF F

Bulb checkperiod

Main ode 21 Subcode1)

DTC -lMost recentp.oblem

2. Intermittent failure, SRS ndicator blinks like this:ON

Main code 1l Subcode 3) Main code 11 Subcode 'l ) Indicationsare lepeatedtn cese otcontinuousfailure.

lndicator stays on incase of i nterm ttent failu re.

(cont

DTC1-3 DT C1- 1Sscond-mostrecent Third-mostrocentproblem problem

OF F

Bulbcheckperiod DTC5-1

3. Normal no ailure|,SRS ndicator l inks ike his:ON

OFFBulb chockperiod

No DTC,systom is normal, the indicatorstays on.

0. 3

23-



sRs


Erasinghe DTGMemory

Specisl Tool Required

SCSservice onnector07PAz-0010100

To erase he DTC(S)fromhe SRSunit,us ea Honda

PGMTester se e he HondaPGfM esterSRSVehicle

SystemSupplement) r the followingprocedure.

1. Makesure he gnitionswitch s OFF.

2. Connect he SCSservice onnector A) o the MES

2Pconnector B).Do not use a umper wire.

07PAZ-0010100


4. The SRS ndicatorwill come on fo r about6 seconds,and hen go off. Remove he SCSservice onnectorfrom th e ME Sconnectorwithin 4 seconds fter he

indicatorgoesoff.

5. The SRS ndicatorwill come on again.Reconnect

the SCSservice onnector o the MESconnector

within 4 seconds fter he ndicator omeson .

6. When he SRS ndicatorgoesoff, remove he SCS

service onnector rom the MESconnectorwithin 4

seconds.

7 . TheSRS ndica tor i l l b l l nk wo imes nd ica t ing

that he memory has beenerased.

8. Turn he gnitionswitch OFF,and wait fo r'1 0

seconds.

9 . Turn he gn i t ion w i t chON ( l l )aga in . heSRS s

OK f the SRS ndicator omeson fo r 6 seconds nd

thengoesoff.

23-26

\

Troubleshooting ntermittent Failures

l f therewas a malfunction, ut t doesn't ecur. t wil l be

stored n the memory as an ntermittent ailure,and he

SR S ndicatorwill come on.

After checking he DTC, roubleshoot s ollows:

1. Read he DTC se e Readingthe DTC").

2. Erase he DT Cmemory (see Erasingth e DT C

Memory").

3. With the shift ever n neutral, tart he engine,an d

le t t d le .

Th e SRS ndicatorwill come on for about6 seconds

and hen go off.

Shake he wire harnessand he connectors.ak ea

test drive(quickacceleration, uickbraking,

cornering),urn the steeringwheel ully left and

right,and hold t there or 5 to'1 0

seconds. f theproblemrecurs, he SRS ndicatorwill come on.

lf you can't duplicate he ntermittent ailure, he

system s OK at this ime.

4 .



Initializinghe OPDS Occupant ositionDetection ystem}Unit

Special Tool RequiredSCSservice onnector 7PAz-00'1100

Whena seat-back over,seat-back ushion,and/orOPDSunit s replaced, nit ializehe OPDSby following heprocedurebelow.NOTE:Makesure he front passenger's eat s dry. Set he seat-backn the normal posit ion, nd makesure here snothingon the seat.

'1 .l\4ake ure he gnitionswitch s OFF.

2. Connect he HondaPGMTester A) o the DLC 16P) B),andfollowtheTester's prompts n th e ,,SCS,,menu oground he SCS in e(see he HondaPGMTesterOperator'sManuaD.

3. Connect he SCSservice onnector C) o the MES2Pconnector D) .Do not use a iumoerwire.

c07PAZ-00r0100

4. Turn he gn i t ion wi tchON { l l ) .5. The SRS ndic ator omeson for about6 seconds ndgoesoff. Remove he SCSservice onnector rom the MES

connectorwithin 4 seconds fter he SR S ndicatorwent off.6. The SRS ndicator omes on again.Reconnecthe SCSservice onnector o the MESconnectorwithin 4 seconds

after he SR S ndicator omeson .7. The SRS ndicatorgoesoff. Remove he SCSservice onnector rom the MESconnectorwithln 4 seconds.8. Watch he sRS ndicator.

' l f t h e i n d i c a t o r b l i n k s t w o t i m e s a n d t h e n s t a y s o n , t h e O P D S i s i n i t i a l i z e d . b u t t h e D T C S n e e d t o b e e

step9, hen erase he DTCS.. l f t h e i n d i c a t o r b l i n k s t w o t i m e s a n d t h e n g o e s o f f , t h e O P D S u n i t i s i n i t i a l i z e d . G o t o s t e p 9 .

' lf th e indicator tayson without irst blinking.theOPDS s not init ialized. eadtheDTC. f DTC15-'l s ndicatedrepeat he init ialization rocedure. f anotherDTC s indicated, o to the appropriate age n the DTCTroubleshootingndex.

9. Turn he ignit ionswitchoff, and disconnect he PGMTester.

SBS indic.ror

ME S

J DISCONNECTED

23-2



J

r

DTC Detection ltem Notes9-1 Internal ailureof the SRSunit. f intermittent, t could mean nternal

failureof the unit or a faulty ndicator ircuit.Refer oTroubleshootingntermittent ailures se epage23-26).NOTE:Before roubleshootingDT C9-1 or 9-2,checkbattery/systemvoltage. f the voltage s ow, repair he chargingsystembeforet roub leshoot inghe SRS.

(seepage23-69)

9-2 Internal ailureof the SRSunit. f intermittent,t couldmean nternalfailu e of the powersupply(VB ine).Refer o TroubleshootingIntermittent ailures seepage23-26).NOTE:Before roubleshootingDT C9- 1or 9-2,checkbattery/systemvoltage. f the voltage s ow, repair he chargingsystemor replacethe b€tterybefore roubleshootinghe SRS.

9-3 Faultydriver'sseatbelt buckleswitch (seeDaqe23-71)9-49-6

FaultLtglt passenger'sea tbeltbuckle witchFaulty eft ront imDact ensor

lgqgfage 23-74)

{seeDaqe23-77)9-7 Faulty ight ront impactsensor (seepaqe23-79)

1 0 - 1 Seatbelt and seatbelt buckle ensioners an dairbag(s)) eployedDr iver ' s idea i rbag ep loyed

Seatbelt and seatbelt buckle ensione rs an dairbag(s)) nd driver'ss idea i rbag ep loyedFrontpassenqer's id eairbaodeDloved

(see ag e 3-69)10-2r0-3

'10-4

'10-5Seatbeltand seatbelt buckle ensioners an dairbag(s)) nd rontpassenqer's id eairbaqdeDloved

10-6 Driver'sand ront passenqer's id eal10-7 Seatbelt and seatbelt buckle ensioners an dairbag(s)) nd driver's

and ront passenger's id e airbagsdeployed11-1 Openor increased esistancen driver'ssideairbao nflator (see aqe23-81)

Short o anotherwire or decreased esistancen driver'sside airbaoinflator

(see age 3-82)

11-4 Short o power n driver'sside airbaq nflator (seeoaqe23-83)I t - 5 Short o ground n driver'ssideairbaq nflator {seepaqe23-85)

Open or increa sed esistancen front passenger's ide airbaginflator

(seepage23-86)

Short o anotherwire or decreased esistancen front passenger'ssideairbag nflator

(seepage23-87)

12-4 Short o power n front passenqer's ide airbaq nflator {seeDaqe J-uu}I z -5 Shor t o ground n ron tpassenger ' sidea i rbaq n f la to r (seeoaqe23-90)13-1 Internal ailureof the driver'sside mpactsensor (seepage23-70)

No s igna l rom he dr i ver ' s ide mpact ensor (see aqe23-91)13-414-1- 7 i i ,

Faultypowersupply o thedf,rglllug t Opact 9I99LInternalailure fthe rontpassenger'side mpact ensor

(see age 3-92)(see age 3-70)

14-3 No s igna l rom he rontpassenger ' side mpact ensor (seepaqe23-94)14-4 Faultypowersupply o the front passenqer's ide mpactsensor (seepage23-95)15-1 Fau l t vOPDS n i to r OPDS o t n i t i a l i zed (see aqe23-96115-2 Faultysideairbagcutoff ndicator ircuit (seeDaqe23-99)15-3 FaultyOPDS ensor (seeoaoe23-104)

J

23-2



SRS

Symptom Diagnostic rocedure Also check for

SR S ndicatordoesn'tcome on SRS ndica tor roub leshoot ingsee

paoe23-105)

SR S ndicator tayson when in"SCS" menu method SRS ndicatorTroubleshootingse e

step 1 on page23-107)

Inabil ity o retrieveDTCswith the

PGMTester.Retrieve he flash

codesusing he SCSmenu method(seepage23-24).

Slde airbagcutoff ndicator tays

on a f te rbu lbcheck l f the

indicator tayson , t does not set

a DTC).Sideairbagcutoff

indicator s f lashing

. Make urenoth ings on he ron l

passenger's eat.. lf the side airbagcutoff ndicator

stayson after he ignit ionswitch

is urnedON ( l l ) , n i t i a l i zehe

OPDSunit (seepage23-271.- lf the sideairbagcutoff

ind ica tor pera tes ormal lY,he

system s OK.- lf th e sideairbagcutoff

indicator tayson , replace heuFU5 SenSOrSee eCrOnUl .

The sensor s partof the seat-

backDad.

DTC15-2 roubleshooting

SymptomTroubleshootingndex \

t r

23-30

\



SystemDescription

SRSComponents

AirbagsThe SRS s a safetydevicewhich, when usedwith the seatbelt, s designed o help protect he driver and frontpassengern a frontal mpactexceeding certainset imit. Thesystemconsistsofthe SRSunit, ncludingsafingsensorand mpactsensor A), he cable eel B), he driver'sairbag C) , he front passenger,s irbag D).seatbelttensioners l) ,seatbelt buckle ensioners J),and ront impactsensors K).Since he driver'sand ront passenger's irbagsus e he samesensors, oth normally nflateat he same tme.However, t is possible or only oneairbag o inflate.Thiscan occurwhen the severityof a coll ision s at the margin,othreshold, hat determineswhetheror not he airbagswill deploy. n such cases, he seatbelt wil l providesufficientprotection, nd he supplemental rotectionofferedby the airbagwould be mininal.

SideAirbagsThe sideairbags E)are n each ront seat-back. hey helpprotect he upper orso of the driveror front seatpassengeduring a moderate o severe ide mpact.Side mpactsensors F) n eachdoor sil l and n the SRSunit detectsuch animpactand nstantly nflate he driver'sor the passenger's id eairbag.Only one sideairbagwill deployduring a sideimpacl. f th e impact s on th e passenger's ide, he passenger's ide airbagwill deploy even f there s no passenger

Seat Belt and Seat Belt Buckle TensionersThe seatbelt and seatbelt buckle ensioners re inkedwith the SRSairbags o further ncrease he effectiveness fthe seatbelt. n a front-end oll ision, he tensioners nstantly etract he belt and buckle irmly to secure he occupantin their seats.

OPDSTh eside airbagsystemalso ncludesan occupantposit iondetection ystem OpDS). hi s systemconsistsof sensors(G)andan OPDS n i t H) n he ron tpassenger ' seat -back.heOPDS ni tsends ccupant e igh l ndpos i t ion ata othe SRSunit. f the OPDSunit determines hat he front passengers of small stature fo rexample,a child)and hefront passengers eaning nto he sideairbagdeploymentpath, he SRSunit wil l automatically isable he passengesideairbag.The SRSunit wil l alsodisable he airbagwhen the OPDSdetects ertainobiectson the seat.When hesideairbag s disabled,he sideairbagcutoff ndicatoron the instrumentpanelalerts he driver hat he passenger'ssideairbagwill not deploy n a side mpact.When he object s removed,or the passenger its upright, he side airbag

cutoff ndicatorwill go off aftera few seconds, lerting he driver hat th e passenger's ide airbagwill deploy n a sideimDact .

(cont '

23-3



sRs

SystemDescription cont'dl

SRSOperationThe main circuit n the SRSunit senses nd udges he force of impactand, f necessary.gnites he nflatorcharges. f

battery oltage s too low or power s disconnected ue to the impact, he voltage egulatorand he back-uppower

circuit,espectively, i l l keepvoltageat a constant evel.

For the SRS o operate:

Seat Belt Tensioners and Seat Belt Buckle Tensioners(1 )A front impactsensormust activate nd sendelectric ignals o the microprocessor.(2 )The microprocessormust compute he signalsan d send hem to the ensioners.(3 )Th echargesmust gnite and deploy he tensioners.

Driver's and Front Passenger'sAirbagls)(1 )A front impactsensormusl activate. nd send electric ignals o the microprocessor.

(2 )The microprocessormust compute he signals.and dependingon the severityof the coll isionand whether he seat

belt buckleswilch s ON or OFF, t sends he appropriate ignals o the airbag nflator(s).(3 )The nflators hat received ignalsmust gniteand deploy he airbags.

SideAirbaglsl( 1)A side mpactsensormust activate, nd sendelectric ignals o the microprocessor.(2 )The microprocessormust compute he signalsand send hem to the side airbag nflator(s). owever, he

microprocessor uts off the signals o the front passenger's ide airbag f the OPDSunit determineshat he tront

passenger's ea d s in th e deploymentpathof the sideairbag.(3)The nflator hat received he signalmust gniteand deploy he side airbag.

lw$ad..n sl

T 'sEctto

0mPgsfrlctR oXrVEr I9oEAiA$ SOtlr&G

f'**)r !

23-32

\



Self-diagnosisSystem

A self-diagnosis ircuit s built nto he SRSuniUwhen th e ignit ionswitch s turned ON (ll), he SRS ndicator omesoan dgoesoff afterabout6 seconds f the SR S s operatingnormally.lf the ndicatordoes not come on, or does not go off after

6 seconds. r if i l comes on while driving, t indicates nabnormality n the SRS.Th e SR Smust be nspected nd repairedas soon as possible.

Fo r betterserviceabil ity,he SRSunit memory storesa DT C hat relates o the causeof the malfunction, nd he unitconnected o the data ink circuit.This nformationcan be readwith the HondaPG MTesterwhen it is connected o thdata ink connector DLc) seepage23-23).

23-



SRS

CircuitDiagram

rrssfc ssrarsftrrrl$0[n

i _ _ _ ' : - - _ : " 1

r - - - - -T r - i

23-34

\



J

J

tr ozr"*

tr ul"ar

NJflt l

1i|-(tzl

J

23-



sRs

DTCTroubleshooting

DTC -1:Open n Driver 's i rbag nflatorDTC -2: ncreasedesistancen Driver 'sAirbag nflator

SpecialTools Required. SR S nflatorsimulator07SAZ-TB4011A. SR Ssimulator eadF 07XAZ-S230100

1. Erase he DTCmemory (seepage23-26).

2. Turn he ignit ionswitchON {ll),and check hat he

SRS ndicator omeson for aboul6 seconds nd

then goesoff.

Does the SBS indicator stay on?

YES-Go to step3.


Go o TroubleshootingntermittentFailures se e

page23-26).

3. Turn he ignit ionswitchOFF.Disconnecthe

batterynegative able,and wait fo r 3 minutes.

4. Disconnecthe driver'sairbag4Pconnector A)

from the cable eel.

07sAz-TB4011A

07xaz-s230100

5. Connect he SRS nflatorsimulator 2 Q

connectors) nd he simulator eadF o the cable

reet .

23-36

6. Reconnecthe batterynegative able.

7. Erase he DTCmemory.

8. Read he DTC,

ls DTC 1-1or DTC 1-2 ndicated?

YES-Go to step9.

NO Open or increased esistancen the driver's

airbag nflator; eplace he driver'sairbag se epage

2 3 - 1 1 3 ) . t

9. Turn he gnitionswitchOFF.Disconnecthe

batterynegative able,an dwait or 3 minutes.

10. Disconnecthe front passenger's irbag4Pconnector rom dashboardwire harnessB (seestep

3 on page23-21) .

11. Dis connect oth seatbelt ensioners P connectors

from the floor wire harness seestep5 on page23 -

22t.

12. D isconnectRSun i tconnector (18P) f romhe

SRSunit (seestep7 on page23-22).Do not

disconnecthe special ool from th e cable eel.



13. Check esistance etween he No. 7 and he No.16

term ina ls ndbetweenhe No.6 and heNo.15

term ina ls f SRSuni tconnector (18P) . here

shou ld e2 .0 3 .0 0 .

SRSUNITCONNECTORI18P)


ls the resistance as specilied?

YES-Faulty SRSunit or poorcontactat SRSunit

connectorA (18P) nd he SRSunit,check he

connection etween he connectorand he SRS

unit. f the connection s OK, replace he SR Sunit(see age23-122) .1

NO-Open or increased esistancen dashboard

wire harnessB orthe cable eel; eplace he cable

reel. f th e problemstil l present, eplace ashboard

wi re harness .

DTC1-3:Short o AnotherWire or DecreasResistancen Driver 's i rbag nf lator

SpecialToolsRequired. SRS nflatorsimulator07SAZ-T8401A. SR Ssimulator ea dF 07XAZ-S230100

1. ErasetheDT Cmemory (seepage23-26).

2. Turn he ignit ionswitchON (ll),an d check hat he

SRS ndicator omeson fo r about6 seconds nd

then goesof{.

Does the SRS ndicator stay on?

YES-Go to step3.

NO Intermittentailure,system s OK at this imGo o Troubleshooting ntermittent ailures see

page 23-261.

Turn he gnitionswitchOFF.Disconnecthe

batterynegative able,and wait for 3 minutes,

Disconnecthe driver'sairbag4Pconnector A)

from the cable eel.

07sAz-T84011

07xAz-s230100

ConnecttheSRS nflatorsimulator 2 0

connectors) nd he simulator ea dF o the cable

ree l .

Reconnecthe batterynegative able.

Erase he DTCmemory..

(con

23



Rs


8. Read he DTC.

Is DTC 1-3 ndicated?

YE S Go o step9.

NO Short n the driver'sairbag; eplace hedriver'sairbag se epage23-'l 3).1

9. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able,an dwait for 3 minutes.

10. Disconnecthe front passenger's irbag4Pconnector rom dashboardwire harnessB (seestep3 on page23-21) .

1 1.Disconnect oth seatbelt ensioner2P connectors

from the floor wire harness seestep 5 on page23-22t.

12. D isconnectRSun i tconnectorA 18P) f romheSR Sunit (seestep7 on page23-221.

13. Disconnectthe pecial ool from the cable eel.

14 . Check esistance etween he No.7 and he No . 16term ina ls ndbetweenhe No.6 and he No.15term ina ls f SRSuni tconnectorA18P) . here

shouldbe an open circuit,or at least1 M Q

SRSUNITCONNECTOR{18P)

GRN/WHT GRN/RED

GRN/YEL GRN/BLK


ls the rcsistance as specified?

YES FaultySR Sunit; replace he SRSunit (seepage 23-122],.a

NO Go o step 15.

Disconnecthe cable eel rom dashboardwireharnessB. Check esistance etween he No,7 andthe No. 16 erminalsand between he No. 6 and heNo. 15 erminalsof SRSunit connectorA (18P).

Thereshould be an opencircuit,or at least1 MQ

ls the resistance as specified?

YES Replace he cable eel.I

NO-Rep lace ashboard i re harness . l



DTC -4: hort o Powern Driver 's irbagInf lator

SpecialToolsBequired. sRS nflatorsimulator07SAZ-T84011A. SRSsimulator eadF 07XAZ-S230100

1. E rase he DT Cmemory (seepage23-26).

2 . Turn he gn i t ion w i tchON ( l l ) , ndcheck ha t he

SRS n dicator omes on fo r about6 secondsand

then goesoff.

Does he SRS ndicatorstay on ?

YES Go o step3.

NO Intermittent ailure,system s OK at this ime.Go o TroubleshootingntermittentFailures se e

page23-26).


batterynegative able,an dwait for 3 minutes.

4. Disconnecthe driver'sairbag4P connector A)

f rom hecab le ee l .

07sAz-T84011A

ConnectheSRS n f la to r imu la tor 2 0

connectors) nd he simulator ead F o the cableree l .


Erase he DT Cmemory.

6 .

1 .

9 .

1 0 .

't4.

1 1 .

1 2 .

Read he DTC.

ls DTC 1-4 ndicated?

YES-Go to step9.

NO-Short to power n the driver'sairbag; eplac

the dr i ver ' s i rbag see age23-1 3) .1

Turn he gn i t ion w i t chOFF.Disconnecthe


Disconnecthe front passenger's irbag4P

connector rom dashboardwire harnessB (seeste

3 on page23 '21) .

Disconnect othseatbelt ensioner2P connector

from th e floor wire harness seestep 5 on page23221.

Disconnect RSun i tconnector (18P) f romhe

SR Sunit (seestep7 on page23-22).

Disconnecthe special ool from the cable eel.


(cont

23-



RS

1 6 .



Check or voltagebetween he No. 7 terminalof

SRSuni tconnector (18P) nd bodyground,heNo. 16 erm ina l ndbodyground,he No.6term ina l nd bodyground, nd he No.15 ermina land body ground.Thereshould be 0.5V or less.

SR SUNITCONNECTOR{18P)

1 1 .


Is the voltage as specilied?

YES-Faulty SRSuniU eplace he SRSunit (see

page 23-122) a

NO Go o step 17.


Disconnecthe cable eel rom dashboardwireharnessB.


Check or voltagebetween he No. 7 terminalofSRSuni tconnector (18P) nd bodyground, he

No.16 erm ina l nd bodyground,he No.6term ina l ndbodyground, nd he No.15 erm ina land body ground.Thereshould be 0.5V or less.

ls the voltage as specitied?

YES Replacehecab le ee l . l

NO-Rep lace ashboard i reharness . l

1 8 .

1 9 .

20 .

1 .

L

DTC -5: hort o Groundn Driver 's i rbaglnf lator

Special Tools Required. SRS nflatorsimulator07SM-TB4011A. SRSsimulator ead F 07XM-S230100


2. Turn he gnitionswitchON (ll),and checkthattheSR S ndicator omeson for about6 seconds ndthen goesoIf.

Does he SBS ndic atorstay on?

YE S Go to step3.

NO-lntermittent failure,system s OK at his t ime.Go o Troubleshootingntermittent ailures se e

page23-26).

3. Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait fo r 3 minutes.

4. Disconnecthe driver'sairbag4Pconnector A)

from the cable eel.

07sAz-T84011A

07xaz-s230100

ConnectheSRS nf la to r imu la tor2 0

connectors) nd he simulator ea dF o the cablereet .



a



8. Rea d heDTC.


YES-Go to step9.

NO Short o ground n the driver'sairbag nflator;

replace he driver'sairbag seepage23-1 3).I



'10.Disconnecttheront passenger's irbag4P

connector rom dashboardwire harnessB (seestep

2 on page 23-21)

11. Disconnect oth seatbelt ensioner2P connectors

from the floor wire harness (seestep 5 on page23 -

22t.

12. Disconnect RSunit connectorA (18P) romthe

SRS unit (seestep 7 on page 23-22],.

13 . D isconnect thepec ia l too l f romhe cab le ee l .

14. Check esistance etween he No.7 terminalof

SR Sunit connectorA {18P) nd body ground, he

No.16 erm ina l ndbodyground, he No.6

term ina l ndbodyground. nd heNo. 15 erminand body ground.Thereshould be an open circui

o r a t east M Q.

SRSUNITCONNECTORI18PI

GRN/WHT GRN/RED

1 6 .



YES-Faulty SRSunit; replace he SRSunit {seepage 23-1221f

NO-Go to s tep15.

Disconnecthe cable e el rom dashboardwire

harness .

Check esistance etween he No.7 terminalof

SRSuni tconnector (18P) ndbodyground, he

No.16 erm ina l nd bodyground. he No,6

term ina l nd bodyground, nd he No.15 ermin

andbodyground. here hou ldbe an openc i rcu

or at least 1 fvlQ

ls the resistance s specified?

YES Replacehe cab le ee l . I

NO Replace ashboardwire harnessB.l

23



sRs


DTC -1:Open n FrontPassenger'sirbagInf latorDfC 2-2: ncreased esistancen Front

Passenger'sirbag nf lator

SpecialTools Bequired. SRS n f la to r imu la tor 7SAZ-T84011A. SR Ssimulator ead F 07XAZ-S230100

'1 .Erase he DTCmemory {seepage23-26).

2 . Turn he gn i t ion w it chON ( l l ) , ndcheck ha t heSR S ndicator omeson for about 6 sec ondsan dthen goesoff.

Does the SRS indicator stay on?

YES Go o step3.

NO Intermittent ailure,system s OK at this ime,Go o TroubleshootingntermittentFailures seepage 23-261.

3. Turn he ignitionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnecthe front passenger's irbag4Pconnector A) ro m dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100

Connect he SRS nflatorsimulator 2 0

connectors) nd he simulator ead F o dashboardwi re harness .



5 .

6 .

7 .

!

9.

1 0 .

Read he DTC.

ls DTC 2-1 or DTC 2-2 indicated?

YE S Go o step9.

NO-Open or increased esistancen the frontpassenger's irbag nflator; eplace he frontpassenger ' si rbag see age23-114) . I

Turn he ignit ionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe driver'sairbag4Pconnector romthe cable eel se estep2 on page23-21],.

Disconnect oth seatbelt ensioner2Pconnectorsfrom th e floor wire harness se estep5 on page23 -22).

Disconnect RSunit connectorA (18P)ro m theSR Sunit (seestep7 on page23-22).Do notdisconnecthe special ool from dashboardwireharness .

1 1 .



J

13. Check esistance etween he No. 4 and No. 13

term ina ls ndbetweenhe No.5 and No.14

term ina ls f SRSuni tconnector (18P) . here

shou ld e2.0 3 .0 Q.

SR SUNITCONNECTOR {18P)



YES FaultySR Sunit or poorcontactat SRSunit

connectorA (18P).Check he connection; f the

connection s OK ,replace he SRSunit (seepage

23-1221.a

NO Openor increased esistancen dashboard

wire harnessB; replacedashboardwire

harness . I

J

23-

DTC -3:Short o AnotherWireor DecreasResistancen FrontPassenger'sirbaglnJlator

SpecialToolsRequired. SRS nf la to r imu la tor 7SAZ-T8401 '1A. SR Ssimulator eadF 07XAZ-S230100

1 Erase he DTCmemory (seepage23-261.

2 . Turn he gn i t ion w i t chON ( l l ) ,andcheckthat th

SR S ndicator omeson for about 6 seconds nd

then goesoff.

Does he SRS ndicatorstay on?

YES-Go to step3.

NO Intermittentailu e,system s OK at his time

Go o Troubleshootingntermittent ailures seepage23-26).


batterynegative able,and wait for 3 minutes.

4. Disconnecthe front passenger's irbag4P

connector A) rom dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100

ConnectheSRS nf la to r imu la tor 2 0

connectors)nd hes imula toreadF o dashboa

wi re harness .


Erase he DTCmemory.

(cont

6 .

7 .



Rs


1 1 .

Read he DTC.

ls DTC 2-3 ind cated?

YE S Go o step9.

NO-Short in the ront passenger's irbag nflator;replace he front passenger's irbag seepage23-1 1 4 ) .

Turn he gnitionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe driver'sairbag4Pconnector romthe cable eel seestep 2 on page23-21).

Disconnect oth seatbelt ensioner2P connectors

from th e floor wire harness se estep5 on page23 -221.

9 .

1 0 .

T

'12.Disconnect RS unit connectorA (18P)rom th eSRS un t (seestep 7 on page 23-22l.

13. Disconnectthe pecial ool from dashboardwireharness .

14 . Check esistance etween he No. 4 and No. 13term ina ls nd betweenhe No.5 andNo. 14term ina ls f SRSuni tconnector (18P) . hereshou ld e an openc i rcu i t , r a t east M Q.

SR SUNITCONNECTOR I18P)

BLU/RED

BLU/BLK


ls the resistance as specitied?

YES FaultySR Sunit; replace he SRSunit (seepage 23-122)'.a

NO-Shon in dashboard i reharness ; ep lacedashboard i re harness . l



DTC -4:ShorttoPower n FrontPassenger'sAirbag nflator

SpecialTools Required. SR S nflatorsimulator07SAZ-TB4011A. SR Ssimulator ea dF07XAZ-S230100


2. Turn he gnitionswitchON (ll),and check hat he

SRS ndicator omeson for about 6 seconds nd

thengoesoff,

Does the SRS ndicatot stay on?

YES-Go to step3.

NO Intermittentailure,system s OK at his t ime.Go o TroubleshootingntermittentFailures see

page23-26).

3. Turn he ignit ionswitch OFF.Disconnectthe


4. Disconnecthe ront passenger's irbag4P

connector A) rom dashboardwire harnessB.

07sAz-T84011A

07xAz-s230100

Connect he SRS nflatorsimulator 2 Q

connectors) nd he simulator ea dF o dashboard

wi reharness .


Erase he DTc memory.

6 .

7 .

8. Read he DTC.

ls DTC 2-4 indicated?

YES-Go to step9.

NO-Short to power n the front passenger's irba

inflator; eplace he front passenger's irbag see

page23-114) . I

9. Turn he ignit ionswitchOFF.Disconnectthe


10. Disconnecthe driver'sairbag4Pconnector ro m

the cable eel seestep2 on page23-21).

11. Disconnect oth seatbelttensioner2P connector

from th e floor wire harness se estep5 on page2322).

{cont

23-



sRs

13 .

14.


Disconnect RSunit connectorA (18P) ro m th eSR Sunit (seestep 7 on page23-221.

Disconnecthe special ool rom dashboardwireharnessB.



Check or voltagebetween he No. 4 terminalofSRSunit connectorA (18P) nd body ground, heNo.13 erm ina l nd bodyground,he No.5terminaland body ground,and he No. 14 e rminaland body ground.Thereshouldbe 0.5V or less.

SRS UNIT CONNECTOB {18PI

Wire sideo{ {emale erminals

ls thevoltage sspecified?

YES Faulty RS niu eplaceheSRS nit seepage23-1221a

NO-Short o power n dashboard ireharness ;replace ashboard ireharness .

15.

to .

\

DTC -5:Short o Ground n FrontPassenger'sAirbag nf lator

SpecialToolsRequired. SRS nf atorsimulator07SAZ-T84011A. SRSsimulator ead F 07XAZ-S230100


2. Turn he ignit ionswitchON (ll),and check hat heSRS ndicator omes on for about6 seconds ndthen goesoff.


YE S Go o step3.

NO Intermittentailure,system s OK at this ime.Go o Troubleshootingntermittent ailures se epage 23-261.



4, Disconnecthe front passenger's irbag4Pconnector A) rom dashboardwire harnessB.

07saz-T84011A

07xAz-s230100

Connect he SRS n flatorsimulator 2 Qconnectors) nd he simulator eadF o dashboardwire harnessB.

5.



7 .

1 1 .

9 .

10 .


Erase he DTCmemory.

Read he DTC.


YES-Go to step9.

NO-Shon to ground n the front passenger's

airbag nflator; eplace he front passenger's irbag(see age23-1 4) .1

Turn he ignitionswitch OFF.Disconnectthe


Disconnecthe driver'sairbag4Pconnector ro m

the cable ee l se estep2 on page23-21).

Disconnect oth seatbelt ensioner2Pconnectors

from the floor wire harness se estep5 on page23 -

22).

12.

13 .

't4.

Disconnect RSunit connectorA (18P)rom the

SRSunit (seestep7 on page23-221.

Disconnectthe pecial ool from dashboardwireharness .

Check esistance etween he No. 4 terminalof

SR Sunit connectorA (18P) nd body ground, he

No . 13 erminaland body ground. he No. 5

te rm ina l ndbodyground, nd he No.14 erm ina

and bodyground.Thereshouldbe an open circuit

o r a t east MQ.

SR SUNITCONNECTOR {18P}

BLU/RED BLU/YEL

Wire sideol temale erminals

ls the esistance s specitied?

YES Faulty RS niu eplaceheSRS nit se e

page23-122),l

NO Short o groundndashboard ir eharnessreplaceashboardi reharness. l

23-



Rs


DTC -1:Open n Driver'sSeatBeltTensionerDTC -2: ncreased esistancen Driver'sSeatBeltTensioner

Special Tools Required. sRS nflatorsimulator07sAz-TB4011A. SRSsimulator ea dC 07TM-S25011A. SRSsimulator eadF 07XAZ-S230100


2. Turn he ignit ionswitchON (ll),and check hat heSRS ndicator omeson for about6 seconds ndthen goesoff.


YE S Go o step 3.

NO Intermittentailure,system s OK at this ime.Go o TroubleshootingntermittentFailures seepage23-26).

3. Turn he ignitionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnecthe driver'sseatbelt ensioner2Pconnector A) ro m the floor wire harness.

07sAz-T84011A

5. ConnecttheSRS nflatorsimulator 2 0 connector)

and simulator eadC to the floor wire harness.

07TAZ-52501'lA

t 5 .

\



8. Read he DTC.

ls DTC 3-1ot DTC 3-2 ndicated?

YES Go o step9.

NO-Open or increased esistancen the driver'sseatbelt ension er; eplace he driver'sseatbelt(seepage23-4).I

L Turn he gnitionswitch OFF.Disconnectthebatterynegative able,and wait Ior 3 minutes.

10. Disconnecthe floor wire har ness P connectorC403 A)from dashboardwire harnessB.

07sAz-T8401'lA

Connect he SRS nflatorsimulator 2 Qconnectors) nd simulator eadF o dashboardwireharnessB.



Read he DTC.

ls DTC 3-1 or DTC 3-2 ndicated?

YES Go o step 15 .

NO-Open or ncreasedes is tancen he loorwi reharness; eplace he floor wire harness.l

Turn he ignit ionswitchOFF.Disconnecthebatterynegative able.and wait for 3 minutes.

1 1 .

12.

14 .



17.

Oisconnecthe driver'sairbagconnector se estep

2 on page23-21),ront passenger's irbag

connector se estep3 on page23-21),andfront

passenger's ea tbelt ensioner onnector se estep5 on page 23-22).

Disconnect RSunit connectorA (18P) ro m th e

SR Sunit (seestep7 on page23-22).Do not

disconnect he special ool from dashboardwire

harnessB.

Check esistance etween he No.8 terminaland

the No.17 ermina l f SRSuni tconnector (18P) .

There hou ld e2 .0-3 .0 Q.

SRSUNITCONNECTOR(18P)

RED/WHT

i-4\ l e l a ;

E a2 3 5 6 1

10 1 l 1Z t 3 t 5 16

RED/BLU



YES FaultySRSunit or poorcontactat SRSunit

connectorA (18P) nd he SRSunit. Check he

connection;f the connection s OK, replace he

SRSunit (seepage23-'1221.a

NO Openor increased esistancen dashboard

wi reharness ; ep lace ashboard i re harness

B , t

1 8 .

t o . DTC3-3:Short o AnotherWire or DecreaseResistancen Driver 's eatBelt ensioner

SpecialToolsRequired. SR S nflatorsimulator07SAZ-T8401'1A. SR Ssimulator eadC 07TM-S25011A. SR Ssimulator eadF 07XAZ-S230100


2. Turn he gnitionswitchON (ll),and checkthatthe


then goesoff.


YES Go o step3.


Go o TroubleshootingntermittentFailures se epage23-26).

Turn he ignit ionswitchOFF.Disconnecthe


Disconnecthe driver'sseatbelt ensioner2P

connector A) rom the floor wire harness.

-T84011A

07TAZ-S25011A

5. ConnectheSRS n f la to r imu la tor 2 0 connecto

ands imula toreadC o the loorwi re harness.

(cont'

23-



Rs


6. Reconnectthe atterynegative able.


8. Read he DTC.

ls DTC 3- 3 ndicated?

YES-Go to stepL

NO-Shon in the driver'sseatbelt ensioner;replace he driver'sseatbelt (seepage23-4).1

L Turn he ignit ionswitchOFF.Disconnectthebatterynegative able,and wait for 3 minutes.

10. Disconnectloor wire harness4PconnectorC403

(A)from dashboardwire harnessB.

07sAz-TB4orA

ConnecttheSRS nflatorsimulator 2 Qconnectors) nd simulator ead F o dashboardwireharnessB.


Erase he DTCmemory.

Read he DTC.


YES-Go to step 15.

NO Short n th e floor wire harness; eplace hefloor wire harness.l

Turn he ignitionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

1 1 .

13 .

14 .

t

16. Disconnecthe driver'sairbagconnector seestep2 on page23-211,lront assenger's irbagconnector se estep3 on page23-21), nd ront

passenger's eat belt ensioner onnector se estep5 on page 23-22).

17 . D isconnect RSun i t connector (18P)rom heSRSunit (seestep7 on page23-22:,.

18 . Disconnecthe special ool from dashboardwireharnessB.

19. Check es is tanceetweenhe No.8 erm ina l ndthe No.17 ermina l f SRSuni tconnector ( ' l 8P) .

Thereshouldbe an open circuit,or at least1 \4Q



lsthe resistanceas specif ed?

YES FaultySRSunit; eplace he SR Sunit (seepage 23-1221.a

NO- Shor t n dashboard i reharness ; ep lacedashboard i re harness . l

L

RED/WHT

RED/BLU



J

DTC -4:Short o Power n Driver'sSeatBeltTensioner

SpecialToolsBequired. SRS nflatorsimulator07SAZ-TB4011A. SRS imu la toreadC 07TM-S25011A. SRSsimulator eadF 07XAZ-S230100

1. Er ase he DT Cmemory (seepage23-261.


SRS ndicator omeson fo r about6 seconds ndthengoesoff.

Does he SRS ndicatot stay on?

YES Go o step3.

NO Intermittentailure,system s OK at this ime.

Go o Troubleshootingntermittent ailures se e

page23-261.

Turn he ignit ionswitch OFF.Disconnecthe


Disconnecthe driver'sseatbelt ensioner2P

connector A) rom the floorwire harness.

07sAz-T84011A

5. Connect he SRS nflatorsimulator 2 !J connector)

and simulator ea dC o the floor wire harne ss.



8. Read he DTC.


YES Go o step9.

NO-Short to power n the driver'sseatbelt

tensioner; eplace he driver'sseatbelt(see age23-4) .1

L Turn he ignit ionswitchOFF.Disconnecthe


10. Disconnectloor wire harness4PconnectorC403(A ) ro m dashboardwire harnessB.

TB4O11A

ConnectheSRS nf la to r imu la tor 2 0

connectors) nd simlator eadF o dashboardwire

harness .


Erase he DTCmemory.

Read he DTC.


YES - Go o step 15.

NO-Shon to power n he loorwi re harness;

rep lacehe loorwi reharness. I

Turn he gn i t ion w i t chOFF.Disconnecthe


1 1 .

' t2 .

14.

(cont'

23-



sRs


16. Disconneclhe driver'sairbagconnector seestep2 on page23-21l,Irontpassenger's irbagconnector seestep3 on page23-2'l), nd ront

passenger's ea tbelt ensioner onnector seestep5 on page 23-221

17. Disconnect RSunit connectorA (l8P)from th eSRS unit (seestep 7 on page 23-22).

18. Disconnecthe specialtool rom dashboardwireharness .


20. Turn he ignitionswitchON (ll),

21 . Check or voltagebetween he No .8 terminalofSR Sunit connectorA (18P) nd body ground,an dthe No.17 erm ina l ndbodyground. here hou ldbe 0.5V or less.

SRS UNIT CONNECTOR {18PI

ls the voltageas specified?

YES-Faulty RS nit; eplaceheSRS nit seepage23-122],a

NO Shorttopower n dashboard ir eharness ;replace ashboard ireharness .l

L

DTC -5:Short o Ground n Driver'sSeatBeltTensioner

SpecialTools Required. sRS nflalorsimularor07sAz-TB4011A. SRSsimulator ea dC 07TAZ-S25011A. SRSsimulator eadF 07XAZ-S230100

1. Erase he DTCmemory {seepage23-26).

2. Turn he ignit ionswitchON (ll),and check hat heSRS ndicator omeson fo r about 6 seconds ndthen goesoff.


YE S Go o step3.

NO Intermittent ailure,system s OK at this ime.Go o Troubleshootingntermittent ailures see

page23-26).

3. Turn he ignit ionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4, Disconnecthe driver'sseatbelt ensioner2Pconnector A) rom the floor wire harness,

-T84011A

07TAZ-S25011A

L

5. Connect he SRS nflatorsimulator 2 Q conneclor)and simulator eadC to the floor wire harness.



sRs


DTC 1-1: pen r IncreasedesistancenDriver 's eatBeltBuckle ensioner


. SRS nflatorsimulator07SAZ-TB4011A

. SRSsimulator eadF 07XAZ-S230100

1. ErasetheDT Cmemory (seepage23-261.


SRS ndicator omes on fo r about6 seconds ndthen goesoff.

Does he SBS ndicatot stay on?

YES Go to step3.

NO-lntermittent failure,system s OK at his t ime.Go o Troubleshooting ntermittent ailures see

page 23-261.

3. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnecthe driver'sseatbelt buckle ensioner4Pconnector A) rom the floor wire harness.

5. ConnecttheSRSn{latorsimulator 2 Q connectors)and simulator ead F o the Iloor wire harness.



23-54

L

8. Read he DTC.

ls DTC 21-1 nd ica ted?

YES Go o step9.

NO Openor increased esistancen the driver'sseatbelt buckle ensioner; epla ce he driver'sseat

be l tbuck le . I

9. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able.and wait for 3 minutes.

10. Disconnect oth sideairbag2Pconnectors se e

step4 on page23-2lland the front passenger's

seatbelt buckle ensioner4Pconnector seestep6

on page23-22)

11. D isconnectRSun i tconnector (18P) f romhe

SR Sunit (seestep7 on page23'22).Do not

disconnecthe special ool from the floor wirenarness.

12 . Check esistance etween he No. 1 and No. 10

term ina ls f SRSuni tconnector (18P) . hereshou ld e2.0 3.0 O.

SR SUNITCONNECTORIl8PI

Wi re ide f emaleermina ls

ls the resistanceas specified?

YES*Fau l t ySRSuni to r poorcontact t SRSuni tconnector (18P) nd heSRSuni t .Checkheconnection;f the connection s OK, eplace he

SRSunit (seepage23-122).a

NO Openor increased esistancen the floor wireharness;ep lacehe loorwi re harness. l

b

GRN/YEL

l t ' 'A \ I '

Y l r 0] T

I

?t l

3 6 1 6 s1 5 t 6 17 t6

GRN/BLK



DTC 1-3: hort o AnotherWireorDecreasedesistancen Driver 's eatBeltEuckle ensioner

Special Tools Required. SRS nflatorsimulator07SAZ-T840't1A. SRSsimulator ead F 07XAZ-S230100

1. E rase he DTCmemory (seepage23-26).

2. Turn he ignitionswitchON (ll),and check hat heSRS ndica tor omes n or about6 seconds ndthengoesoff.

Does he SR S ndicatorstay on?

YE S Go o step3.

NO Intermittentailure.system s OK at this time.Go o TroubleshootingntermittentFailuresse epage23-26).

Turn he ignit ionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

D isconnecthedr iver ' s ea tbe l tbuck leens ioner4Pconnector A) rom the floor wire har ness.

Connect the RS n f la to r imu la tor2 i )connectors)nd s imu la toreadF o the loorwt renarness.


Erase he DTCmemory.

6 .

7 .

8. Read he DTC.

ls DTC 21-3 nd cated?

YES-Go to step9.

NO - Short n the driver'sseat belt buckletensioner; eplace he driver'sseatbelt buckle.l

9. Turn he ignit ionswitchOFF.Disconnectthebatterynegative able,and wait for 3 minutes,

10. Disconnect oth side airbag2P connectors see

step4 on page23-21) nd he front passenger's

seatbelt buckle ensioner4P

connector se eslep 6 on page23-22).

11 . D isconnectSRSni tconnectorB18P) f romtheSR Sunit {seestep7 on page23-22l .

'12.Disconnecthe specialtool rom the floor wireharness.

13 . Check esistance etween he No. 1 and No. 10term ina ls f SRSuni tconnector (18P) . hereshou ldbe an openc i rcu i t , r a t east M Q.

SRS UNIT CONNECTOR {18PI



YES FaultySR Sunit; replace he SRSunit (seepage23-1221.a

NO Short n the floor wire harness; eplace hef loorwi re harness. l

GRN/YEL

GRN/BLK

23-



Rs

DTCTroubleshootangcont'dl

DTG 1-4:Short o Power n Driver'sSeatBeltBuckle ensioner

SpecialToolsRequired. SRS nflatorsimulator07SAZ-TB4011A. SRSsimulator ead F 07XM-S230100


2. Turn he ignitionswitchON (ll),and check hat he


thengoesoff.

Does the SRS indicatot stay on?

YES-Go to step3.

NO Interminent ailure,system s OK at this ime.Go o TroubleshootingntermittentFailures se e

page23'26).

3. Turn he ignitionswitchOFF.Disconnecthe


4. Disconnecthe driver'sseatbelt buckle ensioner

4Pconnector A) ro m th e floor wrre narness.

ConnecttheSR S nflatorsimulator 2 0connectors) nd he simulator eadF o the f oorwi reharness.


Erase he DTCmemory..

5 .

\,

L

Read he DTC.


YES Go o step9.

NO Shon to power n the driver'sseatbelt buckle

tensioner; eplace he driver'sseatbelt buckle.l

Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnect oth sideairbag2P connectors se e

step4 on page23-21) nd he front passenger's

seatbelt buckle ensioner4Pconnector seestep6

on page 23-22)

1 0 .

t,



1 1 .

1 2 .

14.

Disconnect RS unit connectorB (18P) rom th eSR Sunit (seestep7 on page23-22).

Disconnecthe special oo l from the floor wireharness.



Check or voltagebetween he No. 1 erminal ofSRSunit connectorB {18P) nd body ground,an dthe No. 10 erm ina l ndbodyground. here hou ldbe 0.5V or less.

SR SUNITCONNECTOR18PI

ls thevoltage sspecitied?

YES Faulty RS ni t; eplacehe SRS nit seepage23-1221f

NO Short o powern he loorwireharness;replacehe loorwireharness.l

J4.

DTC 1-5: hort o Groundn Driver 's eatBeltBuckle ensioner

SpecialTools Required. SR S nflatorsimulator07SAZ-TB4011A. SR Ssimulator eadF 07XAZ-S230100

1. Erase he DTCmemory {seepage23-26}.

2. Turn he ignit ionswitchON (ll),and check hat heSRS ndicator omeson fo r about6 secondsan dthen goesoff.

Does the SBS indicator stay on?

YES-Go to step 3.

NO Intermittent ailure,system s OK at this imeGo o TroubleshootingntermittentFailures se epage23-26).

Turn he gnitionswitch OFF.Disconnecthebatterynegative able,an dwait for 3 minutes.

Disconnecthe driver'sseatbelt buckle ension er4Pconnector A) ro m the floor wire harness.

Connecthe SRS n f la to r imu la tor 2 Qconnectors) nd simulator e ad F o the floor wirena ness.


Erase he DTCmemory.

(cont'd

6 .

7 .

23-5



Rs

9 .

10 .


1 1 .

Read he DTC.


YES Go o step9.

NO Short o ground n the driver'sseatbelt

buckle ensioner; eplace he driver'sseatbelt

buck le . l



Disconnect oth side airbag2Pconnectors se e

step 4 on page23-21)and he front passenger's

seatbelt buckle ensioner4Pconnector seestep 6

on page23-221.

Disconnect RSunit connectorB (18P) ro m theSRS unit (seestep 7 on page23-22)

Disconnecthe special ool from th e floor wireharness.

Check esistance etween he No .'1

terminalofSRSunit connectorB (18P) nd body ground,an d

the No.10 erm ina l ndbodyground. here hou ldbean openc i rcu i t , r a t east1 M Q.

12 .

13 .

SRSUNITCONNECTOR{18PI

ls the esistance s specilied?

YES Faulty RS niu eplaceheSRS nit se epage23-122)a

NO-Shor t ogroundn he loorwireharness;replacehe loorwire harness.l

\

'L

DTC -1:Open n FrontPassenger'seatBeltrens tonerDTC -2: ncreased esistancen FrontPassenger'seatBeltTensioner

Special Tools Required. SR S nflatorsimulator07SM-T84011A. SR Ssimulator eadC 07TAZ-S25011A. SR Ssimulator ead F 07XAZ-S230100

Erase he DTCmemory (seepage23-26).

Turn he gnitionswitchON {ll),and check hat he

SR S ndicator omeson fo r about6 seconds ndthen goesoff.

Does he SBS ndicatorstay on?

YES-Go to step3.

NO- Intermittent ailure,system s OK at his ime.

Go o Troubleshootingntermittent ailures se epage23-26).



Disconnecthe front passenger's eat belttensioner2Pconnector A) rom the floor wire

harness.

07TAZ-525011A

5. Connect he SRS nflatorsimulator 2 0 connector)ands imula toreadC o the loorwi reharness.





8. Read he DTC.

ls DTC 4-1 or DTC 4-2 ndicated?

YES Go o step9.

NO-Open or increased esistancen the frontpassenger's ea tbelt ensioner; eplace he frontpassenger's ea tbelt (seepage23-4).

L Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

10, Disconnecthe floor wire harness PconnectorC403 A)from dashboardwire harnessB.

07sAz-T840'tA

Connect he SR S nflatorsimulator 2 i)connectors) nd simulator eadF o dashboardwireharnessB.


Erase he DTCmemory.

Read he DTC.

ls DTC 4-l or DTC 4-2 ndicated?

YES-Go to step15 .

NO-Open or increased esistancen the floor wireharness; eplace he floor wire harness.I

1 1 .

12 .

1 4 .

15. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able.an dwait for 3 minutes.

'16.Disconnecthe driver'sairbagconnector

se estep2 on page23-211,ront passenger's irbagconnector seestep3 on page23-21), nd driver'sseat belt ensioner onnector seestep5 on page

23-221.

17. Disconnect RSunitconnectorA (18P) rom theSR Sunit (seestep7 on page23-22).Do notdisconnecthe special ool from dashboardwireharnessB.

18 . Check esistance etween he No. 9 terminalan dthe No.

18terminalof SRSunit connectorA (18P).

There hou ld e2.0-3 .0 Q.

SRS UNIT CONNECTOR {18P}



YES FaultySRS unit or poorcontactat SRSunitconnectorA (18P) nd he SRSunit.Check he

connection; f the connection s OK, replace heSR Sunit (seepage23-122l,.a

NO-Open or increased esistancen dashboardwire harnessB; replacedashboardwire harnessB . T

RED/YEL

{ ll 6r8l \ t

r l1 2 3 4 5 7 8

1 0 11 12 1 5 1 7

RED/BLK

23-5



Rs


DTC -3:Short o AnotherWireor DecreasedResistancen FrontPassenger'seatBeltTensioner

SpecialTools Required. SRS nflatorsimulator07SAZ-TB40l1A. SR Ssimulator ea dC 07TM-S25011A. SR Ssimulator eadF 07XAZ-S230100


2. Turn he ignitionswitch ON (ll),and check hat he

SR S ndicator omes on for about6 seconds nd

then goesoff.


YES-Go to step3.

NO Intermittent ailure.system s OK at this ime.Go o TroubleshootingntermittentFailures se e

page23-26).

3. Turn he ignit ionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnecthe front passenger's eat belttensioner2Pconnector A) rom th e floor wire

narness.

07TAZ-S25011A

Connect he SRS nflatorsimulator 2 Q connector)and simulator ea dC o the floor wire harness.



6 .

7 .

1 5 .

\

8. Read he DTC.


YES-Go to stepL

NO-Short in th e front passenger's eatbelttensioner; eplace he front passenger's eat belt(see age23-4) .1



'10.Disconnecthe floor wire harness Pconnector

C403 A)from dashboardwire harnessB.

TB40,I1A

L

1 1 .Connect he SRS nf latorsimulator 2 0

connectors) nd simulator eadF o dashboardwireharnessB.



Read he DTC.

ls DT C 4-3 ndicated?

YES-Go to s tep15.

NO Short n th e floor wire harness; eplace he

f loorwi reharness. I

Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait fo r 3 minutes.

13 .

14 .



16 . Disconnectthe river'sairbagconnector se estep2 on page23-211,ront passenger's irbagconnector seestep3 on page23-21), nd driver,sseatbelt ensioner onnector see

step 5 onpage

23-221.

17. Disconnect RSunit connectorA (18p) ro m th eSRS unit (seestep 7 on page 23-22).

18. Disconnecthe special ool from dashboardwireharnessB.

19 . Check esistance etween he No.9 terminalan dthe No. 18 ermina l f SRSuni tconnector (18p) .

There hou ld ean openc i rcu i t , r a t east Me.

SR SUNITCONNECTOR I18P}



YES-Faulty RS nit; eplaceheSRS nit seepage 3-1221f

NO-Short ndashboard ireharness ; eplacedashboardi reharness .

RED/YEL

I ]t 6r8 \P

T

2 3 4 5 6 8

10 t l 12 t 3 15 16 1 7

RED/BLK

DTC -4:Short o Power n FrontPassengeSeatBelt ensioner

SpecialTools Required. SRS nflatorsimulator07SAZ-T84011A. SRS imu la toreadC 07TAZ-S25011A. SR Ssimulator ead F 07XAZ-S230100


2. Turn he ignit ionswitchON {ll),and check hat heSR S ndicator omes on for about6 seconds ndthen goesoff.


YE S Go o step 3.

NO- Intermiftentailure.system s OK at his t imeGo to Troubleshootingntermittent ailures se epage 23-261.

3. Turn he ignitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnectthe ront passenger's eat belttensioner2P connector A) ro m the floor wireharness.

07TAZ-S2501'lA

5. Connect he SRS nflatorsimulator 2 e connector

and simulator eadC to the floor wire harness.

{cont'd

23-6



Rs



7. Erase he DT Cmemory.

8. Read he DTC.


YES Go o step9.

NO-Short to power n the front passenger's ea t

belt ensioner; eplace he front passenger's ea t

be l t see age23-4) . I


batterynegative able.and wait fo r 3 minutes.

'10.Disconnectloor wire harness4P connectorC403 A)from dashboardwire harnessB.

07sAz-TB4o11A

Connect he SRS nflatorsimulator 2 0

connectors) nd simulator ead F o dashboardwire

harness .


Erase he DTCmemory.

Read he DTC.


YES-Go to s tep15.

NO - Short o power n the floor wire harness;

replace he floor wire harness.l

1 1 .

t J .

1 4 .

23-62

1 1 .

1 5 .

t o .

1 8 .

1 9 .

20 .

21 .



Disconnecthe driver'sairbagconnectorseestep

2 on page23-211,ront passenger's irbag

connector se estep3 on page23-21), nd drivefs

seatbelt ensioner onnector seestep5 on page

23-22t.

Disconnect RS unit connectorA ('l8P) rom the

SRSunit (seestep7 on page23-22).

Disconnecthe special ool from dashboardwire

harness .




SRSuni tconnector (18P) ndbodyground, nd

the No. 18 erm ina l ndbodyground. here hou ld

be 0.5V or less.

SRSUNITCONNECTOR(18PI

Wire ide J emaleerminals

Is the voltageas specified?

YES FaultySRSunit; replace he SRSunit (see

page 23'1221.a

NO Shor t topower n dashboard i reharness ;

rep lace ashboardi reharness . l

t'



DTC -5:Short o Ground n FrontPassenger'sSeatBelt ensioner

Special Tools Required. SRS nflatorsimulator07SAZ-TB40'11A. SRSsimulator eadC 07TAZ-S25011A. SRSsimulator eadF 07XAZ-S230100

1. ErasetheDT Cmemory (seepage23-26]|.

2 . Turn he gn i t ion wi tchON ( l l ) , ndcheckthat theSRS ndicator omeson for about6 secondsan dthengoesoff.


YES-Go to srep .

NO-lntermittent failure,system s OK at this ime.Go o Troubleshootingntermittent ailures se epage 23-26l,.

3. Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnecthe front passenger's eat belttensioner2Pconnector A) rom the floor wireharness.

07TAZ-SZ501rA

Connect he SRS nflatorsimulator 2 e connector)ands imula toreadC o the loorwi reharness.


Erase he DT Cmemory..

8. Read he DTC.


YES-Go to step9.

NO Short o ground n the front passenger's ea tbelt ensioner; eplace he front passenger's ea tbe l t see age23-4) . I


10. Disconnecthe floor wire harness4PconnectorC403 Alfrom dashboardwire harnessB.

TB40 1A

Connect he SRS nflatorsimulator 2 econnectors) nd simulator ea dF o dashboardwireharness .


Erase he DTCmemory.

Read he DTC.


YES Go o step 15.

NO-Short toground

n the floor wire harn ess;rep lacehe loorwi re ha ness. l

Turn he ignit ionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

1 1 .

1 2 .

1 4 .

(cont'd

23-6



Rs


16. Disconnecthe driver'sairbagconnector seestep

2 on page23-21),ront passenger's irbag

connector seestep3 on page23-21). nd driver's

seatbelt ensioner onnectorsee

step 5 on page23-22).

17 . D isconnectRSun i tconnector (18P) f romhe

SRSunit (seestep7 on page23-221.

18 . Disconnecthe specialtool rom dashboardwire

harnessB.

19. Check esistance etween he No.9 terminalof

SRSuni tconnector (18P) nd bodyground, nd

the No. 8 te rm ina l ndbodyground. here hou ld

be an openc i rcu i t . r a t east M Q.

SR SUNITCONNECTOR {18P)

w i re s ideo f em a le e rm ina l s


YES Fau l t y RSun iU ep laceheSRSuni t see

page 23-1221.1

NO-Short to ground n dashboardwire harnessB;

rep lace ashboard i reharness . I

DTC 2-1:Openor Increased esistancenFrontPassenger'seatBeltBuckle ensioner

SpecialToolsRequired. SRS nflatorsimulator07SAZ-T84011A. SR Ssimulator ead F 07XAZ-S230100

1 Erase he DTC memory (see page23-261.


SRS ndicator omeson for about6 seconds nd

then goesotf.


YES-Go to step3.

NO-lntermittent failure,system s OK at this ime.Go o Troubleshootingntermittent ailures see

page23-26).

3. Turn he gnitionswitchoFF. Disconnecthe


4. Disconnectthe ront passenger's eat belt buckle

tensioner4Pconnector A) rom the floor wire

harness.

5 . Connecthe SRS nf la to r imu la tor 2 Q

connectors) nd he simulator ea dF o the floor

wt reharness.

\,



6. Reconnecthe bafterynegative able.


8. Read he DTC.


YES-Go to step9.

NO Openor increased esistancen the frontpassenger's ea tbelt buckle ensioner; eplace hefront passenger's ea tbelt buckle.l

9. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able,and wait or 3 minutes.

10 . Disconnect oth sideairbag2Pconnectors seestep4 on page23-21) nd he driver'sseatbeltbuckle ensioner4Pconnector seestep6 on page23-22).

11 . D isconnectRSun i tconnector (18P) f romheSRSunit (seestep7 on page23-22).Do notdisconnecthe special ool from the floor wireharness.

12 . Check es is tanceetweenhe No.2 and No.11terminalsof SRSunitconnectorB ('l8P). hereshou ld e2 .0 3.0 0.

SR SUNITCONNECTOR I,I8PI

)m 6 7 8 9

r5 r6 1T 1 8



YE S FaultySRS unit or poorcontactat SRS unitconnector (18P) nd heSRSuni r .Checkheconnection;f the connection s OK, replace heSR Sunit (seepage23-122).a

NO Openor increased esistancen the floor wireha ness; eplace he floor wire ha ness.lt

23-6

DTC 2-3:Short o AnotherWireorDecreasedesistancen FrontPassenger'SeatBeltBuckle ensioner

SpecialToolsRequired. SRS nflatorsimulator07SAZ-TB4011A. SR Ssimulator eadF 07XAZ,S230100

'1 .Erase he DTCmemory (seepage23-26).

2. Turn he gnitionswitchON fll),an dcheck hat heSRS ndicator omeson fo r about6 seconds ndthen goesoff.


YES Go o step3.

NO Intermiftent ailure,system s OK at this t ime.Go o TroubleshootingntermittentFailures se epage 23-26),.


4. Disconnecthe front passenger's ea tbelt buckletensioner4Pconnector A) rom the floor wireharness.

5 . Connecthe SRS n f la to r imu la tor2 Qconnectors)

nd he simulator ea dF o the floorwt reharness.


7 . Erasehe DTCmemory.

{cont'd



Rs


8. Read he DTC.


YES Go o slep9.

NO-Short in the front passenger's ea tbelt buckle

tensioner; eplace he front passenger's eat belt

buck le . l

9. Turn he gnitionswitch OFF.Disconnecthe


10. Disconnect oth side airbag2P connectors see

step4 on page23-21)andhe dr i ver ' s eatbe l t

buckle ensioner4Pconnector se estep6 on page

23-22).

'11 .D isconnectRSun i tconnector {18P) f romhe

SR Sunit (seestep7 on page23-221.

12. Disconnecthe special ool from the floor wire

ha ness.

13 . Check es is tanceetweenhe No.2 andNo.11

terminalsof SRSunit connectorB (18P). here

shouldbe an open circuit,or at leastlM !) .

SR SUNITCONNECTOR {18P}

GRN/RED

Wire ide I emaleerminals


YES FaultySRSunit; replace he SRSunit(see

page 23'1221a

NO Short n the floor wire harness; eplace he

f loorwi re harness. I

GRN

23-66

\

DTC 2-4:Short o Power n FrontPassenger'sSeatBeltBuckle ensioner

SpecialToolsRequired. SRS nf la to r imu la tor 7SAZ-TB4011A. SRS imu la toreadF 07XAz5230100


2 . Turn he gn i t ion w i t chON { l l } , ndcheck ha t he

SRS nd ica tor omes n or about6 seconds nd

then goesoff.

Does he SHS ndicatorstay on?

YES Go o step3.

NO In lerm i t ten t fa i lu re ,sys temsOKat th is t ime.Go o Troubleshootingntermittent ailures se e

page23-261.



4. Disconnecthe front passenger's eat belt buckle

tensioner4Pconnector A) rom the floor wire

narness.

5 . Connecthe SRS nf la to r imu la tor 2 !J

connectors) ndsimulator ea dF o the floor wire

ha ness.

u





8. Read he DTC.


YES Go o stepg.

NO-Short to power n the front passenger,s ea tbelt buckle ensioner; eplace he front passenger,sseatbelt buckle.

9. Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes,

10 .Disconnect oth sideairbag2P connectors seestep4 on page23-21)andhedr iver ' s ea tbe l tbuckle ensioner4Pconnector seestep6 on page

,1_r'>\

Disconnect RS unit connectorB (18P) ro m th eSR Sunit (seestep7 on page23-221.

Disconnecthe special ool from the floor wireharness.



Check or voltagebetween he No. 2 terminalofSRSuni tconnector {18P) ndbodyground, nd

the No. 11 ermina l ndbodyground. here hou lbe 0 .5V or Iess .

SRSUNITCONNECTOR18P)


YES-Fau l t ySRSuni t ; ep lacehe SRSuni t seepage 23-1221l

NO Short o power n the floor wire harness;replace he floor wire harness.l

1 1 .

' t2 .

t 5 .

1 4 .

23-6



Rs


DTC 2-5:Short o Ground n FrontPassenger'seatBeltBuckle ensioner

SpecialTools Required. SRS nflatorsimulator07SAZ-T84011A. SRSsimulator ea dF 07XAZ-S230100

1 Erase he DTCmemory (seepage23-26).

2. Turn he gnitionswitch ON (ll),and check hat he

SR S ndicator omes on for about6 secondsan d

then goesoff.


YES-Go to step3.

NO Intermittentailure,system s OK at his t ime.Go o TroubleshootingntermittentFailures see

page23-26).

3. Turn he gnitionswitchOFF.Disconnectthe


4. Disconnecttheront passenger's ea tbelt buckle

tensioner4P connector A) rom the floor wire

harness,

Connect he SRS nflatorsimulator 2 Q

connectors) nd simulator ea dF o the floor wire

narness.


Erase he DTCmemory.

5 .

6 .

1 .

! U

8. Read he DTC.


YES-Go to step9.

NO Short o ground n the front passenger's ea t

belt buckle ensioner; eplace he front passenger's

seatbe l tbuck le . l



10. Disconnect oth sideairbag2Pconnectors se e

step4 on page23-21) nd he driver'sseatbelt

buckle ensioner4Pconnector se estep6 on page

23-22t.

11 . D isconnectRSun i tconnector (18Pl f romhe

SRS unit (seestep7 on page 23-221.

12. Disconnecthe special ool from the floor wire

harness,

13. Check esistance etwee n he No. 2 terminalof

SR Sunit connectorB (18P) nd bodyground,an d

the No, 11 erminaland body ground.Thereshould

be an open circuit,or at east 1 M Q.



YES-Faulty SRSunit; replace he SRSunit (see

page 23-1221a

NO Short o ground n the floor wire harness;


b




DTC -1,5-2,5-4, -8,6-3,6-4,6-7,6-8,7-1,7-2,7-3, -1,4-2, -3 ,8-4,8-5,8-6,9-1,9-2:Internal ai lure f heSRSUnit

NOTE:Before roubleshooting ny of theseDTCs, heckthe battery/systemoltage. f the voltage s ow, repair

the chargingsystemor replace he batterybeforetroubleshootinghe SRS. f the battery/system oltage

is now OK,ask he customer f the batteryever went

oeao,

1. Erase he DT Cmemory (seepage23-26).

2. Turn he ignitionswitchON (ll),and check hat heSRS ndicator omeson for about6 secondsan d

thengoesoff.

Does he SRS ndicatot stay on ?

YES Rep lacehe SRSuni t see age23-122) .1

NO Intermittent ailure,system s OK at this ime.Go o TroubleshootingntermittentFailures se e

page23-26).

DTC10-1, 0-2, 0-3, 0-4, 0-s, 0-6, 0-7:Airbags, ideAirbags, nd/or eatBelt ndSeatBeltBuckle en sioners eployed

Th e SR Sunit must be replaced fterany airbagsand/otensioners ave deployed seepage23-122).

23-



RS


DTC 3-1, 3-2:nternal ai lure f heDriver 'sSide mpact ensor

1. Erase he DT Cmemory (seepage 23-26).

2. Turn he ignitionswitch ON (ll),and check hat heSRS ndicator omes on for about6 seconds ndthengoesoff.


YES Replacehe driver'sside mpactsensor seepage 23-123) a

NO Intermittent ailure,system s OK at this ime.Go o Troubleshootingntermittent ailures se e

page 23-261.

I

DTC 4-1, 4-2:nternal ai lure f the FrontPassenger'side mpact ensor


2. Turn he ignit ionswitchON (ll),and check hat he

SRS ndicator omeson for about6 seconds ndthen goes off.


YES-Replace he front passenger's id e mpact

sensor (see page23-123],.1

NO-lntermittent failure,system s OK at his t ime.Go o Troubleshootingntermittent ailures see

page23-26).

U



DTC -3:Fauty Driver'sSeatBeltBuckleSwitch

1. Erase he DT Cmemory (seepage23 26).

2 . Turn he gn i t ion w i t chON ( l l ) , henbuck le nd

unbuck lehe dr i ver ' s ea tbe l tsevera limes.

3. Read he DTC.


YES Go o step4.

NO Intermittent ailure,system s OK at this ime.Go o TroubleshootingntermittentFailures see

page23-261.


Disconnecthe driver'sseatbelt buckleswitch3Pconnector A) rom th e floor wire harness.

4 .

5 .

6. Buckle he driver'sseatbelt.

Check esistance etween he No. 1 and No.3

terminalsofthe driver'sseatbelt buckle witch3Pconnec lor . here hou ld e0 1 (J .

Check esistance etween he No. 1 an d No.2

terminalsof the sameconnector. hereshould be

an openc i rcu i t , r a t east1 MQ

DRIVER'S EATBELTBUCKLE WITCH3PCONNECTOR

BLU/RED


Termina lide fma leermina ls

Ate the resistance eadingsas specif ed ?

YES Go o step7.

NO Replacehe driver'sseatbelt buckleassemb

thenc lear he DTC. I

(cont

23-



Rs


7, Unbuckle he driver'sseatbelt.


terminalsofthe driver'sseatbelt buckleswitch 3Pconnector .here hou ld e0 1 Q.

Check esistance etween he No. 1 and No. 3terminalsof the same connector. hereshould bean open circuit,or at least1 MQ

DRIVER'S EATBELTBUCKLE WITCH PCONNECTOR

Term ina l i de f m a le e rm ina l s

BLU/RED

Termina lide I ma leermina ls


YES Go o step8.

NO-Replace the driver'sseatbelt buckleassembly,

then clear he DTC.I

\

8. Check esistance e tween he No. 1 erminalofthefloor wire harness3P connector nd bodv oround.There hou ld e0

'10 .

FLOORWIREHARNESS PCONNECTOR



YES Go o step9.

NO Open n he loorwi re harness r poorground

connect ion t G551.f G55 '1sOK, ep lacehe loorwrreharness. l

Disconnecthe negative able rom the battery.

Disconnect RSunit connectorC (8P) rom the SRSunit {seestep7 on page23-22).

9 .

1 0 .



g3

11. Check esistance etween he No. 2 terminalof thefloor wire harness Pconnectorand body ground.

Thereshould be an open circuit.or at least1 fvlQ

FLOORWIREHARNESS3P CONNECTOR

Wire ide t emaleerminals


YES-Go to s tep12.

NO Short o ground n the floor wire harness r

multiplexcontrolunit.Replacehe faulty harnessorpar t . I

Check esistance etween he No. 3 terminalof the

floor wire harness P connector nd bodyground.

There hou ld ean openc i rcu i t , r a t east M Q.

FLOORWIREHARNESS P CONNECTOR

LT GRN



YES Go to step 13.

NO-Shor t to ground n he loorwi rereplace he floor wire harness.I

1 2 .

13. Check esistance etween he No .8 terminalofSR Sunit connectorC (8P)and he No. 3 terminalo

the floor wire harness3Pconnector. hereshould

b e 0 1 Q .

FLOORWIREARNESS SRS NITCONNECTOR83PCONNECTOB



YES Go to step 14.

NO Open n th e floor wire harness; eplace he

floor wire harness.l

Check esistance etwe en he No. 4 terminalof

SRSuni tconnector (8P) nd he No.2 te rm ina l

the floor wire harness Pconnector. hereshould

b e 0 - 1 0 .

1 4 .

FLOORWIREHARNESS3PCONNECTOR SRSUNITCONNECTOR IsP




NO Open n he loorwi reharness r mul t ip lex

control unit,or poor connection t the floor wireharness, he under-dashuse/relay ox, and hemultiplexcontrol unit.Check he connection t hefloor wire harness , he under-dashuse/relay oxand he multiplexcontrolunit. f the connection sOK, replace he faulty harnessor part. l

harness;

23-



RS


DTC -4:FaultyFrontPassenger'seatBeltBuckleSwitch

1. Erase he DTCmemory {seepage23-26).

2 . Turn he gn i t ion w i t chON { l l ) , henbuck le ndunbuckle he front passenger's ea tbelt severalt imes.

3. Read he DTC.

ls DTC 9- 4 ndicated?

YES-Go to step4.

NO Intermittent ailure,system s OK at this t ime.Go o Troubleshooting ntermiftent ailures seepage 23-26)'.


5. Disconnecthe front passenger's eat belt buckleswitch3P connector A) rom th e floor wire harness.

6. Buckle he front passenger's ea tbelt.


terminalsof the front passenger's eat belt buckleswitch3Pconnector. hereshould be 0- 1 Q.

Check esistance etween he No. 1 and No.2terminalsof the sameconnector. hereshould bean ooenc i rcu i t , r a t east M Q

FRONT ASSENGER'SEAT ELTBUCKLE WITCH PCONNECTOR

BLU/RED


Terminal ide f male erminals

Is the rcsistanceas specified?

YES-Go to step7.

NO Replacehe front passenger's eat belt buckle

assembly, hen clear he DTC.I



7. Unbuckle he front passenger's ea tbelt.

Check esistance etween he No. 1 and No. 2

terminalsof the ront passenger's ea tbelt buckleswi tch Pconnector .here hou ld e 0 1 ! ) .

Check esistance etween he No. 1 and No. 3

terminalsof the sameconnector. hereshould be

an oDencircuit,or at east1 M Q

FRONT ASSENGER'SEATBELTBUCKLE WITCH PCONNECTOR

Terminal ideof male erminals

Terminal ideof male erminals

ls the resistance s specil ied?

YES Go o step8.

NO-Replace the front passenger's ea tbelt buckle

assembly, hen clear he DTC.I

9 .

1 0 .

8. Check esistance etween he No. 1 erminalofth

floor wire harness3Pconnectorand bodyground

T h e r e h o u l d e0 1 Q .



ls the tesistance as specified?

YES Go o step9.

NO-Open in the floor wire harnessor poor grou

connection t G551. f G551 s OK, replace he floo

wi re harness. I

Disconnecthe negative able rom the battery,

Disconnect RSunit connectorC (8P) ro m the SRunit (seestep 7 on page 23-22).

(cont

23-



Rs


11. Check es is tanceetweenhe No.2 ermina l f thefloor wire harness P connector nd body ground.

Thereshould be an opencircuit,or at least1 M0 .

FLOORWIREHARNESSPCONNECTOR



YES-Go to s tep12.

NO-Short to ground n the floor wire h arness;

replace he floor wire harness.I

Check esistance etween he No. 3 terminalof thefloor wire harness P connectorand body ground.

Thereshould be an open circuit,or at east1 l\4 .

FLOOR IRE ABNES SPCONNECTOR



YES-Go to s tep13.

NO Short o ground n the floor wire harness;replace he floor wire harn ess.I

23-76

\

13 . Check esistance etween he No. 7 terminalofSRSuni tconnector (8P) nd he No.3 erm ina l fthe floor wire harness Pconnector.

There hou ld e0-1 Q.

FLOORWIREARNESS SRSUNITCONNECTOR(8P)3PCONNECTOR


ls the tesistance as specified?

YES-Go to step 14.

NO Open n the floor wire harness; eplace hef loorwi re harness. I

Check esistance etween he No, 3 terminalofSR Sunit connectorC (8P) nd he No. 2 terminalofthe loorwi re harness Pconnecto fT h e r e

h o u l d e01 Q .

L1 4 .


SRS UNIT CONNECTOR ISPI



YES Rep laceheSRSuni t see age23-122) .1

NO Open n he loorwl re harness;ep lacethef loorwi re harness. l



DTC -6:Faulty eftFront mpactSensor


. SRS nflatorsimulator07SAZ-TB4011A. SR Ssimulator eadH 07YM-S3AA100


2. Turn he ignitionswitchON (ll),and check hat heSRS ndicator omeson for about 6 seconds nd

then goesoff.


YES-Go to step3.

NO Intermiftentailure,system s OK at this ime.

Go o Troubleshootingntermittent ailures se epage23-26).

3. Turn he ignit ionswitchOFF.Check heconnections etweenSRSunit connectorA (18P)

and he SRSunit.between he enginecompartmentwire harness Pconnectorand he

left ront impactsensor seepage23-13), nd atconnectorC401.

Are theconnectionsOK ?

YES Go to step 4.

NO-Repair th e poorconnections nd retest. f DTC

9- 6 s sti l l present, o to step 4.

Turn he ignitionswitchOFF.Disconnecthe

batterynegative able.and wait for 3 minutes.

Disconnecthe driver'sairbag4P connector rom

the cable ee l seestep2 on page23-21).


connector rom dashboardwire harnessB {seestep

3 on page23-21).

Disconnect oth seatbelt ensioner2P connectorsfrom the floor wire harness se estep 5 on page23 -22).

7 .

9.

1 0 .

8. Disconnectheengine ompartmentireharnes2PconnectorA) rom he eft ront mpact enso

Disconnect RSunitconnectorA {18P)rom the

SRSunit (seestep7 on page23-22J.

Check esistanc e etween he No.10an d No. 11

terminalsof SRSunit connectorA (18P). here

shouldbe an oDen ircuit.or at least1 M 0 .

SR SUNITCONNECTOR (18PI



YES Go o step 11.

NO-Shor t in heeng ine ompanment i re

harnessor dashboardwire harnessB; replace hefau l t yharness. I


Turn he ignit ionswitchON { l) .

{cont

RED

1 1 .

12.

2 3 5 6 7 8 9

10 t l 1Z t 3 15 16 17 1 8

IT

ILK

23-



Rs


13. Check oltage etweenheNo .10 erminal f SRSunitconnector (18P) ndbodyground. hereshouid e l V or ess.

SRS UNIT CONNECTOR {,I8P)

1 2 3 7 8 I

10 11 12 l 3 t 4 15 1 6 1 1 t6

RED

Wire side oI female erminals

ls the voltage as specitied?

YES-Go to step 14 .

NO-Short to power n the enginecompartmentwire harnessor dashboardwire harnessB; replace

the faulty harness.l


Connect he SRS nflatorsimulator jumper

connector) nd simulator ead H o the engine

compartmentwire harness PconnectorA).

07YAZ-S3AA100

07SAZ-TB,O11A

1 4 .

t 5 .

\."

16 . Check esistance etween he No. 10an d No. 11terminalsof SRSunit connectorA (18P). hereshou ld e 1 0 or ess.

SRS UNIT CONNECTOR Il8PI



YES Faulty eft ront mpactsensoror SRSunit;replace he left ront impact sensor seepage23-125).lf the problem s sti l l present, eplace he SRSunit(see age23-122) .1

NO-Poor connection t C401, aultyenginecompartmentwire harness, r faultydashboardwire harnessB. nspectC401. f it is OK, replace hefaulty harness.l

=



DTC -7: aulty ight ront mpact ensor

SpecialTools Bequired

. SRS nflatorsimulator07SAZ-TB4011A

. SRSsimulator eadH 07YM-S3AA100

1. Eras e he DTCmemory {seepage23-26).

2 . Turn he gn i t ion w i t chON { l l ) , ndcheckthat theSRS ndicator omeson fo r about 6 sec onds ndthen goes off.


YES-Go to step3.

NO Intermittent ailure,system s OK at this ime.Go o TroubleshootingntermittentFailures se epage 23-26).

3. Turn he ignit ionswitchOFF.Check heconnections etweenSRSunit connectorA 18P)

and he SRSunit,between he enginecompartmentwire harness Pconnectorand heright ront impactsensor se epage23-13), nd atconnectorC401.

Ar e the connectionsOK ?

YES-Go to step4.

NO Repair he poorconnections nd retest. f DTC9-7 s sti l l present, o to step4.

Turn he gnitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe driver'sairbag4P connector rom

the cable ee l se estep2 on page23-21).

Disconnecthe front passenger's irbag4Pconnector rom the dashboardwire harness se e

step3 on page23-21).

Disconnect oth seatbelt ensioner2Pconnectorsfrom the floor wire harness se estep 5 on page23 -22).

4 .

5 .

7 .

'10.

Disconnecthe enginecompartmentwire harness2Pconnector A) ro m the right ront impactsenso

Disconnect RSunit connectorA (18P)ro m th eSRS unit (seestep 7 on page 23-221.

Check esistance etween he No. 1 and No. 12terminalsof SRSunit connectorA (18P). hereshould be an open circuit,or at least1 M 0.

SRS UNITCONNECTOR (18PI

GR N

1 1 .

Wire sideol female erminals


YES Go o s tep11.

NO-Shor t in heeng ine ompanment i re

harness r dashboardwire harnessB; replace hefau l t yharness, I



(cont'd

IF!-

t 1 t 2 ) lI r o l r l r

5 6 I 6

13 1 6 1 7 18

SL K

23-



Rs


13 .Check oltage etweenhe No.1terminal fSRSunitconnector (18P) ndbodyground. hereshould e1 V or ess.

SR SUNITCONNECTOR I18P}


ls the voltage as specified?

YES Go o step 14.

NO-Short to power n the enginecompartmentwire harnessor dashboardwire harnessB; replacethe faulty harness.l


Connect he SRS nflatorsimulator jumper

connector) nd simulator ea dH to the engine

compartmentwire harness P connectorA).

1 4 .

07YAZ-S3AA100

16. Check esistance etween he No. 1 and No.12

terminalsof SRSunit connectorA (18P). hereshou ld e 1 O or ess.


GR N


ls the resistance asspecitied?

YES Faulty ight ront mpactsensoror SRSunit;replace he rightfront sensor seepage23-125).ftheproblem s sti l l present, eplace he SRSunit (see

page23-1221.a

NO- Poorconnection t C401, aultyenginecompartmentwire harness, r faultydashboardwire harnessB. nspectC401. f it is OK, eplace hefaulty harness,

L

J_l r 1 2 l r

tE.]I/A

5 6 7 8 9

t 3 1 1 r5 16 1 1 t 6

BLK



J

DTC 1-1: pen r IncreasedesistancenDriver 's ideAirbag nf lator

SpecialToolsRequired. SRS nf la to r imu la tor 7SM-TB4011A. SR Ssimulator ead E 07XM-S140200

1. Erase he DTCmemory (seepage23-26),

2. Tu n he ignit ionswitchON (ll),and check hat heSRS ndicator omeson fo r about6 secondsandthen goes off.

Does the SBS indicatot stay on?

YES Go o step3.

NO Intermittent ailure,system s OK at this ime.Go o Troubleshootingntermittent ailures se e

page 23-261.


4. Disconnecthe floor wire harness Pconnector A)

from the driver'ssideairbag.

07sAz-T84011A

5. Connect he SRS nflatorsimulator 2 Q connector)and simulator ead E o the floor wire harness.



8. Read he DTC.


YE S Go o step9.

NO-Open or increased esistancen the driver'sside airbag nflator; eplace he driver'ssidea i rbag see age 3-1 '15) .1

9. Turn he ignitionswitch OFF.Disconnecthe


10 . Disconnecthe front passenger's ide airbag2Pconnector seestep 4 on page23-21) nd both sea

belt buckle ensione r4Pconnectors seestep6 onpage 23-221.

{cont'

23-



Rs

' It .

1 2


DisconnectRSun i tconnector (18P) f romhe

SRSunit (seestep7 on page23-22).Do notdisconnect he special ool from the floor wire

harness P connector.

Check esistance etween he No.6 and No. 17term ina ls f SRSuni tconnector (18P) . here

shou ld e 2 .0 3 .0 Q.


WHT/BLU

rr--r-{l T l s l s l a

IdFFI \2 0

10 t l 15

WHT/BLK



YES-Faulty SRSunit or poorcontactat SRSunitconnector (18P) nd heSRSuni t .Checkheconnection;f the connec tion s OK, replace heSR Sunit (seepage23'1221.a

NO Openor increased esistancen the floor wireharness; eplace he floor wire har ness.l

DTC 1-3: hort o AnotherWireorDecreasedesistancen Driver 's ideAirbaglnf lator

SpecialToolsRequired' SRS nf la to r imu la tor 7SAZ-T84011A. SRSsimulator eadE o7XAZ-S140200

1. Erase he DTCmemory (seepage23 26).

2 . Turn he gn i t ion wi tchON ( l l ) , ndcheck ha t heSRS ndicator omes on fo r about6 seconds ndthen goesoff.


YE S Go o step 3.

NO Intermittent ailure,system s OK at his t ime.Go o Troubleshootingntermittent ailures see

page23-26).

Turn he ignitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe floor wire harness Pconnector A)

f rom he dr i ver ' s idea i rbag.

07sAz-T84011A

Connecthe SRS nf la to r imu la tor2 0 connector )ands imula toreadE o the loorwi re harness.


Erase he DT Cmemory..



8. Read he DTC.


YES-Go to step9.

NO*Shon to anotherwire in he driver'ssideairbag n flator; eplace he driver'ssideairbag see

page23-115) . I

9. Turn he ignit ionswitchOFF.Disconnecthebatterynegative able.and wait for 3 minutes.

10. Disconnecttheront passenger's id eairbag2Pconnector se estep4 on page23-21) nd bothseatbelt buckle ensioner4P connectors seestep6 onpage23-22l,.

11. Disconnecthe special ool from the floor wireharness2Pconnector.

12 . D isconnectRSun i tconnector {18P) f romheSRSunit {seestep7 on page23-221.

13. Check esistance etween he No.6 a nd No. 17term ina ls f SRSuni tconnector (18P) , hereshou ld ean openc i rcu i t , r at east1 M 0.

SR SUNITCONNECTOR {18PI



YES FaultySRSunit; replace he SRSunit {seepage23-'t221a

NO Shon o another i re n he loorwi reharness; eplace he floor wire ha ness.I

WHT/BLU

WHT/BLK

DTG 1-4: hort o Powern Driver 's ideAirbag nf lator

SpecialTools Required. SRS nflatorsimulator07SAZ-T84011A. SRSsimulator ea dEo7XAZ-S140200

1. Erase he DTCmemory {seepage23-261.

2 . Turn he gn i t ion w i t chON ( l l ) , ndcheck ha t theSRS ndicator omeson for about 6 seconds ndthen goesoff.


YES Go o step3.

NO Intermittent ailure,system s OK at this imeGo o Troubleshootingntermittent ailures see

page 23-26l,.



4. Disconnecthe floor wire harness P connector A

from the driver'sside airbag.

07sAz-TB4011A

5. Connecthe SRS n f la to r imu la tor 2 0 connectoands imula toreadE o the loorwi re harness.

(cont'

23-



sRs


6. Reconnecthe battery egativeable.

7. Erasehe DTCmemory,

8. Readhe DTC.

Is DTC 11-4ndicated?

YES-Go o step .

NO Short o power n hedriver's ideairbaginflator;eplacehedriver's ideairbag see ag e2 3 - 1 1 5 ) . t

Turn he ignit ionswilch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe front passenger's ide airbag2Pconnector seestep4 on page23-21) nd both seatbelt buckle ensioner4P connectors seesteD6 onpage 23-221.

9 .

'10.

\

1 1 .Disconnect RSunit connectorB (18P)rom theSR Sunit (seestep7 on page23-22l,.

Turn he gn l t ion wi tchON ( l l ) .


SR Sunit connectorB (18P) nd body ground,an d

between he No. 17 erminaland body ground.

Thereshould be 0.5 V or less.


WHT/BLK

ls the voltageas specitied?

YES- FaultySRSuniU eplace he SRSunit (see

page23-1221.a

NO Short o power n th e floor wire har ness;

rep lacehe loorwi re harness. l

' t2 .

1 3 .

U



DTC 1-5: hort o Groundn Driver 's ideAirbag nflator

Special Tools Required. SRS n f la to r imu la tor 7SM-T84011A' SRSsimulator eadE o7XAZ-S140200

'1 .Erase he DTCmemory {seepage23-26).

2. Turn he ignit ionswitchON {ll),and check hat heSRS ndicator omeson for about6 seconds ndthen goesoff.


YE S Go o step3.

NO Intermittentailure,system s OK at his t ime.Go o Troubleshootingntermittent ailures se epage23-261.


4. Disconnecthe floorwire harness Pconnector A)

from the driver'ssideairbag.

07saz-TB,r011A

Connect he SRS nflatorsimulator 2 Q connector)and simulator eadE o the floorwire harness.


Erase he DTCmemory.

6 .

7 .

8. Read he DTC.


YES Go o step9.

NO Short o ground n the driver'sside airbaginflator; eplace he driver'sside airbag seepage2 3 - 1 1 5 ) . t


10. Disconnecthe front passenger's id eairbag2Pconnector se estep4 on page23-21)andboth seabelt buckle ensioner4Pconnectors se estep6 onpage 23-221.

11. D isconnectSRSni tconnectorB18P) f romthe

SR Sunit (seestep7 on page23-22).

'12.Check esistance etween he No. 17and No. 15term ina ls f SRSuni tconnector (18P) . ndbetweenhe No.

17andNo. 16 erm ina ls . hen

check esistance etween he No. 17 erminalan dbody ground.Thereshould be an opencircuit,or aleast M 0.


WHT/BLK



YES FaultySRSunit; replace he SRSunit(see

page 23-122).a

NO-Short to ground n the floor wire harness;rep lacehe loorwi reharness. I

23-



Rs


DTG 2-1: pen r IncreasedesistancenFrontPassenger'sideAirbag nf lator

SpecialToolsRequired. SRS n f la to r imu la tor 7SAZ-T84011A. SR Ssimulator ead E o7XAZ-S140200


2 . Turn he gn i t ion wi tchON ( l l ) , ndcheck ha t he

SRS ndicator omes on for about6 seconds nd

then goesoff.

Does he SBS ndic atorstay on?

YES Go o step3.

NO Intermittent ailu e,system s OK at this ime.Go o TroubleshootingntermittentFailures see

page23-26).



4. Disconnecthe floor wire harness P connector A)

from the front passenger's ide airbag.

07xAz-s1A0200

5. Connect he SRS nflatorsimulator 2 Q connector)

ands imula toreadE o the loorwi re harness.

I

7 .

'10.

9.


Erase he DTCmemory.

Read he DTC.

ls DTC 12-l indicated?

YES Go o stepL

NO-Open or increased esistancen the frontpassenger's ide airbag nflator; eplac e hefrontpassenger ' sidea i rbag see age 3-1 5) .1


batterynegative able.and wait for 3 minutes.

Disconnecthe driver'ssideairbag2P connector{seestep4 on page23-21)andboth seatbelt buckle

tensioner4Pconnectors seestep6 on page23-22).



1't

12 .

Disconnect RS unit connectorB ('l8P) rom th eSR Sunit (seestep7 on page23-22).Do notdisconnecthe special ool from the floor wireharness Pconnector .

Check esistance etween he No.7 and No . 18term ina ls fSRSuni t connector (18P) . hereshou ld e 2 .0 3 .0 (J .


WHT/GRN



YES FaultySRSunit or poor contactat SRSunitconnector ( 8P)and he SRSuni t .Checkheconnection; f the connection s OK , replaceheSR Sunit (seepage23-1221.a

NO Openor increased esistancen the floor wire

harness;ep lacehe loorwi re harness. I

WHT/RED

DTC 2-3: hort o AnotherWireorDecreasedesistancen FrontPassenger'SideAirbag nflator

SpecialToolsRequired. SRS nf la to r imu la tor 7SAZ-T84011A. SR Ssimulator eadE o7XAZ-S140200

1. Erase he DTCmemory (seepage 23-261.

2. Tu n he ignit ionswitchON (ll),and check hat heSRS ndicator omeson for about6 secondsan dthen goesoff.


YES Go to step 3.

NO - Intermittent ailure,system s OK at hi s timeGo o TroubleshootingntermittentFailures seepage23-26).

Turn he ignitionswitchOFF.Disconnecthebatterynegative able,and wait for 3 minutes.

Disconnecthe floor wire harness P connector A

from th e front passenger's ide airbag.4.

07xAz-s1A020

5. Connect he SRS nflatorsimulator 2 0 connectoands imula toreadE o the oorwi reharness.

(cont'

23-8



Rs



7, Erase he DT Cmemory.

8. Read he DTC.


YES-Go to step

NO Short o anotherwire in the front passenger's

side airbag nflator; eplace he front passenger's

s idea i rbag see age23- l l5 ) .1



10. Disconnecthe driver'ssideairbag2P connector(seestep4 on page23-21) nd both seatbelt buckle

tensioner4Pconnectors se estep 6 on page23-22).

' ! 1 .D isconnecthe spec ia l too l f romhe loorwi re

harness2Pconnector.

12. Disconnect RSunit connectorB ('lSPlfrom he

SRS unit {seestep 7 on page23-221.

13. Check esis tance etween he No.7 a nd No. 18

term ina ls f sRSun i tconnector (18P) . here

shou ld e anopenc i rcu i t , r a t east M 0.

SRSUNITCONNECTOR18P)

WHT/RED

-r-'r-Jl' 8 l e l ni['tl,Bl S-T

3 6

10 l l 15

WHT/GRN


ls the resistance as specilied?

YES Faul t y RSun i t ; ep lacehe SRSuni t seepage23-1221.a

NO Shor t o ano lherwi re n he oorwi re

harness; eplace he floor wire harness.I

23-88

\

DTC 2-4: hort o Powern FrontPassenger'sSideAirbag nf ator

Special Tools Required. sRS inflatorsimulator07sAz-TB4011A. SRSsimulator eadE 07XM-S140200


2 . Turn he gn i t ion w i t chON ( l l ) , ndcheck ha t theSRS ndicator omeson fo r about6 seconds nd

then goesoff.


YES-Go to step3.

NO - Intermittent ailure,system s OK at this ime.Go o Troubleshootingntermittent ailures se epage23-26).


banerynegative able,and wait for 3 minutes.

4. Disconnecthe floor wire harness Pconnector A)

from the front passenger's ide airbag.

07xAz-s1A0200

5. Connect he SRS nflatorsimulator 2 Q connector)ands imu a tor eadE o the loorwi reharness.





8. Read he DTC.

ls DTC 12-4 ndicated ?

YES Go o step9.

NO-Short to power n the front passenger's id eairbag nflator; eplace he front passenger's id ea i rbag see age23-115) .

9. Turn he ignit ionswilchOFF.Disconnectthebatterynegative able,and wait for 3 minutes.

'10.Disconnecthe driver'ssideairbag2Pconnector(seestep 4 on page23-21) nd both seat beltbuckletensioner 4P connectors (seestep 6 on page 23-22l,.

1 1 .Disconnect RS unitconnectorB (18P) rom theSRS unit (seestep 7 on page 23-221.

Turnhe

ignitionswitchON

(ll).

Check or voltagebetween he No. 7 terminalofSR Sunit connectorB ( 8P )and body ground,andbetween he No . 18 erminaland body ground.There hou ld e 0 .5V or less .


WHT/GRN


YE S FaultySRSunil; replace he SRSunit (seepage23-1221a

NO Short o power n th e floorwire harness;rep lacehe loorwi re harness. l

1 ?

1 3 .

23-



sRs


DTC 2-5: hort o Groundn FrontPassenger'sideAirbag nf lator

SpecialToolsRequired. SRS nflatorsimulator07SAZ-T84011A. SRSsimulator eadE o7XAZ-S140200

1. Erase he DT Cmemory (seepage23-26).

2. Turn he ignit ionswitch ON (ll),and check hat he

SR S ndicator omes on for about6 seconds nd

thengoesoff.


YES-Go to step3.

NO Intermittentailure,system s OK at this ime.Go o Troubleshootingntermittent ailures se e

page23-261.



4. Disconnecthe floor wire harness P connector A)

from the front passenger's id eairbag.

07xAz-s1A0200

5. Connect he SRS nflatorsimulator 2 Q connector)and simulator ead E o the floor wire harness.

23-90

6. Reconnectthe atterynegative able.


8. Read he DTC.


YES Go o step9.

NO-Short to ground n the front passenger's id e

airbag nflator; eplace he front passenger's id e

a i rbag see age23-1 5) .1



10, Disconnectthe river'sside airbag2P connector(seestep 4 on page 23-211and both seat belt buckle

lensioner4P connectors se estep6 onpage23-22).

11 . D isconnectRSun i tconnector (18P) f romhe

SRS unit (seestep 7 on page 23-22).

12. Check esistance etween he No. 15and No. 18

term ina ls f SRSuni tconnector (18P) nd

between he No. 16 and No. 18 erminals.Then

check esistance etween he No. 18 erminalan d

body ground.Thereshouldbe an open circuit,or atleast M Q.

SR SUNITCONNECTOR{18PI

2 3 6 7 8

1 0 11 t6 1 7 1E

LTGRN/REDdi 116\l9 Y 9

GRY/REDo


WHT/GRN


YES FaultySRSunit; replace he SRSunit (see

page 23-1221.a

NO-Shor t to ground n he loorwi reharness;

rep lacehe loorwi re harness. l



DTC13-3:NoSignal rom he Driver'sSidelmpact ensor

Special Tools Required. sRs inflatorsimularor07SAZ-TB4011A. SR Ssimulator eadH 07YM-S3AA100

1. ErasetheDT Cmemory (seepage 23-261.

2. Turn he ignit ionswitchON (ll),and check hat heSR S ndicator omeson for about6 seconds ndthen goesoff.


YES Go o step3.

NO Intermittent ailure, ystem s OK at this ime.Go o Troubleshootingntermittent ailures seepage 23-261.


4. Check he connection etween he floor wireharness P connector nd he driver'sside mpactsensor.

ls the connectionOK ?

YES Go to step5.

NO-Replace the driver'sside mpactsensorand/or the loor harness, s needed.

5. Disconnectthe river'sside airbagan d rontpassenger's id eairbag2P connectors se estep 4on page23-21). lso disconnect oth seat beltbuckle ensioner4Pconnectors se e

step 6 onpage

23-22).

6. Disconnecthe floor wire harness2Pconnector A}from the driver'sside mpactsensor.

07sAz-TB4011A

7. Connect he SRS nflatorsimulator 2 Q connector)and simulator ead H to the floor wire harness.

(cont'd)

23-9



Rs


8. DisconnectRS nitconnector (18P)ro m heSRS nit see te p7 on page 3-221.

9. Checkesistanceetweenhe No.8 andNo .15

terminals f sRSunitconnector ('l8P). hereshould e0 1.0Q.

SR SUNITCONNECTOR18P)

BRN/YEL

I:fr;f;l n

1 0 t l l l r or zr s \

LT GRN/RED


Is the resistance as specitied?

YES Faultydriver'sside mpactsensoror SRS

unit; replace he driver'sside mpactsensor se e

page23-123).f the problem s sti l l present, eplace

the SRSunit (seepage23-122).1

NO Open n he loorwi reharness;ep lacehe

floor wire harness.l

23-92

DTC13-4: aultyPowerSupply o the Driver'sSide mpact ensor

1. E rase he DT Cmemory {seepage23-261.

2. Turn he ignit ionswitchON (ll),and check hat he

SRS ndicator omeson for about6 seconds nd

then goesoff.


YES Go o step3.


Go o Troubleshootingntermittent ailures see

page23-26).

3. Turn he gnitionswitchOFF.Disconnectthebatterynegative able,an dwait for 3 minutes.

4. Disconnecthe driver'ssideairbagand rontpassenger's ide airbag2P connectors seestep4

on page23-21). lso disconnect oth seatbelt

buckle ensioner4Pconnectors se estep6 on page

23-22).



5. Disconnecthe loorwireharness PconnectorA)from hedriver's ide mpact ensor.

Disconnect RSunit connectorB (18P)ro m theSRS unit (seestep 7 on page 23-22)

Check esistance etween he No. 8 terminalofSR Sunit connectorB (18P) nd body ground.Thereshould be an open circuit,or at east1 M Q

1 .


Wire sideof female e.minals

ls the resistance s specitied?

YES-Go o step .

NO-Short o groundn he loorwireharness;replacehe loorwireharness.I

BRN/YEL

8. Check esistance etween he No.8 and No. 5terminalsof SRSunil connectorB (18P). hereshould be an opencircuit,or at least1 M 0 .

SR SUNITCONNECTOR {18P'

BRN/YEL

IflliT;l n3

10 11 1tr6l1tf;l \

LT GRN/RED

Wire side oI female erminals


YES-Faulty driver'sside mpactsensoror SRSunit; replace he driver'sside mpactsensor seepage23-1251.lfhe problem s sti l l present, eplacetheSRSuni t see age23-1221.a

NO- Short n the floorwire harness; eplace hef loorwi reharness. I

23-9



Rs


DTC 4-3: oSignalrom heFrontPassenger'side mpact ensor

SpecialToolsRequired. SRS nflatorsimulator07SAZ-TB401'lA. SRSsimulator ea dH 07YAZ'S3AA100


2. Tu n he ignit ionswitchON (ll),and check hat he


then goesoff.


YES Go o step3.



page 23-26).


batterynegative able,an dwait fo r 3 minutes.

4. Che ck heconnectionbetween he floor wire

harness P connectorand he front passenger's

side mpactsensor.

Is the connectionOK ?

YES-Go to step5.

NO- Poorcontactbetween he floor wire harness

2Pconnectorand he front passenger's ide mpact

sensor; eplace he front passenger's ide mpact

sensorand/or he floor harness, s needed.

23-94

5. Disconnectthe river'sside airbagand rontpassenger's ide airbag2Pconnectors se estep4

on page23-21). lso disconnect oth seatbelt

buckle ensioner4Pconnectors se estep6 on page23-22t .

Disconnecthe floor wire harness Pconnector A)

from the front passenger's id e mpactsensor.

07sAz-TB4o11A

7. Connect he SR S nflatorsimulator 2 0 connector)

and he simulator ea dH to the floor wire harness.



8. Disconnect RSunit connectorB (18P)from heSR Sunit (seestep7 on page23-221.

9. Check esistance etween he No.9 and No. 16terminalsof SRSunit connectorB (18P). hereshou ld e0-1 .0 S2.


PNK/BLU

t -l-u5l niFf;l \

3 0

1 0 t1 t 5

GRY/RED

Wire ide l emaleerminals


YES-Faulty front passenger's ide mpactsensoror SRSunit; replace he front passenger's id eimpactsensor se epage23-125).f the problem sstil l present, eplace he SRSunit (seepage23-122).I

NO-Open in the floor wire harness; eplace hefloor wire harness.

DTC14-4: aultyPowerSupply o the FrontPassenger'side mpact ensor


2. Turn he ignitionswitchON (ll),and check hat heSRS ndicator omeson fo r about6 seconds ndthen goesoff.


YES-Go to step3.

NO-lntermittent failure,system s OK at this t ime.Go o TroubleshootingntermittentFailures see

page 23-261.

3. Turn he gnitionswitch OFF.Disconnecthebatterynegative able,and wait for 3 minutes.

4. Disconnectthe river'sside airbagand rontpassenger's id eairbag2P connectors se estep4on page23-21). lsodisconnect oth seatbeltbuckle ensioner4Pconnectors se estep6 on page

23-22t.

5. Disconnecthe floor wire harness2Pconnector A}from the front passenger's id e mpactsensor.

Disconnecl RS unit connectorB (18P) rom th eSRSunit (seestep7 on page23-22i.

(cont'd

"-;s.\\ / \--)

\ f r l l 1

- F.,=j

23-9



Rs


7. Check esistance etween he No. 9 terminal of

SRSunit connectorB (18P) nd body ground.There

shouldbe an ooen circuit,or at east1 N4Q.



ls the tesistance as specilied?

YES Go to step 8.

NO-Short to ground n the loor wire harness;


Check esistance etween he No.9 and No. 16

terminalsof SRSunit connectorB (18P). here

should be an open circuit,or at least1 M O

SRSUNITCONNECTOR(18P)

PNK/BLU

_-r1 8 s l / itltlis-l \

2 3 6

1 0 t l

GRY/RED

Wire ide t emaleerminals


YES-Faulty front passenger's ide mpactsensor

or SRSunit; replace he front passenger's id e

impactsensor se epage23-125).f the problem s

st i l lp resent ,ep laceheSRSuni t see age23-122) .

I

NO Short n the floor wire harn ess; eplace he

f loorwi reharness. l

PNK/BLU


DTC 5-1: aultyOPDS nit

NOTE:

. An incorrectOPDSunit can causeDT C15-1.. A new un in i t i a l i zed)PDS n i t ns ta l led i th a fau lt y

OPDS ensor ancauseDTC15-1 .. lf yo u installa new OPDSunit and a ne w SRSunit at

thesame ime, n i t i a l i zehe OPDSmanua l l y see

page23-27), o not use he HondaPGMTester.

1. Makesure nothing s on the front passenger's eat.

2. Init ializehe OPDSunit (seepage23-27).

3. Erase he DTCmemory (seepage23-26]'.

4. Read he DTC.


YES Go o step 5.

NO Intermittent ailure,system s OK at this ime.


page23-26).

Check he No. 9 (10A) use n the under-dashuse/

relayDox,

ls th e tuse OK ?

YES Go o step6.

NO Go o step9.

Disconnect PDSunit harness P connector A)

from the OPDSunit (A) seepage23-124).



8. Check or voltagebetween he No. 4 terminalofOPDSunit harness Pconnectorand body ground.


OPDSUNIT HARNESS8P CONNECTOR



YES-Go to step 16.

NO Open n th e floor wire harness r OPDSunitharness; eplace he faulty harness.I

Rep lacehe No.9 (10A) fusen he under -dashfuse/relay ox .

Turn he ignit ionswitchON (ll) or 30 seconds, henturn it off.

Checkhe No.9 (10A) fuse.

ls the tuse OK ?

YES lntermittent ailure,system s OK at this ime.Go o Troubleshootingntermiftent ailures see

page 23-26).

NO Go o step 12.

Replace he No. 9 (' l0A) use.

9 .

1 0 .

1 1 .

14.

t o .

1 1 .

13. DisconnectOPDSunit harness Pconnector A)

from the OPDSunit.

Turn he ignit ionswitchON (ll) or 30 seconds, hen

turn it off.

CheckheNo.9 (10A)use.

ls the f use OK ?

YES Short o ground n the OPDSunit; replace heOPDSunit (seepage23-1241.1

NO-Short to ground n the No. 9 (10A) us ecircuit(f loorharness, r OPDSharness); eplace heaffectedharness.I


Check esistance etween he No.8 terminalof

OPDSunit harness P connectorand body ground.Thereshould be 0

'1.0Q

OPDSUNIT HARNESS PCONNECTOR

l4V-'l^lTVjEl#

BLK

@I



YES Go o step 18 .

NO Open n the floor wire harness r OPDSunitharness, r poorground G551) .f G551 sOK,replace he faulty harness.I

(cont'd

23-9



sRs

18.

19.

20.


Turn he gnitionswitch OFF.Disconnecthebatterynegative able.an dwait for 3 minutes.

Disconnect oth side airbagconnectors seestep 4on page23-21)and othseatbe l tbuck le tens ioner4Pconnectors seestep6 on page23-22).

Disconnect RSunit connectorB (18P)rom the

SRS unit (seestep 7 on page 23-221.


SRSunit connectorB (18P) nd body ground.There

should be an oDencircuit,or at least1 MQ .


Wire id eot emaleerminals


YES- Go o step22 .

NO Short o ground n the floor wire harnessorOPDSunit harness; eplace he faulty harness.l

GRN/ORN

22. Check esistance etween he No. 3 terminalofSR Sunit connectorB (18P) nd he No. 7 terminal

of OPDSunit harness P connector. hereshould

b e 0 1 . 0 Q .

SRSUNITCONNECTOR(18PI

GRN/ORN


OPOSUNIT HARNESS8P CONNECTOR

24.

BLU


ls the resistance sspecitied?

YES Go o step23.

NO Openn he loorwireharness r n heOPDSunitharness;eplacehe aultyharnessl

Reconnecthe baftery egativeable.




J

25. Check or voltagebetween he No. 3 terminalofSR Sunit connectorB (18P) nd body ground.Thereshou ld e0 .5V or less .

SR SUNITCONNECTOR (18P)


ls the voltageas specil ied?

YES Go o step26 .

NO Short o power n th e floor wire harness r in

the OPDSunit harness; eplac e he faulty

harness. l

Replacehe OPDSunit (seepage23-'124),he ninit ializehe system seepage23-27).

Erase he DTCmemory, hen check or DTC15-1.

ls DTC 15-l indicated?


NO Th esystem s OK.l

26.

27.

PNK

DTC15-2: aultySideAirbagCutoff ndicatCircuit

1. Makesure nothing s on the front passenger's ea

2. Erase he DTCmemory (seepage23-26]-.

3 . Turn he gn i t ion w i t chON ( l l ) ,andcheckthat t


then goesoff.


YES-Turn th e ignit ionswitchOFF,an d go to step

NO Intermittent ailure,system s OK at his t im

Go o TroubleshootingntermittentFailures se epage23-26).

NOTE:ThisDT Cma y havebeencausedby turnin

the gn i t ion w i t chON ( l l )w i th hegauge ssemb

disconnected.

Turn he gn i t ion w i t chON ( l l ) , ndchecktha t th

sideairbagcutoff ndicator omeson .

Does the side airbag cutoft indicator come on?

YES Go o step 5.

NO Go o step6.

Makesure he side airbagcutoff ndicatorgoesof

after5 seconds.

Does he side airbag cutoff indicatorgo otf after

seconds?

YES FaultyOPDSunit or SRSuniu replace heOPDSunit (seepage23-1241.f the problem s sti lpresent, eplace he SRSunit (seepage23-122).

NO Go o step 32.


{cont

23



Rs


7. Check he No. 10(7.5A)fuse n the under-dashfuse/relay ox .

ls the f use OK ?

YES Go to step8.

NO Replacehe fuse, hen urn the ignit ionswitchON (ll). f the fuse blows again,check or a short nthe No. 10 7.5A) us ecircuit EC Mwire harness.floor harness, r OPDSharness).1

8. Disconnecthe OPDSunit harness P connector A)

from the OPDSunit (seepage23-124).

Turn he ignitionswitchON (ll).

Check or voltagebetween he No .3 terminalof theOPDSunit harness P connector nd bodyground.

Thereshould be battery oltage.

OPDSUNtT HARNESS P CONNECTOR



YES Go o s tep11.

NO Go o step23.

9.

10 .

1 1 .

12 .

1 4 .

Turn he ignlt ionswitchOFF.

Disconnecthe dashboardwire harness17 P

connectorK from the under-dashuse/relay ox ,


Check or voltagebetween he No. 3 terminalof theOPDSunit harness8P connector nd body ground.

Thereshouldbe 0.5V or less.

OPDSUNITHABNESSPCONNECTOR


ls the voltageas specitied?

YES-FaultyOPDS nit; eplaceheOPDS nit seepage23-124)a

NO-Go to step15 .



t 5 .

1 7 .

1 8 .


Remove he gaugeassembly se epage22-64).

Thendisconnect augeassembly onnectorA fromth e gaugeassembly.

Turn he ignitionswitchON (ll).

Check or voltagebetween he No .3 terminal of the

OPDSunit harness P connector nd bodyground.

Thereshould be 0.5V or less.

OPOS NITHARNESSPCONNECTOR



YES Short o power n the gaugeassembly;replace he gaugeassembly.l

NO Go o step 19.

A\t

\,

1 9 .

20 .

22.


Disconnectloor wire harness P connectorC509

(A)from the dashboardwire harness.


Check or voltagebetween he No.3 terminalof theOPDSunit harness P connectorand body ground

Thereshould be 0.5V or less.

OPDS NITHARNESSPCONNECTOB

Wire sideo{ female erminals


YES Short o power n dashboardwire harnessA;

replace ashboardwire harnessA. l

NO-Short to power n th e floor wire harness r inthe OPDS n i tharness;f heOPDS n i tharnesssOK, replace he floor wire harness.I

(cont'd

23-1



Rs

23.

24 .



Remove he gaugeassembly se epage22-64l,.

With the connectors t i l l connected o the gaugeassembly, ackprobe he No .

15terminalof gauge

assembly onnectorA (22P).

Turn he ignit ionswitch ON {ll).

Check or voltagebetween he No. 15 erminalofgaugeassembly onnectorA {22P) nd bodyground.Thereshould be batteryvoltage.

GAUGE SSEMBLY ONNECTOR{22P)



YES-Go to step 27.

NO Go to step31.


Dlsconnectloor wire harness P connectorC509

{A ) rom dashboardwire harness.

26.

27.

28.

\

29. Turn he gn i t ion w i t chON ( l l i

30 . 02mode l :Checkforvo l tageetweenhe No.4

terminalof dashboardwire harnessA 6P connectorC509and body ground.Thereshouldbe battery

vor lage.'0 3 model:Check or voltagebetween he No .5

terminalof dashboardwire harnessA 8P connector

C509and body ground.Thereshouldbe batteryvo l lage.

'02 Model:

OASHBOARDIRE ARNESS6PCONNECTOF

Terminal s ide of male erminals

'0 3 Model:

DASHBOARDIREHARNESS 8PCONNECTOR

Termina lide f maleermina ls


YE S Poorcontactat he dashboardwire harness

A 6Por 8Pconnector nd loorwi re harness, nopen n he loorwi re harness, r an open n he

OPDS n i tharness. heckheconnect ion ;f he

connection s OK, replace he faulty harness.l

NO Poorcontactat gaugeassembly onnectorA

{22P) r an open n dashboard i re harness .Checkgaugeassembly onnectorA {22P);f the

connections re OK, replacedashboardwire

harness . I



Check or voltagebetween he No. 2 terminalofgauge ssembly onnector (22P) nd bodyground.Thereshould be batteryvoltage.

GAUGE SSEMBLYONNECTOR{22P)


ls ther e battery voltage?

YES Faultyside airbagcutoff ndicator ircuit;rep lacehegauge ssembly . l

NO Open n dashboardwire harnessA; replacedashboard i reharness . I

YEL

1 2 3 4 5 X 6 8 9 10

1t 12 I J ,/1,/1,/)1 1 21 22

\,

32.

33 .

35.

36 .

34.


Disconnecthe OPDSunit harness P connector

f rom he OPDS n i t see age23- 24) .


Does he slde airbag cutotf indic atorcomeon ?

YES Go to step35 .

NO FaultyOPDSunit; eplace he OPDSunit. l


Remove he gaugeassembly seepage22-64).

Thendisconnect augeassembly onnectorA fro

thegauge ssembly .

(cont

23-1



Rs

DTGTroubleshootingcont'dl

37. Check esistanc e etween he No. 15 erminalofgaugeassembly onnectorA (22P) nd bodyground.Thereshould be an open circuit,or at least

1 M 0 .

GAUGE SSEMBLY ONNECTORI22PI


YES-Short to ground n the side airbagcutoffindicator ircuit; eplace he gaugeassembly.l

NO Short o ground n the dashboardwire

harnessA, floor wire harness, r OPDSunit

harness; eplace he faulty harness.l

Wire sideoffemale

erminals

23-104

DTC 5-3: aultyOPDS ensor

1. Erase he DT Cmemory {seepage23-261.

2 . Turn he gn i t ion wi tchON ( l l ) , ndcheck hat heSRS ndicator omes on for about 6 seconds nd

then goesoff.


YES-Go to step3.

NO Intermittent ailure,system s OK at his t ime.Go o Troubleshootingntermittent ailures se e

page23-26).

NOTE:Aftermarket evices fluorescentights,

laptopcomputers, tc.)usednear he frontpassenger's eat-back an nterferewith th e seat-

backsensorsand causea falseDT C15-3. f one of

thesedeviceswas used,erase he DTC,operate he

devicenear he seat-back, nd recheck or DTCs. fDT C15-3 s reset, rase t, and do not use he

devicenear he seat-back.

3 .

4 .

Check he connection t the OPDS ensorharnessconnectorand he OPDSunit connector.

Are theconnectionsOK ?

YES-Go to step4.

NO Reconnecthe OPDS ensorharness

connector, nd clear he DTC.I

Replace he OPDS ensor/seat-backoa m (seepage

20-141, nd nitializehe OPDS seepage23-27).

Erase he DTCmemory, hen check or DT C15-3.


YES Replacehe OPDSunit (seepage23-1241.a

NO The system s OK.l



d\9

SRS ndicatorCircuitTroubleshooting

TheSRS ndicatorDoesn'tComeOn

1. Turn he ignit ionswitchON (ll),and see f theother

indicators om e on {brake ystem,etc).

Do the other ndicatorscomeon ?

YES Go o step2.

NO-Go to s tep .

2. Turn he gnitionswitchOFF, hen remove hegaugeassembly se epage22-641. isconnectgaugeassembly onnectorA and B from the gaugeassembly.

Check esistance etween he No. 12 erminalofgauge

assembly onnectorB(22P)

nd bodyground. here hou ld e 0 1 .0Q.

GAUGE SSEMBLYONNECTORI22PI

1 2 3 4 5 X 6 8 9 1 0

11 12 l 3 /)x1 1 1B 21 22

BLK

o.


Is the resistance as specified?

YE S Go o step4.

NO Open n he BLKwi reo f dashboard i reharness or au l t ybodyground ermina l G501) .fthe bodyground ermina l s OK, ep lace ashboardwi reharness . I

,

23-1

4. Check or voltagebetween he No. 4terminal ofgaugeassembly onnectorA (22P) nd bodygroundwithin the first 6 secondsafter urning he

ignitionswitchON (ll).Thereshould be 8.5 V or le

GAUGE SSEMBLY ONNECTORI22PI

Wire ide f emaleerminats

Is the voltage as specified?

YES-Fau l t ySRS nd ica tor l rcu i tn hegauge

assembly; eplace he gaugeassembly.I

NO-Go to s tep5.


(cont'



Rs

6.

SRS ndicatorCircuitTroubleshootingcont'dl

7 .

Disconnect RSunit connectorC (8P) ro m the SRS

unit {seestep 7 on page 23-22).

Disconnect augeassembly onnectorA (22P).Connect voltmeterbetween he No, 4terminal ofgaugeassembly onnectorA (22P) nd body

ground. urn he gn i t ion w i t chON ( l l ) , nd

measure oltage.Thereshouldbe 0.5 V or less.

GAUGE SSEMBLY ONNECTOR{22P)


ls th e voltageas specitied?

YES-Faulty SRSunit; replace he SRSunit (see

page23-'l22l.a

NO-Short to power n th e PN Kwire of dashboard

wire harnessA or in th e floor wire harness; eplace

the au l t yharness. l

L Turn he ignit ionswitchOFF.Check he No. 10

{7.5A)fuse n the under-dashuse/relay ox.

ls the tuse blown?

YES-Go to step 10.

NO Go o step9.

9. Connect voltmeterbetween he No.2 terminalofgaugeassembly onnectorB (22P) nd body

ground. urn he gn i t ion w i t chON ( l l ) , nd

measure he voltage.Thereshouldbe batteryvoltaqe.

GAUGE SSEMBLYONNECTOR(22P}

YEL

1 2 3 4 5 X 6 8 9 1 0

l l 12 ,/ ,/ ,/x 11 o 21 22



YES FaultySR S ndicator ircuit n the gauge

assemblyor poorcontactat gaugeassembly

connectorB (22P) nd he gaugeassembly; f the

connection s OK,replace he gaugeassembly.l

NO Open n the under-dashuse/relay ox No. 10(7.5A)use circuit,or open n the YELwire of

dashboardwire harnessA. lf the under-dashuse/

relaybo xis

OK ,replace he faulty harness.l

Replacehe No. 10 7.5A) use, hen check o see f

th e ndicators omeson .

Do the n dicatorscomeon ?

YES The system s OK at hls ime.l

NO Repa i rhe shor t o ground n he under -dash

fuse/ re lay ox No. 10 7.5A) fusei rcu i t . l

1 0 .



JTheSRS ndicatorStaysOn When n "SCS"

MenuMethod

NOTE:. lf yo u cannot etrieveDTCSwith he PGMTesterusing he SRSmenu method. etrieve he flashcodeswith th e Tester n SCSmode {seepage23-24|,.

. A ne w SRSunit mustsense he entiresystem s OKbeforecompleting ts nit ialself-test. he mostcommoncauseof an incomplete elf-test s hefailure o replace ll deployedpartsaftera coll ision,in particular, ea tbelt ensioners nd seatbelt buckletenstoners.

. An incomplete elf-test revents he PGMTester ro mretrievingDTCS, lthough lashcodesare available nthe Tester'sSC Smode.

1 Erase he DTCmemory using he MESconnector(seepage23-26).

Does he SRS ndicatorgo off whileyou ar eerasing he DTC memory?

YES-Go to step42.

NO Go o step2.

Check he No.13

{10A) use n the under-dashfuse/relay ox .

l s the f useOK?

YES--Go o step 19.

NO Go to step3.

Rep lacethe o.13 10A) use.

Turn he gn i t ion wi tchON ( l l ) , ndwai t o r 30seconds. hen urn the ignit ionswitchOFF.

Check heNo.13 10A)use.

ls the f use OK?

YES Thesystem s OKat h is ime. I

NO Go o step6.

3 .

6. Rep lacehe No.13 10A)use.



8. Disconnecthe driver'sairbag4Pconnector se e


9. Disconnecthe front passenger's irbag4Pconnector seestep3 on page23,21).

10. Disconnect oth seatbelt ensioner2P connectors(seestep5 on page23-221.

'11 .D isconnectSRSni tconnectorA{18P) f romtheSRS unit (seestep 7 on page 23-22],.

'12.Reconnecthe batterynegative able.

13 . Turn he gn i t ion wi tchON ( l l ) , ndwai t o r 30seconds. hen urn the gnitionswitchOFF.

14. Checkthe o. 13 '10A)use.

ls the f use OK?

YES-Shor t o ground n he SRSuni t ; ep laceheSRSunit (seepage23-122).a

NO Go o s tep15.

15. Rep lacehe No.13 10A)use.

{cont'd

23-1



Rs

from th e under-dash use/relav or .

1 1 .

1 8 .

SRS ndicatorCircuitTroubleshootingcont'd)

'16.Disconnect ashboardwire harnessB connectorS

Turn he ignitionswitchON {ll),and wait for 30seconds. hen urn the ignit ionswitchOFF,

Checkhe No. 13 10A)use.

ls th e f use OK?

YES Short o ground n dashboardwire harness

B; replacedashboardwire harnessB.I

NO-Short to ground n the under-dashuse/relay

box; replace he under-dashuse/relay ox.l



Disconnecthe driver'sairbag4Pconnector se e

step2 on page23-2'l).


connector seestep3 on page23-21).

Disconnect othseat belt ensioner2P connectors(seestep 5 on page23-22).

Disconnect RSunit connectorA (18P)ro m th e

SRS unit (seestep 7 on page23-22).

1 9 .

20.

21.

22.

24 . Beconnecthe batterynegative able.

Connect voltmeterbetween he No. 3 terminalof

SR Sunit connectorA (18P) nd bodyground.Turnthe gnitionswitchON (ll),and measure he voltage.

Thereshouldbe baftery oltage.

SR SUNITCONNECTOR(18PI



YES Go o step29 .

NO Go o step 26.


Disconnect ashboardwire harnessB connectorS

26.

27.

PN K

from the under-dashuse/relav ox.



28. Check esistance etween he No. 3 terminalofSR Sunit connectorA (18P) nd he No. 2 terminalof dashboardwire harnessB connectorS. Thereshou ld e 0 1 .00 .

DASHBOARDIREHARNESS CONNECTOR

Wire sideoffemale er m

l 2

r nasPN K

a,PNKT

SRS Nrr

l 2 3 5 7 8 I

1 0 11 12 l 3 14 1 5 16 1 1 l 8

CONNECTORI18P)



YES-Open in the under-dashuse/relay ox orpoorcontactat dashboardwire harnessBconnectors; heck he connection. f the connectionis OK, replace he under-dashuse/relay ox.l

NO-Open in dashboardwire harnessB; replacedashboardwire harnessB.I


Disconnect RSunit connectorC {8P) rom the SRSunit (seestep 7 on page 23-22],.

29 .

30 .

SRS UNIT CONNECTORC I8P}

31. Connecthe No.3 te rm ina l fSRSuni t connecto(18P) nd he No. 5 terminalof SRSunit connectoC (8P)wi th umperwi re .

PNKJUMPERWIRE

PNK




32 . Turn he ignit ionswitchON (llf

33 . Check he SRS ndicator.

Di d the SRS ndica torgo off?

YES FaultySR Sunit; replace he SRSunit (seepage23-122l.a

NO-Go to step34 .

34 . Turn he gnitionswitch OFF.

35. Disconnecthe umper wire between he No. 3terminalof SRSunit connectorA (18P) nd heNo. 5 terminalof SRSunit connectorC (8P).

36 . Check he No.13 10A) fusen he under ,dashfuse/relay ox .

ls the fuse OK?

YES Go o step40 .

NO Go o step37 .

37. Rep lacehe No.13 10A) fuse.

(cont'd

23-1



Rs

39.

SRS ndicatorGircuitTroubleshootingcont'dl

38. Remove he gaugeassembly se epage22-64),he n

disconnect augeassembly onnectorA from thegauge ssemDly ,


SR SunitconnectorC (8P)and body ground.There

shouldbe an ooen circuit,or at east1 fMQ



ls the resbtance as specitied?

YES-Faulty SRS ndicator ircuit n the gauge

assembly ;ep lacehe gauge ssembly . I

NO Shor t o ground n he loorwi re harness r in

dashboardwire harnessA; replace he faulty

harness. l

40. Remove he gaugeassembly seepage22-64),hen

disconnect augeassembly onnectorA from th egauge ssembly .

Check esistance e tween he No. 14 erminalofgauge ssembly onnector (22P) nd he No.5

terminalof SRSunit connectorC (8P). hereshould

be'l

0 or less,

4 1 .

SRS UNIT CONNECTOR (8P}


YES FaultySR S ndicator ircuit n the gauge

assemblyor poorcontactat gaugeassembly

connectorA (22P); heck he connection.f the

connection s OK, replace he gaugeassembly,I

NO Open n he loorwi re harness r in

dashboardwire harnessA; replace he faultyharness.


GAUGEASSEMBLY ONNECTOR I22P)




43 . lf necessary,emove he SCSservice onnectorfrom the l\4ES onnector.

44 . Turn he gn i t ion wi t chON { l l } .

Does he SB S ndicatorcomeon for about 6seconds and then go off?

YES Th e system s OK at this ime.

NO Go o step45 .

45. D isconnectRSun i tconnector (8P) romtheSRSunit (seestep 7 on page 23-221.

46 . Connect he HondaPG MTester A) o the DataLinkConnector B) ,an d ollow the Tester'sprompts nth e "SCS" menu(see he Tester's peratingmanu ) .

.r9

I,l

L,

23-1

47 . Check esistanceetweenhe No.6 erminal fSRS nitconnector (8P) ndbodyground. hs h o u l de0 - 1 . 0 Q .

SRS UNIT CONNECTOR I8P)



YES FaultySR Sunit or poor contactat SRSunconnectorC (8P); heck he connection. f theconnection s OK, replace he SRSunit (seepag

23-1221..

NO Open n the SCS ine between he No.6terminalof SRSunit connectorC (8P)an d he Noterminal BR Nwire) ofthe data in k connector(DLC), r open between he No. 4 terminal of theDLC nd bodyground.Repa i rhe openwi re(s) .

I 2

5 0

BRNn



Rs

ComponentReplacement/lnspectionfter Deployment

NOTE:Beforedoingany SRS epairs. se he PG M

TesterSR Smenu method o check or DTCS; efer o the

DT CTroubleshootingndex or the lessobvious

deployedparts seatbeit ensioners,ront sensors, ide

airbagsensors, tc.)

Aftera coll isionwhere he seatbelt ensioners

deployed, eplace hese tems:' Seatbelt ensioners. Seatbelt buckle ensioners. SRSuni t. Front mpactsensors

After a coll isionwhere he front airbag(s) eployed.

replace hese tems:. SRSuni t. Deployed irbag(s)

. Seatbelt ensioners

. Seatbeltbuckle ensioners

. Front mpactsensors

After a coll isionwhere he sideairbag{s) eployed,

replace hese tems:. SRSuni t. Dep loyed idea i rbag(s). Side mpactsenso(s)for the side(s) hat deployed

During he repairprocess, nspect heseareas:. lnspectallthe SRSwire harnesses. eplace, on't

repair,any damagedharnesses.. Inspect thecab leee l fo rheatdamage.f here s any

damage, eplace he cable eel.

Afterthe vehicle s completely epaired, urn th e

ignit ionswitchON (ll). f th e SRS ndicator omeson fo r

about 6 seconds nd hen goesoff, he SRSairbag

system s OK. f the ndicatordoesnot functionproperly,

use he PG MTesterSRS Menu Method o read he DTC(seepage23-23). f this doesn't etrieveany codes,us e

the Tester'sSCSmenu method(seepage23-24). f yo u

stil l cannot etrievea code,go to SRS ndicatorCircuit

Troubleshooting.

\ |



A\'l9

Driver'sAirbagReplacement

Removal

1. Disconnectthe atterynegative able,and wait atleast3 minutesbeforebeginningwork.

2. Remove he access anel A) rom th e steeringwheel, hen disconnecthe driver'sairbag4pconnector B)from the cable eel.

Remove he maintenance over (A), hen removethe wo Torx bolts B)usinga Torx T3Obit.

Disconnecthe hornswitchconnector 1P ) D).

Remove he driver'sairbag C)..

c

23-1

Installation

1. Connect he horn switchconnector 1P ) o th e

driver'sairbag.

2. Place he new driver'sairbag A) nthesteeringwheel,and secure t with new Torx bohs(B),an dinstallthemaintenance over (C).

a9.8 N.m {1.0 gf.m,7.2 bt. f t)

Connect he cable eel o the driver'sairbag4Pconnector A) , hen nstalltheaccess anel B)onthe steeringwheel.

Connect he batterynegative able.

After nstall ing he airbag, onfirm propersystemopera t ion :

. Turn he gn i t ion w i t chON ( l l ) ; heSRS nd ica tshouldcome on fo r about 6 seconds nd hen gooff.

. Makesure he horn works.

4.

5 .



Rs

FrontPassenger'sirbagReplacement

Removal

1. Disconnectthe atterynegative able,an dwait at

least3 minutesbeforebeginningwork,

2. Remove he glove bo x stops,and ower he glove

box.

3. Disconnecthe rontpassenger'sirbag PconnectorA) romdashboard ireharness .

Remove he threemounting nuts(A) rom the

bracket.Cover he lid and dashboardwith a cloth,

an d pr y carefullywith a screwdriver o l ift he frontpassenger ' si rbag B)outo f the dashboard .

NOTE:The i rbag id haspawlson tss idewhich

4 .

aftach t to the dashboard.

t

Installation

1. Place he new front passenger's irbag A) nto he

dashboard. ighten he front passenger's irbag

mount ing u ts B) .

9. 8N m {1.0 gf.m,7.2lbft}

Connect he front passenger's irbag4P connector(A) todashboard i reharness .

Raise he glove box, and reinstall he stops.


After nstall ing he airbag, onfirm propersystem

opera t ion ; u rn he gn i t ion w i t chON ( l l ) ; heSRS

indicator houldcome on for about6 seconds nd

then go off.

L

4.



SideAirbagReplacement

NOTE: eviewheseat eplacementro6eduren heBody ection efore ertormingepairs r service.

Removal

1. Disconnecttheattery egativeable, ndwaitatleast minutes efore eginning ork.

2. Disconnecthesideairbag arness PconnectorA).

Remove he seatassembly seepage20-71) ndseat-back over seepage20-75).

Remove he mountingnu t (A )and he sidea i rbag B) .

3.

o

23-11

Installation

NOTE:. l f he s idea i rbag id ssecured yatape, emove lh

rape.. Do not open he lid of the sideairbagcover.. Use new mountingnuts ightened o the specified

torque.. Makesure hat he seat-back over s nstalled

properly, mproper nstallationma y preventproper

deployment.. Be sure o install he harnesswires so hat hey ar e

no t pinchedor interferingwith other parts.

1. Place he new sideairbagon the seat-backrame(A).Tighten he sideairbagmountingnuts(B).

2. Installtheseat-back over se epage20-75).

3. Installtheseatassembly seepage20-71),he nconnect he side airbagharness2P connector.

4. Move he front seatand he seat-backhrough heifull rangesof movement,makingsure he harnesswires are not pinchedor interferingwith otherpart


6. After nstall ing he sideairbag,confirm propersystemoperation;Turn he gnitionswitch ON (ll);

t he SRS nd ica tor hou ld omeon fo r aboutsecondsand hen go off.



Rs

AirbagDisposal

Special Tool Required

Deployment ool 07HAz-SG00500

Beforescrappingan yairbags, ide airbags, eatbelt

tensioners, r seatbelt buckle ensioners including

those n a whole vehicle o be scrapped),he airbags,

sideairbags, eatbelt ensioners, r seatbelt buckle

tensionersmust be deployed. f th e vehicle s sti l lwithin

the warrantyperiod, he HondaDistrictService

Managermust giveapprovaland/orspecial nstruction

beforedeploying he airbags, ide airbags, eatbelt

tensioners, r seatbelt buckle ensioners.Only after he

airbags, ideairbags, eatbelt ensioners, r seatbelt

buckle ensionershavebeendeployed as he resultof

vehicle oll ision, or example), an hey be scrapped.

lf the airbags, ide airbags, eatbelt ensioners, nd

seatbelt buckle ensioners ppear ntact no tdeployed),treat hem with extremecaution.Follow his Drocedure.

Deploying irbagsn the Vehicle

l f an SRSequipped ehicle s to be entirelyscrapped, ts

airbags, ide airbags. eat belt ensioners. nd seatbelt

buckle ensioners hould be deolovedwhile sti l l n the

vehicle.The airbags, ideairbags, eatbelttensioners,

and seatbelt buckle ensioners houldno t be

considered s salvageable artsan d should neverbe

installed n anothervehicle.

1. Turn he ignit ionswitchOFF, hen disconn ect he

batterynegative able,an dwait at least3 minutes.

2. Confirm hat eachairbag,sideairbag,or seatbelt

tensioner s securelymounted.

3. Conf rm that he specia tool isfunctioningproperly

by following he checkprocedure n the ool label.

$

Driver's Airbag:

4. Remove he accesspanel ro m th e steeringwheel,

then disconnect he driver'sairbag4Pconnector

from the cable ee l se estep2 on page23-21).

Front Passenger'sAirbag:

5. Lowerthe glove box, hen disconnectthe rontpassenger's irbag4Pconnector ro m dashboard

wire harnessB (seestep3 on page23-211.

Side Airbag:

6. Disconnecthe side airbag2Pconnectors rom the

floor wire harness se estep 4 on page23-211.

Seat belt tensioner:

7. Disconnecthe seatbelt ensioner2P connectors

from the floor wire harness seestep 5 on page23 -

22).Pull h e seatbeltout all he way, andcut it off.

Seat belt buckle tensioner:

8, Disconnecthe seatbelt buckle ensioner4P

connectors rom the floor wire harness se estep6

on page23-221.



9. Cut off eachconnector, trip he endsof the wires,and connect he deployment ool all igatorclips (A )

to the wires. Place he deployment ool at least30

feet (1 0meters)away rom the vehicle.

NOTE:The driver'sairbagand he front passenger's

airbageachhave our wires, wo yellow and wored.Twist eachDairof unlikecoloredwires

together,and connectan all igatorclip o eachpair.

10. Connect 12volt battery o the ool.

. lf the green ight on the tool comes on, he ignite

circuit s defective ndcannotdeDlov hecomponent.Go o Disposal f DamagedComDonents.

. lf th e red ighton the tool comeson , he

component s ready o be deployed.

11. Push he oo l ' sdep loyment w i t ch . hea i rbags ntensioners houlddeploy deployment s bothh igh ly ud ib le ndv is ib le : oudno ise nd ap idinflationof the bag, ollowed by slow deflation).

. lf the componentsdeployand he green ight on

the tool comes on, continuewith this procedure. lf a componentdoesn'tdeploy,yet he green

light comeson , ts gniter s defective.Go oDisposal f Damaged omponents.

. Duringdeployment, he airbags an becomeho t

enough o burnyou. Wait 30 minutesafter

deploymentbefore ouching he airbags.

12. Dispose fthe completeairbag.No pa n of it can be

reused.Place t in a sturdyplasticba g (A),and seart securery.

(cont'

/ :

i'..-':

23-1



Rs

AirbagDisposal cont'dl

DeployingComponents ut of the Vehicle

l f an ntactairbagor tensionerhas been emoved rom

a scrapped ehicle,or has been ound defective rdamagedduring ransit,storage, r service, t shouldbedeolovedas ollows:

1. Confirm hat he special ool isfunctioningproperly

by following he checkprocedure n this pageoron he oo l abe l .

2. Position he airbag ace up, outdoors,on flatground,at least30 feet (1 0meters) rom an yobstacles r DeoDle.

3. Followsteps9 through 11 of the in-vehicledeploymentprocedure.

Disposalof DamagedComponents

1. lf installed n a vehicle, ollow the removal

procedure or the driver'sairbagse e

page23-113),front passenger's irbag se epage23-114), id ea i rbag see age23-115) .ea tbe l t ens ionersee

page23-4), nd seatbelt buckle ensioner.

2. In all cases.makea short circuitby cutting,stripping, nd wisting ogether he two inflatorw i res .

NOTE;The driver'san d passenger's irbageachhave our wires: wist eachpairof l ike-coloredwires ogether

Packagehe component n the samepackaging ha t

th e new reolacementDart ame n.

Mark he outsideof the box "DAMAGEDAIRBAGNOT DEPLOYED'"'DAMAGED

SIDEAIRBAGNO TDEPLOYED",DAMAGED

SEATBELT ENSIONERNO TDEPLOYED" r "DAlvlAGEDSEATBELTBUCKLE ENSIONER OT DEPLOYED" o it doesno t ge t confusedwith your partsstock.

Contact our HondaDistrictServiceManager orho w an dwhere o return t for disposal.

I

Deployment oolCheck

1. Connectheyellow lips o both witch rotector

handles n he ool;connecthe ool o a battery.

2. Pushheoperationwitch: reenmeanshe ool sOK; edmeanshe ool s aulty

3. Disconnecttheattery nd heyellow lips.



3.

4.

CableReelReplacement

Removal

1. Make ure he ron twhee ls rea l igned t ra igh t

ahead.

Disconnecthe batterynegative able,and wait atleast3 minutes.

Remove he driver'sairbag seepage23-113).

Disconnecthe connector Al ro m the cruisecontrolsevresume witch, he n remove hesteer ing hee lbo l t B) .

Align he front wheelsstraightahead, hen removethe steeringwheel with a s teeringwheel puller se e

step3 onpage 17-6).

Do not ap on the steeringwheel or steeringco lumn haf twhen emoving hesteer ing hee l .

5.

6. Remove he dashboard owercover (Ai.

Remove he column cover screws A) , hen removtheco lumn overs 8 ,C) .

7 .

(cont'

23-1



Rs

CableReelReplacementcont'd)

Disconnecthe dashboardwire harness4P

connector A)from the cable eel, hen disconnect

the dashboardwire harness5P connector B} rom

the cable eel.

9 . Re leasehe ab B) , henpu l lo f f thecab le ee l A) .

23-120

Installation

1. Before nstall ing he steeringwheel.align he front

wheels straightahead.

2. lf not alreadydone,disconnect he batterynegativecable,and wait at least3 minutes.

3. Setthe cancelsleeve A) so the projections B)are

a l igned er t i ca l l y .

Carefully nstall he cable ee l A)on the steeringcolumn shaft.Thenconnect he 5Pconnector B)and he 4P connector C) .

.



Install he steering olumn covers.

lf necessary, enter he cable eel. Ne w

replacement able eelscomecentered.)Do his byfirst rotating he cable eelclockwiseuntil t stops,Then rotate t counterclockwiseabout2 1 2 urns)untilthe arrow markon the cable eel abelDointsstraightup .

-A gn th e projections n the cable eelwith th enoleson the steeringwheel,and nstallthe steeringAi\eelwith a new steeringwheel bolt (A).

c

23-1

8. lns ta l l t he r i ver ' s i rbag see age 3-113) .


10. After nstall ing he cable eel,confirm proper

syslemoperalton:

. Turn he gnitionswitch ON (ll); he SR S ndicatshouldcome on for about 6 seconds nd hen go

off.. After he SRS ndicatorhas urned off, urn the

steeringwheel ully left and right o confirm heSR S ndicatordoes not come on.

. Make ure hehornworks .

. Makesure he cruisecontrolworks,



Rs

SRSUnit Replacement

Removal

'1 .Disconnecthe batterynegative able,and wait at

least3 minutesbeforebeginningwork.

2. Disconnecthe driver'san d ront passenger's

airbagconnectors se epage23-21).

3. Disconnectthe ide airbagconnectors se epage

23-211.

4. Disconnect oth seatbelt ensioner onnectors se e

page23-22) nd both seatbelt buckle ensionerconnectors{see page 23-221.

Remove he dashboard enter owercover se e


Pulldown the consolecarpeton the passenger's

side, he n remove he Torx bolt (A)from th e SRSuni t .

lnstallation

1, Ins ta l l t he ewSRSuni t A)wi thTorxbo l t s B) , hen

connect he connectors C) o the SRSuniu pushthem into positionuntil hey clicks.

NOTE:When ightening he Torx bolts o thespecified orque,be careful o turn them in so thattheir heads estsquarelyon the brackets.

9. 8N. m (1.0 gf m, 7.2 bf f t)

Civic Manual EP3 Tyre r Manual

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