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ACURA TL Service Manual 2004 A Few Words About Safety Service Information ‘The service and repair information contained in this ‘manual is intended for use by qualified, professional technicians. Attempting service or repairs without the proper training, tools, and equipment could cause injury to you or others. It could also damage the vehicle or create an unsafe condition. ‘This manual describes the proper methads and procedures for performing service, maintenance, and repairs, Some procedures require the use of specially designed tools and dedicated equipment. Any person who intends to use a replacement part, service procedure, or a tool that is not recommended by Honda, ‘must determine the risks to their personal safety and, the safe operation of the vehicle. you need to replace a part, use Honda parts with the ‘correct part number or an equivalent part. We strongly recommend that you do not use replacement parts of inferior quality. FOR YOUR CUSTOMER'S SAFETY Proper service and maintenance are essential to the ‘customer's safety and the reliability of the vehicle. Any terror or oversight while servicing a vehicle can result in faulty operation, damage to the vehic'e, or injury to others. Improper service or repairs can create an unsafe condition that can cause your customer or others to be seriously hurt or killed. Follow the procedures and precautions in this ‘manual and other service materials carefully. FOR YOUR SAFETY Because this manual is intended for the professional service technician, we do not provide warnings about ‘many basic shop safety practices (e.g., Hot parts—wear gloves). If you have not received shop safety training or do not feel confident about your knowledge of safe servicing practices, we recommend that you do not attempt to perform the procedures described in this ‘manual Failure to properly follow instructions and ] | precautions can cause you tobe seriously hurt or | kites || Follow the procedures and precautions in this |_ manual earetully ‘Some of the most important general service safety precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing service and repair procedures. Only you ‘can decide whether or not you should perform a given task. IMPORTANT SAFETY PRECAUTIONS + Make sure you have a clear understanding of all basic shop safety practices, and that you are wearing appropriate clothing and using safety equipment. ‘When performing any service task, be especially careful of the following: = Read all ofthe instructions before you begin, and make sure you have the taols, the replacement or repair parts, and the skills required to perform the tasks safely and completely. ~ Protect your eyes by using proper safety glasses, ‘goggles, or face shields anytime you hammer, drill, ‘rind, or work around pressurized air or liquids and ‘springs, or other stored-energy components. ff there is any doubt, put on eye protection. ~ Use other protective wear when necessary, for ‘example, gloves or safety shoes. Handling hot or sharp parts can cause severe buns or cuts. Before you grab something that looks like it can hurt you, stop and put on gloves. ~ Protect yourself and others whenever you have the vehicle up in the air. Anytime you lift the vehicle, either with a hoist or a jack, make sure that itis. always securely supported. Use jack stands. ~ Protect yourself by wearing an approved welding helmet, gloves, and safety shoes anytime you are welding. You can receive burns from hot parts, allow the parts to cool before working in that area. ~ Protect yourself from paints and harmful chemicals by wearing an approved respirator, eve protection, and gloves whenever you are painting. Spray paint only in an approved paint booth that is well ventilated. Make sure the engine is off before you begin any servicing procedures, unless the instruction tells you to do otherwise. This will help eliminate several potential hazards: = Carbon monoxide poisoning from engine exhaust. Be sure there is adequate ventilation whenever you run the engine. = Burns from hot parts or coolant. Let the engine and. ‘exhaust system cool before working in those areas. ~ Injury from moving parts. If the instruction tells you torun the engine, be sure your hanés, fingers, and, clothing are out of the way, Gasoline vapors and hydrogen gases from batteries are explosive, To reduce the possibility of a fire or explosion, be careful when working around gasoline or batteries. = Use only a nonflammable solvent, not gasoline to clean parts, ~ Never drain or store gasoline in an open container. = Keep all cigarettes, sparks and flames away from the battery and all fuel-related parts, 7 oF INTRODUCTION Now to Use This Manual “This manual ie divided into 22 eections. The frst page of each section is marked witha black tab that lines up with ts Corresponding thumb index ab on this page and the back cover You can quickly find the frst page of each section without looking through afl table of contents, The symbols printed at ‘the top corer of each page can also be uted as quick ‘ference system. Ech section includes: 1. table of contents, r an exploded view indax showing * Parts disassembly sequence, + Bott torques and thread sizes. + Page references to descriptions intext 2, Disassembiyiassembiy procedures and tools 3. Inspection, Safety Messages Your safty, and the safety of others, ie very important. To help YYou make informed decisions, we have provided safety eseages, and other safety information throughout this manual (Ofcourse, iti not practical or possible to warn you about alle hazards associated with servicing this vehicle, You must Use ‘aur own good judgment. ‘You will find important safety information in 8 variety of forme including: ="Gafety Labels ~ on the vehicle. + Safety Messages ~ preceded by a safety alert symbol fk and (one of three signal words, DANGER, WARNING, or CAUTION, ‘These signal words mean: PTAVERE You WiLL be KILLED or SERIOUSLY HURT if you dan't follow instructions PRUNING You CAN be KILLED or SERIOUSLY HURT if You don’ follow instructions. FREMTTENY You CAN ve HURT ityou don't follow instructions, + Instructions — how to service this vehicle corectly and safely Allinformation contained in this manual is based on the latost product information avalabie atthe time of printing. We reserve the right to make changes at anytime without notice. No part of this publication may be reproduced, or stored in a rtrioval ‘systom, oF tranemittad, in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior writen permission ofthe publisher. This includes text, figures, and tables. ‘As you read this manu, your wil fing information that is preceded by a NOTICE] symbol. The purpose ofthis message fs to help prevent damage to your vehicle, ther property, oF he First Edition 08/2003.2,176 pages “HONDA MOTOR CO..LTD, All Rights Reserved ‘Serves Publetion Office ‘Speeleations apply toUSA, and Coneda ‘As sections with * include SRS components special precautions are required when servicing, General Info ra Specifications g acs | Maintenance Ea ——_—— Engine Electrical Engine pet cooing = ss A Fuel and Emissions Pa *Transaxle *Steering CH *Brak {including VSA) nn *Heating, Ventilation and Air Conditioning *Restraints Ea SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ‘The Acura TL SRS includes a driver's airbag in the steering wheel hub, passenger's airbag in the dashboard above the glove box, seat belt tensioners in the front seat belt retractors, side curtain airbags in the sides of the roof, and side irbags in the oat seat-backs. Information necessary to safely service the SRS is included in this Service Manual. Items marked with an asterisk (* | an the contents page include or are located near SRS components. Servicing, disassembling, or replacing these items requires special precautions and tools, and should be done only ky an authorized Acura dealer. + To avoid rendering the SRS inoperative, which could lead to personal injury or death in the event ofa severe frontal collision, all SRS service work must be Performed by an authorized Acura dealer Improper service procedures, including incorrect removal and installation ofthe SRS, could lead to personal injury caused by wnintentional deployment ofthe airbags and/or side airbags. Do not bump or impact the SRS unit, front impact sonsors, side impact sensors whenever the ignition switch is ON (I), oF for atleast 3 minutes after the ignition switch is turned OFF. Otherwise, the system may fail in acolision, ‘or airbags may deploy. 'SRS electrical connectors are identified by yellow color coding. Related components ace located in the steering Colum, front console, dashboard, dashboard lower panel, in the dashboard above the glove box, inthe {ont seats, inthe oof side, and around the floor. Donot use electrical test equipment on these circuits. General Information Chassis and Paint Codes Identification Number Locations... Warning/Caution Label Locations Under-hood Emission Control Label .. Lift and Support Points... Towing . Parts Marking . General Information Chassis and Paint Codes Vehicle Identification Number Engine Number 19U UAB 5 5 * 4 A 000001 DT b cdefgh ‘4. Manufacturer, Make and Type of Vehicle QU: HONDA OF AMERICA MFG., INC. U.S.A. ACURA passenger vehicle b. Line, Body and Engine Type UAB: ACURA TLJ32A3 ¢. Body Type and Transmission Type 4-door Sedan/6-speed Manual .4-door Sedan/S-speed Automatic d. Vehicle Grade (Series) 2:TL with 5-speed AT 5:TL with 6-speed M/T 6: TL with 6-speed MT and summer tre Check Digit ‘Model Year 4:2004 9. Factory Code AcMarysville, Ohio Factory in U.S.A. h. Serial Number ‘900001—: U.S. mode! 800001: Canada mode! Safety Standerd Certifeation 1-2 3.2uliter SOHC VTEC Sequential Muttiport Fuel-injected engine ». Serial Number ‘Transmission Number ECE - 1800001 - ‘a. Transmission Type DECE: 6-speed Manual BDGA: 5-speed Automatic . Serial Number Paint Cade Code Color Canada NH-603P) ie Diamond Pearl 3 [NH-623M_| Satin Silver Metallic o-| NH-643M _| Anthracite Metallic © B-82PV [Nighthawk Black Pearl [© |O B-527P | Abyss Blue Peart oTé G-516P__| Deep Green Pearl o R522P | Redondo Red Pearl © | _O YR-536M | Desert Mist Metallic © Identification Number Locations Vehicle Mdentifieation Number (VIN) > “Transmission Transmission Number ‘Number (Automatic) (Manual 1-3 General Information Warning/Caution Label Locations NOTE: FRONT PASSENGER (CHILD SEAT) AIRBAG. WARNING TAG is on the glove box in the U.S. model. Front Passenger’s Compartment: ‘SRS WARNING INFORMATION SRS INFORMATION US: modal FRONT PASSENGER MODULE DANGER STEERING ‘SIDE MODULE. cotuM BANGER NOTICE” moNITOR SIDE AIRBAG AND SIDE NOTICE GURTAIN AIRBAG Located on drivers and passenger's doorjamb Rear Passenger’s Compartment: ROOF SIDE MODULE DANGER 1-4 Steering Wheel: CABLE REEL ‘CAUTION. AR ‘covomonins INFORMATION SERVI {Under OR CAP CAUTION ICE INFORMATION LABEL, ‘TIRE INFORMATION. General Information Engine and Evaporative Families: Engine Family: 4 HNXV 032 CKR iff 7 ab cd e , Model Year ‘THIS VEHICLE CONFORMS TO U.S. EPA TIER 2 BIN 5. 4:2004 REGULATIONS APPLICABLE TO 2004 MODEL YEAR. b. Manufacturer Subcode NEW PASSENGER CARS AND CALIFORNIA, HINX: HONDA REGULATIONS APPLICABLE TO 2004 MODEL YEAR. , Family Type NEW LEV II ULEV PASSENGER CARS. v:LDV Displacement ‘Sequence Characters Evaporative Family 4 HNX R 0140 BBA LTT T ab cd e Model Year 4: 2004 b, Manufacturer Subcode HNX: HONDA ©. Family Type Rr EVAP/ORVR 4. Canister Work Capacity ‘Sequence Characters Lift and Support Points NOTE: If you are going to remove heavy components ‘such as suspension or the fuel tank from the rear of the vehicle, first support the front of the vehicle with tall, safety stands. When substantial weight is removed from the rear of the vehicle, the center of gravity can ‘change and cause the vehicle to tip forward on the hoist. Frame Hoist 1. Position the hoist lift blocks (A), or safety stands, under the vehicle's front support points (B) and rear support points (C). 2, Raise the hoist 2 few inches, and rock the vehicle gently to he sure itis firmly supported. 4, Raise the hoist to full height, and inspect the lift points for solid contact with the lft blocks. Safety Stands ‘To support the vehicle on safety stands, use the same support points (8 and C) as for a frame hoist. Always. use safety stands when working on or under any vehicle that is supported only by @ jack Floor Jack 11. When lifting the front of the vehicle, set the parking brake. When lifting the rear of the vehicle, put the ‘gearshift lever in reverse for manual transmission, ‘or in the P position for automatic transmission. 2. Block the wheels that are not being lifted. 3. Position the floor jack under the front jacking bracket (A) or rear jacking bracket (8). Center the jacking bracket in the jack lft platform (C) and jack Up the vehicle high enough to fitthe safety stands under it 4 Position the safety stands under the support points, ‘and adjust them so the vehicle is level. 5. Lower the vehicle onto the stands. General Information Towing Ifthe vehicle needs to be towed, calla professional towing service. Never tow the vehicle behind another vehicle with just a rope or chain. Itis very dangerous. Emergency Towing ‘There are three popular methods of towing a vehicle, two of which are recommended and one that is not. Flat-bed Equipment — The operator loads the vehicle fon the back of a truck. This is the best way of transporting the vehicle, To accommodate fat-bed equipment, the vehicle is. ‘equipped with a rear towing hook (A) and rear tie down hook slots (8). ‘The rear towing hook can be used with a winch to pull the vehicle onto the truck, and the tie down hook slots ‘can be used ta secure tha vehicle to the truck. NOTE: The rear tie down hook slots use rubber plugs to cover the openings. 1-8 Front Towing Hook Installation Use the front tow hook for very short distances such as freeing the car, use the detachable towing hook that ‘mounts on the anchor in the front bumper. + To avoid damage to the vehicle use the towing hook for straight flat ground towing only. Do not towas an angle. + The tow took should not be used to tow the vehicle onto a fat bed. Do not use it as a tio down. 1. Remove the cover (A) from the front bumper. 2. Remove the towing hook, hook extension, and wheel wrench from the tool case in the spare tire. 3. Using the wheel wrench, fasten the extension into the bolt hole in the anchor. _ S 4, Screw the towing hook into the extension, and tighten it securely by hand. (cont'd 1-9 General Information Towing (cont'd) Whee! Lift Equipment — The tow truck uses two pivoting arms that go under the tires (front or rear) and lifts them off ground. The other two wheels remain on the ground. This is an acceptable way of towing the vehicle. Sling type Equipment ~ The tow truck uses metal cables with hooks on the ends. Thase hooks go around parts of the frame or suspension and the cables lift that ‘end of the vehicle off the ground. The vehicle's ‘suspension and body can be seriously damaged i this ‘method of towing is attempted. Do not use this method of towing, Ifthe vehicle cannot be transported by flat-bed, it should be towed with the front wheels off the ground. if due to damage, the vehicle must be towed with the front wheels on the ground, do the following: ‘Manual Transmission + Release the parking brake. + Shift the transmission to neutral. ‘Automatic Transmission + Release the parking brake. + Start the engine. + Shift to the D position, then to the N position. + Tura off the engine. Itis best to tow the vehicle no farther than 80 km (50 miles), an keep the speed below 5 ken/h (25 mph. [NOTICE] + Improper towing preparations will damage the transmission. Follow the above procedure exactly. If ‘you cannot shift the transmission or start the engine (automatic transmission), the vehicle must be transported on a flatbed. + Trying to lift or tow the vehicle by the bumpers will cause serious damage. The bumpers are not ‘designed to support the vehicle’s weight. 1-10 Parts Marking ‘To deter vehicle thett, certain major components are, marked with the vehicle identification nurnber (VIN). Original parts have self-adhesive labels. Replacement body parts have generic self-adhesive labels. The original engine or transmission VIN plate is transferred toareplacemant engine ar transmission and attached with break-off bolts. NOTE: Be careful not to damage the parts marking labels during body repair. Mask the labels before repairing the pant, Specifications Standards and Service Limits Engine Electrical Engine Assembly Cylinder Head Engine Block Engine Lubrication Cooling Fuel and Emissions... Cluteh = = Manual Transmission and M/T Differential Automatic Transmission and A/T Differential Steering Suspension oes 2-10 Automatic Transmission Steering Suspension Brakes Tires Air Conditioning Electrical Ratings: sm. Body Specifications Ilustrations Standards and Service Limits Engine Electrical em ‘Measurement ‘Gualiication tandard or New [Service Limit ignton coil | Ratedvoroge av Fig ordar eae Sparkpog | Tre NGK THOR DENSO: 2008 NN4 _ oe —}io= 111mm (e896 in) Tritton ting ‘tide (check | AIT(in Nor P positon): 10:+2° BTC —~ _ the redmart__| MT Gana 102 2°8TDC “Brn. | Tosion aut Aut tention compressor bt _| ‘aterator | Out 188 Ved poral engine 7308 temper Cel rotor oon RerGIO ska Siping OD. L 144mmiS7ini idm Osin| Brushlength [08mm oat ind 18mm (008i) Brush ving tension - 321 (0394gf, 0791 Sire Output “8K Comma mies dep 24- 0mm (00E-0In) OAS mmIOdOE A Commuter runout 2 mm 10.001 in) mn 0.6 mn (00028) Commutsto’ OD. [0 28. mn (.12 1.108in) | 27.5 mm 1.088 Brush length “1BB~ 162 mm (0.82-O.84in.) [Ae enn 10.43 ted Brush sping tenaon Tow 167—T77NIe0~ 180g 369~3.7 Ih Engine Assembly _ [tem Messurement ‘ialfcation | ___ Standard or New [_Serviee Limit Compression Posse Ticimum | a0RPH Stale, 250 — Check the engine withthe tater | Maximum | 20087 2.0K 28 px — rmting, vacation 2-2 Cylinder Head tm ‘vaieaon Sandor few Serie Td —— 2.05 mn 8.02 ind : THiS a mT ATESIT | — Cana 005-028 mm 00%2-0068in) [620mm B06Tny Cars ldr o clearnce 00-0686 a020- 00135 Ia) 018 mm 0005) Tat runout 603mm DOT in) ve 804m 928m) Carnie a ide primary [25047 mn 378 = ioe mid 95445 rm (448m) = ihe, 35.284 mm (3887 in} = wonton Exhost [26386 mm = Vale eran ah intake [920-024mm 006 -0028i—) | — Exhaust | 028-038 mm @oN1—oorsin) | — Sen in B55 95 mn 07159-0716) | SAB nm OTA [estat [4505.60 mm 0 146-02150in) | 20 am 2Kot in Tani pie dears ithe 020-048 mm {8a008~0.0018 In) 08m (0003 in Exh] 0.055050 mm (60220 O05 in) [0.9 mn 04 in Tae wiih ia. 125-185 nml0045-c9stin) | 2e0mm(O97Sinh Exhaust [125-155 mm 10045—0081 in) [2.00 mm 07m} Siaincaled rahe intake S375-¥755 mm VBA 187ein] 478mm 87m) Echo [456847 48mm 8961888 in) [4778 mM inh Vane ng | Fler th Bistmm 20z8in} Exheust [51.06 mm 2010 = Vale ais [78 inne S515. 5580nm 027 -O277in) | SBM WAWind Exiga |B 815-£590mm(02171-07777in) [Ss mm (028m) Taal ae intake 22-2220 nm (0g —EATEIN) | Echo |2060-21.60mm att o8ein) | — Tope cance ro | G26=0061 mm(6. 0010-0002 in] | ane mm WORInd [Exhaust [0260 77 mo 0.616 0000in) | 4077 mm 0.030 in 2-3 Standards and Service Limits Engine Block em Maan Sec Ln Bio Warpge a deck Ee mm Gootiny Bore iometer 33.065 mm 065) Boreas = 808 mmi800zin) akring ik = 028 mm nh Fata Ski 0.0. at 155 mm ATTA TOM 750mm SOS BBORSTn| 88.95 mm (38007) betiom ot earacein onder z 0G OHO OOTTBTn) BO mm STAD fing groove with Tee 2401260 mm (6.0488 00887 in} | 127 mm(005ind Second $2201290mm (00490-0484) [1.28 nm 0089 oi 2052825 mm TT6¢=01TTZin} | 2SmMiG In) Tiong | Rngtgraovederaice op] 0085060 mn 6.00220 00nd [0.15 mm (6.0083 Second 1.630=0.65 mm 661200027 in} [0.13 mm (0.08ind Tipendanp Tee 020-035 nm (0008-20t¢in | oBbrmm i atin) Second 040088 mm (0016=0872in) [070mm (0028 int oi 020=1.70 mm (0080-0 028 In [050m (O03t ink Faionsia (00 21-92-21 S65 01648-08618 | 2.84 mn 0.964375] Pirie ionclonace =0.008b(0 +6010 mm 108 mm 000 (aootz0 6 09000) Convesina rod | nterod eae 005-0 6002-OBHE in) OTH iam OORT Smalend bore matt 21370=21 576 mm (0.800.968 Large endboredanetr opine [80 mm 22sin3 = | End lay inal on rar 018-035 mm 0306-OaT4in) | eamlODIwinI ianishat | Mainjournal diameter 73878-72000 mm (24997 -288in)| —— Fount leer 54576 £5.00 184-2 15tind| — Rdmin jure per 0.08 ram (00 in) max 070m ann journal out found 0.005 mn (0.0002 i.) max. (0.010 mm (0.0004 in) ‘010-0:5mm(0.006-0.074in) | A45mmiO018in | 11025 mn 00010) max 068 mm (000%zin} ‘anishat | Moin sng our ol Gerace 1020-0044 mm {068 EOOTIn 0080 mm O02 in tearing Fodbesing saree = BS4 rm (0.0006-O0TTini | 0050 mm Oi 2-4 Engine Lubrication tT Messirenenr unification Sian or New Series Uni Traiteo | Caoaty Engine overha_|SOURSUS a 7 : [oitchang 434145 US a _ inelacng ite Oichangs, | SOERZUS a without : Oirpiing [nirvana 2G4- 0 mm (OOR2—9908in) [O70 mm OHO) Pump housing t-outer tor clearence £100.19 mm (0.90¢~0.007 in) [20mm 10008in) Pump housing outer tora 002-697 mm{O001-9.003in) J ox2mm(0006in) Oil pressure with altemperature at | Atial 7OKPa (0:7 kaon, TO pai —_ - 5 a0) {a3000%9m [490 ¥Pa a kg. ps Cooling ‘tem “Measurement | Qualification ‘Standard or New: Tadiator | Coclantcapacty ude engine, | Engine overaut [AT moder 81 F186US a) eater hoses and eer TMT mov: 7 90183 US a | Coolntchonge [ATT mode- 648 (68 US gt MT moe: 634167 US at exert | Cia coast as810SUS a) = | Resiatorcap | Opering presse ~~ |s5- 125i 095-128 aD Thermostat] Opening trpertire Bogie open | 169—T7eF 76-80) Fullyopen [19a GO) [Va aay oe [0.0 mm 639ini min 25 Standards and Service Limits Fuel and Emissions tem ‘Mieseurement ‘Gualiction Standard or New Fuel pressure | Pressure 400-— 450 kPa (4.04.5 kglem, BB —B4 psi) | regulator Fuel tank Capaciy - 4911771 US gal ~ 7 Engine icle | Ile speed withoutload TWiT in neutral | 750350 pm - AMTInNorP position idle speed with high eleciviclosd | MTinnautral | 760280 om ‘with HVAC on) ATinNorP | position ‘Clutch ‘tem Measurement ‘Qualification ‘Standardor Naw: ‘Service Limit) ‘Guich pedst | Height rom floor 1eimm(7S2in) — ‘Siroke 190 140 mm (6.12 85tin Phy. 10= 18 mm (038-071 in) — [Disengagement height from floor_ {90.5 mm (3:56 in, min. — [Fiywest uncut on cluih mating surface [05 mm (0.0020) max 0:18 mm (0006in.) Cutch aise [Rivet head depth “10 mm (0.039n.) 22mm0.m08in} [ “Thickness ‘868-953 mm 0342—0376in) | 7.2 mmi028in) Pressure plate | Warpage (0.08 rm (0.00% in) max 0.15 (0.006 in.) (0.8 mm (0.02 in} max (08mm (003in) 2-6 eit of iaphragin spring fingors ‘measured with special ool and fooler |vauge l Manual Transmission and M/T Differential em Messurement Oualeton Standard orfow Senet TFonsmissln” | Copecly Fuidchonge [22 7B30S ot . fia Use Honds mre ‘Ouehaut [258 60S Mainshakt | Endploy 0.4 021mm 0005-0008) = iat flict bearing auc 18.957 — 19.90 mm 07861-07665) 1991 mem iO7BEin) Diameter of ah and eh gore [96796 000 mm (4168 1.4173 in 3599 mm (415i) distance colar | Diameter of bal Barna cotta FRG Ba. OT mm 104110] BFE am ADIT (catch noving sie! ‘Diameter of reele beating conact "SA 60 mn BT BERS] Bm LETT Diameter of 6h ger discs ek 2867-3 0 mm (FATT in| BHA MAA | Diameter fal bering contact 30.907 31.000 mm (.2200-.205ini| 9038 mm (1238in) | ranamision hosing sda _ nowt 02 mm aU in me 0 mm 007i) ‘ansba 0. ~~ 009= 7.025 (1.9507 AE | 47.08 mn (1.854). rd goa End pay [208-019 mmi0002-0067in) 03mm (001 ind “Thickness 7309-7397 mm 0941-844 in} | 238mm (094in) amaha 1 7.05702 rm. 8507-19514] 4.08 1.954 in) Anand 5h overs [End lay 206-019mm(0002-0007in) [3mm (00m) Thickness 7239-7247 mm 0881-0896in) | 723.4 038 in) Wainsba—[1. 4.00844. 025 rn (1. 7926— 17208) 44.08 rm (1.735 0). Bn ger End pay 7 006-019mm 0662-009Tin) [adm eatin Thickness F99= 715 rm 962-0865 in) | 71.8 mn 0.6). Cauniersha® | Bomete feed bearing oract 8.974980 1.7319 17T9 W497 1.72818) cic housing ie) | Diameter of distance calor conc GETS ABER am (.OSTO™ BOR] HA wn DIN Diameter of ball befng contact 36002 S007 mm (1819 Hin] BABE MM TON |(wonamisionnusing sa) - ‘Diretr of counters vee ger ESA WE 95 nO BGT | LE In) Aunoat 62mm (0001 nd ma. 105 mm 008 in) 35 mim ahimso-beong 04-0.10 mmioo16-0008) | Adve Counts : H.910- B79 mm aS —2BIin| HHaaMMERATIN| gear 206-011 mm (0002-0007in) 1 028mm(00rt in} z2s1- 2298 mm 902 0905in) 17286 mm 0300 in)_| oneal 9.010 57.029 min 2445-2265 57.08 (2247 in) and ge Endplay 04-0: mm 0Ge2-o00Tin) [0.28 mm 0014 in) Thekoess 71-7259 mm 902 -0305in) | 22.98mm O800in) Coonietna (10. 4597045 588 mm (1800818108) 46.06 mm (1.873in} everson [05 3198752000 mm (2046720472) 51.99 mm 04 in) I" Length e308 mm 10907-0908) | — Cournot —[10. 2.990 48,000 rn. 6985 16929) 13.0 EA) arageer (00. 1.505.000 mm (046820472 in 5. 9¢ mm 065m) dines cotar {engin 203-7208 0.907008 n) | — (cones) 2-7 Standards and Service Limits Manval Transmission and M/T Differential (cont'd) tem Mesburement uaification ‘Standard or New, [Service unit | Mainsnet | iD. f [36,002 36.012 mm (1.4174 1.4178 in)] 36.06 mm (1.420 in ‘ty and 5th gears [O. {1.989 42.000 rym (7.6851 ~ 1.6535 in. 84.94 mm (1.651) stance collar | Length a 1995 80.05 mm (1.967-1570in) — |—— “| a a | ’ , - 5 2285- 72.68 mm (0.887 GARIN) |— ’ Yr Mainshatt iB, ‘Bb02 38072 mm 1200812087 in] 3808 mm 1 BOBIn) etn gear OD, 38,989 ~ 28.00 mm (1.5360 1.5854 in| 38.94 mm (1.533 in) distance collar [Length 22.08~72.08 mm (0863-868 in) | ——_ Reversegear | OD. 19.989 ~20.000 mm (0.7670—0.7874n}} 9.93 mem (O.7BBIN shaft Reverse drive | 1D, "25.007 25.020 mm (0.9645 0.98BD in] 25.07 me (0.98 in) riven: Sth synchro ing | Ring-o-9earcoarance Ting pushed | 070~%40mm 0028 0.059in) | OAmm(0078in) against gear ‘synchro ring | Rivato-gear clearance ing pushed | 073~1.44 mm (0029-0067 in) | QAmm (0076 In) 7 against gear Dovbiecone | Outer synchro ingtoavnchro cone [Ring pushed [0.70.19 mm(0028-0047in) | oSmmVOT2iny synchro clearance _| sgainer gear ‘Synchro eone-o-gear clearance Ring pushed] 050—104mmO020--O0a1in) | 3mm(O0T2im) against gear ‘Qitereynahvo ing to-gearcone | ing pushed | 035~168mm/(0037-0086in) | 08mm (0.024in) clearance against gear “itiripl cone | Outer synchro ing toynchro cana | Ring pushed [0.70 1.19mm(0028-00«7 in) | 6Smm|0072im) synchro clearance gsines gear - _| ‘Synchro cone-to-gear clearance Ring pushed) OE. 14 mmiO01@—O046in) | O3mm(O0TZIm) L sgainst gear “Gutersynahroving e-gear cone | Ringpushed | L12-168mm00ei—0066in) | 06mm (0024in) —_ cleerance against goar _ ‘2rd tiple cone | Outer synchro ing tosynchrosene [Ring pushed [070-119 mm(0028-O047in) | O3mm(O0T2In) syncho clearance | aosiner gear _| ‘Synchro cone-to-gear clearance Ring pushed | 980 1.88 mmi0024—0074in) | ©3mm(O0.0T2im) againstgear | - ‘Outer eynchro ing te-gear cone | Ring pushed | 087—182mm(003—0072In) | O6mm(002¥In} |__ clesranco against goar Tana, Fingor thickness t [787.6 rm 1029-03010. = rat, Forkto-synchro alcove learance (0.35=0.5 mm (0074~0.026in) | LO mm(0030in) Sth Shit fork - Reverse shit | Fingor thickness 62-64 mmi0ae 028 in) = | fork Forkto-eynchro sleeve Gearance (0.35=0.65 mm (0,014=0.026in) | 1.0mm (0.03910). Reverse shift | Finger thickness LC 6.400 6,650 mm (0.2520 0.2618 n)_|— lever ‘Shitteverto-sift fork desrance (0.05=050 mm (0.002-0.020in) | 06 mm (0.024 in) ‘Shift over giameter at contact area 1307 13.2mm(051-.82in) — Shift lovertomteroek clearance: {204mm 0-0015in) ‘25mm 0.020%) ‘Shiftplecs (LD. "4.000 = 14.088 rm (05812-08859 in| —— _ ‘Shi York ameter at contact area 128 180 mm (0.50051 in) —— Shift pieceto-siftfork clearance. (02-06 mm (0.008 -0.024in) [07 em 0028 nd 2-8 item Measurement | Qualification ‘Standard or New ‘Service Limit Shitam [1D | 3.75005 mm 062890550 Shiltpis damstorat conta 739-1ommiast-ossin) | — _ Shinar tosis cleronce 205-025 mm 0002-0010in) [aS mmiGa20in) ‘Select arm 10. 11.01 11.05 mm (0.433 0.436 in.) = into dametar at one aan 129-190 (050-05tin) ————— Selec or toinariek clearance 105-025 mm 602-0010in} [06mm l0000in) ‘iin | Opump trust clearance 009-0.13mm{o001_OaISin} — [0.18mm 0006in} [ovterrotorso boy earance (01-02 mm(0006-0008in) [02mm 0008in) | Inne retr o-oo rotor clearance 2.1mm (0006 na me 92 mm 008m} i pump inna rotor. 174-172 0067-088in) | — |__ Oi pump se 0 168-17.0mm'06-06rin) ——|—— WT dieroniat[Baoklash 0413 mm\05%6—0051in) = care Drives contac aaa 3009530045 yn 1821180] — Carrer bearing starting torque (prelead) 343-451Ne (3548 kgher, 30-40 Ibfin) ‘Aajust Standards and Service Limits Automatic Transmission and A/T Differential ikem Measurement ‘Qualfetion ‘Standard or New. ~ [Series Lime ‘ATF tatomatc | Capacity Fiuidcnenge | 308208 at “Transmission Fuel | Use Honda ATE-Z1 ‘Overhul 700 (7.4US qb "ATF pressure | Line pressure "At 2,000 prin | 900-860 KPa woe | NoxP postion _| 8.28. katlom’ 130—140 ps) (2.7 kom’, 120 pit Sih chah pressure "At 2,000 cpm in| 690870 6Pa Baka Myostion —_| (91-99 kgHlen, 130-140 psi) (8.6 katlom’ 120 psi) “th clutch pressure "At 2,000 min | €90~970¥Pa ‘B40 KPa Mposiion __| (1-99 ken’, 190-140 psi (8.6 oem’, 120 psi 3d dutch pressure ‘At 2,000 prnin | 690~870KPa B40a Mposiion __|(9.1-9.9katlem’ 190140 ps (@.8katlem’, 120 pai ‘2adltch pressure ‘At 2,000¢pm in| 690970 B40 kPa Moston __|(8~¢.8afem’, 190~ 140 psd (@.8kaflem’ 120 ps) Tt clutch pressure ‘&t2,000 min | €90~B7OKPa BHOWPs Mposition | (9.1-9: kgtem’, 130~140 ps (.6kgtem, 120psi)_} Tet hold elath pressure ‘At2,000 rprnin | 760630 kPa 710163 position (2.785 halle 110-120 ps) (7.2 kate, 10 pat “Torque converter | Sal speed 2,000 rpm 11850~2.180 pe L ‘Check with vehicle on level ground ute {clutch end plate-to-op-dise st = a= 1amm clearance (0.043~0.051 in) 2d — (0851.05 mm _ 10.033-0041 in) ad = 07-09 mm 10228-0035 in) ash = (055-075 mm | (01022-0030 in) Tethald = 05-09mm (@.020-0035in) _| ‘latch return spring fee Tenath tet wesmm 269i) 663mm 261in! 2nd Smm 210in) 'Si.¢mm(202in.) 3a 52.0 mm (206 in) 50.0 mm (197 in} [an 335mmi132in) 315 mm (126m) _ [sn a7Ammi147 in} 35.4 mm(1.39in) ‘lutch aise thickness 194mm (0076 in} — ‘Clute pate thickness 58mm (0.0650) ‘When dacalanad 2:3 mm (0.097 in) ‘When ciscolored 2.0 mm (0.079in) When discolored 1.8mm (007tin) Wien discolored ‘et lish endplate hicks 310mm 0.122in) [When discolored | 320mm (0.126i0.) ‘When discolored 330mm (0.190in.), [When discolored 340 mm (0.138in) ‘When discolored "3.50 men 0.198 in.) When discolored "3.60 men(0.142 in) Wien discolored 270mmi0.UGin) ‘When discolored 380mm (0.150%n) ‘Wher diacoirod 390mm (0.168in) ‘When discolored] [evo uth end pate thickne 5.00 mm (0.197 in) When discolored item ‘Weasurement ‘unieation | SiandardorNew | — Serdea um —] Giuch “ndeuteh ond plate ines Mark Bid (0.089%) Wen discolored 2.20 (0.087 in) When dolores 2:30 mn (0.098i8) ~[ When icoored 20 rm (0.096 in) When discolored 2.50 mm (0088in) When discord 2.60 mm(0.102in) When declared 2.70 mn (0106in) When dsolored 280 mm (0.110in) When dcolores | [280 mmo. t14in) When dissoloed ‘ed lh end plate ices 2.0m (0.083in Winendcolores | 2.20 mm 007 nt [nen icolores 2.30/mm (0.091in) Wien discolored Fata mm 0.09¢i0 When dolores 150mm (058in) When decolord 2.60 mn (0.1021) When cicoloed 270mm (010618) When declores 280mm (0.41015) ‘When discolored 290mm{0118in) When diclore 00mm 0.118in) [jwnenaiscolored | Mater iomm@.22in)— When ciscolored [sand buh end plate ickness | Mare? 210mm (0.083) Wher dolores Mark 2.20 mn (0.07 in) When declored 2.30 (0.09% in) ‘When dolores 240 mm 0.09¢in) Wine diclored 250mm (.098in Whe ieoloed 2.60 mm (0102in) When ciscolored 210m (0.105in) When discolored | 250 mn (0.410i8) When declared 7 Mans 250 mm (.414in) When discolored [RTF pump | Stor aha needle bering contact. | Torque converter | 27000-77021 me 06501 938in| When worn or anaged } side oo CATE pump ide | 28000 29,2% me (1 5417— 1.408 When wor or damaged "ATE pump goar thas claarance ~Jaas=0.6 nm (6.001-0.062inj [007 mm Oon3in) | "ATF pump gero-bodyceerance | Dive gear [0210-0285 mm 0.0083~O0104in)_|— vr brven gear | 0070=0,125 mm (.0028=0.0049 in TATE pnp dive geo. "H.0T6- 14.034 men (5516 0.525 no When wor daraged | ATE pump driven gear soit OD. 18,900 13.00 mm (05504—0.508 in| When worn cr camaped Feverseahit | Fork finger thickness $906.00 mm(0232-0226in) | 840mm (02T3in} fork : | Pack gear and = ‘When wun odanaped aw 7 _ “ Servo body | Shift fork shat bore 10 74.000— 14 0mm 05512-O55i6in] Shi fork shat valve bore LD _ "7.00 = 97.029 mm (1.4867 — 1.489 in 3745 mm 1-85 Regulater valve | Sealing ring const. 2. 000- 2.025 mm (1.25981 208i] 82.050 12618 ody ‘Aceutlatr | Sealing Wing contac, 00085005 min (137801 TED IAI] 38 mM TTBBIN body Sistorshat | Sealing ring cone 5002.08 mpm 1.109] 28060 mm 1-137 toon 2-11 ‘Standards and Service Limits Automatic Transmission and A/T Differential (cont’d) Rem Mosturerent ~[_Quslifestion ‘Standard ot New Service Limit ‘ainehatt Diameter of needle bearing contact | Alstator shaft | 223984 73.000 mmn(0.9048 0.9085 in| Whan wor or damegad rea ‘Atéth gear | 52875 52.991 mm (2.0856 2.0863 When wom or mage | Att gear cata | 38.975—38.991 mm (13876= 1.3982.) When worn or damages 1D of ah gear - 59.000 69.019 mm 2.3228 2.3236), When wom of dameged LD. of Sth goer "40.000 40.016 mm (1.5748 ~1.5754n)| When worn or damaged | End play of ath goat _ (0.03031 mm (0.001=0012in) [End ply of sh gear (0.10022 mm(00¢= 0.009) | —— {14.73 mm thrust shim thickness | Na? 7.85 mm (0.309 i) When wom or damaged No.2 7.90 mm{0311 in) When worn or tara No.3 7.95 mm (0313in) When worn or damaged | Nod 800mm (0315in) ‘When worn or damaged No.6 {05 mm (0377 in Wien worn or damaged No.6 Tato mm oan! When worn or damaged | “Thrust woshor thickness —___—_|27 x47 «5mm | 5.00 mm (0.197 in) When worn or damaged Longth of th gor collar '585~58.6 mm (2308-2307 in) | — ‘Sth gor elle flange thickness 445460 mm (0.175 —0.18tin.) | When wom or damaged ‘Sealing ring thickness ‘Samm 187=1.97 mm (0074-0078 in) | 1800 mm (0.071) | seating veg, 29mm 187137 mm (0074 -0078in} | 1.800 mm (O07 In) sealing ring Wath of sealing ring groove 2.025 2.060 ra (0.080--0.081 in.) | 2.080 ran 0.0820 luted pie O.. ‘theltch 3.97598 mm (0.2850~0.2356in) | 595mm (02343in.) th eluten 11.67 11.48 mn (0.4576 ~0.4520 in) _| 11.45 mm (0.4508 in) (hutch fed pipe bushing 1D. ‘inetuioh | 6078 6.090 mm (0.2969 0.2374} | 6.085 mm (0.2300in) | ‘th euteh 11300-11518 mm "1.530 mn (0.4539 i.) (0.4528 0.4535 in) 2-12 item essrement ualetion ‘Standardor New Sevieetint | Couriers | Diameter of needle bearing contact’ [Arsh gear | 30975-24901 mn(1.2770—13776in| Whe worn or aaged ae ‘and gear | 995794000 mm (1574—1575in) | When wornor ane | ‘park gear | #.954—4,90 rn 1.652% 1.6528 | When worn or aged Atrightend | 88505=38.15 mm .5169="L5169 in) When wom or damaged ot Rh gear 000 4.016 min (18142 1.8148) When won rdaaned | LD-of 3d gear - '0,000—60.016 mm (1.9685 — 1.9691 In| When worn or damaged UD. ofreversegear 46,000 ~ 46.016 mm (1.8110— 1.8116 in.)] When worn or damaged [End pay oft eer 00-0. mm (00-0018) End ply of th gear ‘04-027 mm a02-0011n) | — End ply of dg ‘2015-0015 mm namo6-000%8in) | — End pay ofrverse oar 110-025 nm 1004-0010) /31*69.5x85mmsplined washer [A 4509-3515 mm g379—0.1904in)_| When wor erage diference 3 2.490 2.502 men (015740.1979in) | When ern or dared c 3. 477~8.489 ym (0988 ~0.1374in) | When womnor drape _ > 2.404 2.475 men (0 964—0.1969 in) | When rn of arg eng of dite colar SXAIE [AREER 178iN) | — 35x 47x a mm [692 S96mm ORD oz86in) —_|— Cotter hicks 1.99202 mm (.0789,090 in) Reverse selector ub OD. ‘55.87 56.90 mm (2.18982 2008n) ‘When worn or damped | Clutch fed pipe 00, {497 ~B99 mm 0:353-0354 in [cue ed pipe busing {9.000 9.015 mm (0.354~0,95 in} ‘8.95 mm (0362in) | 9.030 mm 0:56 in (cones) 2-13 Standards and Service Limits Automatic Transmission and A/T Differential (cont'd) [___ttem Measurement ‘usifiation| ‘Standard or New ‘Service Limit aa78 Secondary shaft | Diameter t needle bearing contact | At tet ge 7983 mm (.4951~ 1.4955 in| When wom or aomeged ee {AtBnd year | 28868-28969 (.3580=1 965i] Whe anor aged i of gear 4.04408 1 728-1.749 | Whe wor or mad 0 ofand ger 2.000— 40 16mm (1.5748 —15754 | Whe nono dae [Enda oft gor 007-838 mm(E008- Onin) | — Endl fn geo 7 at= 058m 0t8a= 0.006 n3 | — 38x58 mm pled washer ines | Ne-T 8.8 mm (0270in) ‘Wenn mage No? 90mm (0272in) | Wena draped No.3 898 nm (0274 in} Wen wero omeped Not] 700mm 078i [er we doped No.8 Tosmmiga7sin} Wheto or omg No.6 2x0 mm 0280 in) er nr a draped STE rahi knees [Not 490mm 013m) her na maped No £95mmi098in} en weno amaped | No. 500m. er wr raped | No.4 | 05mm 9nd Wr wen or raged Nos Simm (azsti Wr wn drape No.8 Si5mm 022zin} ier won aged No.7 [Sao mm 0205in} here draped 198-202 mn 0-OORIA) 1880-1950 mm(0.0T 0877 in) [1800 mm UTD ‘With of ling ring pore as =2.080 mm t0.850081 in) | 208 mm 0.082} ch ed pre 0. 7a7=Ta mm (03108-03142in) [785 mm 03o0in} Gites bie busing IB 5000-8615 mm 03160-03168) [8050 mm OT6TIND Teves lar | Doms of needle eating coset A voor War | 8.08014 000m (0.580 851i] When wor diged goer even eerste Endl [8-8 rm 06200] —_|— o 106718629 mn (07089-07084 Wn war donne | Tv water ines “raremieon [088-104 mm Ot 09¢Tin) housing side Fever ger 097188 HB BOAT) | — |store “ a6 adv STA OER Wen wa 1D-oftareision bousing of revese 6160247 (0881405821) ‘Mar goarshatecontact area 2-14 item Measurement ‘Gualfcation | ‘Standard orNew 7 WireDiameter| 0.0. | Freetangth | No ofGoie Wain vive body | ShIRaWeBapring 07mm [65mm | 3a.7mm | 128 soring (see pape tooreiny | 10260in) _| (327m) 16260) Shikvalve Capring ‘o8mm [66mm | 4atmm [217 L oosriny _|10260in) | n933in) Kick down vale pring asmm [66mm | 49.1mm | ZiT . (o03riny | 260ie) | 1.993 in0 Modulator valve spring [38am Todmm —|xasmm [98 (o068iny | o4osin) _| ar9iny Relief valve seving 12mm Timm [380mm [88 tooeriny —_|roasriny | (1596%m) _ Toakup ait vale spring ‘ogmm [76mm | 6.0mm | 224 |_ (oa26iny _|10280in) | r4aniny | Cooler check valve spring asmm semm [145mm | 68 (o024iny | @z2sin) | 10571109 Torave converter check 12mm [8mm [34mm - valve sring ooeriny | o33¢in)_| narsind Serve conto/vave sping ‘09mm [64mm [328mm [175 10035in) | 10282ia1 | .280in0 averse GPC valve Sing ‘o7mm [1mm — | 178mm | 79 (o028iny __|10240in) | (0701 in equator valve | Stator reaction spring ‘45mm 354mm 323mm | 21 body spring (see coxtiny —_[erse4iny [182i page 14266) [Regulator valve spring A 19mm 147mm | 806mm | Yet oorsin) | osveiny | 1739 [Regulator valve srng B tem 92mm [44mm | 125 _ tooesiny —_|roseziny | (1732%ny Tod contol valve spring ‘o7mm [66mm [28mm | 183 ‘oozeins —_|10260%n) _|(1.689in) | oakp ing valve spring assmm 66mm sham | vat (oneein) | 0260in) | 1.370%m9 Sevabody | CPC vaive 8 spring Tormm [61mm [178mm 179 spring (se page o02ein) | (02401) _| o70rin) 16267) | eRe vave Rowing o7mm [61mm [78mm [78 coozeiny _|i0240iny_| (0701) - Shi valve 8 pring oamm [86mm [421mm [a7 | coosriny —_|10260%n) | (933%) | ‘Shit vive A spring ‘o8mm Sem | 421mm | BT wastin) _|(0260in) _| 1.933in) Top Shit vale E spring [osm [71mm [0mm 172 seceumstor - {o0stiny | ozaniny | 1929100 ody sring ie | CPC valve ering O1mm [61mm | vamm [78 age 14-268) toazsiny _|10240in) _| (0701) _| ‘ih acsumulator spring A 22mm 164mm [757mm | AE L (oar iny —_|10846iny | c2980in ‘th accumulator ring 20mm womm — |455mm | 116 _ (oorsiny | 0384iny _| in. 7911n9 “Ais old seumuletor spring 34mm 196mm —|Si4mm |B toraeiny | w0772iny | @a60in) 2-15 Standards and Service Limits \utomatic Transmission and A/T Differential (cont'd) ‘tem Measurement ‘Qualification | ‘Standard or New [Wire Diameter! 0.0. | Free Length | No.of Colle ‘Accumulator | et accumulator spring B 23mm mm 20mm 99 body soring tee (o.091in) | 0486in) | (2.658) page 14263) | Tstaccumuator spring A 24mm 195mm [677mm | 102 _ eatin) —_|10.768in) | 665i.) “nd acoumulator spring B 26mm taomm [440mm [80 (or02iny | fost2iny | 1.732%m0 - 2d aosumulator spring A 25mm 196mm [87.7 mm 195 — |to.0seiny | o772iny | 2z72ind 3rd accumulator | ed secumulator sping 31mm Tamm [294mm 65 Spring (see page (orzziny — | (oz72ing | (2.85110) 14-270) em Measurement Cualcation ‘Standard or New ‘Service Limit ‘ATT dioreniat | Pinion shaft contact area. ~ | 3BH0= 18.628 mn (0:7091 ~0:7006 ind) — cation ‘Carierto-pinion shat clearance (0.023 =0.057 mm (0.0008 - 10022 n.)_[ 0-1 mmm (0.008in) | Driveshaft contact ares 1D, 28.025 30.056 mm (1.108-—1.104i0.)_ | — Carrirto-driveshat clearance (0.045 0.096 mm (0.002=0,00¢in) | 0-12 mm (0.005 mn) Corrierto intermediate shaft clearance ~~ .080= 0.116 me (0.003 -0.008in.) | —— “Tapered roller bearing starting torque | For new bearing | 29-41 Nm Adjust (preload) (3042 kgtem, 26-96 fin) 26-36NNm ‘Adjust _ (27-29 katem, 23-34 loin) _ ‘ATT diferetia! | Backah (0.05 =0.15 mm (0.002=0.006in.) | — piniongear [10 16042 .006 mm (0.7103 0.717318), —— Pinion gear to pinion shaft clearance (0.055 0.095 mm (0.0022-S.0037 in| 0.12 men (005i 2-16 Steering oa Tiana Goatees Sanaa ‘Steering wheel | Rotational play measured at outside 0=10 mm (0-0.39in) sages cgi runing i ing eo mene NGL BEA eure ge henge unig Gabor | glock guide eo eoened we tem te potion, | mom pu retire wi aaa vahe 70S SOW TBO TGVER OTRO aT dle Power steering | Capacity Reservoir 0.32 0 (0.33 US at) as Use onda Power Steering hid |especty Srtor ovo [HATO = Dive ba fa nse! ‘Suspension I Ticeaament aan Sina oer Tene Vial sigan | Canin [Font raed s feat Sy 30 ta om ars - ‘Total Toe-in ~ Front 02mm (00.08 in.) fr WN? Fmim(0082 68H) Tot aboaltrina oe ini wheel —| 306" Gatide whed |S nero el Taina wd ana fat 0-07 nn G03) Tam OAD Tdi 3-07 mm 10=B08in} {im On) ‘Wheel bearing | End play Front fe Standards and Service Limits Brakes te Measurement ‘ualeaton Standard or ew Sere int Parking bake | Distance ravelod when over pulled Bio Wels tever with 961 (20 igh 4b force ‘rake pedal | Peal height earet removed! MT made! | 7mm 673in} ‘ATmodel | 170mm (688in) Freely 1= 5mm (@04~020in) Master yinder_| Pietorto-pahvod clearance t i adusiment Brake dae | Thickness Front 718-28. ym .i0-1T i) ommend wat mode Front 9 25:1 mm 058 O99In) womm@atind | wt mode ——— |__| fear 9-81 mm (0360 0388in) | 7mm I030Im) Rano Front = {10 mm O004in) Rear — 2:10mm(0.04n) Paral Frontand rar [— {0.015 mm (00060) Brake ped | Thickness Front Toad mm OAT OadIn *.6mm(0.08in) wt mod) Z Front 38=100 mm (035-029im) Temm O8in) WT mode Rear a5-35mmOH-0a7IN) TSmm (Gein) Conditioning item Messarement ‘Guaeation Standard or New Refrigerant | Type, “HFC-134a (R-1340) Copechy oan — 00~$60 g 7.6 TBA od atigerant oi [Type TOENSO NO-O1 8/N 38857 PT. AOTAN or S00-PRT-AOT) Capacity of components ‘Condenser (25 m& (5/6 fl oz) - Evaporator [46m (020g ach ine and | 10 ma (3 foe). howe _ Compressor | 120— 135 ma da V2 Moa) ~ a Compreaoor | Fld collresoace ‘meeF GOO) [39-43 __[Puteyo-peesure pata — 0.20-08smmi@012=OuRin) Divebet [Tension ‘Ano tensione 2-18 Design Specifications Tem Measurement ‘Gualiication Speafication DIMENSIONS | Overllionath “2730 am (188.2) ‘vec width 7.895 mem (722 at (Overall height _ 5441 mm 1562 in) - 2740 mm (1073in) Front 41577 mm (62.10) 7 ear 1.576 mm (620in) - __[ Seating capaci ive 8) _—_ WEIGHT (USA) | Gross Vehicle Weight Rating 4525 bs L icvwal 4.435 bs WEIGHT (Gross Vehicle Weight Rating 2.050 kg (canana) | evn 2010s ENGINE Toe ‘Water coved, stroke SORE VTEC engine Cylinder arrangement ‘0 vé-eyiinder,ransverso ‘Bore ond stoke 19.0 86.0 mm (3.80 %3.391n) Displacement 3.210 em (196.60 n) - Compression ratio 110 Valve ain Belt drive, SOHC VTEC & valves par ayinder “Lubrication system Forced, wot sump, with rochoid pump ‘Oil pump displacoment ‘ALS00 rpm min | 52.84 (55.8 US axl 7 ‘Water pump displacement 'At 6,000 rpm (min) | 820187 US atvminute Fuel required ‘Premium UNLEADED gasoline with 81 pump octane numbor corhigher _ STARTER Toe - ‘Gear reduction - Normal output 184 ‘Nominal votags r wv. [Hour ating s0seconds | Rotation of direction ‘Clockwise as viewed from gear ena cuTeH ‘Clutch type [arr ‘Single pate dry. diaphragm spring 7 at 3-)slement rave converter with lockup clutch ‘lutch Fetion material suroce | MT 264 cm 40.86 sqm) MANUAL ‘Tye ‘Synchronized, 6apeed forward 1 reverse TRANSMISSION [Primary reduction Direet 11 _ Gear ratio i 3.909 | 2nd 2078 Sea 1300 ah 1250 sth 0975 | ath 0790 _ Reverse 4.00 7 | Final reduction Type ‘Single helical gear (Geer ratio 3.285 (eon 2-19 Design Specifications (cont'd) eet Measurement Qualification ‘Spectcation ‘muTOMATIC [Type vorealy controlled automatic, speed forward, Levers TRANSMISSION | Primary reduction —_—_ Gear ratio 1 ‘nd Sed ‘th 0.66 Eo ‘0.480 Reverse 1846 Final reduetion Type Single halen gear (Geer ratio 428 ‘STEERING [Type Power assisted rack end pinion ‘Overavatio ise “Ture, loko look 2n ‘Steering whee! aiameter ‘380 mm (150m) "SUSPENSION | Type Front Independent double wishbone with able, collsring Rear Independent multlinkwith stabilizer, col sping ‘Shock asearber Front Telescope, hydraulic, nitrogen gas-filed Rear Telescopic, hydraullc nitrogen gas filed ‘BRAKES Type afeervioe brake Front Power-asssted se adjusting ventilated ise Re ~[Power assisted sol adjusting solid die Type of parking brake ‘Mechanica actuating ear wheols ad fiction surface FrontiarTmedell | $52em! x2 882sqin.x2) Front (M/T modell | 74.0? «211.47 sqin. x2 Rear 27.9em'x2 (433ain.x2) TiRES Sie 'P285/45A17 SW or 2354817 83W (optional Size of spare tire ‘Ait model "T135/60816 1010 MIT mode! “T145/70R17 106M a Corapressor ‘Tye Piston CcONDTONING ‘Capocity 188 mé (1.47 cu inirew. ‘Maximum speed | 7.922rpm ‘Lubricant capacity | 120 mé a flex) - — [ubfeanttype DENSOND-OILE Condens Type ‘Corrugated fin Evaporator Type. (Corrugatadfin [Blower “Type Radia - ‘Motor ype 250 WV, - ‘Speed control Infinite variable Maximum capacity | 560m (10,780 607) “Temperature control Alrembxtype. ‘Compressor clutch [vee Dry. single pate poly Vbel drive Electrical power | 42 W maximum at 12V consumption at 63 oe) Reirigerant yoe HFC Taao (1348) Copecity {500-550 9 (17.6— 19.4 02), 2-20 Tem ‘Measurement ‘Guslcation| Speciation TLECTRICAL [Batty T2V=65 ARO hours RATINGS ‘Starter T2v=18 kW ‘Alternator - 12V= 1900 Fuses ‘Under-hood fuse! | 1208, 50A, 40A,30A, 208, TBA, TOA, 7.5A relay box Under dash fuse’ | 308,208, 15A, 0A, TR relay box Tightbuibe Headlighthigh beem_| 12 —asWiHID) Heclightlow beam | 12 —35W (HID) Frontfog lights (US. | 12-51 W (HB) mode : Daytime running | 12V=60W (HBS) lights (Canada model Front Turnaignal | 2V—2W lights Front parking ights_| ¥2V-8 Front sigemarker [LED | lights _| Rear side merker | LED lights Reerturnsignal | 2V-21W [ghee — Stoptailights| 1 Tallights to High-mount brake [LED light Backup lights Teva vense late ight | 12V=3.p, Ceiling ight mav=5W - ‘Map ight TV 400, “Trunk ght T2v-sw Door courtsayights_| 12V=2ep Glove boxlight | 12V=14W Vanity miro ights_|¥2V=8W. Gauge likes uD indestor ghia | LED Console box ight | 12V=14W 2-21 Body Specifications Maintenance Lubricants and Fluids Maintenance Multi-information Service Informati Resetting the Multi-information Display Maintenance Main Items... Maintenance Sub Items Lubricants and Fluids For details of lubrication points and type of lubricants to be applied, refer to the strated index and various work procedures (such as Assembly/Reassembly, Replacement, Overhaul, Installation, tc.) contained in each section. LUBRICATION POINTS LUBRICANT Engine Honda Motor Oil: PIN 08798-9015 Use 5W-20 motor oil, Look for the API Certification seal on the. oll container as shown below. Make sure it says “For Gasoline Engines.” SAE Viscosity: See chart below. | Manual Transmission [Automatic Transmission Honda Manual Transmission Fluid (MTF): PIN 08798-8016 Always use Honda MTF. Using motor oil can cause stiffer shifting because it does not contain the proper additives. Honda Automatic Transmission Fluid (ATF-Z1): PIN 08200-9001 ‘Always use Honda ATF-21. Using a non-Honda ATF can affect shift quality © | Brake system (includes VSA line) Honda DOT 3 Brake Fluid P/N 08798-9008 Always use Honda DOT '3 Brake Fluid. Using a non-Honda brake fluid can cause corrosion and decrease the life of the system. D | Clutch Tine Honda DOT 3 Brake Fluid: PIN 08798-9008 ‘Always use Honda DOT 3 Brake Fluid. Using a non-Honda, brake fluid can cause corrosion and decrease the life of the systom. - E_| Power steering gearbox ‘Steering grease: P/N 08733-BO70E F | Shift and select cable ends (WT) Silicone grease | Throttle cable end (dashboard lower panel hole) H_| Brake booster clevis ‘Multiparpose grease 1 | Clutch master cylinder cl J. | Release fork K_ | Shift lever (manual transmission) L_| Battery terminals M | Pedal linkage N | Fuel fill door © | Hood hinges and hood latch P| Door hinges, upper and lower [0 | Trunk hinges _ _ _ R__| Caliper piston boat, caliper pins and boots _| Honda Caliper Grease: P/N 08C30-B0236M —] ‘S| Power steering system Honda Power Steering Fluid Always use Honda Power Steering Fluid. Using any other type | ‘of power steering fluid or automatic transmission fluid can __| cause inereased wear and poor steering in cold weather. T | Airconditioning compressor ‘Compressor cit: DENSO ND-OIL 8 (P/N 38897-PR7-AD1AH or '38899-PR7-AD1) for refrigerant HFC-134a (R-134a) 3-2 Ripe itcesn ts emoencumewanen anges ary 3-3 Maintenance Minder Multi-information Display The Maintenance Minder is an important feature of the Multi-information Display. Based on engine operating conditions and accumulated engine revolutions. The TL’s onboard computer (ECM/PCM) calculates the remaining engine oil life. The system also displays the code for other scheduled maintenance items needing service. MULTLINFORMATION DISPLAY 3-4 Service Information 1. The remaining engine oil life is displayed as a percentage on the mult-information display when the ignition is turned to ONIN). inp tien ee ey 2, When the remaining engine oil fe is at 15 percent, the maintenance message “SERVICE DUE SOON”, along with the maintenance items currently requiring service will be displayed. + Complete list of maintenance main items “A” (see page 3-7) + Complete list of maintenance sub items “B” (see page 38) ow ‘When the remaining oil life is less than 5 percent, ‘the maintenance message "SERVICE DUE NOW”, along with the items shown in “SERVICE DUE ‘SOON will display. At this point, the indicated maintenance must be performed as soon as. possible. le aes ee 3-5 Maintenance Minder Resetting the Multi-information Display 1. Turn the ignition switch to ON(N, 2. Press the SELECTRESET button repeatedly unti the oil life is displayed (it more than 15 %) or the maintenance message is displayed (i of if is less than 15%). NOTE: Ifyou are resetting the display when the oll life is more than 15 %, the maintenance message “SERVICE DUE SOON’ will be displayed. Make sure the maintenance items requiring service have been performed before resetting this display. 3. Press and hold the SELECT/RESET button for 10 seconds until you see the maintenance message or “MAINTENANCE RESET”. Ifthe nance message is displayed, press and hold the SELECT/ RESET button again for 10 seconds until you see “MAINTENANCE RESET”, + To reset the display, press the SELECT/RESET button to select “OK”. The next time the ignition ‘switch is turned to "ON", the display will show “OIL LIFE 100% + Ifyou do not want to reset the display, press the side of the INFO button to select “Cancel”. 3-6 NOTE: + Ifthe required service is performed and the display is not reset or ifthe display is reset without performing the service, the system will not show the proper maintenance levels. This can lead to serious mechanical problems because there will be no record of when ‘maintenance is neaded. Ifthe indicated maintenance service fs not performed and the remaining ehgine oil ife is less than 0 percent, “SERVICE PAST DUE" will display, have the service performed immediately and make sure to reset the display as previously described. oy Maintenance Main Items I the message “SERVICE DUE NOW” does not appear more than 12 months after the display is reset, change the engine oil every year. NOTE: + Independent of the mainter snce messages in the Multi-information Display, replace the brake fluid every 3 years. + Inspect idle speed every 160,000 miles (256,000 km). + Adjust t vvalves during services A, B, 1,2 or 3 if they are noisy. [Symbol A ‘Maintenance Main items Replace engine oil see page 86). Capacity: without oil filter: 4.0.0 (4.2 US qt). Replace engine oil and oil filter (see page 8-6) Capacity: with ol filter: 4.3 9 (4.5 US qv. Rotate tires, and check tire inflation and condition. Follow the pattern shown in the Owner's Manual. Check front and rear brakes (see page 19-3). * Check pads and discs for wear {thickness), damage, and cracks. + Check calipers for damage, leaks, and tightness of mount bolts. ‘Check parking brake adjustment (see page 19-7). __Number of clicks (6 to 10) when the parking brake lever is pulled with 196 N (20 kgf, 4 Ibf) of force. Visually inspect the following items: + Check for correct installation and position, check for cracks, deterioration, rust, and leaks. | + Check tightness of screws, nuts, and joints. If necessary, retighten. Inspect tie rad ends, steering gearbox, and gearbox boots (see page 17-8). * Check rack grease and steering linkage. + Check boots for damage and teaking grease. + Check fluid fines for damage and leaks. Inspect suspension components (see page 183). + Check bolts for tightness. + Check condition of ball joint boots for deterioration and damage. Tnspect driveshaft boots (see page 16:4). Check boots for cracks and boot bands for tightness. inspect brake hoses and lines including VSA (see page 19-37) Check the master cylinder, and VSA modulator for damage and leakage. Tnspect all uid levels and condition of ids. +" utomatic transmission fluid (ATF-21) (see page 14-203). + Manual transmission fluid (MTF) (ee page 13-10). + Clutch fluid (see step 11 on page 12-12) + Power steering fluid (see page 17-12) ( tuid (see page 199). + Windshield washer fuid + Engine coolant (see page 10-6). inspect exhaust system (see page 957” ‘Check catalytic converter heat shields, exhaust pipes, and muffler for damage, leaks, ond tightness. inspect ful lines and connections (see page 11-249). Check for loose connections cracks, and deterioration; retighten loose connections and replace damaged parts. NOTE: According to state and federal regulations, failure to do the maintenance tems marked with an asterisk (*) will ‘not void the customer's emissions warrar . However, Honda recommends that all maintenance services be done at the recommended interval, to ensure long-term reliability, 3-7 Maintenance Minder Maintenance Sub Items ‘Symbol Maintenance sub items 1 | Rotate tires, and check tire inflation and condition. Follow the pattern shown in the Owner's Manual. 2 | Replace air cleaner element (see page 11-273). If you drive primarily in dusty conditions, replace every 15,000 miles (24,000 km! Replace dust and pollen filter (see page 21-74). ‘+ Replace the filter at 15,000 miles (24,000) km intervals ifthe vehicle is driven mostly in urban areas ‘that have high concentrations of soot inthe air from industry and diesel-powered vehicles. + Replace the filter whenever airflow from the heating and coolingiclimate control system is less than normal Inspect drive belt (see page 429), Look for cracks and damage, then check belt deflection by pushing on the belt about 98 N (10 kgf, 22 Ib midway between the pulleys. 3 | Replace automatic transmission fluid (see page 14-208), + Driving in mountainous areas at very low vehicle speed requires transmission fluid changes more frequently than recommended by the Maintenance Minder. f you regularly drive your vehicle under this conditions, have the transmission fluid changed at 60,000 miles (96,000 km}, then every 30,000 smiles (48,000 km). | + Capacity: 3.0 0 (3.2 US gt); use Honda ATE _ Replace manual transmission fluid (see page 13-10). Capacity: 2.20 (2.3 US qt}, use Honda MTF. 3-8 © | Replace spark plugs (see page 421). Use IZFR6K-11 (NGK) or SKJ20DR-M11 {DENSO), Roplace timing belt (see page 6-14), i the vehicle is regularly driven in very high temperatures (over 110, 43°), or in very low temperatures ( under —20F, 23%), replace every 60,000 miles (U.S.)/ | 100,000 km (Canada) and inspect water pump (see page 10-5). Inspect the valve clearance (cold) (see page 6-8). + Otherwise adjust only if noisy. + Intake: 0,200.24 mm (0,008—0,009 in.), Exhaust: 0.28 0.32 mm (0.010.013 in. | Replace engine coolant (see page 10-6). Capacity (including the reserve tank): MT: 6.3 0 (6.7 US qtl, A/T: 6.4 0 (6.8 US qui: use Honda All ‘Season Antifreeze/Coolant Type 2. Engine Electrical Engine Electrical Special Tools .. Starting System Component Location Index... 4-3 ‘Symptom Troubleshooting Index Circuit Diagram Starter Circuit Troubleshooting Clutch Interlock Switch Test Starter Solenoid Test .. Starter Performance Test .. Starter Replacement Starter Overhaul. 4-10 an Ignition System Component Location index .... 4-16 Circuit 417 Ignition Timing Inspection ..... 4-18 Ignition Coil Removal/ Installation Ignition Coil Relay Circ Troubleshooting Spark Plug Inspection 4.20 421 Charging System Component Location Index .... 4-22 Symptom Troubleshooting Index Circuit Diagram Charging Circuit Troubleshooting /e Belt Inspection Drive Belt Replacement .. Drive Belt Auto-tensioner Inspection . Drive Belt Auto-tensioner Replacement . Tensioner Pulley Replacement Alternator Replacement Alternator Overhaul 4-23 424 425 4-29 4-29 4-30 431 431 432 4-34 Cruise Control Component Location Index .... 4-38 Circuit Diagram... . 4-39 Symptom Troubleshooting Index 4-40 Cruise Control Input Test nue 4-47 Cruise Control Combination Switch Test/Replacement .... 4-43 Cruise Control Combination Switch Illumination Bulb Replacement . 4-83 Clutch Pedal Position Switch Test .. 444 Engine Mount Control System Component Location Index .... 4-45 Circuit Diagram . 4-46 Troubleshooting . 4-47 Engine Electrical Special Tools Ref. No. ‘Tool Number ~ Description Oty, D | ASTEX041-XXXXX Vacuum Pump/Gauge, 0-30 in.Hg 1 ® | 07746-0010300 ‘Attachment, 42 x 47 mm 1 @ _ | 07749-0010000 Driver 1 Starting System Component Location Index UNDER-DASH FUSE/RELAV BOX STARTER CUTRELAY Test, page 22-75. starrer CLUTCH INTERLOCK SWITCH (MT) Stat Ccult Troubleshooting, page 48 Festipape ee Scion Tet page 8 Repinconort.pape 0 TRANSMISSION RANGE SWITCH (A/T) zl ca page raat poe el Replacement, page 14-242 43 Starting System Symptom Troubleshooting Index. ‘Symptom Diagnostic procedure: ‘iso check for] Engine does not start (Check for loose battery terminals or connections. * Poor ground at G107, {does not crank) Test the battery for a low charge (see page 22-74). 18102 (A/T) or G503 Check the starter (see page 4-6) wn) Check the starter cut relay (see page 22-78). Check the transmission range switch (A/T) (see page 14- 240). Check the clutch interlock switch (M/7) (see page 4-8). ‘Check the ignition vaitch or wire (see page 22-77), Troubleshoot the immobilizer systam (see page 22-328). Test the fuel pump (see page 11-241). Check for plugged or damaged fue! line (see page 11- 249), Check for plugged fuel filter (see page 11-256). Check the throttle body (see page 11-272). Check for PGM-FI DTC's. ‘Check for low engine compression (see page 6-6). Check for damaged or broken timing belt. Test the fuel pump (see page 11-241) Check for plugged or damaged fuel line {see page 11- 249). Check for plugged fuel filter (see page 11-256). Check for restricted three way catalytic converter (TWC) or exhaust system, | 5. Check for PEM-IDTC’s. Engine cranks, but does not start Engine is hardto start 4-4 Circuit Diagram rae 5 el | | aeee i $e 4 ——~—--2 Ss ag s8y i 7 | ul | fa i . ii ! ttt 2 va 5 bn er et i at z a ns z 2] z Tul i . ii qi i 87 45 Starting System Starter Circuit Troubleshooting NOTE: + Air temperature must be between 58° and 100 (15° ‘and 38°C) during this procedure. + Alter this inspection, you must reset the engine. control module (ECM)/powertrain control module (PCM), using the Honda Diagnostic System (HDS) (see page 11-4), otherwise the ECM/PCM will Continue to stop the fuel injectors from operating. + The battery must be in good condition and fully charged, Recommended Procedure: + Use a starter system tester. + Connect and operate the equipment in accordance with the manufacturer's instructions. Alternate Procedure 1, Remove the left side engine compartment cover, (see step 3 on page 5-2) 2. Hook up the following equipment: + Ammeter, 0— 4008 + Voltmeter, 0-20 V {accurate within 0.1 volt) ‘3. Connect the HDS to the data link connector (DLC) (see step 2 on page 11-3). 4. Select PGM-I, then INSPECTION, then ALL INJECTORS OFF function on the HDS. 4-6 5. With the shift lever in N or P (A/T) or clutch pedal pressed (M/T), turn the ignition switch to start (Il) Did the starter crank the engine normally? ‘YES~ The starting system is OK. Go to step 12. NO~Goto step 6. 6. Check the battery condition. Check electrical connections at the battery, the negative battery cable to body, the engine ground cables and the starter far looseness and corrosion. Then try ‘cranking the engine again, Did the starter crank the engine? ‘YES Repairing the loose connection corrected the problem. The starting system is OK. Go to step 12. NO— Check the following: + Ifthe starter will not crank the engine at all, go to step 7. Hitcranks the engine erratically or too slowly, 90 to step 9. If itwon't disengage from the flywheel or torque converter ring gear when you release the key, check the following: ~ Solenoid plunger and switch malfunction = Dirty drive gear or damaged overrunning clutch a ENGINE 17. Make sure the transmission is in neutral, then disconnect the BLK/WHT wire from the starter ‘solenoid § terminal. Connect a jumper wire from the battery positive terminal to the solenoid terminal. Did the starter crank the engine? YES—Go to steps. NO—Remove the starter, and repair or replace as necessary. 8. Check the following items in the order listed until, you find the open circuit: + The BLK/WHT wire and connectors between the under-dash fuse/relay box and the ignition switch, and between the under-dash fuse/relay box and the starter. + The ignition switch (see page 22-77). + The transmission range switch and connector (AMT (see page 14-240) or the clutch interlock switch and connector (M/T) (see page 4-8) + The starter cut relay (see page 22-75). 9, While cranking the engine, check the cranking voltage and current draw. Is cranking voltage greater than or equal to 8.5 V and current draw less than or equal to 380A? YES—Go to step 10, NO Replace the starter, or remove and disassemble it, and check the following: + Starter armature dragging + Shorted armature winding + Excessive drag in engine 10. Check the engine speed while cranking the engine. Is the engine speed above 100 rpm? YES~Goto step 11. NO—Replace the starter, or remove and disassemble it, and check the following: m= + Open circuit in starter armature commutator segments + Excessively worn starter brushes + Open circuit in commutator brushes + Dirty or damaged helical splines or drive gear + Faulty drive gear clutch 11, Remove the starter, and inspect its drive gear and the flywheel or torque converter ring gear for damage. Replace any damaged parts. 12, Select ECM/PCM reset \see page 11-4) to cancel the ALL INJECTORS OFF function on the HDS. 13. Reinstall the left side engine compartment cover (see step 68 on page §-22) 47 Starting System 4-8 Clutch Interlock Switch Test 1. Disconnect the clutch interlock switch 2P connector wy. Terminal side of sale terminals, 2. Remove the clutch interlock switch (B), 3. Check for continuity between the terminals according to the table. + Ifthe continuity is not as specified, replace the clutch interlock switch. + IfOK, install clutch interlock switch and adjust ‘he padal height (see page 12-6). as 4 2 Clutch interlock Switch PRESSED o—}—o RELEASED Starter Solenoid Test 1. Check the hold-in coil for continuity between the terminal and the armature housing (ground). “There should be continuity. + Hf there is continuity, go to step 2. + Hf there is no continuity, replace the solenoid, 2. Check the pullin coil for continuity between the S terminal and M terminal. There should be continuity. + If there is continuity, the solenoid is OK. + If there is no continuity, replace the solenoid. Starter Performance Test sonnect the wire from the M terminal. 2. Make a connection as shown using as heavy a wire 2s possible (preferably equivalent to the wire used for the vehicle). To avoid damaging the starter, ever leave the battery connected for more than 10 seconds. 3. Connect the battery as shown. Be sure to isconnect the starter motor wire from the solenoid. Ifthe starter pinion moves out, itis working properly. A 7 ® ©] | ihren I (SrouNn) 4, Disconnect the battery from the M terminal. If the pinion does not retract, the holdin coil of the solenoid is working properly. 5. Disconnect the battery from the starter body. If the pinion retracts immediately, itis working properly. A | @ Oo wv BATTERY 6. Clamp the starter firmly in a vise. 7. Reconnect the wire to the M terminal. 8. Connect the starter to the battery as shown in the diagram, and confirm that the motor starts and keeps rotating wv BATTERY 9. Ifthe electric current and motor speed meet the ‘specifications when the battery voltage is at 11.5, the starter is working properly. Specifications Electric current: &0A or less Motor speed: 2,600 rpm or more 49 Starting System Starter Replacement 1. Make sure you have the anti-theft code for the radio, ‘and the navigation system, then write down the XM radio channel presets, Make sure ignition switch OFF, 2. Remove the left side engine compartment cover (see step 3 on page 5-2), 3, Disconnect the negative cable from the battery first, then disconnect the positive cable. 4, Remove the battery hold-down bracket, then remove the battery and battery tray. 5. Remove the harness clamp (Al. 6. Disconnect the starter cable (B) from the B terminal, ‘hen disconnect the BLK/WHT wire (C) from the Sterminal. 7. Remove the two bolts holding the starter, then remove the starter. 4-10 8, Install in the reverse ordor of removal. Make sure: the crimped side of the ring terminalis facing out. 9. Connect the battery positive cable and negative cable to the battery. 10. Start the engine to make sure the starter works property. 11. Enter the anti-theft codes for the radio and the ion system, then enter the customer's XM radio channel presets. 12, Setthe clock. Starter Overhaul Disassembly/Reassembly RUSH ARMATURE HOUSING END COVER, BRUSH HOLDER nur Nim (0.9 kghim, 7 bt) {Apply moyen va vent Tus ae “Wage Za sem wun ce ‘SOLENOID LEVER / GEAR HOUSING OVERRUNNING (CLUTEH ASSEMBLY GEAR HOUSING cover (cont'd) 4-11 Starting System Starter Overhaul (cont'd) Armature Inspection and Test 1. Remove the starter see page 4-10), 2. Disassemble the starter as shown at the beginning 3, Inspect the armature fot wear or damage from contact with the permanent magnet. Ifthere is wear ‘of damage, replace the armature. 4. Check the commutator (A) surface. Ifthe surface is dirty or burnt, resurface with emery cloth or a lathe within the following specifications, or recondition with #800 or #600 sandpaper (B). 5. Check the commutator diameter. Ifthe diameter is below the service limit, replace the armature. Commutator Diameter ‘Standard (New: 28.0~28.1 mm (1.102—1.106 in.) 27.5 mm (1.083 in.) Service Limit: 6. Measure the commutator (A) runout. + Ifthe commutator runout is within the service ‘imi, check the commutator for carbon dust or brass chips between the sogments. + Ifthe commutator runout is not within the service limit, replace the armature. Commutator Runout ‘Standard (New!: 0.02 mm (0.001 in.) max. Service Limit: 0.05 mm (0.002:in.) 4-12 7. Check the mica depth (A) Ifthe mica is too high (B), undercut the mica with 2 hacksaw blade to the proper depth. Cut away all the mica (C) between the commutator segments. The undercut should ‘not be too shallow, too narrow, or V-shaped (0). Commutator Mica Depth 9, Place the armature (A) on an armature tester (B). Hold a hacksaw blade (C) on the armature core. Hf the blade is attracted to the core or vibrates while the core is turned, the armature is shorted. Repiace the armature. 8 c 8 Check for continuity between the segments of the commutator. If an open circuit exists between any segments, replace the armature. 10. Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core (B), and between the commutator and armature shaft (C). If continuity exists, replace the armature, (cont'd) 4-13 Starting System Starter Overhaul (cont'd) Starter Brush Inspection 11. Measure the brush length. ifit is not within the ‘service limit, replace the brush holder assembly. Brush Length ‘Standard (Now): 15.8—16.2 mm (0.62—0.64 in.) Service Limit: 11.0 mm (0.43: 4-14 ‘Starter Brush Holder Test 12. Check that there is no continuity between the (-+) brush holdes (A) and (—) brush holder (B). there is continuity, replace the brush holder assembly. Brush Spring inspection 13, Insert the brush (A) into the brush holder, and bring the brush into contact with the commatator, ther attach a spring scale (B) to the spring (C). Measure the spring tension at the moment the spring lifts off the brush. Ifthe spring tension is not within ‘specification, replace the spring. ‘Spring Tension: 15.7—17:7 N (1.60~1.80 kgf, 3.53—3.97 Ib) ENGINE 114, Pry back each brush spring with a screwdriver, then | Overrunning Clutch Inspection position the brush about halfway out of its holder, and release the spring to hold it there. 17. Slide the overrunning clutch afong the shaft. Replace it fit does net slide smoothly. NOTE: To seat now brushes, slipa strip of #500 or # 600 sandpaper, with the grit side up, between the | 18, Rotate the overrunning clutch (A) both ways. fit commutator and each brush, and smoothly rotate does not lock in either direction or it locks in both the armature. The contact surface of the brushes directions, replace it. will be sanded to the same contour as the ‘commutator. 15. Install the armature in the housing. Next, pry back each brush spring again, and push the brush down nti it seats against the commutator, then release ‘the spring against the end of the brush, in 19, tthe starter dive goar (8 is worn or damaged, i zeplace the overrunning clutch assembly; the gear is not available separately. NOTE: Check the condition of the torque converter ring gear to see if the teeth are damaged. i) 20. Reseomete sarin th rvere oar of Scoot. 18, ns anarond cover orth bush re Ignition System Component Location Index UNDER-DASH FUSE/RELAY BOX IGNITION Col RELAY Test, page 22-75, ‘SPARK PLUG Inspection, page 4-21 IGNITION co amovalineatencn, page 238 4-16 Circuit Diagram ® wn satu in , u os ufo i re i sxe exh sae ce ae i , 1) >< >< >< >< >< a 4-17 ignition System Ignition Timing inspection 1 Connect the Honda Diagnostic System (HDS) ‘0 the data link connector (DLC) (see step 2 on page 11-3), ‘and check for DTC's. fa DTC is present, diagnose ‘and repair the cause before inspecting the ignition, timing. 2. Start the engine. Hold the engine at 3,000 rpm with ro load (in Neutral! until the radiator fan comes on, then letitidle. . Check the idle speed (see page 11-238). Select “SCS” mode using the HDS. Remove the right side engine compartment cover, (s2e step 1 on page 4-29) Connect the timing light to the service loop. 4-18 7. Aim the light toward the pointer (A) on the timing bolt cover. Check the ignition timing under no load condition: headlights, blower fan, rear window defogger, and air conditioner are not operating. Ignition Timing M/T: 10°+2°BTDC (RED mark {B) at idle in Neutral A/T: 10°::2°BTDC (RED mark (B)) at idle in 8, Ifthe ignition timing differs from the specification, ccheck cam timing. If cam timing is OK, update the engine control module (ECM\/powertrain control ‘module (PCM) ift does not have the latest software (see page 11-6), or substitute a known-good ECM/ PCM (see page 11-7), then recheck. Ifthe system ‘works properly, and the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171) 9. Disconnect the HDS and the timing light. Ignition Coil Removal/installation 1, Remove the intake manifold cover. 2, Remove the right side engine compartment cover (A), then remove the left rear engine compartment cover (B) and right rear engine compartment cover (C). 3, When removing the No. 6 coll you must remove the reserve tank heat shield and reserve tank. 4, Disconnect the ignition coil connectors (A), then remove the ignition coils (B). 5. Install the ignition coils in the reverse order of removal. 4-19 Ignition System 1. Check the No. 2(18A) fuse relay box. the under-dash fuse/ Is the fuse OK? YES—Goto step 2. NO—Replace the fuse. 2. Remove the ignition coil relay from the under-dash fuse/relay box and test it (see page 22-75). Is the retay OK? YES—Go to step 3. NO—Replace the ignition coil relay. 3, Measure the voltage between ignition coil relay 4 ‘sacket terminal No. 1 and body ground, then terminal No. 4 and body ground. IGNITION COIL RELAY 4P SOCKET ‘Terminal side of female terminals Is there battery voltage? YES—Goto step 4. NO~Replace the under-dash fuse/relay box.m 4-20 n Coil Relay Circuit Troubleshooting 4. Check for continuity between ignition coil relay 4P socket terminal No. 2 and the No. 1 ignition coil 3P connector terminal No. 3. IGNITION CoM. RELAY a? SOCKET H ‘Terminal side of female terminals G7) aterm [2 3 [No.1 IGNITION COWL 3° CONNECTOR Is there continuity? YES~Goto step 5. NO—Repair an open in the wire between ignition coil relay 4P socket terminal No. 2 and ignition coil '3P connector terminal No. 3. 8. Check for continuity between ignition coil relay 4P socket terminal No. 3 and body ground. IGNITION COIL RELAY 4P SOCKET Terminal side of female terminals Is there continuity? YES—Ropair a short in the wire between ignition coil relay 4P socket terminal No, 3 and ECM/PCM.m NO~Repair an open in the wire between ignition ‘oil relay 4P socket terminal No. 3 and ECM/PCM. ‘sy ENGINE Spark Plug Inspection 1. Inpect the electrodes and ceramic insulator, + Burned or worn electrodes may be caused by: = Advanced ignition timing = Loose spark plug = Plug heat range too hot = Insufficient cooling + Fouled plug may be caused by: = Retarded ignition timing = Olin combustion chamber = Incorrect spark plug gap = Plug heat range too cold ~ Excessive idling/low speed running = Clogged air cleaner element = Deteriorated ignition coils Worn or detormed loctrodes { :!mproper gap ices 1 | :2itbon déposie 2, Do not adjust the gap (A) of iridium tip plugs ; replace the spark plug ifthe aap is out of specification. Electrode Gap ‘Standard (Neve: 1.0—1.1 mm (0.039-0.043 in.) 3, Replace the plug at the specified interval or ifthe center electrode is rounded (A). Use only the spark plugs as listed. ‘Spark Plugs NGK: —IZFRGK.11 DENSO: SKJ200R-M11 4. Apply a small quantity of anti-seize compound to the plug threads, and screw the plugs into the cylinder head finger-tight. Then torque them to 1B Nem (1.8kgfim, 13 IBF. 4-21 Charging System Component Location Index (CHARGING SYSTEM INDICATOR (inthe gauge assembly) LUNDER-HOOD FUSE/RELAY BOX {Was builtin ELECTRICAL LOAD DETECTOR (ELD) UNIT BATTERY ‘Test, page 22-74 a 10 Inspection, page #30 Moublanootng sage £25 Replacement, page 4-31 ag Replacement page, 22 Gvormaul page 434 RIVE BeLT Inspection. page 429 4-22 a ENGINE Symptom Troubleshooting Index ‘Symptom sgnostie procedur ‘Also check for Charging system indicator stays on ‘Troubleshoot the charging system indicator circuit (see page 4-25), 2. Check or a broken drive belt (see page 4-2) 3. Check the drive belt auto-ensioner (see page 4-30). a age 4:25) _ Battery discharged 1. Check for poor connection, open or shorted wits) in charging systom, 2. Check or electrical currnt draw. 3. Check or a broken drive bolt (see page 4-29). 44 Check the drive bolt auto-tensioner (see page 4-20) 5. Testtho alternator (see page +25). 6. Troubleshoot the alternator control system (see page 425) 7. Check for poor connection at battery terminal 8._Test the battery (see page 22-74), Battery overchoroed 1. Test the alternator (see page 425) 2. Troubleshoot the alternator control system (see page 425). 3._Test the battory (see page 22-74) 4-23 Charging System Circuit Diagram a ase Fc a on ‘or en moan ‘Lee = te I Fh } c = LI Lt A tetttt | 4-24 Charging Circuit Troubleshoo' g Ifthe charging system indicator does not come on or does not go off, or the battery is dead or low, test the following items in the order as listed: + Battery (see page 22-74) + Charging system indicator test + Alternator and regulator circuit test + Alternator control system test Charging System Indicator Test 1, Turn the ignition switch ON (I). Does the charging system indicator come on? /ES—Goto step 2. NO-Goto step 3. 2. Start th gine. Does the charging system indicator go off? YES~Charging system indicator circuit is OK. Go to the Alternator and Regulator Circuit Test. NO~Go to step3. 3, Troubleshoot the multiplex integrated control system (see page 22-108). 1s the multiplex integrated control system OK? YES~Goto step 4, NO—Repair the multiplex integrated control systorn.m 4, Run the gauge control module self-diagnostic function (see page 22-262). Does the charge indicator flash? YES ~Goto step 5. NO— Replace the gauge control module (see page 22-265). 5. Turn the ignition switch OFF. 6. Disconnect the alternator 4P connector. 7. Turn the ignition switch ON (th, 8, Measure the voltage between alternator 4P ‘connector terminal No. 1 and body ground, ALTERNATOR 4P CONNECTOR Ic (BLK ve) Is there battery voltage? YES—Goto step 9 NO~Check for a blown No. 18 (15A) fuse in the tunder-dash fuse/relay box. If the fuse is OK, repair ‘open in the wire between the alternator and under- dash fuse/relay box. ‘8. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC). Turn the ignition switch (ON (IN, and jump the SCS line with the HDS, then turn the ignition switch OFF, NOTE: This step must be done to protect the engine control module (ECMl/powertrain control module (PCM) from damage. 10. Disconnect ECM/PCM connector é (31P). (cont'd 4-25 Charging System Charging Circuit Troubleshooting (cont'd) 114. Check for continuity between ECM/PCM connector terminal E11 and alternator 4P connector terminal No. 3 ECM/PCM CONNECTOR E (31P) C1, T[27T3]4]5]6]7} [els Folia] Tiafislie| 7ps]ig|z2o| 27 22iapl24 (25126) [2 7l28|29|301 31 ACT (WHT BLU) = (4 | 2) avreavaton heenaaan 3 [4) “enn Wire side of female terminals Is there continuity? YES~Go to step 12. NO—Repair an open in the wire between the alternator and the ECM/PCM. 12, Check for cantiuity between ECM/PCM connector terminal E11 and body ground, ECM/PCM CONNECTOR E (21P) TT2T3[4[s[6l7] [al iol if'2]Trafislie| sy 920 1 22jasle4l [2s|26] [27/28|29/30/ 31 ALTL a“ Wire side of female terminals. N|o| Is there continuity? YES~Repair a short in the wire between the alternator and the ECMVPCW. NO— Goto the Alternator and Regulator Circuit Test. 4-26 Alternator and Regulator Circuit Test 1. Be sure the battery connections are good, and that the battery is sufficiently charged (see page 22-74). 2. Connect a VAT-40 (or equivalent tester), and turn the selector switch to position 1 (starting). LOAD ADJUSTER FOU.FIELO TESTER (CARBON PILE) {isd (BLU) VOLTMETER NEGATIVE EAD (aLK) VOLTMETER Posmive LEAD (RED) TERMINAL GABLE VBLiC Posmve TERMINAL GABLE (RED) INDUCTIVE, PICK-UP (GRN) INDUCTIVE Pick 3. Shift to Park or Neutral, and start the engine. Hold the engine at 3,000 rpm, with no load until the radiator fan comes on, then let it idle. 4, Raise the engine speed to 2,000 rpm, and hold it there. Is the voltage over 15.1 V7 ‘YES — Replace the alternator (see page 4-32) or rear housing assembly (see page 4-34). NO-Goto step 5. + ENGINE 5. Release the accelerator pedal, and let the engine idle. 6. Make sure all accessories are turned off. Turn the selector switch to position 2 (charging). 7. Remove the inductive pick-up, and zero the 8, Place the inductive pick-up over the B terminal wire Of the alternator so that the arrow points away from the alternator. 9, Raise the engine speed to 2,000 rpm, and hold it there. Is the voltage less than 13.5 V? YES~Go to Alternator Control System Test. NO-Go to stop 10. 10. Apply a load with the VAT-40 until the battery voltage drops to between 12—13.5V. 1s the amperage 87.5A or more? ‘YES—The charging system is OK. NOTE: Ifthe charge system indicator is stil on, replace the alternator (see page 4-32). NO— Repair or replace the alternator (see page 4- Alternator Control System Test 1. Connect the Honda Diagnostic System (HDS) to the data link connector (DLC), and check for DTC's. Ifa DTC is present, diagnose and repair the cause before continuing with this test. 2. Disconnect the alternator 4P connector from the alternator. 3, Start the engine, and turn the headlights ON to high beam. 4, Measure voltage between alternator 4P connector terminal No, 2 and the positive terminal of the battery. BATTERY \c (WHT/GRN) I avtennaron {1 ‘a@Pconnector [214 Isthero 1 V or less? YES—Go to step 5. NO-Go to step, ‘5, Jump the SCS line with the HDS, then turn the ignition switch OFF. NOTE: This step must be done to protect the engine ‘control module (ECM)/powertrain control module (PCM) from damage. 6. Disconnect ECM/PCM connector E (31P). (conta) 4-27 Charging System Charging Circuit Troubleshooting (cont'd) 7. Check for continuity between ECM/PCM connector terminal £24 and body ground. ECM/PCM CONNECTOR E (31P) c—1 Tj23T4]s[éel7 819 roy ifi2| Mansel 8[i9]20[21 22|zaleal [2526] [27lze|zo{a0l 31 Wire side of female ereninale Is there continuity? YES— Repair short in the alternator and ECM/PCM. mt fe between the INO— Updote the ECM/PCM if it does not have the latest software (see page 11-8), or substitute a known-good ECM/PCM (see page 11-7), then fecheck. I the symptom/indication goes away with ‘2 known-good ECM/PCM, replace the original ECM/ FCM (see page 11-171). 8, Jumpthe SCS line with the HDS, then turn the ignition switch OFF. NOTE: This step must be done to protect the engine ‘control module (ECM)/powertrain control module (PCM) from damage. 9. Disconnect ECM/PCM connector E (31P). 4-28 10. Check for continuity between ECM/PCM connector terminal E24 and alternator 4P connector terminal No.2. ECM/PCM CONNECTOR E (31P) C7} 1[2]3[4[5[6[7 89 iol ii2]Trafisiie| i718] 9]20[21 zalza|ea). [2s|26). [27/z8/29130] 31 axe L_@-——_¢ (WHT/GRN) (WHT/QRN) Wire side of female terminate Isthere continuity? jeplace or repair the alternator (see page 4 NO Repair an open in the wire between the alternator and ECM/PCM. mt Drive Belt Inspection 1, Remove the right side engine compartment cover. Drive Belt Replacement 1. Remove the right side engine compartment cover. 2. Inspect the belt for cracks or damage. If the beltis, cracked or damaged, replace it. ‘Check that the auto-tensioner indicator (A) is within the standard range (B) as shown. If itis out of the ‘standard range, replace the drive belt (see page 4- 29). 3, Install the new belt in the reverse order of removal, 4-29 Charging System Drive Belt Auto-tensioner Inspection 1. Remove the right side engine compartment cover (see step 1 on page 42}. 2. Check the position of the auto-tensioner indicator’s pointer (A), start the engine, then check the position of the pointer again. If the position changes, replace the auto-tensioner. ‘3. Check for abnormal noise from the tensioner pulley. I you hear abnormal noise, replace the auto- tensioner pulley (see page 4-31) 4, Remove the drive belt see page 4-28). 5, Move the autoensioner within its limit with the ‘wrench in the direction shown. Check that the tensioner moves smoothly and without any abnormal noise. I the tensioner does not move ‘smoothly or there is abnormal noise, replace the ‘auto-tensioner (see page 4-31), 4-30 6. Remove the auto-tensioner (see page 4-31). 7. Clamp the auto-tensioner (A) by using a 10 mm bolt {81,8 mm bolt (C) and a vise (D) as shown. Do not clamp the auto-tensioner itself. 8 Attach a torque wrench (A) to the pulley bolt. ‘measure the torque when the tensioner is turned counterclockwise. If the torque is less than the specified value, replace the auto-tensioner (see page 4-31). 50.5 Nem (5.15 kgfm, 37.2 Ibf-f) Drive Belt Auto-tensioner Replacement 1. Remove the drive belt (see page 4-29). 2, Remove the splash shield, 3, Remove the auto-tensioner. (22 Kotm. 16 oF 4, Install the auto-tensioner in the reverse order of removal. Tensioner Pulley Replacement 1. Remove the auto-tensioner (see page 431). 2. Remove the pulley bolt (A) (left-hand threads), and remove the tensioner pulley (B). A 40x15 mm BON e.2 kgf, 59 bE) 3, Install the tensioner pulley in the reverse order of removal. 4-31 Charging System Alternator Replacement 1. Make sure you have the anti-theft code for the radi and the navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 2. Disconnect the negative cable from the battery, then disconnect the positive cable. 3. Disconnect the fan motor connector (A) and compressor clutch connector (B), then remove the coserve tank (C). E 6x 1.0mm T2N-mIT 2 ktm, 3.7 IEA) 4. Remove the two bolts (D), and loosen bolt (E), then remove the condenser fan shroud. 4-32 5. Remove the drive belt (see page 4-29). 6. Disconnect the slternator connector (A) and BLK wire (B) from the alternator. AZ Nien Beg on 8.7 ot) 7. Remove the bolt (C) securing the harness bracket. . ENGINE 8. Remove the mounting bolt (A) and alternator bracket mounting bolt (B), then remove the alternator. 5 Bilan Bot ft) . a ™ 41.25 mm 44 Nein 1B Eg, 33 WEA 9, Install the alternator and drive belt in the reverse order of removal 10. Connect the battery positive cable and negative cable to the battery. 11, Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel presets. 12, Set the clock. 4-33 Charging System Alternator Overhaul Exploded View BEARING RETAINER & FRONT BEARING ® TO VASE aust ngLDER ( i 0) eae =~. DRIVE-END HOUSING & ® ‘TERMINAL INSULATOR, REAR HOUSING ASSEMBLY ROTOR 4-34 /hment, 42 x 47 mm 07746-0010300 NOTE: Refer ta the Exploded View as needed during this procedure, 1, Test the alternator and regulator before you remove them (see page #25), 2. Remove the alternator {see page 4-32). 3. Ifthe front bearing needs replacing, remove the pulley focknut with a 10 mm wrench (A) and a 22 mm wrench (B). If necessary, use an impact wrench. 5. Remove the end cover (A) and the insulator (B). cont'd 4-35 Charging System Alternator Overhaul (cont'd) 7. Remove the four bolts, then remove the rear housing assembly (A) and washer (8) &. you are not replacing the front bearing, go to step 13, Remove the rotor from the drive end housing. 4-36 9. Inspect the rotor shatt for scoring, and inspect the bearing journal surface in the drive end housing for seizure marks. ‘It the rotor is damaged, replace the rator assembly. + Ifthe rotor is OK, go to step 10. 10. Remove the front bearing retainer plate. 11. Drive out the front bearing with a brass drift and hammer. 12. With a hammer and special tools, install a new front bearing in the drive end housing. Alternator Brush inspection 18, Measure the length of both brushes (A) with vernir calipers (8). + Ifeither brush is shorter than the service fimit, replace the brush holder assembly. +H brush length is OK, goto step 14, Alternator Brush Length ‘Standard (New): 10.5 mm (0.41 in.) Service Limit: 1.5 mm (0,06 in.) Rotor Slip Ring Test 14. Check that there is continuity between the slip rings. (A. + Hf there is continuity, go to step 15. + Ifthere is no continuity, replace the rotor assembly. 18. Check that there is no continuity between each slip 19 and the rotor (B) and the rotor shaft (C). + there is no continuity, replace the rear housing assembly, and go to step 16. + If there is continuity, replace the rotor assembly. 16. Assemble the alternator in reverse order of disassembly, and note these Items: + Be careful not to get any grease or oif on the slip, rings. + ifyou removed the pulley, tighten its locknut to 110 N-m (11.2 kgf-m, 81.0 IbFft) when you reinstall it. 4-37 Cruise Control Component Location Index _— €RUISE CONTROL INDICATOR ittinto gauge assembly). cauise conTmot, COMBINATION SWITCH ‘YeovReplecement pope 449 ENGINE cowrRo. MODULE (ECan, IATRAIN CONTROL ‘MODULE (Pew) ‘CRUISE CONTROL MAIN INDICATOR PEDAL POSITION SWITCH M7 {Guilt into gauge ascermaiy) guru Temtpoge st itch Badal Adjustment, page 126 BRAKE PEDAL POSITION SWITCH Test page 2.181 Pedal Height Adjustment, page 19-6, TRANSMISSION RANGE SWITCH (A/T) Testpage 14-240, 4-38 Circuit Diagram 4-39 Cruise Control Symptom Troubleshooting Index NOTE: Before troubleshooting. + Check for PGM-Fl and body DTC's. + Check the No. 13 (20A) fuse in the under-hoot fuse/relay box, and the No, 18 (16) fuse in the under-dash fuse/relay box. + Check that the horn sounds. + Check the speedometer to see if it works properly. Symptom _ Diagnostic procedure ‘iso check for ‘Grulse conttol cannot be set | Perform the eruise control input test (sos pago #7). Cruise control can be set, but | Perform the cruise control input test ses page 4-1). cruise main indicator does | net came on Cruise control canbe set, but | Perform the er cruise contol indicator does noteome on _ Vehicle does nat decelerate | Perform the cruise contol input test (soe page ©) or accelerate accordingly when SET/RESUME/CANCEL button is pressed ‘Set speed does not cancel | Perform he eral coniral Input test (soe page #41) when brake pedal is pressed Set speed does not eancel | Perform the cruise control input test (see page b-. when MASTER button is | turned OFF ‘Sot speed dose nat cancal | Perfarm the orulse contol input teat (see page #47) when CANCEL button is, pressed Set speed will nt resume | Perfor the cruise control input test (see page 4-47). wihon RESUME button is pressed (with MASTER button ON, and set speed temporarily canceled by pressing the brake pedal) With the ignition swith ON (i, ana she tghting sitoh ON, the cruise control combination switch iluminetion does not come on J control input test (see page 4-47) place the cruise control combination switch lumination bulb(s) (see page 4-43) 4-40 + ENGINE Cruise Control Input Test 1 Connect the Honda Diagnostic System (HDS) to the data link connector (DLC). 2. Gota B-CAN System Diagnosis Test Mode A and check for DTC's, 3. Goto PGM-Fl and check for DTC's. 4, Turn the ignition switch ON (I). '5, Perform the following tests while monitoring parameters in the PGM-FI DATA LIST with the HDS. ‘Signal tobe tested | ___Test condition ‘Parameter: Desired resi Possible cause i results not objained Brake switch | Brake pedal pressed, | CRUISE BRK SW * Faulty brake pedal position switch signal then released should indicate OFF | + Blown No. 18 (15A) fuse in the when the brake pedal is | _under-dash fuse/r pressed and ON should | » An open in the wit be indicated when the | PCM and the brake pedal position switch brake pedal is released. | + A wire shorted to ground between the ECM/PCM and the brake pedal position switch Clutch pedal | Clutch pedal pressed, | SHIFT/CLUTCH SW | Faulty clutch pedal position switch position then released should indicate OFF | « An open in the wire between the ECM switch signal when the clutch pedal | andthe clutch pedal position switch is pressed and ON + Awire shorted to ground between the should be indicated ECM and the clutch pedal position when the clutch pedal | switch is released. + Poor ground G803 Transmission | Shiftin D ord TRANS RANGE SW | « Faulty transmission range switch range switch | position should indicate OFF in| + An openin the wire between the PCM signat P,R, andN position and the transmigsion range switch and ON in D and2 + Awire shorted to ground between the position, PCM and the transmission range switch | + Poor ground G101, 6102 Cruise contrat | Cruise control ‘CRUISE MASTER SW = Faulty cruise control combination switch master button | master button ON | shout indicateON —_| + An open in the wite between the gauge signal and OFF when the cruise control | assembly and the cruise control master button is turned | combination switch ON and OFF when the | + Awire shorted to ground between the cruise control master | gauge assembly and the cruise controf button isturned OFF. | combination switch + An open in the wire between the cruise Control combination switch and the ground Satbutton | Set button pressed | CRUISE SET SW * Faulty cruise control combination switch signal ‘and released should indicate ON __| + An open in the wire between the gauge when the set button is pressed and OFF when the set button is released. ‘assembly and the cruise control ‘combination switch + Awire shorted to ground between the gauge assembly and the cruise control ‘combination switch cont'd) 4-41 Cruise Control Cruise Control Input Test (cont’d) when the cancel ‘buttons pressed ‘and OFF when the ‘cancel button is ‘Signal tobe tested Test condition ‘Parameter Desired result | Possible cause results not obtained Resume Resume button CRUISE RESUME | = Faulty cruise control combination switch button signal | pressed and released | SW should indicate | + An open in the wire between the gauge ON when the resume | assembly and the cruise control button is pressed combination switch ‘and OFF when the resume button is ‘gauge assembly and the cruise control roleased. __|_comibination switch —_| Cancel button | Cancel button pressed | CRUISE CANCEL SW | + Faulty cruise control combination awitch signal and released should indicate ON control is set and OFF when the cruise contol is cancelled. drive the vehicle to speeds over 25 mph | (#0 km/h) with the Cruise control set and cancel the cruise control | + Awire shorted to ground between the | - released. - Cruise contrat | Startthe engine, turn | CRUISE LIGHT * Faulty gauge assembly indicator the cruise contro should indicate ON | + A burntcruise control indicator bulb signal master button on and | when the cruise 4-42 Cruise Control Combination Switch Test/Replacement 1, Remove the driver's airbag (see page 23-128) 2, Remove the two screws, then disconnect the ‘connector, and remove the switch. Cruise Control Combination Switch Illumination Buib Replacement 1, Remove the driver's airbag (see page 23-128). 2. Remove the two screws, then disconnect the ‘connector, and remove the switch. ‘Terminal side of ‘male terminals 3. Check for continuity between the terminals in each ‘switch position according to the table. + Ifthere is continuity, and it matches the table, but switch failure occurred on the cruise control unit input test, check and repair the wire harness on the switch circuit. + If there is no continuity in one or both positions, replace the switch. Terminal coo ti2fa] las MASTER Ow) | O--O [MASTER (OFF) SET (ON) 5 RESUME (ON) oto. cance (oN CLT ro | illumination bulb. 4, Install in the reverse order of removal. 4-43 Cruise Control Clutch Pedal Position Switch Test 1. Disconnect the 3P connector from the clutch pedal position switch (A). Terminal side of 2. Remove the clutch pedal position switch. 3. Check for continuity between the terminals according to the table. + ifthe continuity s nat as specified, replace the clutch pedal pasition switch, + IFOK, install the clutch pedal position switch and adjust the pedal height (see page 12-6). Terninat lutch Pedal ' 2 : Position Switch PRESSED RELEASED o—}—o 4-44 Engine Mount Control System Component Location Index ENGINE CONTROL / MODULE: Mot oan? REAR MOUNT POWERTRAIN CONTROL MODULE from) Troubleshooting, page 447 FRONT MOUNT ENGINE MOUNT CONTROL SOLENOID VALVE Troubleshooting, page 4-47 4-45 Engine Mount Control System Circuit Diagram wero rea neziU ma 4-46 oe, ) ‘orn Betas ‘alt | am sue Troubleshooting ‘Special Tools Required Vacuum pumpigauge, 0-30 in.Hg ABTBX-081-XXXXXK NOTE: Check the vacuum hoses and lines for damage ‘and proper connections before troubleshooting. Follow this procedure if the engine vil when idling, (es excessively 1. Start the engine and let it idle (see page 11-238). 2, Raise the engine speed from idling to 2,000 rpm. ‘3. Check the MOUNT CTRL SOL in the PGM-FI DATA LIST with the Honda Diagnostic System (HDS). Is ON indicated at idling and OFF indicated at 2,000 rpm? YES~Go to step 4. NO—Update the engine control module (ECM) / powertrain control module (PCM) if it does not have the latest software (see page 11-6), or ‘substitute a known-good ECMIPCM (see page 11-71, then recheck. ifthe engine mount control system ‘works properly, and the ECM/PCM was updated, the troubleshooting is complete. If the ECM/PCM ‘was substituted, replace the original ECM/PCM (see page 11-171). 4, Shift the transmission to park (A/T), oF neutral (M/T) position. 5. Disconnect the engine mount control solenoid valve 2P connector from the engine mount control solenoid valve, 6, Measure voltage between engine mount control solenoid valve 2P connector terminal No. 2 and body ground. ENGINE wouNT CONTROL SOLENOID VALVE 2 CONNECTOR ot Is there battery voltage? YES~Go to step7. No—Repair an open in the wire between engine ‘mount control solenoid valve and No. 18 (15A) fuse inthe under-dash fuse/relay box. 7, Measure voltage between engine mount control ‘solenoid valve 2P connector terminals No. 1 and No. 2, with the engine at idl. ENGINE MOUNT CONTROL SOTENOtD VALVE 3° CONNECTOR Is there battery voltage? YES~Go to step 8. NO—Repair an open in the wire between ECM/PCM (B7) and the engine mount control solenoid valve 2P connector. If the wire is OK, update the ECM/ PCM if it does not have the latest software (see ‘page 11-6), or substitute a known-good ECM/PCM (see page 11-7), and recheck. Ifthe engine mount control system works properly, and the ECM/PCM was updated, the troubleshooting is complete. If the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171). cont'd) 4-47 Engine Mount Control System Troubleshooting (cont'd) 8, Raise the engine speed above 1,000 rpm. 9. Measure voltage between engine mount control solenoid valve 2P connector terminals No. 1 and No. 2. ENGINE MOUNT CONTROL, SOLENOID VALVE 2P CONNECTOR Mes. aa (BLU /veL) (eukrveL) Is there battery voltage? ‘YES —Repair a short to body ground in the wire between ECM/PCM (87) and the engine mount control solenoid valve. If the wire is OK, update the ECMIPCM if it does not have the latest software (see page 11-6), oF substitute a known-good ECM/ PCM (see page 11-7), and recheck. Ifthe engine ‘mount control system works properly, and the ECM/PCM was updated, the troubleshooting is ‘complete. If the ECM/PCM was substituted, replace the original ECM/PCM (see page 11-171). NO-Gotostep 10. 4-48 10. Disconnect the vacuum hose (A) that is closest to the solenoid connector from the engine mount control solenoid valve (BI, and connect a vacuum pump/gauge to the hose. Apply about 20 in.Hg of vacuum, and wait for 20 seconds. a B AGTEX-041 XXX Does the engine mounts hold vacuum? YES—Goto step 11. NO~Either the vacuum hose or one of the engine mount has a vacuum leak. Repair as needed. m a ENGINE 11, Release the vacuum, then apply vacuum agai {s there a noticeable change in idle smoothness with and without vacuutn applied? YES—Go to step 12 NO—Replace the front engine mount and/or rear ‘engine mount. 12. Connect a vacuum pump/gauge to the engine ‘mount control solenoid valve port (A) that is closest, to the solenoid connector. —_ 972.061.1000 |s there manifold vacuum at idle, and a decrease ‘in manifold vacuum when you raise the engine ‘speed above 1,000 rpm? YES—The system is OK. NO—Replace the engine mount control solenoid valve. 4-49 Engine Mechanical Engine Assembly Engine Removal Engine Installation... Engine Mount Replacement Cylinder Head .... Engine Block . Engine Lubrication . Intake Manifold and Exhaust System .. Engine Assembly Engine Removal ‘Special Tools Required + Front subframe adapter VS802C000016 + Engine support hanger, A and Reds AAR-T-12666 (available through Honda Tool and Equipment program, 888-424-6857) . aur Pros + Engine hanger balance bar VSB02000019 NOTE: + Use fender covers to avoid damaging painted surface: + To avoid damage, unplug the wiring connectors. carefully while holding the connectar portion. + Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring, hoses, or interfere with other parts. 1, Make sure you have the anti-theft codes for the radio and navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 2, Disconnect the support struts from both sides of the pivot ball (bolted to the hood). Secure the hood (A) ina vertical position, Remove the right si vot ball and install it into the lower threaded hole (B), then reattach the support strut. NOTE: Do not attempt tv close the hood with the support strutin the vertical position, a it will damage the support strut and hood. 5-2 ‘3. Remove the left side engine compartment cover (A) ‘and the left rear engine compartment cover (B) 4, Remove the right side engine compartment cover (A), then remove the right rear engine ‘compartment cover (8). 5, Remove the intake manifold cover. 11, Remove the harness clamp (A). 6. Drain the power steering system fluid (see page 17- 12), 7. Disconnect the negative cable from the battery, then disconnect the positive cable. 8, Remove the battery. 8. Remove the air cleaner housing (see page 11-273). 10, Remove the resonator {see page 11-274). 12. Remove the four bolts, then remove the battery base (8). 13, Remove the battery cables (A) from the under-hood use/relay box, then disconnect the harness ‘connector (B). 114, Remove the under-hood fuse/relay box (C) from the body. (cont'd) 5-3 Engine Assembly Engine Removal (cont'd) 15, Remove the harness clamp (A), and remove the two 6 mm bolts (B), then remove the strut brace (C). 117, Remove the brake booster vacuum hose (Al, evaporative emission (EVAP) canister hose (B). 16, Relieve fuel pressure (see page 11-245). 5-4 18. Remove the harness clamp (A), and disconnect the engine wire harness connectors (8) an the left side of the engine compartment. 19, Remove the three bolts securing the shift cable holder, then remove the shift cable and select cable. Do not bend the cables excessively (M/T} (see step 17 on page 13-16). 20, Remove the clutch slave cylinder and clutch line bracket mounting bolt. Do not operate the clutch ppedal once the slave cylinder has been removed (MM (see step 19 on page 13-16). 21. Remove the drive belt (see page 4-29). 22. Remove the power steering (P/S) pump inlet hose (A) and P/S pump outlet hose (8) from the P/S. pump, 23, Remove the P/S hose from the clamp. 24. Remove the steering joint cover (A). 25. Lock the steering wheel. Make a reference mark (B) ‘across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt C), and disconnect the steering joint from the steering ‘gearbox pinion shaft (D). To prevent damage tothe cable reel, do not turn the steering wheel once the steering joint has been removed. (cont'd) 5-5 Engine Assembly Engine Removal (cont'd) 26. Disconnect the fan motor connector (A) and. compressor clutch connector (B), and remove the reserve tank (C). Wipe up any spilled engine coolant immediately. 27. Remove the two bolts (D), loosen the bottom bolt {€), then remove the condenser fan shroud. 28, Remove the four bolts securing the A/C compressor. 29, Remove the radiator cap. 30. Raise the vehicle on the hoist to full height. 81, Remove the front tires/wheels. 5-6 32, Remove the engine under cover. 34, 35. a, g a a2, 43. Loosen the drain plug in the radiator, and drain the engine coolant (see page 10-6). Drain the transmission flu + Manual transmission (see page 13-10). + Automatic transmission (see page 14-204). Drain the engine oil (see page 8-6). Disconnect the stabilizer links (see page 18-22). 3. Remove the damper fork (see page 18-25). . Disconnect the tie-rod end ball joints (see step 10 ‘on page 17-30), . Disconnect the suspension lower arm ball joints (see page 18-20). Remove the driveshafts (see step 11 on page 16-5) Coat all precisior-finished surfaces with clean tengine oil Tie plastic bags over the driveshaft ends. Remove the shift cable. Do not bend the shift cable excessively (AT) (soe step 48 on page 14-212). Romove exhaust pipe A. 44, Remove the P/S hose (A). 45, Disconnect the power steering pressure switch connector. (cont'd) 5-7 Engine Assembly Engine Removal (cont’d) 46, Remove the nuts securing the transmission lower front mount and transmission lower rear mount. 47. Lower the vehicle on the hoist. 48. Remove the upper radiator hose (A) and lower, radiator hose (8. 48. Remove the heater hoses. 50. Remove the two bolts securing the side engine ‘mount bracket. 5. Lift and support the engine with engine hanger (A) and engine balancer bar (8). Attach the front arm (C) to the front cylinder head with a spacer (D) and the connector bracket bolt. (10x 1.25 mm) (E). Attach the rear arm (F) to the rear cylinder head with the harness clamp bracket. bolt (8 x 1.25 mm) (G). 52. Remove the ground cable (A). mt: 153, Remove the transmission upper mount bracket (B), and remove the vacuum hose (C). (cont'd) 5-9 Engine Assembly Engine Removal (cont'd) 54, Remove the front mount stop (A), then remove the front mount bolt (B) 56. Remove the rear mount stop (A), then remove the rear mount bolt (B). ‘damper (M77). 5-10 57. Remove the vacuum hose (C). 58. Remove the two bolts securing the shift cable bracket (MT). 59. Make sure the hoist brackets are positioned properly. Raise the vehicle on the hoist to full height. 60. Make the appropriate reference lines (A) at both ‘ends of the subframe (B) that line up with the edge 61. Attach the special too! to the subframe by hanging the belt (A) over the front of the subframe (B), then secure the belt with its stop (C). 62. Raise the jack and fine up the slots in the special oof arms with the bolt holes on the jack base, then securely attach them with four bolts. 3, 65. 70. 2. Slowly raise the vehicle about 150 mm (6: Remove the subframe mid-mounts. Check that the engine/transmission is completely free of vacuum hoses, fuel and caatant hoses, and electrical wiring. Lower the vehicle and securely support the ‘engine and transmission assembly. . When the engine and transmission is securely supported, and there is no tension on the engine support hanger, remove the engine hanger from the engine. ) Check once again that all hoses and wires are disconnected from the engine/transmission assembly. Raise the vehicle all the way. Remove the engine/transmis from under the vehicle. ion assembly 5-11 Engine Assembly Engine Installation ‘Special Tools Required + Front subframe adapter VSBO2C000016 + Engine support hanger, A and Reds NAR-T-12566 (available through Honda Tool and Equipment program, 888-426-6857) + Engine hanger balance bar VSB02000019 1. Install the accessory brackets and tighten their bolts and nuts to the specified torques. 8x3.25 mm MeSkgtm, _REARENGINE. hizo" MOUNT BRACKET PIS PUMP BRACKET 121.25 mm BNmisokatm, seibery Replace ENGINE MOUNT BRACKET ‘Alc COMPRESSOR ‘Racker FRONTENGINE MOUNT BRACKET, (am 1044.25 mm Stim eS ktm, 40 IF ft) ae Fepice 1oxi250m 10x125 mm Mhumisetotm, aire teBeatem ‘urn sin Repice. 5-12 b=] 2, Position the engine/transmission assembly under the vehicle. Lift and support the engine with engine hanger (A) and engine balancer bar (8. Attach the front arm (C) to'the front cylinder head with a spacer (D) and the connector bracket bolt (10x 1.25 mm) {E). Attach the rear arm (F) to the rear cylinder head with the harness clamp bracket, bolt (8x 1.25 mm) (G). ifthe engine into postion in the vehicle a taan-r-12566) [NOTICE] Reinstall all mounting bolts/support nuts in the sequences given. Failure to follow this may cause excessive noise and vibration, and reduce bushing life. 3, Attach the special tool to the subframe by hanging the belt (A) over the front of the subframe (B), then secure the belt with its stop (C). Raise the subframe Up to the body with a jack. 4. Loosely install the four subframe mounting bolts (A) and four 12 x 1.25 mm bolts (8), (C) with the stiffeners. 2x125mm ©. Shine exiz5mm ex15mm SB kgtm, im Taam’ be” —Seigim, — Hosagtm, sony” etme Replace. Replace. 5. Loosely install the subframe mid mounts, then remove the special tool 1041.25 mm 22x 125mm SNe eokgim, — da Nm (as kghm, semen 33 ibe nd place, Replace. (cont'd) 5-13 Engine Assembly Engine Installation (cont'd) 6. Align the reference marks (A) with edge (B) of both rear stiffener (C), and tighten the rear subframe ‘mounting bolts, then front bolts, and tighten the stiffener bolts to the specified torque. 7. Tighten the bolts securing the subframe mid- mounts, 8. Tighten the nuts securing the transmission lower, front mount and trarnsmission lower rear mount. 10x1.25 mm aR (83 kom, 33 bet) Replace. 98, Remove the jack and front subframe adapter. 5-14 10. Lower the vehicle on the hoist. 11. Install the shift cable, and tighten the two bolts securing the shift cable bracket (M/T). 12, Install the vacuum hose (A). 8 a 22x125m 11.25m BACT, Bet / Bae ihe inc 13, Tighten the rear mount bolt (B), then install the rear mount stop (C). 114, Tighten the two bolts securing the rear engine damper (MIT). Replace. 16. Tighten the front mount bolt (A), then install the front mount stop (B. 2yz0m (ee eat, 47 tt) 8 aes eal A 40x 1.25 mm tm (55 kgtm, somen) Replace. 16. Tighten the two bolts securing the side engine mount bracket. 101.25 mm (cont'd) 5-15 Engine Assembly Engine Installation (cont'd) 17. Install the transmission upper mount bracket (A), then tighten the bolts in the numbered sequence shown, mr: Sait? et SZnim 1 katm, sabi) OR ¥ 125mm sen eke 18, Install the vacuum hose (B). 19. Install the ground cable (Ci. 5-16 20. Raise the vehicle on the hoist to full height. 21. Connect the power steering pressure switch connector. 23, Install exhaust pipe A (A) using new gaskets (B) and new self locking nuts (C) 10x1.25 mm 54Nm 22Nm 30x 1.25 mm (ekgtm, fazkgtm, 33 Nem (sakgtm, Somme reer 2eibtt 24, Install the shift cable (A/T) (see step 26 on page 14-221), 25. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring “clicks” into place in the differential and. intermediate shaft 26. Connect the suspension lower arm ball joints (see step 9 on page 18-21) 27. Connect the tie-rod end ball joints (see step 27 on page 17-56). 28. Install the damper fark (see step 2 on page 18-28). 29. Connect the stabilizer links (see page 18-22) 8x 1.9mm 2Nmi12 kgtm, 87 lot) 31. Install the engine under cover. 32, Install the front tires/wheels. NOTE: On MT models be careful not to damage or chip the paint of the brake calipers when installing the wheels. 33, Lower the vehicle on the hoist. cont'd) 5-17 Engine Assembly Engine Installation (cont'd) 34, Install the heater hoses. 35, Install the upper radiator hose (A) and lower radiator hose (8). 5-18 36. install the A/C compressor. 37, Install the condenser fan shroud (A) and coolant reserve tank (B), then connect the fan motor connector (C} and compressor clutch connector (D). 38, Align the reference mark (A) on the steering joint ‘and steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bole. 39. Install the steering joint cover (D). 40. Install the P/S pump inlet hose (Ai and P/S pump outlet hose (8) with @ new O-ring (C) 41. Install the P/S hose to the clamp. 42. Install the drive belt (see page 4-28). 43, Install the clutch stave cylinder and clutch line bracket mounting bolt (M/T) (see step 35 on page 1327) 44, Install the shift cable and solect cable, then tighten the three bolts securing the shift cable holder (M/T) (see step 36 on pags 13-28). 45. Connect the engine wire harness connectors (A), then instatf the harness clamp (B). (cont'd) 5-19 Engine Assembly Engine Installation (cont'd) 46. Install the brake booster vacuum hose {A\,and evaporative emission (EVAP) canister hose (B). 47. Connect the fuel feed hose (see page 11-253), then Install the quick-connect fitting cover (A). 5-20 48, Install the strut brace (A), then instal the harness ‘clamp (B), and install the two 6 mm bolts (C). 49. Install the under-hood fuse/relay box (A), and. connect the harness connector (B). 8x10mm T2NmIT2 kal, 8.7 tf) 150. Install the battery cable (C), be] 51, Install the battery base (A), then install the harness, clamp (8), 52. Install the air cleaner housing (see page 11-273). 53, Install the resonator (see page 11-274. 54. Install the intake manifold cover. 55. 56, 51, 58. 59. 6 62, 63. Install the battery. Clean the battery posts and ie terminals with sandpaper, then assemble them and apply grease to prevent corrosion, ‘Move the shift lever to each gear, and verify that the ATT gear position indicator follows the transmission range switch (A/T). (Check that the transmission shifts into gear ‘smoothly (MT) Inspect for fuel leaks. Turn the ignition switch ON. } {do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line, Repeat this operation two or three times, then ‘check for fuel leakage at any point in the fuel line. Refi the engine with engine oll (see page 8-6) Refil the transmission with fluid: + Manual transmission (see page 13-10). + Automatic transmission (see page 14-204). Refill the radiator with engine coolant, and bleed the air from the cooling system with the heater valve open (see step 8 on page 10-7) Rofill the power steering system fluid (see page 17- 12, Perform the engine contro! module (ECM) powertrain control module (PCM) reset procedure (see page 17-4) Perform the crankshaft position (CKP) pattern clear/ CKP pattern learn procedure (see page 11-4). Inspect the idle speed (see page 11-238), 3. Inspect the ignition timing (see page 4-18). (cont'd) 5-21 Engine Assembly Engine Installation (cont'd) 67. Install the right rear engine compartment cover (A), then install the right side engine compartment cover (8), 68. Install the loft rear engine compartment cover (A) and the left side engine compartment cover (8). 5-22 Enter the anti-theft codes for the radio and the ‘navigation system, then enter the customer's XM ‘channel presets. 1. Set the clock. Engine Mount Replacement 1241.25 mm Gam eskgtm, a7ibin 10x1.25 mm REAR MOUNT 54m 65 kgtm, a01bi ne) Replace 16Nm 16st, 12 IbF ft) a REAR ENGINE 2x i25mm GEN (oS Kgtm, 7 oe). ae inuwr 101.25 my [7 38m Shot, 2a wen Reploce 1041.25 mm Mm Ub gem, ssibit ‘TRANSMISSION UPPER MOUNT TRANSMussioN \\ TRANSMISSION LOWER tower mount \\ MOUNT «(M7T) tam FRONT MOUNT 10x1.25mm BAN skgtm, ‘omen Replace, 1041.25 mm 4aNim a5 kote, Stott) 10x125mm Roplace, LN eB kot, s31btR) 5-23 Engine Mechanical Cylinder Head Special Tools ; Component Location Index... Engine Compression Inspection .. 66 VTEC Rocker Arm Test 6-7 Valve Clearance Adjustment . 68 Crankshaft Pulley Removal and Installation 612 Timing Belt Inspection 6-13 Timing Belt Removal 614 Timing Belt Installation . 6-16 Timing Belt Drive Pulley Replacement ...... . 6-26 Timing Belt Adjuster Replacement 6-26 Cylinder Head Cover Removal 627 Cylinder Head Cover Installation... 6-28 Cylinder Head Removal. 629 Camshaft Replacement . 6:33 Cylinder Head Inspection for Warpage Rocker Arm Assembly Removal. . Rocker Arm and Shaft Disassembly/Reassembly . Rocker Arm and Shaft Inspection Camshaft Inspection Valve, Spring, and Valve Seal Removal Valve Inspection Valve Stem-to-Guide Clearance Inspection 6-43 Valve Guide Replacement . 6-44 Valve Seat Reconditioning... 6-46 Valve, Spring, and Valve Seal Installation 6-48 Camshaft, Rocker Arm, Camshaft Seal, and Pulley Installation Cylinder Head Installation Sealing Bolt installation .. Cylinder Head Special Tools RefNo. | “Tool Number Description [ay @ | OTAALBNAATOO ‘ir Pressure Regulator 1 ® | o7HAH-PITATGA Valve Guide Reamer, 5.5mm 1 © | o7JAA-0010204 Socket, 18 mm 1 ® | 074a8-0010208 Holder Handle 1 © | o7MAB-PY3010A Holder Attachment, 50 mm, offset 1 ® | o7PAD-0010000 Stem Seal Driver 1 ® | O7VAJ-PBAOIOA VTEC Air Adapter 4 ® | o70as-0030100 VTEC Air Stopper 1 ® | 07742-0010100 Valve Guide Driver, 5.5 mm 1 30_|07757-PJ1010a. Valve Spring Compressor Attachment 1 6-2 Component Location Index EAR UPPER COVER AUBBER SEAL AAUPPERCOVER 29 \ J \ LOWER covER [FRONT UPPER COVER ENGINE MOUNT of wa | 7 BACK COVER | ism eromeneey wramonn | ee mice, FF esones wucnrvulveos eases eee ~ (cont'd), 6-3 Cylinder Head Component Location Index (cont'd) ICYLINDER HEAD COVER Removal, page 8-27, instalation age 6-26 ‘CYLINDER HEAD BOLT onines eh 3 a GASKET eyioen np 4 Ronen aoe cyulign nea Asner \ \ cMNDER HEAD GASKET vowér pm owen Pav O1L CONTROL ORIFICES, 6-4 ay CORTES) /ROCKER ARM ASSEMBLY Digassembly/Reactombly, page 6-36 Inspection, page 6-37 ‘SPRING RETAINER LOST moTION ‘ASSEMBLY INTAKE VALVE SPRING. asnnee VALVE SPRING SEAT 8 sean seat INTAKE VALVE GUIDE Replacement, age 6-48 EXHAUST VALVE GUIDE Replacement, page 8-44 ‘S0U10 DOWEL PINS [Onthe camshaft thrust cover end! vouowGownms YE; {On the camshaft X ollseal and) a On SEAL \ CAMSHAFT x Replacement, page 6.33, Inapection, page 6-38 CYLINDER HEAD Removal, page 6-29 Inspection, page 635 seaenuiste ene EXHAUST VALVE Removal, page 8.42 Inspection: page 6-43 INTAKE VALVE, Installation, page 6-48 Removal, page 6-42 Inspector: page 643 Instat, pape 6-48 Cylinder Head Engine Compression Inspection NOTE: After this inspection, you must select engine control module (ECMl/powertrain control module (PCM) reset using the Honda Diagnostic System (HDS) (see page 11-4), otherwise ECM/PCM will continue to ‘stop the fuel injectors from operating. 1. Warm up the engine to normal operating temperature (cooling fan comes on). 2. Turn the ignition switch OFF. 38. Connect the HDS to the data link connector (DLC) {see page 11-3). 4, Select PGM-I, select inspection, then select the ALL INJECTORS OFF function on the HDS. 6. Remove the six ignition colls (see page 4-19). 8. Remove the six spark plugs. 7. Attach the compression gauge to the spark plug hole. 6-6 10, " ‘Open the throttle fully, then crank the engine with the starter motor and measure the compression ‘Compression Pressure: Above 930 kPa (9.5 kaf/em’, 135 psi) ). Measure the compression on the remaining cylinders. Maximum variation: ‘Within 200 kPa (2.0 kgf/cm’, 28 psi) Ifthe compression is not within specifications, check the following items, then remeasure the compression. + Damaged or worn valves and seats + Damaged cylinder head gasket + Damaged or worn piston rings + Damaged or worn piston and cylinder bore ‘Select ECM/PCM reset (see page 11-4) to cancel the ALL INJECTORS OFF function on the HOS. be] VTEC Rocker Arm Test Special Tools Required “VTEC air adapter 07VAJ-PBA010A, “VTEC air stopper 0704)-0030100 + Air pressure regulator 07 AAJ-PNAA100 1. Startthe engine and let it run for 5 minutes, then turn OFF the ignition switch. 2. Remove the cylinder head covers (see page 6-27). 3, Set the No. 1 piston at top dead center (TDC) (see ‘step 3 on page 6-8). 4, Push on the intake mid racker arm (A) for the No. 1 cylinder. The mid rocker arm should move independently of the primary rocker arm (B) and secondary rocker arm (C), + Ifthe intake mid rocker arm does not move, remove the mid, primary, and secondary intake rocker arms as an assembly, then check that the pistons in the mid and primary rocker arms move smoothly. If any rocker arm needs replacing, replace the primary, mid, and secondary rocker ‘arms as an assembly, and retest. Ifthe mid rocker arm moves freely, repeat the ‘above procedure for the remaining intake mid rocker arms with each piston at TDC. When all the mid rocker arms pass the test, go to step 5. 5. Check that the air pressure on the shop air compressor gauge indicates over 690 kPa (7.0 kgfiem’, 100 psi) 6. Inspect the valve clearance (see step 4 on page 69). 7. Remove the No. 1 and No. 6 intake rocker shaft ‘mounting bolts, then install and connect the special tools as shown. FRONT: cain O7VAs-PA010 REAR: O7VAL-PBADIOA, “4 OTARSPNARI00 070A5-0030100 8, Loosen the valve on the regulator, and apply the specified air pressure, ‘Specified Air Pressur 440540 kPa (4.5—5.5 kgf/om’, 64~78 psi) NOTE: Ifthe synchronizing pistons do not move after applying air pressure, move the primary or secondary rocker arm up and down manually. (cont'd) 6-7 Cylinder Head VTEC Rocker Arm Test (cont'd) 9. Make sure that the intake primary rocker arm (A) ‘and intake secondary rocker arm (B) are mechanically connected by the piston and that the ‘mid rocker arm (C) does not move when pushed ‘manually. If any intake mid rocker arm moves independently of the primary and secondary rocker arms, replace the rocker arms as a set. 10, Remove the special tools. 11. Tighten the rocker shaft bolts to 24 Nim (2.4 kgf-m, TTF) 12. Install the cylinder head covers (see page 6-28) Valve Clearance Adjustment NOTE: Adjust the valves only when the cylinder head temperature is less than 100 (38°C). 1. Remove the right side engine compartment cover {eee step 1 on page 6-13). 2, Remove the cylinder head covers (see page 6-27). 3, Set the No. 1 piston at top dead center (TDC). Align the pointer (A) on the front upper cover with the No. 1 piston TDC mark (B) on the front camshaft pulley. 4, Select the correct thickness feeler gauge for the valves you're going to check. Intake: 0.20~0.24 mm (0.008~0.009 in.) Exhaust: 0.28—0.32 mm (0.011~0.013 in.) Adjusting screw locations: REAR: EXHAUST Net No.2 Na 7) i si Sade ONNO C if Ml ot Ia Lng i} | Co or « oO OU oy 2 ASB SP Not No.2 Noe nTaKe FRONT: Not NSN. EXHAUST ‘gauge (A) between the adjusting snd of the valve stem on No. 1 jor and slide it back and forth; you should feel a slight amount of drag, 6. Ifyou feel too much or too little drag, loosen the locknut (A), and turn the adjusting screw (B) until the drag on the feeler gauge is correct. 20 Nim 20 kgtm, 14 bt) 7. Tighten the locknut and recheck the clearance. Ropeat the adjustment, if necessary. (cont'd) 6-9 Cylinder Head Valve Clearance Adjustment (cont'd) 8, Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 4 piston ‘TDC mark (B) on the front camshaft pulley. K Ssn, Sis 9. Check and, if necessary, adjust the valve clearance ‘on No. 4 cylinder. 10. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 2 piston TDC mark (B) on the front camshaft pulley. 12, Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. § piston ‘TDC mark (8) on the front camshaft pulley. 13. Check ang, if necessary, adjust the valve clearance on No. 5 cylinder. 14. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 3 piston ‘TOC mark (B) on the front camshaft pulley. 11. Check and, ifnecessary, adjust the valve clearance ‘on No. 2 cylinder. 6-10 1. Check and, if necessary, adjust the valve clearance on No. 3cylinder. 16. Rotate the crankshaft clockwise. Align the pointer (A) on the front upper cover with the No. 6 piston ‘TDC mark (B) on the front camshaft pulley. 17. Check and, if necessary, adjust the valve clearance ‘on No. 6 cylinder. 18, Install the cylinder head covers (see page 6-28). 18. Install the right side engine compartment cover. 6-11 Cylinder Head Crankshaft Pulley Removal and Installa’ Special Tools Required Holder handle 07JAB-0010208 ‘Holder attachment, 60 mm, offset O7MAB-PY3010A, ‘Socket, 19 mm 07JAA-001020A, or a commercially available 19 mm socket Removal 1. Remove the right front tirefwheel. 2. Remove the splash shield. ‘3. Remove the drive belt isee page 4-28). 4. Hold the pulley with the holder handle (A) and holder attachment (8). © 7sAA-0010208 (orcommercially available) & 7a8-0010208 8. Remove the bolt with a heavy duty 19 mm socket (C) and breaker bar, then remove the crankshaft pulley, 6-12 Installation 1. Clean the pulleys (A), cranksahft (B), bolt (C), and washer (0). lubricate with new engine oil as shown. @: Lubricate with new engine oil O:ctean 2. Install the crankshaft pulley, and tighten the bolt to 245 Nem (25.0 kgf-m, 181 Ibf-ft). Do not use an impact wrench. 1 Hold the pulley with the holder handle (A) and holder attachment (B). 2 Tighten the bolt with a torque wrench and 191mm socket (C). Franv-coro20e 3. Install the drive bot (see page 4-28). 4 Install the splash shield 5. Install he right front tree NOTE: On MIT models be careful not to damage chip the paint of the brake calipers when inetalling the wheels. Timing Belt Inspection 1. Remove the right side engine compartment cover. 4. Inspect the timing belt for cracks and oll or coolant soaking. Replace the belt ifit is cracked or soaked. Remove any oil or solvent that gets on the belt. OZ 8x10 TEN (1.2 kgm, 8.7 Wtf) 6-13 Cylinder Head Timing Belt Removal 1, Remove the right side engine compartment cover 4. Remove the right front tire/wheel. (see step 1 on page 6-13) '5, Remove the splash shield. 2, Turn the crankshaft so its white mark (A) lines up, with the pointer (B). 3. Check that the No. 1 piston top dead center (TDC) 6. Remove the drive belt (see page 4-29) ‘mark (A) on the front camshaft pulley and the pointer (B) on the front upper cover are aligned. 7. Support the engine with a jack and wood block under the oil pan. 8, Remove the ground cable (Al, then remove the side engine mount bracket (8). 6-14 9. Remove the front upper cover (A) and rear upper cover (B). 10. Remove the crankshaft pulley (see step 4 on page 6-12). 11, Remove the lower cover. 12. Remove one of the battery clamp bolts from the battery tray, and grind the end of t as shown. 18, Screw the battery clamp bolt in as shown to hol the timing belt adjuster in its current position. Tighten it by hand; do not use a wrench. (cont'd 6-15 Cylinder Head Ti 9 Bett Removal (cont'd) 14. Remove the engine mount bracket. 15. Remove the idter pulley bolt (A) and idler pulley (B), then remove the timing belt. 6-16 Timing Belt Installation NOTE: The following procedure is for installing a new ing belt. If you are installing avused belt, refer to the used belt installation procedure (see page 6-22). New Belt 1, Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers. 2, Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) on the tooth of the timing bel drive pulley with the pointer (B) on the oil pump. ‘Set the camshaft pulleys to TDC by aligning the 5. Remove the auto-tensioner. ‘TDC marks (A) on the camshatt pulleys with the - pointers (B) on the back covers. 6. Align the holes on the rod and housing of the auto-tensioner, 7. Use a hydraulic press te sfowly compress the auto- tensioner. Insert a 2.0 mm (0.08 in.) pin through the housing and the rod, 4. Remove the battery clamp bolt from the back cover. NOTE: The compression pressure should not exceed 8,800 N (1,000 kgf, 2,200 lb). ~ cont'd) 6-17 Cylinder Head Timing Belt Installation (cont'd) 8. Install the auto-tensioner. NOTE: Make sure the pin stays in place. 8x1.0mm S2num (12egtm, 8.7 we Nv 9. Screw the battery clamp bolt in as shown to hold. the timing bolt adjuster. Tighten it by hand, do not se a wrench. 6-18 10. Apply liquid thread lock (P/N 08713-0001) to the Idler pulley bolt, then loosely install the idler pulley. 111, Install the timing belt in a counterclockwise: sequence starting with the drive pulley. “A Drive pulley (A). Idler putiey (B). 3 Front camshatt pulley (). “4 Water pump pulley (0). + Rear camshaft pulley (6). 8 Adjusting pulley (F). (as kgtm, 33 we \ 18, Remove the pin from the auto-tensioner. 14, Remove the battery clamp boit from the back cover. 16, Install the engine mount bracket. $x10mm 2 Nim 2 kgm, 8.7 wet) 16. Install the timing belt guide plate as shown, (cont'd) 6-19 Cylinder Head Timing Belt Installation (cont'd) 17. Install the lower cover. &x 10mm TaN 12 kfm, 8:7 thet) 18, Install the crankshaft pulley (see page 6-12). 1. Install the front upper cover (A) and rear upper cover (B), 8x4.0mm T2Nmi12 kgf, 8.7 WEA) 20. Rotate the crankshaft pulley about five or six turns. clockwise so the tirring belt positions itself on the pulleys. 6-20 21, Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B). 1, 22, Check the camshaft pulley marks. + Ifthe camshaft pulley marks are at TDC, goto step 23. + Ifthe camshaft pulley marks are not at TOC, remove the timing belt and repeat steps 2 through 22. FRONT CAMSHAFT PULLEY: 23, Install the drive belt (see page 4-29). 24, Install the side engine mount bracket (A), then. tighten the bolts in the numbered sequence shown, 0224125 mm bx19mm BEAM BETTatm aoe S88 25. Install the ground cable (B). 26. Instai! che right front tire/whee! NOTE: On M/T models be careful not to damage or chip the paint of the brake calipers when installing the wheels. 27. Perform the crankshaft position (CKP) pattern clear/ CKP pattern learn procedure (see page 11-4). (cont'd) 6-21 Cylinder Head Timing Belt Installation (cont'd) Used Belt 2. Set the camshat pulleys ta TOC by aligning the ks (A) on the camshaft pulleys with the Follow this procedure when installing a used timing (B) on the back covers. belt. 1. Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers. 2, Setthe timing belt drive pulley to TDC by aligning ‘the TOC mark (A) on the tooth of the timing belt drive pulley with the pointer (8) an the oil pump. 6-22 4. Apply liquid thread lock (P/N 08713-0001} to the idler pulley bolt, ther foosely install the idler pulley. 5. Ifthe auto-tensioner has extended and the timing belt cannot be installed, perform the new belt installation procedure. 6, Install the timing belt in a counterclockwise ‘sequence starting with the drive pulley. Take care not to damage the timing belt wher installing it. 4 Orive pulley (A 2 Idler pulley (B). Front camshatt pulley (C). “4 Water pump pulley (0). % Rear camshatt pulley © 6 Adjusting pulley 101.25 mm Nm (as kgtm, 33 yest 8 Remove the battery clamp bolt from the back cover. 9. tnstatt the ;Agine mount bracket. 6x 1.0mm AON 112 kgm, 87 Ef) 5 44h (Skat, 33 wt) (cont'd) 6-23 Cylinder Head Timing Belt Installation (cont'd) 10. Install the timing bet guide plate as shown. 1.0mm Sn kot, 87 bt 12, Instat the erenkahatt pulley (soe page 6-12). 6-24 18, Install the front upper cover (A) and rear upper ‘cover (8). 8x 1.0mm TaN 12 kgém, 827 WE) 14, Rotate the crankshaft pulley about five or six turns clockwise so the timing belt positions itself on the pulleys. 16. Turn the crankshaft pulley so its white mark (A) lines up with the pointer (B. bE] 16. Check the camshaft pulley marks, + Ifthe camshaft pulley marks are at TOC, go to ‘step 17. + If the camshaft pulley marks are not at TDC, remove the timing belt and repeat stops 2 through 16, FRONT CAMSHAFT PULLEY: 17. Install the drive belt (see page 4-29). 18, Install the side engine mount bracket (A), then tighten the bolts in the numbered sequence shown. 0124125 mm 4 Nim (5 kof-m, 40 bt) 19, Install the ground cable (B). 20. Install the right front tire/wheel. NOTE: On M/T models be careful not to damage or chip the paint of the brake calipers when installing the wheels. 21. Perform the crankshaft position (CKP) pattern clear/ CKP pattern learn procedure (see page 11-4). 6-25 Cylinder Head Timing Belt Drive Pulley Replacement 1. Remove the timing belt (see page 6-14). 2. Remove the crankshaft position (CKP) sensor (see age 11-168). 3. Remove the timing belt drive pulley. 4. Install the new timing belt drive pulley. 5, Install the CKP sensor (see page 11-168). 6. Install the timing belt (see page 6-16). 6-26 Timing Belt Adjuster Replacement 1. Romove the timing belt (see page 6-14). 2, Remove the auto-tensioner (see step 5 on page 6- 1m. 3. Remove the bolt (A), then remove the timing belt adjuster (B) and colar (C). 4, Install he timing belt adjuster. 5, Install the timing belt (see page 6-16) Cylinder Head Cover Removal 1, Remove the intake manifold (see page 9-3) 2, Remove the six ignition coils (see page 4-19) 3, Remove the three bolts (A) securing the harness holder, and remove the dipstick (B. 4, Remove the bolt (A) securing the power steering hhose bracket. '5, Remove the two bolts (8) securing the harness, holder. 6. Remove the breather hose (C). 7. Remove the cylinder head covers, 6-27 Cylinder Head Cylinder Head Cover Installation 1. Clean the shop tow \cover contacting surfaces with a 5. Tighten the bolts in two or three steps. In the final stop tighten all ofthe bolts, in sequence, 12 N.m (1.2 kgf-m, 8.7 bf.) (front cover shown). 2, Sot the spark plug sess (Alon the spark plug tubes, ‘and install the cylinder head covers (8, @ ® ® 7. Tighten the two bolts (B) securing the hamess holder. 8. Tighten the bolts (C) securing the power steering hose bracket. ‘3. Visually check the sperk plug seals for damage. 4. Inspect the cover washers (C). Replace any washer that is damaged or deteriorated. 6-28 b=} 9, Tighten the three bolts (A) securing the harness holder, and install the dipstick (8). 10. Install the six ignition colls (see page 4-19). 11, Install the intake manifold (see page 9-4). Cylinder Head Removal NOTE: + Use fender covers ta avoid damaging painted surfaces. + To avoid damage, unplug the wiring connectors carefully while holding the connector portion. + To avoid damaging the cylinder head, wait unti the engine coolant temperature drops below 100 (38°C) before loosening the cylinder head bolts. + Mark all wiring and hases to avoid misconnection, Also, be sure that they do not contact other wiring or hoses, or interfere with other parts. 1, Make sure you have the anti-theft codes for the radio and the navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF, 2, Disconnect the battery negative cable from the battery, 3, Drain the engine coolant (see page 10-6) 4. Remove the front warm up three way catalytic converter front WU-TWC) (see page 11-281) and rear warm up three way catalytic converter (rear WU-TWC) (see page 11-282). 5, Remove the drive belt (see page 4-28). 6. Remove the timing belt (see page 6-14) 7. Remove the power steering (P/S) pump (A), and P/S. hose bracket (B). (cont'd) 29 Cylinder Head Cylinder Head Removal (cont'd) 8. Remove the alternator (see page 432) 9, Relieve fuel pressure (see page 11-245), 10, Remove the intake manifold (see page 9-3) 11, Remove the six ignition coils (see page 4-19). 12. Remove the engine wire harness connectors and wire harness clamps from the cylinder head. + Six injector connectors « Engine coolant temperature (ECT) sensor ‘connector + Crankshaft position (CKP} sensor connector + Exhaust gas recirculation (EGR) valve connector + VTEC solenoid valve connector + VTEC oil pressure switch connector + Oil pressure switch connector + Two air fuel ratio (A/F) sensor connectors + Two secondary heated oxygen sensor (secondary HO2S) connectors 13, Remove the upper radiator hose (A) and lower radiator hose (8). 6-30 14, Remove the heater hose (A) and water bypass hhose(s) (8). mrt 16. Relieve the fuel pressure (see page 11-248), 16. Remove the bolt (A) securing the harness holder. 17, Remove the bolt (B) securing the harness bracket. 18. Remove the fuel rails. (cont'd) 6-31 Cylinder Head Cylinder Head Removal (cont’d) 20. Remove the water passage. 21, Remove the front and rear camshaft pulleys (A) and front and rear back covers (8. 6-32 22. Remave the cylinder head covers (see page 6-27). 2 Remove the cylinder head bolts. To prevent warpege, unscrew the bolts in sequence 1/3 turn at atime; repeat the sequence until all bolts are loosened. 24, Remove the cylinder heads. 1 Camshaft Replacement FRONT 1, Make sure you have the anti-theft codes for the radio and the navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF, 2, Remove the left side engine compartment cover (see step 3.0n page 5-2). 3. Disconnect the negative cable from the battery first, then disconnect the positive cable. 4. Remove the battery. 8, Drain the engine coolant (see page 10-6), 6. Remove the upper radiator hose. 7. Remove the exhaust gas recirculation (EGR) valve (see page 11-238), 8, Remove the timing belt (see page 6-14). 9, Remove the rocker arm assembly (see page 6-25). 10. Remove the front camshaft pulley. 11, Remove the thrust cover (A), then remove the front camshaft (8. 841.25 mm 22Nm G22 kgtm, 16) 12, Install the frant camshaft in the reverse order of removal. Always use a new O-ring {C}. Apply new ‘engine oil ozhe journals and camshaft lobes. 18. Apply new engine oil to the threads of the camshaft pulley mounting bolt, then install the front camshaft pulley (see step 10 on page 6-50). 14, Install the rocker arm assembly, then tighten the _mounting bolts (see step 7 on page 6-48). 16, Install the timing belt (see page 6-16) 16, Adjust the valve clearance (see page 6-8. 17, Fill the radiator with engine coolant and bleed the air out (see step 8 on page 10-7). 18, Install the battery. Clean the battery posts and. cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. 19, Perform the crankshaft position (CKP) pattern cleat/ CKP pattern learn procedure (see page 11-4). 20. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel presets. Set the clock, (cont'd) 6-33 Cylinder Head Camshaft Replacement (cont'd) REAR 1. Relieve fuel pressure see page 11-248). 2. Make sure you have the anti-theft codes for the radio and the navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 3. Remove the under-hood fuse/relay box. 4, Drain the engine coolant (see page 10-6). 5, Remove the heater hose (A), and two nuts (B) securing the fuel line. 0mm Y2Nm (12 kgf, 8.7 tf) 6. Remove the timing belt (see page 6-14). 7. Remove the rocker arm assembly (see page 6-35). 8. Remove the rear camshaft pulley. 6-34 9. Remove the thrust cover (A), then remove the rear camshaft (B. 2m 2kgt-m, 16 wet) 10. Install the rear camshaft in the reverse order of removal. Alway use a new O-ring (C). Apply new ‘engine oil to the journals and camshaft lobes. 11. Apply new engine oil to the threads of the camshaft pulley mounting bolt, then install the rear camshaft pulley (see step 10 on page 6-50) 12. Install the rocker arm assembly, then tighten the ‘mounting bolts (see stap 7 on page 6-49). 13, Install the timing belt (see page 6-16). 14, Adjust the valve clearance (s page 6-8). 16. Fill the radiator with engine coolant and bleed the air out (see step 8 on page 10-7). 16. Perform the crankshaft position (CKP) pattern clear/ CKP pattern learn procedure (see page 11-4). 17. Enter the anti-theft codes for the radio and the ‘navigation system, then enter the customer's XM radio channel presets. Set the clock. be] Cylinder Head Inspection for Warpage 1. Remove the cylinder head (see page 6-29). 2. Inspect the camshaft (see page 6-38). 3. Cheok the cylinder head for warpage. Measure along the edges, and three ways across the. + Ifwarpage is less than 0.05 mm (0.002 in), cylinder head resurfacing is not required. + If warpage is between 0.05 mm (0.002 in.) and (0.2mm (0.008 in.), resurface the cylinder head, + Maximum resurface limit is 0.2 mm (0.008 in.) based on a height of 121 mm (4.76 in). Cylinder Head Height Standard (New): 120.95~121.05 mm (4.762~4.766 in.) PRECISION STRAIGHT EDGE Rocker Arm Assembly Removal 1. Remove the cylinder head cover (see page 6-27). 2. Loosen the adjusting screws (A). A 3, Remove the bolts and the rocker arm assembly. “1 Unscrew the rocker shaft mounting bolts two ‘urns at a time, in a crisscross pattern, to prevent damaging the valves or rocker arm assembly. -2 When removing the rocker arm assembly, do ‘nat remove the rocker shaft mounting bolts. The bolts will keep the springs and the rocker arms on the shafts. ‘Camshaft Holder Bolt Loosening Sequence > o® 6-35 Cylinder Head Rocker Arm and Shaft Disassembly/Reassembly NOTE: + Identify parts as they are removed so they can be reinstalled in their original fecations. + Inspect the rocker shafts and rocker arms (see page 6-37). + Rocker arms must be installed in the same positions if reused. + When removing or installing the cacker arm assembly, do not remove the rocker shaft mounting bolts. The bolts will keep the springs and rocker arms on the shaft. + Bundle the intake rocker arms with rubber bands to keep them together as a set. + Prior to reassembling, clean all the parts in solvent, dry them and apply new engine oil to any contact points. INTAKE ROCKER SHAFT InTaKe ROCKER ARM ASSEMBLY extaust RocKeR ARM. EXHAUST ROCKER SHAFT Letter Bis stamped Lotter Aiestamped bn rocker arm fon rocker arm 6-36 be] Rocker Arm and Shaft Inspection 1. Remove the rocker arm assembly (see page 6-35). 2. Measure the diameter of the shaft atthe first rocker location. 4, Measure the inside diameter of the rocker arm, and ccheck it for an out-of-round condi Rocker Arm-to-Shaft Clearance Standard (New): Intake: 0.026-0.067 mm (0.0010 0.0028 in.) ‘Service Limit: 0.067 mm (0.0026 in.) Exhat 0.026-0.077 mm (0.0010~0.0030 in Service Limit: 0.077 mum (0.0030 in.) Inspect rocker arm {ace for woor 5. Repeat for all rockers and both shafts. fthe clearance is over the limit, replace the rocker shaft and all over-tolerance rocker arms. f any intake rocker arm needs replacement, replace all three rocker arms in that set (primary, mid, and secondary). (cont'd) 6-37 Cylinder Head Rocker Arm and Shaft Inspection (cont'd) VTEC Rocker Arms 6, Inspect the rocker arm synchronizing pistons (A). Push them manually. If they do not move smoothly, replace the rocker arm set. NTE: + Apply new engine cilto the pistons when reassembling. + When reassembling the primary rocker arm (B), carefully apply air pressure to the oil passage of the rocker arm, 6-38 be) Camshaft Inspection 1, Remove the cylinder head (see page 6-29). 2, Remove the rocker arms (see page 6-38). 3, Putthe rocker shafts on the cylinder head, then tighten the bolts to the specified torque. NOTE: Apply new engine oil to the threads and flange of the exhaust rocker shaft mounting bolts. Specified torque: 8x1.25mm 241Nm 2.4 kghm, 17 IbE) 4, Seat the camshaft by pushing it toward the rear of 6, the cylinder 5. Zoro the dial indicator against the end of the camshaft. Push the camshaft back and forth and read the end play. Ifthe end play is beyond the service limit, replace the thrust cover and recheck, If itis still beyond the service limit, replace the camshatt. Camshaft End Play Standard (New): 0.08~0.20 mm (0.002—0.008 in.) Service Limit: 0.20 mm (0.008 in.) 6. Remove the camshaft thrust cover (A), then pull out the camshaft (B) (cont'd) 6-39 Cylinder Head Camshaft Inspection (cont'd) 7. Wipe the camshaft clean, then inspect the lift ramps, Replace the camshaft if any labes are pitted, scored, or excessively worn 8. Measure the diameter of each camshaft journal. 9. Zero the gauge to the journal diameter. 6-40 10. Clean the camshaft bearing surfaces in the cylinder head. Measure the inside diameter of each camshaft bearing surface, and check for an out-of- round condition, + Ifthe camshaft-to-holder elearance is within limits, go to step 12. + Ifthe camshaft-to-holder clearance is beyond the service limit and the camshaft has been replaced, replace the cylinder head, + If the camshaft-to-holder clearance is beyond the ‘service limit and the cashaft has not been replaced, go to step 11 ‘Camshaft-to-Holder Oil Clearance Standard(New): —0.050~0.089mm {0.0020 ~ 0.0038 in.) Service Limit: 0.15 mm/0.006 in.) 1, 111. Check total runout with the camshaft supported on Veblocks. + If the total runout of the camshaft is within the service limit, replace the cylinder head. + Hf the total runout is beyond the service limit, ‘replace the camshaft and recheck the oil Clearance. Ifthe oil clearance is stl out of ‘tolerance, replace the cylinder head, Camshaft Total Runout ‘0.03 mm (0.001 in.) max. (0.04 mm (0.002 in.) Standard (New: Service Limit: 12, Measure cam lobe height. ‘Cam Lobe Height Standard (New: INTAKE EXHAUST PAI) 35.041 mm | 36.326 mm (13786in) | (1.4802in) MID | 36.445 mm | (1.6348 in) SEC | 35.284 mm |__(1.3891 in.) sec MD Pat FRONT BANK x ON “18 PRI MID SEC REAR BANK. x oN ex -Te8 Cylinder Head Valve, Spring, and Valve Seal Removal ‘Special Tools Required Valve spring compressor attachment 07787-PJ1010 Identity the valves and valve springs as they are removed so that each item can be reinstalled in its original position. 1. Remove the cylinder head (see page 6-29). sd socket (A) and plastic, ave retainer to loosen 2. Using an appropria ‘mallet (B),ightly tap the valve cotters. 4, Remove the special tool, then remove the valve retainer, valve spring, and valve. 5. Install the valve guide seal remover (A). b=} Valve Inspection 1, Remove the valves (see page 6-42). 2. Measure the valve in these areas. Intake Vaive Dimensions AStandard (New): 34.90—35.10 mm (1.374-1.382 in.) B Standard (New! 115.70-116.30 mm. (4.555—4.579 in) Standard (New): 5.485~5.495 mm (0.2159~0.2163 in) 5.455 mm (0.2148 in.) € Service Limit: Exhaust Valve Dimensions. A Standard (New): 29.90~30.10 mm (1.177-1.188 in) B Standard (New): 113.90-114.50mm_ (4.484—4508 in.) (CStandard (New): 5.450~5.460 mm (0.2146~0.2150 in.) © Service Limi 5.420 mm (0.2734 in.) — ue tT Valve Stem-to-Guide Clearance Inspection 1, Remove the valves (see page 6-42). 2, Slide the valve out of its guide about 29mm (0.39 in,), then measure the guide-to-stem clearance with a diat indicator while rocking the stem in the direction of normal thrust (wobble method). + Ifthe measurement exceeds the service limit, recheck it using a new valve. + Ifthe measurement is now within the service limit, reassemble using a new valve. + Ifthe measurement with a new valve still exceeds the service limit, go to step 3 Intake Valve Stem-to-Guide Clearance Standard (New): 0.04—0.09 mm (0.002~0.004 in.) (0.16 mm (0.006 in.) Service Limit Exhaust Valve Stem-to-Guide Clearance ‘Standard (New): 0.11~-0.16 mm {0.004 0.006 in.) Service Limit: 0.22 mm (0.009 in.) 3. Subtract the O.D. of the valve stem, measured with ‘a micrometer, from the |.D. of the valve guide, ‘measured with an inside micrometer or ball gauge. ‘Take the measurements in three places along the valve stem and three places inside the valve guide. The difference between the largest guide measurement and the smallest ster measurement should not exceed the service limit. Intake Valve Stem-to-Guide Clearance Standard (New): 0.020-0.045 mm (0.0008~0,0018 in.) Service Limit: 0.08 mm (0.003 in.) Exhaust Valve Stem-to-Guide Clearance ‘Standard (New): 0.055—0.080 mm (0.0022~0.0031 in.) 0.11 mm (0.004 Service Limit: Cylinder Head + Valve guide driver, 5.5 mm 07742-0010100 + Valve guide reamer, 5.5 mm O7HAH-PJ7A100 1. Inspect valve stem-to-guide clearance (see page 6- 43) 2. As illustrated, use a commercially available ai impact valve guide driver (A) modified to fit diameter of the valve guides. In most cases, the same procedure can be done using the special tool and a conventional hammer. A 5.3mm | (oztiny C Cese, -|—zee,—lf San,“ Bam cee eo 3, Select the proper replacement guides, and chill them in the freezer section of a refrigerator for about an hour. 4, Use a hot plate or oven to evenly heat the cylinder hhead to 300 (150°C). Monitor the temperature with a cooking thermometer. Do not get the head. hotter than 300 (180°C); excessive heat may loosen the valve seats. 6-44 5. Working from the camshaft side, use the driver and hammer to drive the guide about 2 mm {0.1 in) towards the combustion chamber. This will knock off some of the carbon and make removal easier. Hold the air hammer directly in line with the valve guide to prevent damaging the driver. Wear safety goggles or a face shield. 6. Tur the head over, and drive the guide out toward the camshaft side of the head. Ree 7. Ifa valve guide still won't move, dril it out with a ‘&mm (5/16 in, bit, then try agai NOTE: Drill guides only in extreme cases; you could damage the cylinder head if the guide breaks. 8, Remove the new guide(s) from the freezer, one ata time, as you need them. be] 9. Apply a thin coat of clean engine oil to the outside ‘of the new valve guide. Install the guide from the camshaft side of the head; use the special tool to {rive the guide to the specified installed height (A) ‘of the quide (8). If you have all 12 guides to do, you may have to reheat the head. Valve Guide Installed Height Intake: 21.20-22.20 mm (0.835-0.874 in.) Exhaust: 20.60~21.60 mm (0.811—0.850 in.) CA 07742.0010100 10. Coat both the reamer and the valve.guide with cutting ol. 11. Rotate the reamer clockwise the full longth of the valve guide bore. 12. Continue to rotate the reamer clockwise while removing it from the bore. 13, Thoroughly wash the guide in detergent and water to remove any cutting residue. 114, Check the clearance with a valve (see page 6-43). Verify that a valve slides in the intake and exhaust. valve guides without exerting pressure. 6-45 Cylinder Head Valve Seat Reconditioning 1. Inspect valve stem-to-guide clearance (see page 6- 43). tthe valve guides are worn, replace them (see page 6-44) before cutting the valve seats. 2. Renew the valve seats in the cylinder head using @ valve seat cutter. 3, Carefully cut a 45° seat, removing only enough ‘material to ensure a smooth and concentric seat. 4, Bevel the upper edge of the seat with the 30°cutter ‘and the lower edge of the seat with the 67.5" cutter (intake seat) or the 60° cutter (exhaust seat). Check ‘the width of the seat and adjust accordingly 675° lintake seat) 80" exhaust seat), 6-46 5, Make one more very light pass with the 45° cutter to remove any possible burrs caused by the other cutters. Valve Seat Width ‘Standard (New): 1.25—1.55 mm (0.049~0,061 in.) Service Limit: 2.00 mm (0.079 in.) 6. After resurfacing the seat, inspect itfor even valve seating. Apply Prussian Blue compound (A) to the valve face. Insert the valve in its original location in the head, then lft it and snap it closed against the seat several times. 7. The actual valve seating surface (B), as shown by the blue compound, should be centered on the seat. + Hf itis too high (closer to the valve stem), you ‘must make a second cut with the 67.5° cutter sake seat! or the 60° cutter (exhaust seat) to move it down, then ons more cut with the 45° cutter to restore seat width, + Ifit is too low (closer to the valve edge!, you must ‘make a second cut with the 30°cutter to move it up, then one more cut with the 45*cutter to restore seat width. NOTE: The final cut should always be made with the 45° cutter. 8, Insert the intake and exhaust valves in the head, and measure the valve stom installed height (A. Intake Valve Stem installed Height Standard (New): 48.75~47.55 mm (1.841~1.872 in) Service Limit: 47.80 mm (1.882in.) Exhaust Valve Stem Installed Height ‘Standard (New: 46.68~47.48 mm. (1.838~1.869 in.) Service Limit: 47.73 mm (1.879 in.) 8. Ifthe valve stem installed height is over the service limit, replace the valve and recheck. If itis still over the service limit, replace the cylinder head the valve seat inthe head is too deep. 6-47 Cylinder Head Valve, Spring, and Valve Seal Installat Special Tools Required + Stem seal driver 07PAD-0010000 + Valve spring compressor attachment 07757-PJ10104, 1. Coat the valve stems with new engine oil. Install the valves in the valve guides. 2. Check that the valves move up and down smoothly. ‘3. Install the spring seats on the cylinder head. 4, Install the new valve seals (A) using the valve guide ‘eal installer (B). NOTE: Exhaust valve seals (C) have a black spring {(D) and intake valve seals (E) have a white spring {); they are not interchangeable. ‘ 8 57PAp-9010000 NOTE: Use 5.5 mm side. 6-48 5. Instalithe valve spring and valve retainer. Place the ‘end of the valve spring with closely wound coils. toward the cylinder head. 6. Install the valve spring compressor. Compress the spring and install ihe valve cotters. or7s7-Ps10108 wren 7. Remove the valve spring compressor. {8 Lightly tap the end of each valve stem two or three times with a plastic mallet (A) to ensure proper seating of the valve and valve cotters. Tap the valve stem nly along its axis so you do not bend the stom. Camshaft, Rocker Arm, Camshaft Seal, and Pulley Installation 1, Apply a light coat of new engine oil around the camshaft oll seal. 2. Gently tap the new camshaft off seal (A) into the cylinder head. 1 Tap the camshaft cil seal in squarely. 2 Install the oil seal about 0.5 —1.5 mm (0.02-0.06 in.) below the surface of the cylinder head. FRONT: 8x 1.25 22m 22 kgm, 6 A °. 3. Insert the camshaft (B) into the cylinder head, then tall the camshaft thrust cover (C). Always use a new O-ring (D}. Apply new engine oll tothe camshaft journals and lobes. 4. Check that the oil seal lips are not distorted. 5, Install the solid dowel pins (E) and the hollow dowel pins (F). 6. Loosen the valve adjusting screws. 7. Set the rocker arm assembly in place, and loosely install the bolts. Make sure that the rocker arms are properly positioned on the valve stems. 8. Tighton each bolt two turns at atime in the sequence shown to ensure that the rockers do not bind on the valves. NOTE: Apply new engine oil to the threads and. flange of the exhaust rocker shaft mounting bolts. Specified torque: 8x1.25 mm 24.Nem (2.4 kgf-m, 17 Itt ® © oo | 4 ¢ Oo ial ® © ® ® 9. Install the injector base (A). Always use a new ‘gasket (8). 8x4.25 mm 22Nim 22 kgtm, 16 bt) (cont'd) 6-49 Cylinder Head Camshaft, Rocker Arm, Camshaft Seal, and Pulley Installation (cont'd) 10. Apply new engine oil tothe threads of the camshaft pulley mounting bolt (A). Install the back cover (B), then install the camshaft pulley (C) 81.25 mm 22Nmi22 kgtm, 16 bE x1.25mm Rim (a2 kat, 67 Wet) 6-50 Cylinder Head Installation 1. Clean the cylinder head and block surface, 2. Clean and install the oil control orifices (A) with new O-rings (8). 3. Install the dowel pins (C) and new cylinder head ‘gaskets (D). 4, Clean the timing belt pulleys, timing belt guide plate, and the upper and lower covers. 5. Set the timing belt drive pulley to top dead center (TDC) by aligning the TDC mark (A) or the tooth of the timing belt drive puffey with the pointer (B) on the oil pump. GO / 6, Set the camshaft pulleys to TOC by aligning the ‘TDC marks (A) on the camshaft pulleys with the pointers (B? on the back covers. (cont'd) 6-51 Cylinder Head Cylinder Head Installation (cont'd) 7. Apply new engine oil tothe threads and flanges of 8, Install the water passage (A). Always use a new the cylinder head bolts. (O-ring (B) and new gaskets (C). 8. Tighten the cylinder head bolts sequentially in three steps. NOTE: Perform each step twice. ‘Ist step torque: 39N-m (4.0 kgf-m, 29 Ibt-ft) 2nd step torque: 69 N-m (7.0 kgf-m, 51 Ibft) 3rd step torque: 98.1 Nem (10.0 kgf.m, 72.3 Ib f) Use a beam-type torque wrench. When using a preset-type torque wrench, be sure to tighten slowly and not to overtighten. Ifa bolt makes any ‘noise while you are torquing it, loosen the bolt, and retighten it from the 1st step. BFkstm, 16 IbF-ft) a 10. Install the front and rear warm up three way catalytic converter (WU-TWC) (see page 11-281). 6-52 11, Setthe new O-rings tothe injectors then installthe | 19. Tight the bot (A) securing the harness holder. fuel ral, 1.9mm Py Bin \ # gt. Bt 14, Tighten the bolt (B) securing the harness bracket. 12. Connect the fuel feed hose (see page 11-253), then 16. Tighten the bolt securing the harness bracket. install the quick-connect fitting cover (A) (cont'd) 6-53 Cylinder Head Cylinder Head Installation (cont'd) 16. Install the heater hose (A) and water bypass hose(s) | 17. Install the upper radiator hose (A) and lower (8). radiator hose (B). 18. Install the power steering (P/S) pump (A) and P/S. hose bracket (8). 6x1.0mm A2Nm 112 kgf, 8.7 bE) 6-54 be] 19, 20. 2 2. 23. 24, 28. 26, 21, 28. 30. 31. 32 Install the timing belt see page 6-16) ‘Adjust the valve clearance (see page 6-8) Install the eylinder head covers (see page 6-28) instal the intake manifold (see page 9-4). Install the alternator (see page 4-32) Install the drive belt (see page 425). Clean the battery posts and cable terminals with sandpaper. Assemble them and apply grease to prevent corrosion. After installation, check that all tubes, hoses and connectors are installed correctly Inspect for fuel leaks. Turn the ignition switch ON. {l}} 4a not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then ‘check for fuel leakage at any point in the fuel line, Refill the radiator with engine coolant, and bleed alr from the cooling system with the heater valve ‘open (see step 8 on page 10-7). }. Inspect the idle speed (see page 11-238). Inspect the ignition timing (see page 4-18). Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel presets. Set the clock. Sealing Bolt Installation NOTE: When installing the sealing bolt, always use new washer. 28x15 mm ‘eR (8.0 kot, 58 bt) 6-55 Engine Mechanical Engine Block Special Tools Component Location Index Connecting Rod and Crankshaft End Play Inspection ws 76 Crankshaft Main Bearing Replacement 77 Connecting Rod Bearing Replacement ... 79 Oil Pan Removal .. 7-11 Crankshaft and Piston Removal TA2 Crankshaft Inspection 7-14 Block and Piston Inspection 7-15 Cylinder Bore Honing TA ston, Pin, and Connecting Rod Replacement 718 Piston Ring Replacement . 721 Crankshaft and Piston Installation 7-23 Oil Pan Installation sn... Pulley End Crankshaft Oil Seal Installation - In Car Transmission End Crankshaft Oil Seal Installation - In Car .. Drain Bolt Installation Engine Block Special Tools Raf. No. ‘Tool Number Description ‘Oy, © | OTOAD-RCAOI00 Oil Seal Driver, 6& mm 1 @ | o70AD-RCAOZDO Driver Attachment, 106 men 1 @__|.07749-0010000 Driver [4 o ® Component Location Index ‘o1PAN Removal page. instanton: page 1.28 DOWEL PIN L DRIVE PLATE (A/T) DRIVE PLATE BOLT O-RING WASHER ENGINE BLOCK aX END COVER "ANKSHAFT OIL SEAL frctallton: p23 page 7-26 Lywmee. Bout Vigegotsnow FLYWHEEL tm RIVE PUTER lt pume Bverna page 2-9 Vise SOLENoI valve! Brae ASSemeeY ~ (cont'd) 7-3 Engine Block Component Location Index (cont'd) ‘CRANKSHAFT. End play, page 7.8 lunouty pgs 714 Outs page 7-14 Rem: ers Intaation, page 7-23 DRAIN BOLT. Trstallation, page 7-30, 7-4 piston rincs. Replacement, page 7-21 SLO Sr piston Removal, page 7-12 Hani ges CONNECTING ROD End play. page 7-6 Small ef measurement, e718 PISTON PIN, Ingpection page 7-19, Installation, page 7-20, 4) j ae ISS ENGINE ringer bore inspection, page 7-15 far ors ‘CONNECTING ROD BOLT Tnepection, page 7-23, Engine Block Connecting Rod and Crankshaft End Play Inspection 1, Remove the oil pump (see page 8-1. 2, Remove the baffle plate (see step 9 on page 7-12). 3, Measure the connecting rod end play with a feeler ‘gauge (A) between the connecting rod (B) and crankshaft (C). Connecting Rod End Play ‘Standard (New: 0.15~0.35 mm (0.006 ~ 0.014 in. Service Limit; 0.45 mm (0.018 in.) 4. ifthe connecting rod end play is out-of-tolerance, install a new connecting 10d and recheck. If itis still out-of-tolerance, replace the crankshaft (see page 7.12), 5, Push the crankshaft firmly away from the dial indicator, and zero the dial against the end of the crankshaft. Then pull the crankshaft firmly back ‘toward the indicator; the dial reading shauld not exceed the service limit Crankshaft End Play ‘Standard (New: 0.10—0.35 mm (0.004—0.014in.) Service Limit: 8.45 mm (0.018 in.) 6. Ifthe end play is excessive, replace the thrust ‘washers and recheck. If itis still out-of-tolerance, replace the crankshaft (se® page 7-12). be] Crankshaft Main Bearing Replacement Main Bearing Clearance Inspection 11. Remove the main caps and bearing halves (see page 7-12). 2. Clean each main journal and bearing half with a clean shop towel. 8, Place one strip of plastigage across each main journal NOTE: If the engine is stil in the vehicle when you bbolt the main cap down to check the clearance, the ‘weight of the crankshaft and drive plate will flatten the plastigage further than just the torque on the ‘cap bolt, and give you an incorrect reading, For an accurate reading, support the crank with a jack under the counterweights. and check only one bearing at atime. 4, Reinstall the bearings and caps, then torque the bearing cap bolts to 74 N-m (7.5 kaf-m, 54 IDF), ‘and the bearing cap side bolts to 49 N-m (5.0 kgt:m, 36 Ibf-f) in the proper sequence (see step 21 on page 7-25). NOTE: Do not rotate the crankshaft during inspection. 5. Remove the cap and bearing half, and measure the widest part of the plastigage. ‘Main Bearing-to-Journal Oil Clearance ‘Standard (New): 0.020—0.044 mm, (0.0008 - 0.0017 in.) Service Limit: 0.060 mm (0.0020 in.) _ 6. Ifthe plastigage measures too wide or too narrow, remove the crankshaft, and remove the upper half of the bearing. Install a new, complete bearing wit lor code, and recheck the clearance. Do , shim, or scrape the bearings or the caps to adjust clearance, 17: Ifthe plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that ane), and check again. ifthe proper clearance cannot be obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. (cont'd) Engine Block Crankshaft Main Bea g Replacement (cont'd) Main Bearing Selection > Larger rank bore Grankshaft Bore Code Location Bearing Identification Letters or bars have been stamped on the end of the block as a code for the size of each of the four main journal bores. Use them, and the numbers stamped on the crankshaft (codes for main journal size), to choose the correct, bearings If the codes are indecipherable because of an torn Pink | pina | vtow |yetow/ accumulation of dirt and dust, do not sub them with 2 Wire brush or scraper. Clean them only with solvent or = oxy |Yatow |yetow/| Groen detergent. Yellow Green Yetow | Yetow/| Green [Greens ‘ort Green Brown @reen [Green [Brown orm Groen — leor wun [Green |Green/ | Brown | Brown/ ASE OWe SOURNAL — Ea tat No) No 7 NOTE: When using bearing halves UMLEVEND) Smaller ot afferent color it does not main” bearing ‘Tournal (Thicker) the top or botto No, {JOURNAL No. 4 JouRNAL, (PULLEY END) (TRANSMISSION END) 7-8 1 Connecting Rod Beal Rod Be 19 Clearance Inspection 1. Remove the connecting rod cap and bearing half (see page 7-12). 2. Clean the crankshaft rod journal and bearing half with a clean shop towel 3, Place a strip of plastigage across the rod journal. 4, Reinstall the bearing half and cap, and torque the bolts. NOTE: Apply new engine oll tothe bolt threads. Tightening torque: 20 Nm (2.0 kgfim, 14 ttt) +90" NOTE: Do not rotate the crankshaft during inspection, 5. Remove the rad cap and bearing half and measure the widest part of the plastigage. ing Rod Bearing-to-Journal Oil Clearance ‘Standard (New!: 0.020 ~0.044 mm {0.0008 0.0077 in.) (0.050 mm {0.0020 in.) ig Replacement 6. Ifthe plastigage measures too wide or too narrow, remove the upper half of the bearing, then install ‘new, complete bearing with the same color code, and recheck the clearance. Do not file, shim, or scrape the bearings or the caps to adjust clearance. 7. If the plastigage shows the clearance is still incorrect, try the next larger or smaller bearing (the color listed above or below that ane), and check GaPAnGS sealat Ws prover eeamencacanece eo ‘obtained by using the appropriate larger or smaller bearings, replace the crankshaft and start over. (cont'd 7-9 Engine Block Connecting Rod Bearing Replacement (cont'd) Rod Bearing Selection Each rod falls into one of four tolerance ranges (from 0 0.0.024 mm (0.0009 in.) in 0.006 mm (0.0002 in.) increments) depending on the size of its big end bore. It's then stamped with a number or bas (1,2, 3, or 4/l I, Il, or Ul) indicating the range. You may find any ‘combination of 1, 2,3, or 4/ II, or lll in any engine. Normal Bore Size: 58.0 mm (2.28 in.) Inspect the connecting rod for cracks and heat damage. Connecting Rod Journal Code Locations Numbers or bars have been stamped on the side of each connecting rod as a code for the size of the big end. Use them, and the letters or bars stamped on the crank {codes for rod journal size) to choose the correct bearings. the codes are indecipherable because of an accumulation of dirt and dust, do not scrub them with a wire brush or scraper. Clean them only with solvent or detergent. Stamped on rod, 7-10 Bearing Identification Colorcodeisonthe [tort |2ort |3orm |4orm edge of the bearing > Smatier boating (Thicker) Yellow [Groen 'vetiow |Yetlow/ [Green Green 'Yetlow/ [Green |Groen/ |Brown fod) SumnatfTieker) the top or boner, Connecting Rod Journal Code Locations {Letters or Bars) 'No/1 JOURNAL, (PULLEY END ‘No.6 JOURNAL TRANSMISSION END) 1 Oil Pan Removal {the engine is out ofthe vehicle, go to step 7. 1. Raise the vehicle on the hoist to full height. 2. Drain the engine oil see page &6). 2. Remove the splash shield (see step 33 on page 5-6! 4, Remove the under cover. '5, Remove exhaust pipe A Ieee step 43 on page 5-7). 6. Remove the torque converter cover (A) and the two bolts (B) securing the transmission. 7. Remove the bolts securing the oil pan. &. Using a flat blade screwdriver, separate the oil pan. from the block in the places shown, 9, Remove the oil pan. 7-11 Engine Block Crankshaft and Piston Removal 1, Remove the engine assembly (see page 5-2). 2. Remove the transmission: + Manual transmission (see page 13-13). + Automatic transmission (see page 14-208). Remove the cylinder heads (see page 6-29) 4, Remove the crankshaft position (CKP) sensor (see page 11-168). 5, Remove the timing belt drive pulley from the crankshaft Remove the oil pan (see page 7-11). Remove the engine block end cover. 7 9, Remove the cil screen (A), baffie-plate (B), and oll pump (C) 10. If you can feel a ridge of metal or hard carbon ‘around the top of any cylinder, remove it wit ridge reamer (A). Follow the reamer manufacturer's Instructions. I the ridge is not removed, it may damage the piston as it's pushed out. b=} 11, Remove the bearing from the cap. Keep att caps/ bearings in order. 12, Remove the upper bearing halves from the Connecting rods, and set them aside with their respective caps. 13. Remove the connecting rod caps after setting the ‘crank pin at bottom dead carter (BOC) for each cylinder. Remove the piston assembly by pushing (on the connecting rod. Take care not to damage the crank pin or cylinder with the connecting rod, connect 14, To avoid confusion during feassembly, mark each piston/connecting rod assembly with its cylinder ‘umber. 18, Unscrew the bearing cap bolts and bearing cap side bolts in sequence 1/3 turn ata time; repeat the ‘sequence until all blts are loosened, cont'd) 7-13 Engine Block ston Removal Crankshaft and (cont'd) 16, Remove the bearing cap bolts (A) and bearing cap ‘ide bolts (B), then remove the bearing cap (C). 17. Lift the crankshaft (A) out ofthe engine block, being careful not to damage the journals. 18. Reinstall the main caps and bearings on the engine block in the proper order. 7-14 Crankshaft Inspection Out-of-Round and Taper 1, Remove the crankshaft from the engine block (see page 7-12). 2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush. 3. Check the keyway and threads. 4, Measure out-of-round at the middle of each rod and main journal in two places. The difference between measurements on each journal must not bbe more than the service limit, Journal Out-of-Round ‘Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.) 8. Measure taper at the edges of each rod and main Journal. The difference between measurements at ‘each journal must not be more than the service limit Journal Taper (New: 0.005 mm (0.0002 in.) max. ‘0.010 mm {0.0004 in} 1 Straightness 6. Place the engine block on the surface plate. 7. Clean and install the bearings on the No. 1 and No. 4 journal of the engine block. 8, Lower the crankshaft into the block. 9, Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. ‘The difference between measurements on each Journal must not be more than the servict Crankshaft Total Runout ‘Standard (New): 0.025 mm (0.0010 in.) max. Service Limit: 0.030 mm (0.0012 in.) Block and Piston Inspection 1. Remove the piston from the engine block (see page 7-12). 2. Check the piston for distortion or cracks. 3, Measure the piston diameter at a poi (0.63 in.) from the bottom of the skirt. 16.0 mm Piston Diameter ‘Standard (New: 88.975—88.985 mm (3.5029 —3.5033 in.) Service Limit: 88,965 mm (3.5026 in.) Oversize Piston Diameter 0.25: 89.225~ 89.235 mm (3.5128~-3.5132in) 160mm (isin = +! sxarr piamerer (cont'd) 7-15 Engine Block Block and Piston Inspection (cont'd) 4, Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If ‘measurements in any cylinder are beyond the oversize bore service limit, replace the block. If the block has to be rebored, refer to step 7 after reboring, Cylinder Bore Size (3.5039-3.5048 in.) £89,065 mm (3.5068 025: 89.250~ 89,265 mm (3.5138—3.5144 in.) Reboring Limit: 9.25 mm (0.01 in.) Bore Taper ifference between first and third measurement) 0.05 mm (0.002 in.) ee ‘Scored or scratched cylinder bores must be honed (see page 7-17). . Check the top of the engine block for warpage. Measure aiong the edges and across the center as shown, Engine Block Warpage ‘Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0,004 in.) 7-16 be] 7. Calculate the difference between cylinder bore diameter and piston diameter. If the clearance is. near or exceeds the service limit, inspect the piston and engine block for excessive wear. Piston-to-Block Clearance ‘Standard (New!: 0.015—0.040 mm (0.0008 0.001 Service Limit: 0.08 mm (0.003 in.) ‘SERVICE Unart ‘0.08 mm (0.003 in.) | — |} r O)} Cylinder Bore Honing 1, Measure the cylincier bores (see stop 4 on page 7- 16) the engine block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bores must be honed. 2, Hone the cylinder bores with honing oil and a fine. (400 grt) stone in a 60 degree crosshatch pattern. NOTE: * Use only a rigid hone with 400 grit or finer stone, such as Surinen, Ammco, or equivalent. + Do not use stones that are worn or broken. 3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the grit on the cylinder walls. 4, If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the engine block. Some light vertical scoring and scratching is acceptable if tis not deep encugh to catch your fingernail and does mot run the full length of the bore. 7-17 Engine Block Piston, Pin, and Connecting Rod Replacement Disassembly 4, Heat the piston and connecting rod assembly to about 158 (70°C), then remove the piston pin. 1. Remove the piston from the engine block (see page 7-124, 2. Apply new engine oil to the piston pin snap rings. (A) and turn them in the ring grooves until the end ‘gaps are lined up with the cutouts in the piston pin bores (8). NOTE: Take care not to damage the ring grooves. 3. Remove snap rings (A) from both sides of the piston, Start at the cutout in the piston pin bore, Remove the snap rings carefully 80 they do not go flying or get lost. Wear eye protection. 7-18 be] Inspection NOTE: Inspect the piston, piston pin, and connecting rod when they are at room temperature. 1, Measure the diameter ofthe piston pin. Piston Pin Diameter ‘Standard (New): 21.962—21.965 mm (0.8646— 0.8648 in.) Service Limit: 21.954 mnt (0.8643 in.) 2. Zero the dial indicator to the piston pin diameter. 3. Check the difference between the piston pin nd piston pin hole diameter on the Service Limit: 0.004 mm (0.0002! 4, Measure the piston pin-to-connecting rod clearance. Piston Pin-to-Connecting Rod Clearance ‘Standard (New): 0.005—0.014 am {0.0002 0.0006 in.) Service Limit: 0.019 mm (0.0007 in.) (cont'd) 7-19 Engine Block Piston, Pin, and Connecting Rod Replacement (cont’d) Reassembly 4. Assemble the piston (A) and connecting rod (B) with the embossed marks (C) on the same side. 1. Install a piston pin snap ring (A). Install the piston pia (D). 2. Coat the piston pin bore in the piston, the bore in the connecting rod, and the piston pin with new engine oil. 3. Heat the piston to about 158% (70°C). 5. Install the remaining snap ring. 7-20 Piston Ring Replacement 11. Remove the piston from the engine block (see page 7-12), 2. Using a ring expander (A), remove the old piston rings (8). 3. Clean all the ring grooves thoroughly with a squared-off broken ring, or a ring groove cleaner with a blade to fit the piston grooves. File down the blade, if necessary. The top ring and second ring ‘grooves are 1.2 mm (0.05 in.) wide, and the oil ring groove is 2.8mm (0.11 in.) wide. Do not use a wire brush tociean the ring grooves, or cut the ring ‘grooves deeper with the cleaning tool. NOTE: Ifthe piston is to be separated from the ‘connecting rod, do not install new rings yet. 4. Using a piston, push a new ring (A) into the cylinder bore 15~20 mm (0.6-0.8 in.) from the bottom, 5, Measure the piston ring end-gap (B) with a feeler gauge: + Ifthe gap is too small, check to see if you have the proper rings for your engine. + Ifthe gap is too large, recheck the cylinder bore diameter against the wear limits (see step 4 on page 7-16). Ifthe bore is over the service limit, the engine block must be rebored Piston Ring End-Gap Top Ring Standard (New): 0.20-0.35 mm (0.080.014 in.) Service Limit: 0.60 mm (0.024 in.) ‘Second Ring Standard (New: 400.55 mm (0.016 0.022 in) Service Limit: 0.70 mm (0.028 in.) it Ring ‘Standard (Newl: 0.20~0.70 mm. {0.008—0.028 in. Service 0.80 mm (0.031 (cont'd) 7-21 Engine Block Piston Ring Replacement (cont'd) 6. Install the rings as shown. The top ring (A) has a 1D mark and the second ring (B) has a 2C mark. The ‘manufacturing marks (C) must be facing upward. ‘Top Ring (Standard) ‘mm (0-12 In) am (0.05 in) Second Ring Standard 7-22 7. After installing a new set of rings, measure the Fing-to-groove clearance: Top Ring Clearance ‘Standard (New/: 0.055—0.080 mm {(0.0022—0.0031 in.) Service Limit: 0.15 mm (0.006 in.) ‘Second Ring Clearance ‘Standard (New): 0.030—0.055 mm (0.0012 ~0.0022 in.) Service Limit: 0.13 mm (0.008 in.) | 8, Rotate the rings in their grooves to make sure they do not bind. 9. Position the ring end gaps as shown: ‘About 90° omnia gar ‘SECOND RING GAP rout 45° ‘TOP RING GAP \ OIL RING GAP ‘and SPACER \ RING GAP PISTON PIN Crankshaft and Piston Installation Special Tools Required iver 07749-00100 + Driver attachment, 108 mm 070AD-RCA0200 1, Measure the diameter of each connecting rod dott at point A and point B. 35mm issn) A ren, 20mm ‘oni Fy 2. Calculate the difference in diameter between point Aand point B. ‘Specification: 0~0.1 mm (00.004 in.) 3. Ifthe difference in diameter is out of tolerance, replace the connecting rod bolt. 4. Check the connecting rad bearing clearance with plastigage (see page 7-3). 5. Check the main bearing clearance with plastigage (see page 7-7). 6, Install the bearing halves in the engine black and, connecting rods. 2. Apply new engine oil to all the main bearing and. ‘od bearing journals. 8, Lower the crankshaft (A) into the block. 9. Apply new engine oil to the thrust washer surfaces. Install the thrust washers (A) in the No, 3 journal. (cont'd) 7-23 Engine Block Crankshaft and Piston Installation (cont'd) 10, Install the bearings (A) and bearing caps (B) with the arrow) acing the ting bol ond ofthe oncine Oo fe} oO fe} oO fe} oO O° el la ls! Je 11. Apply new engine ol flanges, then loosely install the bearing cap bolts {D) and bearing cap side bolts (E) 7-24 12. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in, 13, Remove the connecting rod cap. Install the ring compressor, and check that the bearing is securely in place. 14, Position the piston with the arrow (A) facing the ‘timing belt side of the engine. 16, Position the piston in the cylinder, and tap it in using the wooden handle of a hammer (A). ‘Maintain downward force on the ring compressor {B) to prevent the rings from expanding before entering the cylinder bore. 16. Stop after the ring compressor pops free, and ‘check the connecting rod-to-crank journal alignment before pushing the piston into place. b=} 117, Line up the mark (A) on the connecting rod and cap, ‘then install the cap. 18. Apply new engine oil to the bolt threads. Torque the bolts (B) to 20 Nem (2.0 kgf-m, 14 IbF-). 19. Mark the connecting rod (A) and bolt head (B) as shown. \ 20. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 907. 21. Tighten the bearing cap bolts (A), and then the earing cap side bolts (B) to the specified torque in the sequence shawn, Repeat the torque sequence again to asure the bolts are properly torqued. f1e15mm {ox125mm TN skgtim, 43Nm GOkgtm, Prsiy Se Ibi te (cont'd) 7-25 Engine Block Crankshaft and Piston Installation (cont’d) 22. The seal mating surface on the engine block end cover should be dry. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal. 23. Drive the new crankshaft oil seal until the special tool bottoms on the engine block end cover. ‘87749.0010000 070AD-ACAQ200 7-26 24. Remove any old liquid gasket from the engine ‘block end cover mating surfaces; bolts, and bolt holes. 25. Clean and dry the engine block end cover mating surfaces. 26. Apply liquid gasket, P/N 08718-0001 or 08718-0003, evenly to the block mating surface of the engine block end cover and to the inner threads of the bolt holes. Install the dowel pins (A), new O-ring (B), land the engine block end cover (C) on the engine block. NOTE: Do not install the parts if 4 minutes or more. hhave elapsed since applying the liquid gasket. Instead, reapply liquid gasket after removing the old residue. c (82kgE-m, 8.7 EA be} 27. Remove any old liquid gasket from the oil pump, ‘mating surfaces, bolts, and bolt holes. 28, Clean and dry the oil pump mating surfaces. 28. Install the oil pump (A\. 1 Install a new crankshaft oil soa! in the oil pump, (see step 2 on page 11). -2 Apply liquid gasket, PIN 08718-0001 or 08718- (0003, evenly to the block mating surface of the oll pump and to the inner threads of the bolt holes. [NOTE: Do not install the pars if 4 minutes or ‘more have elapsed since applying the quid gasket. Instead, reapply quid gasket ater removing he ofd residue. 8 Grease the lip of the oil seal, and apply oil to the new O-rings (B). 4 Install the dowel pins (C), then align the inner rotor with the crankshaft, and install the oil pump. 6 Clean the excoss grease off the crankshaft, and. ‘check the seal for distortion. 8x1.0mm 8x10mm TAN TT2 kot, 8.7 bese) TZ Nm (12 kgm, 8.7 IEA 6x1.0mm TAN 112 kgtem, 8.7 Ie) 30. Install the baffle plate (D), then install the oll screen e. 431, Install the VTEC solenoid valve/oil fiter assembly (A), with a new VTEC solenoid valve filter (B) 2 (22 kgtm, 16 bee 32, Install the oil pan (see page 7-28). 33, install the crankshaft position (CKP) sensor (see page 11-168). 34. Install the cylinder heads (see page 6-50). 35. Install the transmission: + Manual transmission (see page 13-22). + Automatic transmission (see page 14-217). 36. Install the engine assembly (see page 5-12. NOTE: When any crankshaft or connecting rod bearing is replaced, after assembly itis necessary torun the engine at idling speed until it reaches ‘normal operating temperature, then continue to tun it for about 15 minutes, 7-27 Engine Block Oil Pan Installation 1, Remove any old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes. 2. Clean and dry the oil pan mating surfaces. 3. Apply liquid gasket, P/N 08718-0001 or 08718-003,, ‘evenly to the oll pan mating surface of the engine block and to the inner threads of the bolt holes. NOTE: Do not install the parts if 4 minutes or more have elapsed since applying liquid gasket. Instead, reapply liquid gasket after removing the old residue. Apply liquid gasket along the broken lin, 4, Install the oll pan on the engine block. 5. Tighten the bolts in two or three steps. In the final step, tighten all bolts, In sequence, to 12 N-m (1.2 kgf.m, 8.7 ot, NOTE: After assombly, wait at least 30 minutes. before filling the engine with oil ®® @ 2 ® ® 7-28 6. Tighten the two bolts (A) securing the transmission, then install the torque converter cover (B). the vehicle, do the following 7. Install exhaust pipe A using new gaskets and new self locking nuts (see step 23 on page 5-17). 8, Install the engine under cover. 9. Install splash shield (see step 30 on page 5-17). 10. Refit the engine with ol (see step 3 on page 8-6). 11, Lower the hoist. 1 Pulley End Crankshaft Oil Seal Installation - In Car Special Tools Required il seal driver, 64 mm 070AD-RCAO100 1. Remove the crankshaft position (CKP) sensor, timing belt, and timing belt drive pulley (see page 6-26) 2, Remove the pulley end crankshaft cil seal. 3, Clean and dry the crankshaft oil geal housing. 4. Apply a light coat of multipurpose grease to the. crankshaft and to the lip of the seal. 5. Using the seal driver, drive in the crankshaft oll seal until the driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted, 070AD-ACAOT00 6. Install the timing belt drive pulley, CKP sensor, and timing belt (see page 6-26). Transmission End Crankshaft Oil Seal Installation - In Car ‘Special Tools Required “Driver 07749-0010000 * Driver attachment, 108 mm 070AD-RCA0200 1. AIT: Remove the transmission (see page 14-205) and drive plate (see page 14-216). 2. MIT: Remove the transmission (see page 13-13), the clutch disc and pressure plate (see page 12-12), and the flywheel (see page 12-18). 3, Remove the transmission end crankshaft oll seal. 4, Clean and dry the crankshaft oil seat housing. 5. Apply. light coat of multipurpase grease to the crankshaft and to the lip of the seal 6. Using the special tools, drive in the crankshaft oil ‘seal until the driver attachment bottoms against the ‘engine block end cover. Align the hole in the driver attachment with the pin on the crankshaft. ‘07749-0010000 070AD-RCAO200 7. Clean any excess grease off the crankshaft, and ‘check that the oil seal lip is not distorted. 8, AUT: Install the drive plate (see page 14-216), and ‘the transmission (see page 14-217). 9. MT: Install the flywheel (see page 12-18}, the clutch disc and pressure plate (see page 12-16), and the transmission (see page 13-22), 7-29 Engine Block Drain Bolt installation NOTE: When installing the drain bolt, always use new washer. 18x15mm. io egte, 20 49 ms Con * < \ 7-30 Engine Mechanical Engine Lubrication ‘Special Toots .. Component Location Index... Symptom Troubleshooting Index ... Oit Pressure Switch Test Oil Pressure Test Engine Oil Replacement ... Engine Oil Filter Replacement Oil Filter Feed Pipe Replacement Oil Pump Overhaul... Oil Pressure Switch Replacement Engine Lubrication Special Tools Ref.No. [Tool iumber_—_"[-___Deseription O7HAA-PJ70100 | Oil Fiter Wrench — @__| WIVAD-RCAD100 | Oil Seal Driver, 64 mm 8-2 Component Location Index OIL PRESSURE SWITCH {ict Diagram, page 22-256 ‘OWL CONTROL Test, page 5 osincs Spices. Oi Pressure Text, page 8S — O-nING CONNECTING ‘URE g VTEC soLeNont VALVE FILTER. rec SOLENOID VALVE ASSEMBLY i = [= Fe, L TER Replacement, pages-6 DRAIN BOLT 290 8-10 it page 8-10 8-3 Engine Lubrication Symptom Troubleshooting Index = ‘Symptom Excessive engine oil consumption Diagnostic procedure Check for worn valve guide(s) (see page 6-43) or ‘worn valve stem seal(s). ‘Check for damaged or worn piston ring(s). Check for damaged or worn engine internal parts. (cylinder wall, pistons, etc.) (see page 7-15). ‘Check for oil leaks. Check the operation of the ps ventilation (PCV) system ( Check the engine oil for dit. ive crankcase page 11-297). ‘Also check for | Low engine oll pressure 6. Check the oil screen for clogging. Test the oll pump (see page 8-5) Check the relief valve. Test the oil pressure switch. Check for excessive clearance in the engine (bearing-to-jounal, etc). Check the engine oil for dirt or improper viscosity. High engine oil pressure (Check the relief valve, 8-4 be] Oil Pressure Switch Test 1. Remove the YEL/RED wire (A) from the engine oil pressure switch (8). 2. Check for continuity between the positive terminal ©) and che engine (ground). There should be Continuity with the engine stopped. There should be no continuity with the engine running. Oil Pressure Test If the low oil pressure indicator stays on with the engine running, check the engine oil level. I the oil level is correct: 1. Remove the engine oil pressure switch, then install ‘anil pressure gauge (A), 2. Start the engine. Shut it off immediately if the ‘gauge registers no oll pressure, Repair the problem before continuing. 3, Allow the engine to reach operating temperature {fan comes on at least twice). The pressure should be: Engine Oil Temperature: 176 (80°C) Engine Oil Pressure: At Idle: 70 kPa (0.7 kgf/cm’. 10 psi) ‘At3,000 rpm: 490 kPa (5.0 kaf/em’,71 psi) minimum 4, Ifo pressure is NOT within specifications, inspect these items: + Check the oil screen for clogging. + Inspect the oil pump (see page 8-10), 8-5 Engine Lubrication Engine Oil Replacement 1. Warm up the engine. 2, Remove the drain bolt A), and drain the engine oil x Sou aougton, 29 IbF-ft) be Sonat overighton 3. Reinstall the drain bolt with a new washer (8). 4, Refill with the recommended oil (see page 3-2). Capacity 4.00(4.2 US qt) at oil change. 4.3.0 (6.5 US qt) at oll change including filter. 5.0.0 (6.3 US qt) after engine overhaul. '5. Run the engine for more than 3 minutes, then check for oil leakage. Engine Oil Filter Replacement ‘Special Tools Requi Oil filter wrench 07HAA-PI70100 1, Remove the oil filter with the special tool 2. Inspect the filter to make sure the rubber seal is not stuck tothe oil filter seating surface of the engine. 3. Inepact the threads (A) and rubber seal (B) on the new filter. Clear the seat on the. ‘apply alight coat of new engine ail tothe filter rubber seal. Use only filters with a built-in uypass system. 13, 4, Install the oil flter By hand, 5, After the rubber seal seats, tighten the ol filter clockwise with the special tool. Tighten: 3/4 turn clockwise. Tightening torque: 12 N.m (1.2 kgf-m, 8.7 Ibf-ft) o7HAA-P70100 6. Iffour numbers or marks (1 to 4 or W to VV) are printed around the outside of the filter, you can Use the following procedure to tighten the filter. + Spin the filter on until its seal lightly seats against the block, and note which number or mark is at the bottom, + Tighten the filter by turning it clockwise three ‘numbers or marks from the one you noted. For ‘example, if mark ¥ is at the bottom when the ‘seal is lightly seated, tighton the filter until the mark ¥¥¥'¥ comes around to the bottom. Mark when rubber sat Mark ater tightening, Numberor [ft 2] 3 a Markwhen | or | or | or |_ or tubberseal | wv | ¥¥ |ww¥ vv¥v eTit2 3 or | ot | or | or vvvv iv | vv | vw 7. After installation, fill the engine with oil up to the. level, run the engine for more than 3 minutes, then check for oil leakage. 8 Reset the multt-information display (see page 3-6). Engine Lubrication Oil Filter Feed Pipe Replacement 1, Remove the filter ‘see pape &) 2, Remove the oil filter feed pipe. 2. Install two 20 x 1.5 mm nuts (A) onto the new oil filter feed pipe, and hold one net with a wrench, then tighten the other nut. 4, Tighten the oll filter feed pipe to 49 N.m (8.0 kgf-m, 36 Ibf-f, then remove the nuts from the oil filter feed pipe. 8-8 Oil Pump Overhaul Exploded View 2 Resloce PUMP HOUSING Apply liquid gasket cote mating surfoce of the cylinder bloc LIEF VAL\ ‘when installing, Solve must she an Inthe housing \ Replace tis score. en S2nim Me (12g, 8.7 et a oUt Tako, 28 wet (cont'd) 8-9 Engine Lubrication Oil Pump Overhaul (cont’d) ‘Special Tools Required * Oil seal driver, 64 mm O70AD-ACADVOO + Engine support hanger, A and Reds AAR-T-12566 (available through Honda Tool and Equipment program, Seeazegesn ‘aupmens Prost + Engine hanger balance bar VSB02000019 Removal 1D the engine oll (see page 8-6). 2, Remove the timing belt (see page 6-14). ‘3. Remove the crankshaft position (CKP) sensor (see page 11-168). 4, Remove the left side, eft rear, and right rear engine ‘compartment covers. Remove the intake manifold front bulkhead covers. 5. Remove the strun brace (see step 15 on page 5-4). 6. Lift and support the engine with the special tools (see stop 1 on page 5-9) 7. Remove the VTEC solenoid valve and oil iter assembly (see page 11-227), 8. Remove the oil pan (see page 7-11) 9. Remove the oil screen (A). 10. Remove the mounting bolts and the oil pump assembly (B} 8-10 Inspection 1, Remove the screws from the pump housing, then separate the housing and cover. 2, Check the inner-to-outer rotor radial clearance between the inner rotor (A) and outer rotor (B). If the inner-to-outer rotor clearance exceeds the service limit, replace the oll pump assembly. Inner Rotor-t0-Outer Rotor Radial Cl Standard (New): 0.04~0.16 mm (0.002~0.006 in.) Service Limit: 0.20 mm (0.008 in.) 3. Check the housing-to-rotor axial clearance between the rotors (A) and pump housing (8). Ifthe housing- ‘to-rotor axial clearance exceeds the service limit, replace the oil pump assembly. Housing-to-Rotor Axial Clearance ‘Standard (New): 062—0.07 mm (0.001 —0.003 in.) Service Limit: 0.12 mim (0.008 in.) 1s, Check the housing-to-outer rator radial clearance between the outer rotor (A) and pump housing (B). Ifthe housing-to-outer rotor radial clearance exceeds the service limit, replace the oil pump assembly, Housing-to-Outer Rotor Radial Clearance ‘Standard (New: 0.10—0.19 mm (0.004~0.007 in.) Service Limit: 0.20 mm (0.008 in.) Inspect both rotors and pump housing for scoring or other damage. Replace the parts, if necessary. . Apply liquid thread fock to the pump housing screws, chen instal the oll pump cover. Check that the oil pump turns freely, Installation 1, Remove the old oil seal from the oll pump. 2. Gently tap in the new oil seal until the special tool bottoms on the pump. 07080-RCAOT00 3, Remove any old liquid gasket from the oil pump ‘mating surfaces, bolts, and bolt holes. 4, Clean and dry the oil pump mating surfaces. (cont'd) 8-11 Engine Lubrication Oil Pump Overhaul (cont’d) 6. Install the oil pump (A). ~1 Apply liquid gasket, P/N 08718-0001 or (08718-0003, evenly to the block mating surface of the oll pump and to the inner threads of the boot holes. NOTE: Do not instal the parts if 4 minutes or ‘more have elapsed since applying liquid. gasket. Instead, reapply liquid gasket after removing the old residue. 2 Grease the lip ofthe oil seal, and apply oll to ‘the new O-rings (B). 3 Install the dowel pins (Cl, then align the inner rotor with the crankshaft and instal the oil pump. ~4 Clean the excess grease off the crankshaft, and check the seal for distortion. Sxtomm Se gh, Site . US| Je 6. Install the oil screen (0). 7. Insta the oil pan (see page 7-28). 8. Install the VTEC solenoid valve and oit ites assembly (see page 11-227) 9, Install the CKP sensor (see page 11-168) 10. Install the idle pulley. 11. Install the timing belt (see page 6-16). 12, Remove the engine balance bar and hanger. 18. Insta the strut brace (see step 15 on page 5-4). 14. Install the engine compartment covers, the intake ‘manifold cover, and the bulkhead cover. 16. After assembly, wait at least 30 minutes before filling the eng ai Oil Pressure Switch Replacement 1. Disconnect the oil pressure switch connector, then remove the oil pressure switch. 1aNm (rakegtm, 13 tote) 2, Remove any old liquid gasket from the switch and ‘switch mounting hole. 3. Apply liquid gasket to the new oil pressure switch, then install the oil pressure switch, Engine Mechanical Intake Manifold and Exhaust System Intake Manifold Removal and Installation Exhaust Pipe and Muffler Replacement 9-2 96 Intake Manifold and Exhaust System Intake Manifold Removal and Installation Exploded View Lrren coven Ronee h eracted or ine tebing erase tanaged ex10mm saganm SEM vot, (8 Gt, s7ere) Seer) scasker Since PuarE/casKeT Em, INTAKE MANIFOLD u eevee ° scasKer Ti gm, Eos evaronarve EMISSION (EVAP) ‘CANISTER PURGE VALVE 8x1. T2Nm U2 kgtm, a7 ee) wi INTAKE MANIFOLD Replace it's eracked or ithe rating surface damaged, GASKET Replace. ——— 22Nm (22 kgtm, Tern) THROTTLE BODY. Replace, ‘O-RING Replace. INTAKE MANIFOLD. TEMPERATURE AT) SENSOR 18Nm (1.8 eghon, 13 bt) 9-2 Removal 1. Remove the intake manifold cover. 4, Remove the evaporative emission (EVAP) canister purge hose (A) and water bypass hoses (B), then plug the water bypass hoses. 2. Remove the air intake duct, 3, Remove the engine mount control solenoid valve {A), positive crankcase ventilation (PCV) hose (8), brake booster vacuum hose (C), and vacuum hose 0. 5. Remove the engine wire harness connectors and wire harness clamps from the intake manifold + Intake air temperature (IAT) sensor connector, + Idle air control (IAC) valve connector + Throttle actuator connector + Manifold absolute pressure (MAP) sensor ‘connector + Evaporative emission (EVAP) canister purge valve connector + Intake manifold runner control (IMC) solenoid valve connector (cont'd) 9-3 Intake Manifold and Exhaust System Intake Manifold Removal and Installation (cont'd) 6. Remove the upper cover mounting bolts and nuts ‘sequentially in two or three steps. 2 © © Ub \ fe] A ® © {_/ S, } \ oe 7. Remove the intake manifold mounting boits and ‘uts sequentially in two or three steps. Installation 1. Install the intake manifold. Tighten the bolts and ‘huts sequentially in two or three steps. Always use ‘a new intake manifold gasket. ‘Specified torque: 8x1.25mm 22. N.m (2.2 kgt-m, 16 Ibtft) 2, Install the upper cover. Tighten the bolts and nuts sequentially in two or three steps. Always use a new gasket. ‘Specified torque: 6x1.0mm 12.Nem (1.2 kgf-m, 8.7 bE) 3. Install the EVAP canister purge hose (A) and water bypass hoses (8). 4, Install the engine mount control solencid valve (Al, positive crankcase ventilation (PCV) hose (B), brake booster vacuum hose (C), and vacuum hose (D). 6x1.0mm A2NmI12 kgtm, 8.7 bt) “yf 5, Install the intake air duct. 6. Clean up any spilled engine coolant. 7. After installation, check that all tubes, hoses and ‘connectors are installed correctly. 8, Install the intake manifold cover. 9. Refill the radiator with engine coolant, then bleed, air from the cooling system with the heater valve ‘open (see step 8 on page 10-7). 9-5 Intake Manifold and Exhaust System Exhaust Pipe and Muffler Replacement NOTE: Use new gaskets and self-locking nuts when reassembling EXHAUST PIPE B / HEAT SHIELD Sx10mm BENITO kgf, 7.2 bE) . SELF-LOCKING NUT Jox128mm 33 Nan (4 gt, 25 ht) Replace. SELF-LOCKING NUT Jon 125mm 54 Nem (5 5 Kgtm, 40 bt eae Replace. Replace. ee asker Replace, THREE WAY CATALYTIC CONVERTER (TwC} TWwe TIGHTENING SEQUENCE SELF-LOCKING NUT iox125mm 34 Nim (5.5 kgm, 40 bf) Roplace. SELF-LOCKING NUT Ox 125mm. 33 Nm (34 gt, 25 EY Replace. 9-6 Engine Cooling Cooling System Component Location Index Radiator Cap Test Radiator Test Fan Motor Test .. Thermostat Test .. Water Pump Inspection Water Pump Replacement Coolant Check .. Coolant Replacement Thermostat Replacement Water Passage Replacement Radiator and Fan Replacement .. 10-2 10-3 10-3 10-4 10-4 105 105 10-6 10-6 108 10-9 10-10 Fan Controls Component Location Index Symptom Troubleshooting Index... Circuit Diagram Radiator Fan High Speed Circuit Troubleshooting 10-11 10-12 10-13 10-14 Cooling System Component Location Index WATER PUMP Replacoman page 105 WATERPASSAGE RADIATOR CAP Replacement, page 109 Test, page 103 ~ THERMOSTAT Tost, page 10-4 Z placement, page RADIATOR. ae La) ‘Test, page 103 Replacement, page 10-10, 10-2 rd Radiator Cap Test 1. Remove the radiator cap (A), wet its seal with engine coolant, then install it on a commer available pressure tester (B) 2. Apply a pressure of 93 123 kPa (0.95— 1,25 kgffom’, 14~18 psi. 3. Check for a drop in pressure. 4, ifthe pressure drops, replace the cap. Radiator Test 1. Wait until the engine is cool, then carefully remove the radiator cap, and fill the radiator with engine ‘coolant to the top of the filler neck. 2. Attach a commercially available pressure tester (A) tothe radiator, and apply a pressure of 93~123 kPa (0.95~1.25 kgtlem, 1418 psi. 3. Inspect for engine coolant leaks and a drop in Pressure. 4, Remove the tester, then reinstall the radiator cap. 10-3 Cooling System Fan Motor Test 1. Disconnect the 2P connectors from the radiator fan. ‘motor (A) and condenser fan motor (B). Terminal side of male terminals 2. Test each motor by connecting battery power to the Btorminal and ground to the A terminal. 3. If either motor falls to run or does not run smoothly, replace it (see page 10-10). 10-4 Thermostat Test Replace the thermostat fits open at room ‘temperature. To test a closed thermostat: 4. Suspend the thermostat (A) in a container of water. Do not lt the thermometer (B) touch the bottom of the hot container. 2. Heat the water and check the temperature with a ‘thermometer. Check the temperature at which the thermostat first opens, and at which itis fully open. 3. Measure the lift height of the thermostat when itis fully open. Standard Thermostat Liftheight: above 10.0 mm (0.39 in.) Starts opening: 169-176 (76-80) Fully open: 194 (90%) Water Pump Inspection 1. Remove the timing belt (see page 6-74). 2. Turn the water pump pulley counterclockwise. Check that itturns freely. 3. Check for signs of seal leakage. A small amount of “weeping” from the bleed holes (A) is normal. rd Water Pump Replacement 1. Drain the engine coolant (see page 10-6). 2. Remove the timing belt (see page 6-14) 3, Remove the timing belt adjuster (see page 6-26). 4. Remove the water pump (A) by removing the five bolts. | 6x1.0mm ‘ 4 12 Nem (1-2 kgm, 8.7 Ibe 5, Inspect and clean the O-ring groove and the mating surface of the engine block. 6. Install the water pump with a new O-ring (B) in the reverse order of removal. 7. Clean up any spilled engine coolant. 8. Install the timing belt adjuster (see page 6-26). 8. Install the timing belt (see page 6-18). 10, Refllthe radiator with engine coolant, then bleed the air from the cooling system (see step 8 on page 10-7. 10-5 Cooling System Coolant Check 1. Look at the coolant level in the coolant reservoir. Make sure itis between the MAX mark (A) and MIN ‘mark (B). 2. Ifthe coolant level in the coolant reservoir is at or below the MIN mark, add coolant to bring it between the MIN and MAX marks, then inspect the ‘cooling system for leaks. 10-6 Coolant Replacement 1 Start ongine Sot the heater omperture cont dial to maximum heat, then turn off the ignition switch, Make sure the engine and radiator are cool tothe touch, Romove the radiator cap. ‘3. Loosen the drain plug (A), and drain the coolant. 4. Install a rubber hose (A) on the drain bolt (B) located at the rear of the cylinder block, then toosen, the drain bolt. '5. When the coolant stops draining, tighten the drain bott. 6. Tighten the radiator drain plug securely. rd 7. Remove, drain, and reinstall the reserve tank. 8. Fillthe reserve tank to MAX mark (A) with Honda All Season Antifreeze/Coolant Type 2 (P/N OL999- 9001). 9. Pour Honda All Season Antifreeze/Coolant Type 2 into the radiator up to the base of the filler neck. NoTE: + Always use Honda All Season Antifreeze/Coolant Type 2 (P/N 0L999-8001). Using a non-Honda coolant can result in corrosion, causing the cooling system to malfunction or fail + Honda All Season Antifreeze/Coolant Type 2 is a mixture of 50 % antifreeze and 50 % water. Do not add water. Engine Coolant fill Capacity (including the reserve tank capacity of 0.6 00.6 US at: MIT: 6.30 (6.7 US qt) AMT: 640(68US qt 10. "1. 2 12, 4 Install the radiator cap loosely. Start the engine and let it ean until it warms up (the radiator fan comes on at least twice) Turn off the engine. Check the level in the radiator and add Honda All Season Antifreeze/Coolant Type 2, ifneeded. Put the radiator cap on tightly, then run the engine again, and check for leaks. Clean up any spilled engine coolant 10-7 Cooling System Thermostat Replacement 1. Make sure you have the anti-theft codes for the radio and navigation system, then write down the XM radio channel presets, Make sure the ignition switch is OFF. 2. Disconnect the negative cable from the battery first, then the positive cable. 3, Remove the battery. 4, Drain the engine coolant (see page 10-6). 5. Remove the thermostat cover, then remove the thermostat, THERMOSTAT Install with pin up. 6. Insta the thermostat with a new rubber seal. 7. Install the battery. Clean the battery posts and cable ‘grease to prevent corrosion. rminals with sandpaper, then assemble them and apply 8, Refill the radiator with engine coolant, then bleed air from the cooling system (s step 8 on page 10-7), 8. Clean up any spilled engine coolant. 10. Enter thi presets. t-theft codes for the radio and the navigation system, then enter the customer's XM radio channel 11, Ser the clock. 10-8 cid Water Passage Replacement 1. Make sure you have the anti-theft codes for the radio and navigation system, then write down the XM radio channel presets. Make sure the ignition switch is OFF. 2, Disconnect the negative cable from the battery first, then the positive cable. Remove the battery, 3. Drain the engine coolant (see page 10-6). 4, Remove the vacuum hoses, breather pipe, and the intake air duct. 5. Remove the upper radiator hose, lower radiator hose, heater hoses, and water bypass hoses from the water passage. Remove the water passage. ENGINE COOLANT. Tewpenarone tecr) icon SEN TaN (12 kote 8:7 IA 83325 mm Bim 22K, tte uses is, era Gaskets Reace. ax 250m G22 Kgte, we mee = e.n1e 6. Install the water passage in the reverse order of removal. 7. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. 8. Refill the radiator with engine coolant, then bleed air from the cooling system (see step 8 on page 10-7). 9. Clean up any spilled engine coolant. 10. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's XM radio channel Presets. 11. Sox the clock. 10-9 Cooling System Radiator and Fan Replacement 1. Drain engine coolant (see page 10-6). 2, Remove the front bulkhead cover (see page 20-130) 3. Remove the upper radiator hose and lower radiator huse from the radiator. UPPERRADIATORHOSE —_, LOWER RADIATOR HOSE “i 2 “ eign (1.2 kgtm, 8.7 toe) ° Ca S4Nm (055 kgtm, 40 EA) RADIATOR FAN ‘UPPER BRACKET AND CUSHION i ey, si) PS paouaron RADIATOR FAN MoTOR LOWER CUSHION, RADIATOR FAN SHROUD “o-niNG Replace. 6x10 mm S2Nm’ Ta Kgtm, 827 WEA DRAM RESERVE TANK GQNBENGER ean SHROUD ‘6x1.0mm anim U2 kgm, 8.7 wes 4, Disconnect the fan motor connectors, 5. Remove the upper bracket cushions, then pull up the radiator. 6. Remove the fan shroud assemblies and other parts from the radiator. 7. Install the radiator inthe reverse order of removal. Make sure the upper and lower cushions are set securely. 8, Fill the radiator with engine coolant, then bleed alr from the cooling system (see step 8 on page 10-7) 10-10 Fan Controls Component Location Index (CONDENSER FAN RELAY ‘Test page 22-75 ‘CONDENSER FAN ASSEMBLY RADIATOR FAN ASSEMBLY Motor test, page 10-4 Motor test, page 10-4 10-11 Fan Controls Symptom Troubleshooting Index ‘Symptom Engine overheats Diagnostic Procedure {aspect the water pump (see page 10-5). Check the thermostat (se page 10-4. Check for any engine cootant leakage {from gaskets, hoses, O-rings, etc) 4. Check for dint, leaves, or insects on radiator and condenser. ‘Check for a damaged or deformed fan shroud. Check tora plugged or deteriorated radiator hoses. 7. Check the radiator cap (see page 10-3). 8, Inspect the fan motors (see page 10-4) or fan relays (see page 22:78) 8. Check for plugged heater core or hoses. 10. Check the caolant level 11. Check for deteriorated coolant 12\_Check fora damaged cylinder head gasket. ‘Also check for | Radiator fen runs at low speed, but does not run at high speed when the engine coolant temperature is above | 206 (97°¢) Radiator fan high speed circuit troubleshooting (see page 10-14). With the A/G OFF and the engine coolant temperature at 206 (97°C) or below, the condenser fan runs at high speed and the radiator fan does not run. When the coolant temperature is above 208 (97°C), both fans run at | high speed Remove the fan control relay, and test. + Ifthe relay is faulty, replace it + Ifthe relay is OK, repair a short in the wire between fan control relay SP socket terminal No. 1 and ‘condenser fan motor 2P connector terminal No. 1. Radiator fan and condenser fan run at high speed with the ignition switch ON (il) the AIC OFF, and engine coolant temperature below 204 (95°C) Repair a short in the wire between radiator fan relay 4 socket terminal No, 4 and ECM/PCM connector terminat Al. Radiator fan and condenser fan run at low speed with the ignition switch ON All)and the AC OFF Ropair a short in the wire between condenser fan relay 4P socket terminal No. & and ECM/PCM connector ‘terminal AB. ‘Radiator fan and condenser fan do not ‘un at low speed with the A/C ON Radiator and condenser fans low speed circuit troubleshooting (see page 21-52). Condenser fan does not run at at Radiator fan does not run at low speed, but runs at high speed ‘Condenser fans high speed circuit troubleshooting (see page 21-56). Both condenser fan and radiator fan donot run at high speed when the engine coolant temperature is above 206 (97°C) 10-12 Repair an open in the wire between radiator fan relay 4P socket terminal No. 4 and ECM/PCM connector terminal A7. Circuit Diagram Ei Bre q new | oF a 1 a ali ue ihe (le = ct oF rh 2 & | fe . ~~ 4] cts wor one 10-13 Fan Controls Radiator Fan High Speed Circuit Troubleshooting 1, Remove the radiator fan relay from the under-hood fuse/relay box and test it (see page 22-75). isthe relay OK? YES—Goto step 2. NO Replace the radiator fan relay.m 2. Turn the ignition switch ON (l). ‘3. Measure the voltage between radiator fan relay 4P ‘Terminal side of female terminals Is there battery voltage? YES—Goto step 4. NO—Reptace the under-hood fuse/relay box. 10-14 4. Connect radiator fan relay 8? socket terminals No. 1 and No. 2 with ajumper wire. [RADIATOR FAN RELAY 4P SOCKET JUMPER WIRE Terminal side of female terminals Does the radiator fan run at high speed? YES~Goto stop 5. NO— Repair an open in the wire between radiator fam relay 4P socket terminal No. 2 and radiator fan ‘motor 2P connector terminal NO. 2.8 8. Measure voltage between radiator fan relay 4P socket terminal No. 3 and body ground. RADIATOR FAN RELAY 4P SOCKET 1 2 3 4 Terminal side of female terminals Is there battery voltage? YES—Repair an open in the wire between radiator fan relay AP socket terminal No. 4 and the engine control module (ECM)/powertain control module (PCM). NO— Repair an open in the wire between radiator fan relay 4P socket terminal No. 3 and the under- dash fuse/relay box. Fuel and Emissions Fuel and Emissions Systems Spocial Too!s 2 General Teoubioshooting information 113 DTC Troubleshooting indox 118 Simptem Troubleshooting nde ns 1-11 I ag ust PGM-FI System Component Loca TC Troubleshooting MIL Circuit Troubleshooting DLC Circuit Troubleshooting Injector Replacement AVF Sensor Replacement ncn Secandary HO2S Replacement ECT Sensor Replacement IAT Sensor Replacement KP Sensor Replacement Knock Sensor Replacement CMP Sensor Replacement .... Input Shaft (Mainshatt) Speed Sensor Replacement 18-170 (up Sha Counivsha Speed Sensor Replacement. 1-470 ECMIPCM Replacement win Electronic Throttle Control System ‘Component Location index. 11172 DTC Troubleshooting 0-173 [APP Sensor Replacement 11.216 Throttle Actuator Control Mode Replacement. VTEC Component Location Index 27 DTC Troubleshooting -. an2i8 VTEC Solenoid Valve Test. 11-226 VTEC Solenoid Valve Removalinstallation VIEC Oil Pressure Switch Replacome Idle Contrat System ‘Component: 11.228 14-229 ‘AC Signal Circuit Troubleshooting ‘Alternator FA Signal Circuit “Troubleshooting PSP Switch Signal Circuit Troubleshooting Brake Pedal Position Switch Signal Circuit Troubleshooting Idle Speed Inspection . ECM/PCM Idle Learn Procedure Fuel Supply System i os Fitting Precautions .. 11-251 ees Intake Air System Sa is coo — ‘Throttle Body Disassombly/Reassembly ... 11-278 Catalytic Converter System DIC Troubleshooting 11279 Warm Up Three Way Catalytic Canverter Removallnstallatlon 11281 EGR System ‘Component Location Index. 11-283 DIC Troubleshooting 11-284 EGR Valve Replacement 11.295 PCV System BTC Troubleshooting PCV Valve Inspection and Test 11-296 11.297 PCV Valve Replacement 11297 EVAP System Component Lotation Index sens 1-298 DTC Troubleshooting wen. 14299 EVAP Conister Replacement i324 FTP Sensor Replacement 11325 EVAP Canistor Purge Valve Replacement 1005 evAb Canin voi Shikai Replacement v8 Fuel and Emissions Systems Special Tools Ref. No.| Tool Number ——Deseription. ‘ay (© [ABTBK-041-XXXXX ‘Vacuum Purnp/Gauge, 0-30 in.Hg 1 ® | O7AAA'SOXA100 Fuel Sender Wrench 1 © | O7AAL-SEMANSO Fuel Pressure Gauge Attachment Sot 1 @ | 074a2-0010008 ‘Vacuur/Pressure Gauge, 0-4 in.Hg 1 © | 078Az-001000a Backprobe Set 2 @ | o7naJ-Po70108 Pressure Gauge Adapter i @ | 07ZAJ-S5A0200 Hose, Oil Pressure 1 © | 07406-0020201 AIT Pressure Hose 1 @2_ | a7406-0070300 ‘AIT Low Pressure Gauge W/Panel 1 @3 | O™MAL-PYAONIA AIT Pressure Hose, 2,210 mm 1 4 | o7MAL-PY40120 AIT Pressure Hose, Adapter 1 @ _|07406-0040008 Fuel Pressure Gauge 1 11-2 1,02,0:3,04 ® E' General Troubleshooting Information Intermittent Failures ‘The term “intermittent failure” means a system may have had a failure, but itchecks OK now. Ifthe ‘matfunction indicator lamp (MIL) on the dash does not ‘come on, check for poor connections or loose pins at all connectors related to the circuit that you are troubleshoating. The MIL may be turned off by the ECM/PCM if the problem that originally caused the MIL. to be illuminated was an intermittent problem. Opens and Shorts “Open and Short” are common electrical terms, An ‘open is a break in a wire or at a connection. A short is ‘an accidental connection of # wire to ground or to another wire. in simple electronics, this usually means something won't work at all. With complex electronics (such as ECMs and PCMs) this can sometimes mean something works, but not the way it's supposed to. How to Use the HDS (Honda Diagnestic System) ifthe MIL (Malfunction Indicator Lamp) has come on 1. Start the engine and check the MIL (A\. NOTE: Ifthe ignition switch is turned ON «ti, and the engine is not started, the MIL will stay on for 115~20 seconds (see page 11-51). 2. Ifthe MIL stays on, connect the HDS to the data link connector (DLC) (A) located under the driver's side of the dashboard. SL 3. Turn the ignition switch ON (I. 4. Check the diagnostic trouble code (OTC) and note it, then download the onboard snapshot. Also check the freeze data. Refer to the DTC Troubleshooting Index (see page 11-8) and begin the appropriate troubleshooting procedure, NOTE: + Freeze data indicates the engine conditions when the first malfunction, misfire, or fuel trim malfunction was detected, + The HDS can read the OTC, freeze data, current data, and other engine control module (ECM)/ Powertrain control module (PCM) data. + For specific operations, refer to the user's ‘manual that came with the HDS. 5. If no DTCs are found, go to MIL troubleshooting (see page 11-148). {ifthe MIL did not stay on Ifthe MIL did not stay on but there is a driveability problem, refer to the Symptom Troubleshooting. if you can’t duplicate the DTC ‘Some of the troubleshooting caquires you to reset the ECMVPCM and try to duplicate the DTC. Ifthe problem is intermittent and you can't duplicate the code, do not continue through the procedure. To do so will only result in confusion, and possibly, a needlessly replaced ECMIPCM. (cont'd) 11-3 Fuel and Emissions Systems General Troubleshooting Information (cont'd) HDS Clear Command ‘The ECM/PCM stores various specific data to correct the ‘system even when there is no electrical power such as ‘he battery negative terminal or No. 8 FI ECU (ECM/ PCM) (15A) fuse are disconnected. Stored data based (on failed parts should be cleared by using the “CLEAR COMMAND" of the HDS, if parts are replaced. ‘The HDS has three kinds of clear commands to meet the purpose. They are DTC clear, ECM/PCM reset, and CCKP pattern ciear. DTC clear command erases all stored DTC codes, freeze data and readiness codes. This must bbe done with the HDS after reproducing the DTC during ‘troubleshooting in this service manual. ECM/PCM reset command erases all stored DTC codes, {freeze data, readiness codes, and all specific data to ‘correct the system except CKP pattern. Ifthe CKP pattern data in ECM/PCN1 was cleared, you must do the CKP pattern learn procedure. The CKP pattern clear command erases only CKP pattern data. This command for the repair of a misfire or CKP sensor. DTC CLEAR 1. Clear the DTC with the HDS white the engine is stopped. 2. Turn the ignition switch OFF. '3. Turn the ignition switch ON (ll). Wait for 30 seconds. 4, Turn the ignition switch OFF, and disconnect the HDS from the DLC. ECM/PCM RESET This command clears stored specific data from each vehicle such as DTCs freeze data, and readiness codes. It does not clear CKP PATTERN data, 1. Reset the ECM/PCM with the HDS while the engine is stopped. 2, Turn the ignition switch OFF. ‘3. Turn the ignition switch ON (li. Wait for 30 seconds. 4, Turn the ignition switch OFF, and disconnect the HOS from the DLC. 5. Do the ECM/PCM idle learn procedure (see page 11-239). CKP PATTERN CLEAR/CKP Pattern Learn NOTE: The ECT needs to be at 176¥ (80°C) or higher. 1. Clear the CKP Pattern with the HDS while the engine is stopped. 2. Turn the ignition OFF. 3, Turn the ignition ON (I), and wait for 30 seconds. 4, Tost-drive the vehicle on a level road: Decelerate (withthe throttle fully closed) from engine speed of 2,300 fam to 1,000 rpm with the A/T in 2 position, ‘or the MIT in 2nd or 3rd gear. 5. Stop the vehicle. Do not turn the ignition off. 6, Select the ALL DATA LIST in the DATA LIST MENU. of the HDS. 7. Check the status of PULSER F/B LEARN. Hitis setto ING, the enable criteria was probably not met; repeat the procedure from the beginning, How to End a Troubleshooting Session {required after any troubleshooting) 1, Reset the ECM/PCM with the HDS. 2, Do the ECM/PCM dle learn procedure (see page 11-239), 3. Turn the ignition ewitch OFF. 4, Disconnect the HDS from the DLC. NOTE: The ECM/PCM is part of the immobilizer system. If you replace the ECM/PCM, it will have a ifferent immobilizer code. In order for the engine to start, you must rewrite the imnmobililzer code with the HDS. How to Remove the ECM/PCM for Testing OTC troubleshooting requires voltage or resistance ‘checks at the ECM/PCM connectors, remove the ECM/ PCM and test it. 1, Jump the SCS line with the HOS, 2, Pull back the carpet. 8, Remove the ducts (A) 3aNm {0 kgte, T2bie 4. Disconnect the ECM/PCM connectors (B). 5. Remove the bolts (C), then remove the ECM/PCM. 0). 6. Install the ECM/PCM in the reverse order of removal. 7. Open the SCS line with the HDS. How to Troubleshoot Circuits at the ECM/ PCM ‘Special Tools Required + Digital Multimeter KS-AHM-32-003 (1) or a commercially available digital multimeter + Backprobe Set 07SAZ-001000A (2) 1. Connect the backprobe adapters (A) to the stacking patch cords (B), and connect the cords to a digit multimeter, the tip into the connector from the wire side until it touches the end of the wire terminal, 3. Ifyou cannot get to the wire side of the connector or the wire side is sealed (A), disconnect the connector and prabe the ferminals (B) from the terrainal side. Do not force the probe into the ‘connector. Do not puncture the insulation on a wir. Punctures can cause poor or intermittent electrical connections. a 11-5 Fuel and Emissions Systems General Troubleshooting Information (cont'd) ECM/PCM Updating and Substitution tor Testing ‘Special Tools Required Honda Interface Module (HIM) EOS05A35570 Use this procedure when you have to substitute known-good ECM/PCM in a troubleshooting procedure. Update the ECM/PCM only ifthe ECM/PCM does not, have the latest software loaded. NOTE: Do not turn the ignition switch OFF while Updating the ECM/PCM. If you turn the ignition switch OFF before completion, the ECM/PCM can be damaged, How to Update the ECM/PCM NoTE: + To ensure the latest program is installed, do an ECM/ PCM update whenever the ECM/PCM is substituted or replaced. + You can not update an ECM/PCM with the program it, already has. It will only accept a new program. + Bofore you update the ECM/PCM, make eure the vehicle's battery is fully charged. + To prevent ECM/PCM damage, do not operate anything electrical (audio system, brakes, A/C, power windows, moonroof, door locks, etc.) during the update. + It you need to diagnose the Honda Interface Module (HIM) because the HIM's red (#3) light came on or was flashing during the update, leave the ignition switch in the ON ll) position when you disconnect the HIM from the data link connector (DLC). This will prevent ECM/PCM damage. 1. Turn the ignition switch ON (I). Do not start the engine. 2. Connect the HDS or the Honda Interface Module (HIM) to the data link connector (DLC) (A) located under the driver's side of the dashboard, 3. Do the ECM/PCM update procedure as described ‘on the HIM label and in the ECM/PCM update system. 4. Do the ECM/PCM idle learn procedure (see page 11-239). 5. Do the CKP PATTERN Learn Procedure, if you did the troubleshooting for DTC P0300, Pa301, Po302, P0303, P0304, P0305, P0306, P0335, P0339, P0340, 0344, PO38S or P0389. v3 Haw to Substitute the ECM/PCM. 1. Connect the HDS ¢o the data link connector (DLC) (A) located under the driver's side of the dashboard, 2. Turn the ignition switch ON (I. 3. Select READ DATA in the REPLACE ECM/PCM with, the HDS. 4. Tum the ignition switch OFF. 5. Jump the SCS line with the HDS, 6. Pull back the carpet 7. Remove the ducts (A). 8. Disconnect the ECM/PCM connectors (B). 8. Remove the bolts (C), then remove the ECM/PCM (0), 10. Install the ECM in the reverse order of removal. 11. Open the SCS with the HDS. 12. Turn the ignition switch ON (ih. NOTE: If DTC: P9630 “VIN Not Programmed or Mismatch" is stored at this time, ignore it and continue this procedure. 13, Input the VIN to the ECM/PCM with the HDS, 114, Select WRITE DATA in the REPLACE ECM/PCM with the HDS, 15, Rewrite the immobilizer code with the ECM/PCM replacement procedure in the HDS; it allows you to start the engine. 16. Reset the ECM/PCM with the HDS, 17. Do the Idle learn procedure (see page 11-238). 18, Do the CKP pattern learn procedure. OBD Status ‘The OBD status shows the current system status of each DTC and all of the parameters. This function is used to see ifthe technician's repair was successfully inished. The results of diagnostic tests for the DTC are isplayed as: + PASSED: On board diagnosis is successfully finished, + FAILED: On board diagnosis has finished but failed, + EXECUTING: The vahicieis in enable criteria ‘conditions for the DTC and the on board diagnosis is running. ‘+ NOT COMPLETED: The on board diagnosis was running buts out of the enable conditions of the DTC. + OUT OF CONDITION: The vehicle has stayed out of the enable conditions of the DTC. 11-7 Fuel and Emissions Systems DTC Troubleshooting Index Detection erm [mit] We | Mails Absolute Pressure (API Sensor Crt Low Voiogs “ON | eaetaae 175<_| aroh Absolut Pressure MAP] Senor Cat High Voge ‘ON {seepage 1-581] |nike Ac Temperature (i) Sensor Creu Low Voltage ‘ON |" (seepage 1-65) — nate Al Temperature (AT) Sonor Great igh Vatoge ON [Engine Coolant Temperature (ECT) Sensor Range/Porformande Pc=blem | —[ Engine Cootamt Temperature (ECT) Circuit Low Voltage | seenane 1 et — [Post [No 2 Cylinder Misfire Detects go | No: 4 Cylinder Misfire Doweied No, 3Gyinuer Mitre Dete ine Cole Ter ECT) Circuit High Voltape 4 “Thro Pasion (P] Sensor A Circuit Low Vole [Throttle Position (TP Sensor A.Circul High Voltage I [Engine Cool Temperature ECT Sensor Son sponse [Coating System Malfunction | Rar A Pe Rt (A) Seror (Sank, Senor Cc Siow Response | POIs (181) eat Ai Fuel Ratio (AF) Sensor (Bank 1, Sensor 1) Heater System ‘ON | (seepage 11787 __| Maun, . Pras (Ts) =~ Rear Air Fuel Ratio (WF) Sensor Bank , Sensor 1) Heater Circuit ‘ON | Weoepage 11-75) Matfunction Povarciei | Pova7 Feat Secondary Heated Oxygen Sensor [Secondary HOZS Tak, ‘ON | eee age T7987 394 2)1 Creu Low Volage | Poraarien — | Povae Rea! Secondary Heated Oxygen Sensor (Secondary HOZS (a ‘ON Tees Poae |~ ‘Sensor 2] Cwreutigh Voknge a ” | Porsa rien | Povaa ‘Rest Secondary Heated Oxygen, Sewsor Secondary HO2S (Bank, ‘ON | (eee page 17-1057 ‘Sensor 2) Creuk Slow Response over (a) ===} Rear Socondary Heated Oxygen Sonar (Secondary HOZS Tank, ‘ON | eve page 1-108) - ‘Sensor 2) Heater Cteut Maftunction ores riéa) | PoveS Front Air Fuel Ratio (AF) Sensor (Bank 2, Sensor 1) Circuit Siow ‘ON | teow page T1737 | Response POTEET) =| Frnt A Foe Rae OF Sonsar Bank Sensor 0 eer Sytem ‘ON | tees page T774)| Maifunction POTS (8 ==} Front Air Fut Ratio (FY Sensor Bank 2, Sonsor V Heater Cea ON | ee nage 1775)-| Maffunction. _| ors7 (162) | POTST rant Secondary Heated Oxygen Sensor (Secondary HOZS (Bank2, ‘ON | Wee age 1-987 | ‘Sensor 2) Crean Low Voltage ovsa a2) | Paves Front Secondary Heated Oxyged Sewer Secondary HOZS (bank 2, ‘ON | eo bage T7100) ‘Sensor 2)) Cireut High Voltage paisa rea) | Powe rot Secondary esta Ogee Seo Seanday HOS ak ‘ON | oo page T1103) | | Senso 2 cre Stow Rospons over (168) = ‘Secondary Hested Oxygen Senor Sooondary NOZS Tank 2, ‘ON | eee age 1-108) ‘Sensors Hester Grout Malfunction | * ‘| [Porz1 gai | Porri ——| Rear Bonk (Bank 1) Fue System Too ean ‘ON | ee pan 17-108) ora sa) |Poi72 eat Bank (Bank 1) Fuel Syst ‘ON—[ see page T¥-Tos)_| Potre isa) [POW Fro Bank Bank 2) Fun! System Too Lean ‘ON |" eee page 11-106) [pose — ors Front ne (Bare 21 Fue System. Too Ren — ‘ON see page $108 5222 == ottla Postion (1) Sensor 8 Cirutt Low Voilane Nae page 11-1791 | [pozz3 — Fras Peon [Sener Curl ih Votan ‘ON | seepage 11-182) Paso and FFD | Random Mise Detected ‘ON | oe page 11-108) someot | some! Poaatirn, | Poa0Y, osa2(72), | Poast, ans 73), | Poana’ Posner, | Posos, Pos05(75), | Posos. | No. 1 Cylinder Misfire Detected om | ane Ta | Granshatt Postion CK®) Sensor ANa Sigal | Crankshaft Postion (CKP] Sensor AImormitent interuption -{ Cams Poston GMP sere! No Saal = —]etanianat Poison Ck?) Songors No Saya aft Poston (CMP) Senso” Itermiten 11-8 seo page 11-122) =F Crankshat Position (CKP) Senso 5 Intern iter Iiarrupion ‘Te Those DTCSareinaleated by linking MIL when The SCS service signa ine is jumpod with the HOS.