Documente Academic
Documente Profesional
Documente Cultură
How to Use This Manual This manualis dividedinto 23 sections.The first pageof each
seclionis markedwith a blacktab that linesup with its
corresponding
thumb indextab on this pageand the backcover.
You can quicklyfind the first pageof eachsectionwithout
lookingthrougha full tableof contents.The symbolsprintedat
the top cornerof each pagecan also be used as a quick
re{erencesystem.
Sp e c i fi c a ti o n s
1)ll:{l+'
Ma i n te n a n c e
Eachsectionincludes:
1. A tableof contents,or an explodedview index showingl
. Partsdisassemblysequence.
. Bolttorquesand threadsizes.
. Pagereferencesto descriptionsin text.
proceduresand tools.
2. Disassembly/assembly
3 . Inspefiron.
g.
4. Testing/troubleshootin
5. Repair.
6. Adjustments.
Safety
Your safety,and the satetyof others,is very important.To help
you make informeddecisions,we have providedsafety
messages,and othersafetyinformationthroughoutthis manual.
Of course,it is not practicalor possibleto warn you aboutall the
hazardsassociated
with servicingthis vehicle.You must use
your own good judgment.
Emissions
tmEnEErily;,:H,ll i":5*i5"?;rsERIousLYHuBrir
HURT
ir
E$EEEE ys,:
f#,ff ,:hl:3,:JjERrousLY
tlGtltT]llilll
. lnstructions
- howto service
thisvehiclecorrectlv
andsafelv.
All informationcontainedin this manualis basedon the latest
productinformationavailableat the time of printing.We reserve
the right to makechangesat any time without notice.No part of
this Oublication
maVbe reDrodLrced,
or storedin a retrieval
system,or transmitted,in any form by any means,electronic,
photocopying,recording,or otherwise,without the
mechanical,
priorwritten permissiono{ the publisher.This includestext,
figures,and tablesAs vou readthis manual,vou will tind informationthat is
precededby a @
symbol.The purposeof this messageis
to help preventdamageto your vehicle,other property,or the
environment,
* Bo d y
z-tl!
^ t
FirstEdition8/2002 1,168pages
HONDAMOTORCO..LTD.
All RightsReserved
ServicePublicationOffice
Specifications
applyto U.S.A.and Canada
As seclion3 with *inclode SRS comoonentsi
special precautionsare required when servicing.
*Restraints
GeneralInformation
Ghassisand PaintCodes
- 2 0 0 2M o d e l
. . . . . . . . . . . . . 1. .-.2.
Chassisand PaintCodes
- 2 0 0 3M o d e l
. . . . . . . . . . . . .1. .-.3.
ldentification
NumberLocations ........1-4
Warning/Caution
LabelLocations......1-5
Under-hoodEmission
ControlLabel ...........
.... 1-7
L i f ta n dS u p p o r P
t o i n t s. . . . . . . . . , . . . . , . . .1. .-.8. , .
Towing
......1-9
PaftsMarkingLocations......................
1-10
GeneralInformation
Model
Chassisand PaintCodes- 2OO2
VehicleldentfficationNumber
S H H E P 33 5 ' 2
U 300001
[[tttrtF
c d e f g h
EngineNumber
K2OA3 1700001
a
a. EngineType
K20A3: 2.0 0 DOHCVTECSequentialMultiport
Fuel-injectedengine
b. Serial Number
Transmission
Number
NBH3
1000001
a
TransmissionType
N R H 3 ; s - s D e eM
danual
PaintCode
Code
B-92P
NH-578
NH-623M
R-81
Y-62P
Color
Niqhthawk
BlackPearl
TaffetaWhite
Satin Silver lvletallic
M i l a n oR e d
E u r oY e l i o wP e a r l
u.s.
Canada
1-2
U 400001
[--t-rlF
c d e fg h
EngineNumber
K2OA3 2700001
I
a
a. EngineType
K20A3: 2.0 0 DOHCVTECSequentialMultiport
Fuel-injectedengine
b. SerialNumber
Transmission
Number
NRH3 - 2000001
I
a
TransmissionType
N R H 3 : 5 - s p e eM
d anual
SerialNumber
PaintCode
Code
B-92P
B-520P
NH-578
NH-623M
R-81
Y-62P
Color
Niohthawk
BlackPearl
V i v i d B l u eP e a r l
Taffeta White
Satin Silver N4etallic
M i l a n oR e d
EuroYellow Pearl
U , S . Canada
VehicleldentificationNumber
and FederalMotor Vehicle
Saletv Standard Certif ication/
Color Label.
)_.
1-3
GeneralInformation
ldentificationNumber Locations
Vehicle ldentificalion
Numbe.lvlN)
EngineNumber
t)
1-4
, I
O
warning/cautionLabelLocations
NOTE:FRONTPASSENGER
AIRBAG
WARNING
TAG
(CHILD
SEAT)is installedon the glovebox on the U.S.
mooet.
Passenger's
Compartment:
SRSINFORMATION
U.Sm
. odel
Steering Wheel:
DRIVERMODULE
DANGER
CABLEREEL
CAUTION
SRS WARNING
INFORMATION
FRONTPASSENGER
MODULE DANGER
MONITOR
NOTICE
!
,/
FRONT
SEATBELT
TENSIONER
CAUTION
SIDEMODULE
DANGER
SIDEAIRBAG CAUTION
Located on driver's
ano passen9ers
doorjamb(not shown)
..r'
(cont'd)
1-5
GeneralInformation
Warning/CautionLabelLocations(cont'dl
SRSWARNING
LABEL
SERVICEINFORMATIONLABEL
(Undor-hood Emission Control
Informationlabl)and ENGINE
COOLANTINFORMATION
TIREINFORMATION
RADIATOR
CAPCAUTION
BATTERY
CAUTION
1-6
Under-hoodEmissionControlLabel
EmissionGroupldentification
Families:
Engineand Evaporative
Example:2002model
EngineFamily:
rr-tt--[
t
t
l
a b
. P AT I E R2 B I N5
T H I SV E H I C LCEO N F O R MTSO U . S E
APPLICABLE
TO 2002
LEV
REGULATIONS
AND NLEV
CARSAND
MODELYEARNEWPASSENGER
TO 2OO2
APPLICABLE
REGULATIONS
CALIFORNIA
CARS.
MODELYEARNEWLEVIi LEVPASSENGER
c.
d.
e.
Example:2003model
c d
ModelYear
2:2002
3: 2003
ManulacturerSubcode
H N X :H O N D A
FamilyType
V: LDV
Displacement
SequenceCharacters
V B P2: 0 0 2
X K C 2: 0 0 3
Evaporative Family:
rH/
t[-l=[
a b
c d
Model Year
2t 2002
3: 2003
Manufacturer Subcode
H N X :H O N D A
c. Family Type
R: EVAP/ORVR
d . Canister Work Capacity
e . Sequence Charactets
AAH: 2002
AAA: 2003
1-7
GeneralInformation
Lift and Support Points
NOTE:If you are going to remove heavycomponents
such as suspensionor the fuel tank from the rear of the
vehicle,first supportthe front ofthe vehiclewith tall
safetystands.When substantialweightis removed
from the rear of the vehicle,the centerof gravity can
changeand causethe vehicleto tip forward on the hoist.
FrameHoist
1. Positionthe hoist lift blocks(A),or safetystands,
under the vehicle'sfront support points (B)and rear
support points (C).
FloorJack
1. Set the parkingbrake.
2. Blockthe wheels that are not being lifted.
3. When liftingthe rear of the vehicle.put the
gearshiftIever in reverse.
4. Positionthe floor jack underthe front jacking
bracket(A) or rearjackingbracket(B),centerthe
jacking bracketin the jack lift ptatform(C),and jack
up the vehiclehigh enoughto fit the safetystands
u n d e ri t .
0
2. Raisethe hoist a few inches,and rock the vehicle
gentlyto be sure it is firmly supported.
3. Raisethe hoistto full height,and inspectthe lift
pointsfor solid contactwith the lift blocks.
Safety Stands
c
Positionthe safetystandsunderthe support points
and adjustthem so the vehiclewill tevet.
Lower the vehicleonto the stands.
1- 8
Towing
lf the vehicleneedsto be towed, call a professional
towing service.Nevertow the vehiclebehind another
vehiclewith just a rope or chain.lt is very dangerous.
EmergencyTowing
T h e r ea r et h r e ep o p u l a rm e t h o d so f t o w i n ga v e h i c l e .
Flat-bedEquipment The operatorloadsthe vehicle
on the backof a truck.This is the bestway of
transportingthe vehicle.
To accommodateflat-bedequipment.the vehicleis
equippedwith towing hooks(A)and tie down hooks{B).
The towing hook can be usedwith a winch to pull the
vehicleonto the truck, and the tie down hooks slotscan
be used to securethe vehicleto truck.
. l m p r o p e rt o w i n g p r e p a r a t i ow
n i l l d a m a g et h e
transmission.Follow the above procedureexactly.lf
you cannot shift the transmission,the vehicle must
be transDortedon a flat-bed.
. Trying to lift or tow the vehicle by the bumperswill
, h e b u m p e r sa r e n o t
c a u s es e r i o u sd a m a g e T
designedto supportthe vehicle'sweight.
1-9
GeneralInformation
PartsMarking
To deter vehicletheft, certainmajor componentsare markedwith the vehicleidentificationnumber (VlN).Original
partshave self-adhesivelabels.Replacementbody parts have genericself-adhesivelabels.The originalengrneor
transmissionVIN plate is transferredlo a replacementengine or transmissionand attachedwith break-offbolts.
NOTE:Be careful not to damagethe parts marking labelsduring body repair.Maskthe labelsbefore repairingthe part.
r a
1-10
ra
Specifications
Standardsand ServiceLimits
Enqine
ne Electrical
Item
Measurement
lgnitioncoil
Rated voltage
Sparkplug
Type
Oualification
F i r i n go r d e r
Gap
l g n i t i o nt i m i n g
Alternator
A t i d l e ( c h e c kr h e
Output
Coillrotor)resistance
5|lp flng u.u.
Starter
Brushlength
Brushspringtension
Output
Commutator
micadepth
Commutator
tunout
Commutator
O.D.
Brushlength
Standard or New
12V
1 3-4 2
N G K t: Z F B 6 K 1 1
DENSO:
SKJ20DR-M11
1 . 0 1 . 1 m m ( 0 . 0 3 90 . 0 4 3
in.)
in neutral:8t2' ETDCat 650150rpm
Service Limit
1 . 3 m m ( O . OiSn 1. )
At 13.5V and
80A
normalengine
temperature
At 68.F(20'C)
2.2 3.0 A
14.4mm {0_57
in.)
14.0mm (0.55in.)
10.5mm (0.41in.l
1.5mm {0.06in.)
2.9 3.5N (0.30 0.36kgf,0.7-0.8tbs)
0.50 0.80mm (0.020-0.031
in.)
0.20mm 1O.OO8
in.)
o:BlalqryL4i) max
o.o5mm(0.002
in.)
2 8 . 0m m ( 1 . 1 0
in.)
14.0 14.5mm {0.55 0.57in.)
2 7 . 0m m ( 1 . 0 6
in.)
9.0mm {0.35in.)
Enqtne
Item
Measurement
Compression Pressurecheckat 250rpm with wide
openthroftle. (SeeDesignSpecsfor
rato,
Oualification
Minimum
Maximum
vanatton
Standard or New
Service Limit
930kPa(9.5kgflcmr,135psi)
200kPa{2.0kgf/cm',28psi)
e_
.l
2-2
nder Head
Item
Head
Camshaft
Measur6ment
Oualification
'103.95104.05
mm
(4.093 4.096in.)
0.05 0.20mm (0.002 0.008in.)
Endplay
No.l journal
N o . 2 , 3 ,4 , 5
journals
Totalrunout
Cam lobe height
Intake,primary
Intake,
Exhaust
(cold)
clearance
lntake
StemO.D-
lnlaKe
Exhaust
Exhaust
S t e m - t o - g L r i d cel e a r a n c e
lntake
height
stem installed
Exhaust
lntake
Exhaust
lntake
Exhaust
lntake
Exhaust
Valvesprings
Freelength
Valveguides
LD.
Intake
Exhaust
I n s t a l l e dh e i g h t
lntaKe
Exhaust
Rockerarms
Arm-to-shaftclearance
lntaKe
Exhaust
Service Limit
0.05mm {0.002in.)
Warpage
Height
C a m s h a f tt o h o l d e r o i l c l e a r a n c e
Standard or New
0.030 0.069mm
{0.001 0.003in.)
0.060 0.099mm
(0.002-0.004in.)
0.03mrn (0.001in.)max.
in.)
33.925mm (1.3356
in.)
2 9 . 6 3m
8 m (l.1668
in.)
34.092mm (1.3422
0.21 0.2smm 10.0080.010in.)
0.28 0.32mm (0.011 0.013in.)
5.475 5.485mm 10.21560.2159in.)
5.450 5.460mm (0.2146 0.2150in )
0.030 0.055mm (0.0012 0.0022in.|
0.055 0.080mm (0.0022 0.0031in )
1.25 1.55mm (0.049 0.061in.)
1.25 1.55mm (0.049 0.061in.)
4 0 . 8 -4 1 . 0m m ( 1 . 6 0 6 1 . 6 1 4 i n . )
in.)
5 4 . 6 5 4 . 8m m ( 2 . 1 5 02 . 1 5 7
(1.874
in.)
47.61mm
49.64mm (1.954in.)
0.4mm (0.02in.)
0 . 1 5m m { 0 . 0 0i6n . )
0.15mm (0.006in.)
0.04mm {0.002in.)
5.445mm (0.214in.)
5 . 4 2m m ( 0 . 2 1i3n . )
0.08mm (0.003in.)
0.11mm (0.004in.)
2.00mm {0.079in.)
2.00mm {0.079in.)
5.515 5.530mm
|.0.21710.21174n.1
mm
5.515 5.530
\0.2111 0.2177in.l
1 5 . 2" 1 6 . 2m m ( 0 . 5 9 80 . 6 3 8 i n . )
15.5 16.5mm (0.610 0.650in.)
5.55mm (0.219in.)
0.025 0.052mm
(0.00'100.0020in.)
0.018 0.056mm
(0.0007 0.0022in.)
0.08mm (0.003in.)
5 . 5 5m m { 0 . 2 1i9n . )
0.08mm (0.003in.)
lo
2-3
Standardsand ServiceLimits
n q t n e Block
Enqine
Item
Block
Measurement
I Warpageof deck
tsorediameter
Oualification
Aori
Borll
Standardor New
0.07mm (0.003in.)max.
86.010 86.020mm
(3.3862 3.3866in.)
ServiceLimir
foro.. (ulur^^-"1
86.070mm (3.3886
in.)
86.000 86.010mm
(3.3858 3.3862in.)
86.070mm (3.3886
in.)
0 . 0 5m m ( 0 . 0 0 2I n . J
R e b o r i n gl r m i t
Piston
Pistonring
",";"*
lFis,.-"'"
L-
Ringend gap
0 . 2 5m m ( 00 l i n . )
85.980 85.990mm (3.3850 3.3854in.) 85.930mm (3.383'l
in.)
F"
LetterB
s.980 r"i33846
85.920mm (3.3827
l-il?0
in.)
0.020 0.040mm (0 0008 0.0016in.) 0.05mm {0.002in.)
Top
1.220 1.230mm (0.0481 0.0484in.) 1.25mm 10.049
rn )
Second
1 . 2 2 0 1 . 2 3 0m m ( 0 . 0 4 8 1 0 0 a 8 4 I n . ) 1.25mm 10.049
in.)
i 2.005 2.025mm (0.0789 0.0797in.) ?.09rrl9.091lt
)
i.'.f 0.13mm (0.005in )
fo.o:s o.oto.rnlo.oorao.ooza
i") 0 . 1 3m m ( 0 . 0 0i5n . )
EO3t 0 056rn. {OJ01rOOO2
Second(FEDEHAL 0.025 0.060mm (0.0010 0.0024in.) 0.13mm (0.005in )
I\4OGUL)
Top
0.20 0.35mm (0.008 0.014in.)
0.60mm (0.024in.)
btt"' "' A
Second
OiI(REKEN)
OiI(FEDERAL
I\4OG
UL)
Pistonpin
o.D.
0.70mm (0.028in.)
0.75mm (0.030in.)
0.80mm 10.031
in.)
Pin'to-piston
clearance
0.00008
in.)
Connecting
rod
Endplayinslalledon crankshaft
Crankshaft
No. l journal
No.2 journal
N o .4 j o u r n a l
No.5 journal
No.3 journal
5 4 . 9 7 65 5 . 0 0 m
0 m ( 2 . 1 6 4 42 - 1 6 5 4 i n )
Rodjournal diameter
4 4 . 9 7 6 4 5 . 0 0 0m m ( 1 . 1 7 0 7 1 . 1 7 1 7i n . l
Rod/main
0.005mm 10.0002
in.)max.
0.005mm (0.0002
in.)max.
0.10 0.35mm (0.004 0.0'14
in.)
0.03mm (0.0012
in.)max.
0.017 0.041
m m ( 0 . 0 0 0 70 . 0 0 1i6n . )
Rod/mainiournalout of,round
E n dp l a y
Runout
. . - ' . : - - ' +
M a r n o e a r , n 9 - t o J o u r n ao
t t t c t e a r a n c e No. l journal
Deaflngs
c_
0.010mm (0.0004
in.)
0.010mm (0.0004
in.)
0 . 4 5m m 1 0 . 0 1i 8
n.)
0.04mm {0.0016
in.)
0.050mm (0.0020
in.)
No.2 journal
No.4 journal
No.5
No.3 journa/
Bodbearingclearance
0.060mm (0.0024
in.)
2-4
o i
nqlne
Lubrication
|tem
Measurement
Engineoil
Capacity
Oilpump
lnner-toouterrotorclearance
Pumphousingto outerrotor
clearance
axial
Pumphousing-to-rotor
clearance
Balancer
shafts,journaldiameter
Oualificalion
ServiceLimil
Standerdor New
5.30 (5.6US qt)for engineoverhaul
4.20 (4.4US qt)for oil change,includingfilter
4.00 (4.2US qt)for oil change,withoutfilter
0.20mm (0.008in.)
0.02 0.16mm {0.001 0.006in.)
in.)
0.23mm (0.009in.)
0-15 0.21mm {0.006-0.008
0.02 0.07mm (0.001 0.003in.)
No.1 journal,front
shaft
0.12mm (0.005in.)
No 1 journal,rearshaft
Ealancer
shafts,journaltaper
shafts,end play
Balancer
Balancershatts,shaft-to'bear;ng
clearance
shaft
N o . 1 J o u r n a l ,r e a r s h a f t
N o . 2 j o u r n a l ,f r o n t a n d
0.10mm (0.004in.i
0.15mm (0.006in.)
rear shafl
LD.
shaftbearings,
Balancer
R e l i e f v a l v e ,o i l p r e s s u r ew i t h o i l
t e m p e r a t u r ea t 1 7 6 ' F ( 8 0 " C )
At idle
7 0 k P a ( 0 . 7k q ? c m , 1 0 p s r )m i n .
At 3,000rpm
300kPa{3.1ksf/cm',44psi)min.
Standardor New
6 . 7L ( 7 . 1U S
engine,
Coolantcapacity
{includes
heater,hoses,and reservoir)
Thermostat
ServiceLimit
0.53L (0.56US
93 123kPa(0.95 1.25kqtcm , 14 18psi)
't69 176'F(76 80'C)
OPeningtemPerature
8.0mm {0.31in.)min.
TurnsOFF
a
2-5
Standardsand ServiceLimits
Fueland Emissions
Item
Fuelpressure
regulator
Fueltank
Engineidle
Measulement
Oualification
Pressurewith fuel pressuregauge
connected
Capacity
ldlespeedwith headlights
and radiator Neutral
fan off
F a s ti d l e
Neutral
Standardor New
ServiceLimit
320-370kPa13.3-'3.8
kgtcm',47 52psi)
f
.
5 04 ( 1 3 . 2U Sg a l i
750 50 rpm
1,600150rpm
Clutch
Item
Clutchpedal
Mea3uremnl
Heightfromthe floor
Stroke
Oualification
D i s e n g a g e m e n th e i g h t f r o m t h e f l o o r
Clutchdisc
Pressureplate
Bunouton clutchmatingsurface
Bivetheaddepth
Ihickness
Warpage
Heightof diaphragm spring fingers
Measured
with
specialtooland
feelergauge
Slandardor New
193mm (7.60in.)
1 3 0 1 4 0m m 1 5 . 1 5 . 5 i n . )
10 16mm (0.39 0.63in.)
1'15
mm (4.53
i n . )m i n .
0.05mm 10.002
in.)max.
1.65 2.25mm (0.065 0.089in.)
8.3 8.9mm (0.33 0.35in.)
0.03mm (0.001in.)max.
0.6mm (0.02in.)max.
ServiceLimit
0.15mm (0.006in.)
0.7mm {0.03in.)
6.0mm (0.24in.)
0 . 1 5m m ( 0 . 0 0i1n . )
0.8mm (0-03in.)
r a
\ < c
2-6
O E
Adiust
20.75mm 10.817
in.)
3 ' 1 . 9m
3 m ( 1 . 2 5i7n . )
27.92
m m ( 1 . 0 9i9n . )
'1.5354
in.)
38.93mm (1.5334n.)
2 7 . 9 3m m { 1 . 1 0i0n . )
0.02mm (0.001in.)max.
in.)
44.009 44.025mm 11.73261.7333
0.06 0.16mm {0.002 0.006;n.)
23.92 23.97mm (0.94'10.944in.)
in.)
mm (1.3780 '1.3785
35.000-35.015
0.05mm (0.002in.)
44.08mm (1.735in.)
0 . 2 5m m ( 0 . 0 1i0n . )
23.80mm (0.937in.)
34.95mm (1.376in.)
39.88mm (1.570in.)
D i a m e t e ro f b a l l b e a r i n gc o n t a c t a r e a
( t r a n s m i s s i o nh o u s i n g s i d e )
30.020-30.0m
3 3m ( 1 . 1 8 1 91- . 1 8 2i4n . )
29.97
m m ( 1 . 1 8i0n . )
Runout
innerrace
35 mm shim-to'bearing
0.02mm {0.001in.)max.
0.04 0.10mm (0.0016 0.0039in.)
0.05mm (0.002in.)
Adjust
in.i
52.010 52.029mm (2.0476-2.0484
0.06 0.16mm (0.002 0.006in.)
-0.904in.)
22.92 22.91$m 10.902
52.010 52.029mm (2.0476 2.0484in.)
0.06 0.16mm (0.002 0.006in.)
21.92 27.91mtn \1.099 1.101in.)
39.95 39.96mm (1.572a 1.5132in.)
in.)
46.989-47.000mm (1.8499-1.8504
in.i
23.03 23.08mm (0.907-0.909
in.l
39.95 39.96mm {1.5728'-1.5732
in.)
46.989 47.000mm (1.8499 1.8504
mm (l.104 1.106in.)
28.03 28.08
52.08mm (2.050in.)
n.)
0 . 2 5m m 1 0 . 0 1i 0
22.87mm (0.900in.)
52.08mm {2.050in.}
4n.)
0.25mm 10.010
in.)
27.87mm 11.097
39.97mm (1.574in.)
46.94mm (l.848in.)
Transmission Capacity
fluid
Endplav
Mainshaft
Diameter
of bushingsurface
D i a m e t e ro f d i s t a n c ec o l l a r
Diameter
of ballbearingcontactarea
(clutchhousingside)
Diameter
of needlebearingcontact
area
Diameter
of ballbearingcontactarea
(transmission
housingside)
Runout
Mainshaft
3rd, t.D.
4th and sth
Endplay
gears
Thickness
Countershaft Diameterof needlebearingcontact
area(clutchhousingside)
of distance
collarcontact
Diameter
alea
Countershaft
clearance
LD.
End play
Thickness
Countershaft
2ndgear
Countershaft
'lst gear
t.D.
Endplay
Thickness
LD.
o.D.
collar Length
distance
Countersha{l l . D .
o.o.
2ndgear
distance
coliar L e n g t h
Se.viceLimit
Standardor New
Forfluidchange:1.50 (1.6US qt)
F o ro v e r h a u1l :. 70 1 1 . 8
U Sq t )
'
l
0
.
1
7
(
0
.
0
0
4
mm
0.007in.)
0.1
20.80 20.85mm {0.819 0.821in.)
mm (1.2594 1.2598
in.)
31.984-32.000
2 7 . 9 7 72 7 s 9 0m m \ 1 . 1 0 1 -51 . 1 0 2i0n . )
Masurement
Item
Oualification
39.97mm (1.574in.)
46.94mm (1.848in.)
o
2-7
Standardsand ServiceLimits
?
Manual
anuatTransmission
I ransm
and Differentialcont'
Measutemenl
Item
Nlainshaft4th
and5thgears
Oualification
LD.
o.D.
distance
collar L e n g t h
B
MBSdistance LD.
Len9th
t.D.
Reverseidler
gear
G e a r l o r e v e r s eg e a r s h a f i c l e a r a n c e
Synchroring
Bingto'gearclearance
Triplecone
Outersynchroring-tosynchrocone
clearance
Synchrocone-to-gear
clearance
Shift fork
Reverseshift
fork
Shiftarm
Outersynchroring-to-gear
cone
clearance
Fingerthickness
Forkto-synchro
sleeveclearance
Fingerthinkness
Fork-to-reverse
idlergear clearance
t.D.
S h i f t f o r k d i a m e t e ra t c o n l a c ta r e a
S h i f t a r m ' t o - s h i f t l e v e rc l e a r a n c e
Selectlever
Shiftlever
Mfi
differential
carrier
Mfi
differential
pinionqear
80 mm shim
Fingerwidth
Shaft-to-selectleverclearance
Groove{to selectlever)
Shaftto shiftarm clearance
Pinionshaftcontactareal.D.
C a r r i e r - t o - p i n i o ns h a f t c l e a r a n c e
DriveshaftcontactareaLD.
Backlash
t.D.
P i n i o ng e a r t o p i n i o n s h a f t c l e a r a n c e
80 mm shim to-bearing
outerrace
clearance
in transmission
housing
Ringpushed
againstgear
Ringpushed
againstqear
Ringpushed
againstgear
Ringpushed
againstgear
Standardor New
32.00-32.01mm (1.2598 1.2602
in.)
38.989 39.000mm (1.5350 1.5354
in.)
51.95 52.05mm (2.045 2.049in.)
24.03 24.08mm (0.946-0.947
in.)
ServiccLimit
3 2 . 0 2m m ( 1 . 2 6i1n . )
38.94mm (1.533in.)
2 8 . 0 2m m ( 1 . 1 0i3n . )
20.90mm (0.832in.)
0 . 1 6m m { 0 . 0 0i6n . )
0.4mm (0.0164n.)
0.70- '1.19
mm {0.028 0.047in.)
0.3mm (0.012in.)
0.3mm (0.012in.)
0.6mm (0.024in.)
1.0mm (0.039in.)
1.3mm (0.051in.)
0 . 6 2m m ( 0 . 0 2i4n . )
L O
0.50mm (0.020in.)
0.1mm {0.004in.)
0.1mm (0.004in.l
0.15mm (0.006in.)
Adjust
2-8
Rotational
at outside
olavmeasured
0 10mm (0 0.39in.)
at outside
Startingloadmeasured
2 9 N ( 3 . 0k g f . 6 . 6 l b s )
A n g l e o f r a c kg u i d e s c r e w l o o s e n e d
n
Item
W h e e l a l i g n m e nCamber
t
Measurement
Caster
TotalToe
Oualitication
Front
Rear
Front
lrytt
Rear
Frontwheelturningangle
l n s i d ew h e e l
Aluminumwheelrunout
Axial
Outsidewheel
Radial
Wheelbearing
Endplay
Front
Rear
Standardor New
0'00' 45'
0'45'- 45
ServiceLimit
1"33' 11"
in.)
0-3 mm(0::0.12
lN 2 ' , mm (0.08"' ,, in.)
37'40'-2'
29'50'(Reference)
0 0.7mm (0 0.03in.)
0 - 0 . 7m m ( 0 0 . 0 3 i n . )
0 0.05mm (0 0.002in.)
0 0.05mm (0 0.002in.)
2.0mm (0.08in.)
l.5mm{0.06in.)
a
2-9
Standardsand ServiceLimits
Brakes
Item
Parkingbrake
lever
Brakepedal
Mastercylinder
Erakedisc
Masurement
Distance
traveledwhen leverpulled
with 196N (20kgf, 44 lbs) ol force
Pedalheight(carpetremoved)
Freeplay
Piston-to-pushrod
clearance
Thickness
Runout
Parallelism
Brakepads
Thickness
Oualification
Standardor New
7 8 clicks
ServiceLimit
1 8 4m m ( 7 4 / 1 6i n . )
Front
Rear
Front
Rear
Frontand rear
Front
llear
0 . 4 3 . 0m m ( 00 1 6 0 ' 1 1 8
in.)
0 0.4mm (0 0.02in.)
2 1 . 0m m ( 0 . 8 3
in.)
9.0mm {0.35in.)
10.0mm (0.39in.)
9.0mm {0.35in.)
19.0m
0 m (0.75
in.)
8-0mm (0.31in.i
0.10mm (0.004in.)
0.10mm (0.004in.)
0.015mm (0.0006
in.)
1 . 6m m ( 0 . 0 6
in.)
1 . 6m m ( 0 . 0 6
in.)
Air Gonditionin
Item
Refrige.ant
Tvpe
Refrigerant
oil
Capacityof system
Type
Moasurement
Capacity
ofcomponents
Oualilication
Condenser
Evaporator
Eachline and
Standard or New
Service Limit
H F C1 3 4a ( B - 1 3a4)
500 550g 117.6 19.4oz)
S P1 O
(P/N38897-P13-A01AH
or 38899-P13-A01
)
25 m0,15/6fl ozl
45 mA111/2fl ozt
10m0 (1/3fl or)
hose
Compressor
Drivebelt
Startercoil resistance
plateclearance
Pulley-to-pressure
Compressor
At 68"F(20"C)
1 3 0 1 5 0m 0 1 41 / 3 5 f l o z )
3.05 3.350
0.35 0.6mm (0.014 0.024in.)
Autotensioner
lneedsno adjustment)
e-
2-10
DesignSpecifications
Measurement
|tem
DIMENSIONS
Overallwidth
Overallheight
Track
rront
Rear
Groundclearance
G r o s s V e h i c l eW e i g h t R a t i n g
(GVWR)
WEIGHT
(CANADA)
GrossVehicleWeightRating
ENGINE
1,660kg
{GVWR)
Tvpe
Cylinderarrangement
Boreand stroke
Displacement
ratio
Compression
Valvetrain
system
Lubrication
Oil pumpdisplacement
Waterpumpdisplacement
At 6,000engine
rpm
At 3,400engine
82 0 (87US qt)/minute
Tvpe
Normaloutput
12V
30 seconds
Nominalvoltage
Hourrating
Directionof rotation
CLUTCH
C l o c k w i s ea s v i e w e c lf r o m g e a r e n d
C l u t c ht v p e
S i n q l e p l a t ed r y , d i a p h r a g m s p r i n g
Clutchfrictionmaterialsurfacearea
1 7 4c m ' { 2 6 . 9s7q i n . )
forward,1 reverse
s-speed
Svnchronized,
D i r e c1t : 1
3.062
1.769
1.212
0.921
0.738
3.583
Sinolehelicalgear
Tvpe
I\,1AN
UAL
TRANSMISSIONPrimarvreduction
Gearratio
lst
2nd
3rd
4th
Finalreduction
Watercooled.4 strokeDOHCV-ECengin(
transverse
Inline4'cylinder,
86 x 86 mm (3.39x 3.39in.)
cuin.)
1 , 9 9 c8 m ' ( 1 2 2
9.8
Chaindrive.DOHCVTEC4 valvespercylinder
Forced,
wet sump,withtrochoidpumP
(57.4
54.30
US qo/minute
F!el required
STARTER
4 , 2 1 0m m { 1 6 5 .i8n . )
in.)
1,695mm 166.7
in.)
1,44m
0 m (56.7
m m ( 1 0 1 .i2n . )
2,570
1,470mm (57.9in.)
'1,470
mm (57.9in.i
152mm (5.98in.)
four {4)
3,660rbs
S e a t i n gc a p a c i t y
wEtGt-iT
{u.s.A.)
Specilication
Oualification
Overalllength
5th
Reverse
Type
Gearratio
4.164
o
2-11
DesignSpecifications
cont'
Item
Measuremeni
Type
Overallratio
Turns,lockto-lock
Steeringwheeldiameter
Type
STEERING
SUSPENSION
Shockabsorber
WHEEL
ALIGNMENT
Camber
Caster
BRAKES
AIR
I n d e p e n d e n ts r r u l w i t h s t a b i l i T e rc. o i l s p r i n g
Rear
Front
Rear
Front
Bear
Front
Front
Typeof servicebrake
Rear
Front
Bear
CONDITIONING
Front
Rear
Type
Numberof
cylinders
Capacity
Maximumspeed
D o u b l ew i s h b o n e
Telescopic,
hydraulic.
nitrogengas-frlled
Telescopic,
hydraulic,
nitrogengas,filled
0"00'
0.45'
1'33'
0 mm (0 in.)
I n 2 m m ( 1 / 1 6i n . )
P o w e r a s s i s t e ds e l f - a d j u s l i n gv e n t i l a t e dd i s c
Power-assisted
self-adjusting
soliddisc
Mechanical
actuating,
rearwheels
4 5c m ' ( 7 . 0s q i n . ) x 2
2 8c m ' ( 4 . 3s q i n . )x 2
Pl95/6081588V
T125r0 D1595M
Scroll
Type
Motor type
85.7m015.23
cu in.)/rev.
12,000rpm
130m0 {4 1/3floz)
SP-10(P/N38897'P13-A01AH
or38899-P13
A01)
Corrugated
fin
Corrugatedfin
Siroccofan
220 Wl12 V
Speed control
4 Speeo
L u b r i c a n tc a p a c i t y
Condenser
Evaporator
Blower
Specilication
Electric,
Powerassisted
rackand pinion
15.1
3 6 0m m ( 1 4 . 2
in)
Totaltoe
Typeof parkingbrake
Padfriction surfacearea
TIRES
Oualification
Lubricanttype
Type
Tvpe
M a x i m u m c a p a c i t y 480m" 116.900
cu ft)/h
T e m p e r a t u r ec o n t r o l
Compressor
clutch
Tvpe
Refrigerant
Electricalpower
cons!mptronat
68"F(20.C)
Type
Capacity
Airmixtype
Dry,singleplate,poly-Vbeltdrive
42W maximumat 12V
HFC134a(R-134a)
500 550g (17.6 19.4oz)
../a
2-12
Item
ELECTRICAL
RATINGS
Measurement
Under-hood
fuse
Specitication
1 2 V 3 6A H / 5h o u r s
1 2V - . 1 . 1k W ,1 . 2k W
12V 95A,90A
80A, 60A, 50A, 40A, 30A, 20A, 15A, 10A, 7.5A
Under'dash
Iuse
3 04 , 2 0 a , 1 5A , 1 0A , 7 . 5A
Oualilication
Battery
Starter
Alternator
Fuses
Light bulbs
Headlight
high
beam
Headlight
low
beam
Frontturnsignal
liqhts
Front parlinq lights
Bearturn signal
lights
FronVrear
side
markerlights
Brale/taillighls
H i g h m o L r n tb r a k e
'12v.' 60w
12V 55W
12V 21W
12V 5W
1 2 V" 2 1 W
12V 5W
12V 21/5W
12V 5W
light
Backup lights
platelight
License
Ceilinglight
12V 21W
12V 5W
Cargoarea light
12V 5W
12V 5W
Spotlights
'12v'.8 w
Gauge lights
I n d i c a t o rl i g h t s
Sideturn signal
light
LED
12V 5W
2-13
Body Specifications
Unit: mm {in.)
1.555{61.6)
1,i140(56.71
2-14
Maintenance
Lubricantsand Fluids
MaintenanceSchedulefor Normal
Conditions
Listed by Distance/Time
MaintenanceSchedulefor Severe
Gonditions
Listedby Distance/Time
\.4
MaintenanceSchedule
Listedby Maintenance
ltemfor Normal
Conditions
...................
3-8
Listedby Maintenance
ltem for Severe
Conditions
...................3-9
Lubricantsand Fluids
For detailsof lubricationpoints and type of lubricantsto be applied,referto the illustratedindex and variouswork
o v e r h a u l .l n s t a l l a t i o ne.t c . )c o n t a i n e di n e a c hs e c t i o n .
ures{suchasAssem
LUBBICANT
LUBBICATION
POINTS
NO.
1
Eng ine
2
3
Transmission
HondaMTF*'(P/N08798-9016)
5
6
7
I
9
10
11
1'
14
16
17
18
19
S u p e rH i g hT e m p U r e aG r e a s e{ P / N0 8 7 9 8 - 9 0 0 2 )
S i l i c o n eg r e a s e
grease
Multi-purpose
HondaCaliDerGrease(P/N08C30-80234lvl)
o rH
C o m p r e s s o r o iS
l : P - 1 0( P / N3 8 8 9 7 - P 1 3 - A 0 1 A
38899-P'13-A01)
a ( R - 1 3 4a )
F o rr e f r i q e r a nH
t;FC'134
Recommond6dEngineOil
fanges
E n g i n eo i l v i s c o s i l yf o r a m b e n t t e m p e r a l u r e
-30 -20
-10
t0
20
* 1 : Always use HondaManualTransmissionFluid (MTF).Using motor oii can causestiffershifting becauseit does
not containthe Drooeradditives.
" 2 : Always use HondaDOT 3 BrakeFluid.Using a non-Hondabrakefluid can causecorrosionand decreasethe life of
the system.
3-2
t
o o o o
o
o@@
a9
3-3
MaintenanceSchedule
Listedby Distance/Timefor Normal Conditions
Thistwo pagel/lanitenance
Schedule
outlinesthe minimunrequiredmaintenance.
Serviceat the indicated
distance
or time,whichevercomes
if the vehiclemeetsanyof the qualifiers
in the SevereConditions
first.use the lvlaintenance
Schedule
for Severeconditions
schedule
or if the
vehicleis normallydrivenin Canada.
(cold)(seepage6-321r
Intake:
0.21-0.25mm (0.008 0.010in.)Exhaust:
0.28 0.32mm (0.011 0.013in.)
Inspectvalveclearance.
(NGK)or SKJ20DR-M11
(DENSO).
Replace
sparkplugs.UseIZFR6K'11
1 . 0 1 . 1m m
km/6 years
120,000
mi/ 192,000
fluid.UseHondaMTF(seepage13-3).
I Replace
transmission
! Do items in A,B,alqq.,
/
/ Y vcdrs
120,000
mil 192,000
Type2.
5.00 (5.3US qt).UseHondaAll SeasonAntifreeze/Coolant
Beplace
coolant(seepage106).Capacity:
tailureto do the maintenance
itemsmarkedwith an asterisk
According
to stateandlederalregulations,
{*) will not voidthe customer's
intervalto ensurelong-term
warranties,
However,Hondarecommends
thatall maintenance
services
be doneat the recommended
emissions
reliability.
3-4
Replace
air cleanerelementevery30,000miles(48,000
km)(independent
of time).
oI mileage).
i I Replace
brakefluidevery3 years(independent
3-5
MaintenanceSchedule
Listedby Distance/Timefor SevereConditions
or time,whichevercomesfirst.Usethisscheduleif the vehicleis drivenMAINLYin Canadaor in anyof the
Serviceat the indicated
distance
(seepage3-4).
il onlyOCCASIONALLY
tollowingconditions;
drivenin theseconditions,
usethe NormalConditions
schedule
SevereDrivingConditions
. Drivinglessthan5 miles{8 km) pertrip or, in freezingtemperatures,
drivinglessthan 10miles(16km)pertrip
. Drivingin extremelyhot (over90"F/32"C)
conditions
. Extensive
deliveryvehicle.
idl;ngor longperiodsof stopand go driving,suchasa taxior a commercial
. Trailertowing,drivingwith a car-topcarrier,or drivingin mountainous
conditions.
. Drivingon muddy,dusty,or de'icedroads
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F { s e e p a g e 1 3 3 ) .
km/ 6 years
R e p l a c et r a n s m i s s i o nf l u i d . U s e H o n d a M T F ( s e ep a g e 1 3 3 ) .
mil 192,000
km/ 10years,thenevery60,000mi/ 96,000km/5 years
5.0015.3US qt) UseHondaAll SeasonAntifreeze/coo
lantType2.
Replace
coolant(seepage10-6).Capacity:
3-6
L
D
E
Replace
aircleanerelementevery15,000
miles124,000
km) in dustvcondition{independent
ol timei otherwiseuseNormalConditions
(seepage11-162).
scredule
F
lReplaceaircleanerelementevery30,000miles(48,000km)(independento{timei(seepagell-162).
Replace
oJmileagei.
brakefluidevery3 years(independent
H
Replacethe
dustandpollenIilterevery15,000
milesifvehicleis drivenmostlywhereair hashighconcentration
olsootfrom industryand
dieselpoweredvehiclesj
alsoreplace
the dustand pollenfilteranytimeaarflowis lessthanussal(seepags21-39).
A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k( * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d s t h a t a l l m a i n t e n a n c es e r v i c e sb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g - t e r m r e l i a b i l i t y ,
3-7
MaintenanceSchedule
milesx 1,000
t0
20
30
40
50
km x 1,000
16
32
48
64
80
12
months
Replace
engineoil
24
96
70
80
90
100
112
128
144
160
48
110
192
12
60
r20
R o t a t et i r e s
{ C h e c kt i r e i n t l a t i o na n d c o n d i t i o n a t l e a s t o n c e p e r m o n t h )
Replace
engineoil filter
Inspect
frontand rearbrakes
C h e c kp a r k i n g b r a k e a d j u s t m e n t
Visuallyinspectthefollowingitems:
. Tie-rodends,steeringgearboxand boots
. Suspension
components
. Driveshaftboots
. Brakehosesand lines(including
ABSi
. Allfluidlevelsandconditionof{luids
. Exhaust
system*
. Fuellinesandconnections*
Inspectandadjustdrivebelt
Replace
dustand pollenfilter
fluid
Reolace
transmission
Servicethefollowing items at the recommendedintervals
R e p l a c ea i r c l e a n e re l e m e n t
km)
Every
30,000
miles(48,000
Replace
sparkplugs
Lm)
Every
110,000
miles(176,000
Inspectvalveclearance
km),otherwise
adiusl
onlyif noisy.
Inspect
miles{176,000
every110,000
I n s p e c ti d l e s p e e d *
km)or8 years
Every
160.000
mres1256,000
R e p l a c ee n g i n e c o o l a n t
km)or5
miles(96,000
km)or 10years,
thenevery60,000
At 120,000
miles(192,000
brakefluid
Replace
Every3 years
3-8
milesx 1,000
10
km x 1,000
16
months
Replace
engineoil
Rotatetires
intlationandconditionat leastonceper monthi
{Checktire
20
30
40
50
60
70
80
90
100
110
120
48
64
80
96
112
128
144
160
176
192
12
24
36
60
48
72
Replace
every
5,000
miies18,000
km)or6 months
R e p l a c ee n g i n e o i l f i h e r
Inspectfrontand rearbrakes
L u b r i c a t ea l l l o c k s ,h i n g e s ,a n d l a t c h e s
Visuallyinspectthe followingitems:
. Tie rod ends,steeringgearboxand boots
. Suspension
components
' Driveshaftboots
Checlparkingbraleadjuslment
Visuallyinspectthefollowingitems:
. Brakehosesand lines{including
ABSi
. Allfluidlevelsandconditionoflluids
. Exhaust
system*
. Fuellinesandconnections*
. Lightsandcontrols,
vehicleunderbody
Inspectand adjustdrivebeh
Replace
transmission
lluid
Every15,000
miies(24,000
km)in dustyconditions,
otheMiseusenormalschedule.
Replace
sparkplugs
Every
110,000
miles(176,000
km)
Inspectvalveclearance
Inspect
every110,000
miles(176,000
km),otheMise
adiust
onlyif noisy.
I n s p e c ti d l e s p e e d '
Every
160,000
miles(256,000
km)or8vears
Replace
enginecoolant
At 120,000
miles(192,000
km)of 10years,lhen
every
miles(96,000
km)or5
60,000
Replace
brakefluid
Every3 years
* : A c c o r d i n gt o s t a t e a n d f e d e r a l r e g u l a t i o n s ,f a i l u r e t o d o t h e m a i n t e n a n c ei t e m s m a r k e d w i t h a s t e r i s k1 * ) w i l l n o t v o i d c u s t o m e r ' s e m i s s i o n s
w a r r a n t i e s .H o w e v e r , H o n d a r e c o m m e n d st h a t a l l m a i n t e n a n c es e r v i c eb e d o n e a t t h e r e c o m m e n d e d i n t e r v a lt o e n s u r e l o n g { e r m r e l i a b i l i t v .
N O T E 1 : R e p l a c et h e d u s t a n d p o l l e n f i l t e r a t 1 5 , 0 0 0m i l e s / 2 4 , 0 0 0k m i f t h e v e h i c l e i s d r i v e n m o s t l y i n u r b a n a r e a st h a t h a v e h i g h c o n c e n t r a t i o n s
o f s o o t i n t h e a i r f r o m i n d u s t r v a n d d i e s e l - D o w e r e dv e h i c l e s .
t,
3-9
EngineElectrical
EngineElectrical
SpecialTools
4-2
StartingSystem
Comoonent
Location
Index ...............
CircuitDiagram
StarterCircuit Troubleshooting
ClutchInterlockSwitchTest
StarterSolenoid
Test ..............
Starter Performance
Test
StarterReolacement
...............
StarterOverhaul.......................
4-J
4-4
4-5
4-6
4-7
4-8
4-9
4-10
lgnition System
4-15
Component
LocationIndex ...............
4-16
CircuitDiagram
lgnitionTimingInspection
4-17
lgnitionCoilRemoval/1nsta11ation
4-18
.......................
4-19
SparkPlugInspection
ChargingSystem
Component
LocationIndex ..................................
4-2O
CircuitDiagram
...........................
4-21
Charging
.......................
4-22
CircuitTroubleshooting
DriveBeltInspection
...................
4-26
DriveBeftReplacement
..............
4-26
DriveBeftAuto-tensioner
Inspection..................
4-27
DriveBeftAuto-tensioner
Replacement
..............
4-28
Alternator
Reolacement
.............
4-29
Alternator
.... 4-30
Overhaul................
CruiseControl
Component
Location
Index ..................................
4-36
CircuitDiagram
...........................
4-37
Index .......................
4-38
SymptomTroubleshooting
CruiseControlUnitlnDutTest .............................
4-40
MainSwitchTesVReolacement
...........................
4-42
.. 4-42
SeVResume/Cancel
SwitchTesVReplacement
CruiseControlActuatorTest
......4-43
CruiseControlActuator/Cable
Replacement
......4-44
ActuatorCableAdjustment..................................
4-45
ClutchPedalPositionSwitchTest .......................
4-45
\.
ENGINE
EngineElectrical
\ C
SpecialTools
Number
Tool Number
07746-0010400
07749-0010000
Description
Attachment,52 x 55 mm
Driver
otv
1
1
\(a
4-2
Starting System
ComponentLocationIndex
UNDER-DASH
FUSE/RELAYBOX
- l - ar]]]ll
-i
-_rt_.1
-.
_-- _. /
Itti:
: - l t . i t -i t! -t
!t:!|-
CLUTCH INTERLOCKSWITCH
Test,page4-6
STARTERCUTRELAY
Test,page22-51
\ r \ ' l
\'\l I
\r\, l,
, . \ \
\ \ /
'....",r.v
\-
\:,...)
\ /'\
t l
STARTER
page4 5
StanerCircuitTroubleshoot,ng,
SolenoidTest,page 4-7
PerformanceTest,page4-8
Replacement,page
4-9
'10
Overhaul,page4
4-3
Starting System
CircuitDiagram
-
ilo.20lOA) :USAmotkl
No.2!l50A) : C.nid. model
UiIOENH@DfUSE/REI.IY
BOX
STHOTin STA8Tilll
UNDEiOASTI
FUST/ifLAY
80x
Y.
cLuTot
[{Tr8LocK
swtlcH
a
4-4
StarterCircuitTroubleshooting
NOTE:
. Airtemperaturemust be between59'and 100'F(15'
and 38'C) during this procedure.
. After this test, or any subsequentrepair,resetthe
enginecontrolemodule (ECM)to clear any diagnostlc
trouble codes (DTCS){seepage 11-4).
. The batterymust be in good conditionand fully
charged.
. lf you disconnectthe baftery,do the ECM idle learn
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
RecommendedProcedure:
. Use a startersystemtester.
. Connectand operatethe equipmentin accordance
with the manufacturer'sinstructions.
Alternate Procedure
1. Hook up the following equipment:
. Ammeter,0 400A
. Voltmeter,0 20 V (accuratewithin 0.1 volt)
. Tachometer,0 1200rpm
4. Checkthe batterycondition.Checkelectrical
connectionsat the battery,the negativebaftery
cableto body, the engine ground cablesand the
starterfor loosenessand corrosion.Then try
startingthe engine again.
Did the statter crank the engine?
YES Repairingthe looseconnectionfixed the
problem.The startingsystem is now OK.!
N O l f s t a r t e r w i l ln o t c r a n k t h e e n g i n ea t a l l ,g o t o
step 5. lf it cranksthe engine erraticallyor too
slowly, go to step 7. lf it won't disengagefrom the
flywheel ring gear when you releasethe key, check
for the following until you find the cause.
. Solenoidplungerand switch malfunction
. Dirty drive gear or damagedoverrunningclutch
5. Make sure the transmissionis in neutral,then
disconnectthe startersubharness1Pconnector(A)
'lP
from the enginewire harness connector(B).
Connecta jumper wire from the batterypositive
'l
terminalto the startersubharness P connector.
L
(cont'd)
4-5
StartingSystem
StarterCircuitTroubleshooting
(cont'dl
ClutchInterlockSwitch Test
1. Disconnect
the clutchinterlockswitch2Pconnector.
4-6
Terminal
\
Cl","f ri"t.tf ."tS""*Jrl
PRESSED
RELEASED
o--
- --o
StarterSolenoidTest
from thestarter
1. Disconnect
the S andlvlconnectors
solenoid.
et
4-7
StartingSystem
Starter PerformanceTest
1 , Disconnectthe wires from the S terminal and the M
termrnal.
90 A or less (Electriccurrent),
ot more
4-8
Starter Replacement
1. Make sure you havethe anti-theftcode for the radio.
then write down the frequenciesfor the radio's
presetbuttons.
2. Disconnectthe negativecablefrom the batteryfirst,
then disconnectthe positivecable.
{ B )f r o mt h eS t e r m i n a l .
10x 1.25mm
44N.m{a.5kgf.m,33lblft)
3. Disconnectthe knocksensorconnector.
4. Removethe bolt (A) securingthe harnessbracket,
then removethe intakemanifold bracket(B).
A
6x1,0mm
12 N.m {1.2kgf.m,
8.7 tbt.ft)
8 x 1 . 2 5m m
9Nm
10.9kgf.m,7 lbl ft)
S'-12x12smm
6ilNm
{ 6 . 5k g l m , 4 7 l b f f t )
I
Connectthe positivecable and negativecableto
the batterY.
4-9
StartingSystem
Starter Overhaul
Disassembly/Reassembly
STARTERSOLENOID
@
@
----_2<-
,--\
rw.h
\:!@a
,/ 1(-\
SOLENOIDLEVER
- @-A
-z\hsc6
b-.-
,"
OVERRUNNING
CLUTCHASSEMBLY
o*"lu*.
7:- o
S#o
V*rN*
A*@
\#.
\
c^)* -#""Jli[X:""
a<-4
-v t^ fr/ /
ffiA
9\:-/
ffitr
D lW
,..
END COVER
'!4/
t/
BRUSHHOLDER
\ r
4- 10
\
Armature Inspection and Test
Commutator Diameter
Standard(Newl: 28.0mm (1.10in.l
ServiceLimit: 27.0 mm (1.06in.)
?.-
(cont'd)
4-11
StartingSystem
StarterOverhaul(cont'dl
7. Checkthe mica depth (A).lf the mica is too high {B),
undercutthe mica with a hacksawbladeto the
properdepth.Cut away allthe mica (C)between
the commutatorsegments.The undercutshould
not be too shallow,too narrow,or V-shaped(D).
M
\
4-12
Brush Length
Standard{New): 14.0-14.5 mm (0.55-0.57 in.)
9.0 mm {0.35 in.)
Service Limit:
15. Insen the brush (A) into the brush holder,and bring
the brush into contactwith the commutator,then
attacha spring scale(B)to the spring (C).Measure
the spring tensionat the moment the spring lifts off
the brush.lf the springtension is not within
specification,replacethe spring.
Spring Tension: 13.7-17.7 N {1.40-1.80 kgf,
3.09 3.97lbf)
(cont'd)
4-13
StartingSystem
StarterOverhaul(cont'dl
Planetary Gear Inspection
Starter Reassembly
1 6 . C h e c kt h e p l a n e t a r yg e a r s( A )a n d r i n g g e a r{ B ) .
Replacethem if they are worn or damaged.
OverrunningCluich Inspection
17. Slidethe overrunningclutchalong the shaft.
Replaceit if it does not slide smoothly.
18. Rotatethe overrunningclutch(A) both ways.
Doesit lock in one directionand rotatesmoothly in
reverse?lf it does not lock in eitherdirectionor it
locksin both directions,replaceit.
21 l n s t a l l t h ea r m a t u r ei n t h e h o u s i n ga, n d i n s t a l l t h e
brush holder.Next, pry backeach brush spring
a g a i n ,a n d p u s ht h e b r u s hd o w n u n t i li t s e a t s
againstthe commutator,then releasethe spring
againstthe end of the brush.
s
1 9 .lf the starterdrive gear (B) is worn or damaged,
replacethe overrunningclutch assembly;the gear
is not availableseparately.
Checkthe conditionof the flywheel ring gear.
Replaceit if the starterdrive gear teeth are
oamageo.
i.-
4-14
lgnition System
ComponentLocationIndex
SPARK
PLUG
page4-'19
Inspection,
IGNITION
COIL
page4-17
lgnitionTimingInspection,
page4-18
Removal/lnstallation,
4-15
lgnition System
(
GircuitDiagram
'No.20lOA)
:USAmo&l
No.Al50A):Cmrda
model
UNDEBHOOD
FUST/8TIAY
M)(
lG1tioT in 0N {ll)
rd SIARIilll)
4-16
"SCS" menu
{seethe testeroperator'smanual),
4-17
lgnition System
lgnitionCoilRemoval/lnstallation
1. Removethe ignition coil cover (A),then removethe
i g n i t i o nc o i l s( B ) .
6x1.0mm
4-18
---a
SparkPlug Inspection
1 . Inspectthe electrodesand ceramicinsulator.
Burned or worn electrodes may be caused by:
. Advancedignitiontiming
. Loosespark plug
. Plug heat rangetoo hot
.Insufficientcooling
f .lmpropergap
I
J.Oil-touling
. Cs6on deposits
'r- 1I . Crackedcenter
\ electrodeinsulator
1.0 1.1 mm
{0.039-0.0 in.)
1.3 mm {0.051in.l
4-19
GhargingSystem
ComponentLocationIndex
CHARGING
SYSTEMINDICATOR
(ln the gaugeassembly)
q*o
BATTERY
Test,page22-50
DRIVEBELT
page4 26
Inspection,
page4 26
Replacement,
4-20
ALTEBNATOR
page4-22
Troubleshooting,
page4-29
Replacement,
page4-30
Overhaul,
CircuitDiagram
'flo.
{l0Al :uSAhod.l
ilo.20l50Al:C.n.d.mod.l
UNDTRXOOD
FUSI/RILAY
MX
+--,
I fmlil*t"t'
T-
+ilt
= l
4-21
GhargingSystem
ChargingCircuitTroubleshooting
lf the chargingsystem indicatordoes not come on or
does not go off, or the batteryis dead or low, test these
items in the order listedbelow:
Battery(seepage 22-50)
Chargingsystem indicator
Alternatorand regulatorcircuit
Alternatorcontrol system
IBLK/YEL}
ChargingSystemIndicatorTest
1 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
Does the chatging system indicator come on?
YES Go to step 2.
Wiresideof femaleterminals
NO Go to step 3.
ls there battery voltage?
2. Startthe engine.
YES-Go to step 7.
Does the charging system indicator go off?
YES-Charging system indicatorcircuitis OK. Go
to the Alternatorand RegulatorcircuitTest.t
N O - C h e c k f o r a b l o w nN o . 4{ 1 0 A )f u s e i n t h e
under-dashfuse/relaybox. lf the fuse is OK, repair
open in the wire betweenthe alternatorand the
under-dashfuse/relaybox.I
NO-Go to step 3.
9 . Checkcontinuitybetweenthe ECMconnector
ls the multiplex control system OK?
YES Go to step 5.
t e r m i n a lB ' 1 0a n d e n g i n ew i r e h a r n e s s6 Pc o n n e c t o r
t e r m i n a lN o . 6 .
ECM CONNECTOB A (24P)
L (WHT/BLUI
W i r e s i d eo f f e m a l e t e r m i n as
ls there continuity?
YES Go to step 10.
NO-Repair open in the wire betweenthe
a l t e r n a t oar n dt h e E C N 4 . I
4-22
\"4
'10.
Checkcontinuitybetweenthe ECMconnector
t e r m i n a l8 1 0 a n d b o d y g r o u n d .
ECMCONNECTOR
S I24PI
2 3 t 4t 5
8 I 10 ,/1,/ 3
1 1 8 ,N nt,/ 21
6 7
15
23
ACGL(WHT/BLUI
t1'
ls there continuity?
YES- Repairshort to ground in the wire between
the ECMand the enginewire harness6P connector.
t
NO-Go to alternatorand regulatortest.
20 V (accuratewithin
(cont'd)
4-23
GhargingSystem
(cont'd)
ChargingCircuitTroubleshooting
6. Startthe engine.Hold the engineat 3,000rpm with
no load (in Neutral)until the radiatorfan comes on,
then let it idle.
7. Raisethe engine speedto 2,000rpm, and hold it
there.
8. Turn the headlights(high beam)on, and measure
voltageat the under-hoodfuse/relaybox terminal.
ls the voltagebetween 13.9and 15.1v?
YES-Go to step 9.
'13.5V.
BATTERY
YES-Alternator/regulatoroperationis OK.I
NO Repairor replacethe alternatorcomponents
(seepage 4-30).1
C {WHT/GRN)
ENGINE
WIREHARNESS
6PCONNECTOR
Wiresideof femaleterminals
ls there 1 V or less?
YES Go to step 8.
N O - G o t o s t e p5 .
5 . T u r nt h e h e a d l i g h t a
s n d i g n i t i o ns w i t c hO F F .
6 . DisconnectECMconnectorB (24P).
\,
4-24
\
7, Checkfor continuitybetweenECMconnector
t e r m i n a l8 1 8 a n d b o d y g r o u n d .
ECM CONNECTORB {24PI
1 2 3 t 4t 5
8 9 10 ,/1,/ 3
nt,/21
11o
6 1
5
23
ACGC{WHT/GRN}
1 2 3 1 4 l 5 l l6l 7
8 9 10
15
t.)
11o
21 23
ACGC(WHT/GRN)
C (WHT/GRN)
2
ENGINEWIREHARNESS6P CONNECTOR
Wire side oI lemale terminals
ls there continuity?
ls therc continuity?
YES-Repair short to ground in the wire between
the alternatorand the ECM.I
4-25
ChargingSystem
DriveBelt Inspection
indicator(A)is withinthe
Checkthatthe auto-tensioner
(B)
range
as
shown.
lf
it is out of thestandard
standard
range,replacethedrivebelt(seepage4-26).
DriveBelt Replacement
1, Move the auto-tensioner(A) to relievetensionfrom
the drive belt (B).and removethe drive belt.
4-26
DriveBelt Auto-tensionerInspection
1 . Checkwhether there is a changein the positionof
the auto-tensionerindicatorbeforestartingthe
engineand after startingthe engine.lf there is a
c h a n g ei n t h e p o s i t i o nr, e p l a c et h e a u t o - t e n s i o n e r .
C h e c kf o r a b n o r m a n
l o i s ef r o m t h e t e n s i o n e p
r ulley.
lf abnorman
l o i s ei s h e a r d ,r e p l a c et h e t e n s i o n e r
pulley.
4-27
ChargingSystem
DriveBelt Auto-tensionerReplacement
1. Removethe drive belt (seepage 4'26).
4. Removethe auto-tensioner,
2 . R e m o v et h e i d l e rp u l l e y .
6xl.0mm
9.8 N.m
(1,0kgl.m,
7.2 tbf.ft)
6x1,0mm
12 N.m
('1.2kgt.m.8.7lbt.ft)
x 1.25mm
22 N.m
3. Removethe tensionerpulley.
8 x 1.25mm
22 N.m (2.2kgf.m, 16lbt.ft)
5. lnstall in the reverse order of removal.
4-28
\-a
l\-
AlternatorReplacement
1. Make sure you havethe anti-theftcode for the radio,
then write down the frequenciesfor the radio's
preset buttons,
2. Disconnectthe negativecablefrom the batteryfirst,
then disconnectthe positivecable.
9 . Removethe alternator.
1 0 . Installthe alternatorand drive belt in the reverse
order of removal.
'I
1 . Connectthe positivecable and negativecableto
the battery.
4-29
ChargingSystem
AlternatorOverhaul
ExplodedView
ROTOR
W|UF.,.oy." REARBEARING /
\
,/
FRoNrBEARING
B
./
@b.J.y{=RE+LN'"'
I/
vVFko"-% \
qtr*njlv
V ("rV) ,
BRUSH
HOLOER
TNSULATOR
\
\-
BRUSH
HOLDER
\
\
VOLTAGE
REGULATOR
\11
-\\
\l
}
(-
@*F,-\:
\
PULLEY
/
\
PULLEY
LOCKNUT
/@
v_re*^i
\gP^@'I
*ffilw9
TERMINAL
INSULATOR
REARHOUSING
ASSEMBLY
INSULATOR
BUSHING
4-30
\-a
L
Special Tools Required
. Driver07749-0010000
. Attachment,52x 55 mm 07746-0010400
5 . R e m o v et h e e n d c o v e r( A )a n d d u s t s e a l{ B ) .
, (( , t tI
; r _l L t
L1i.21---^
tqLJ
Removethe harnessbracket(A),insulator(B).three
flange nuts (C),and the screw (D),then removethe
p l a t et e r m i n a l( E ) .
B-"--|.
1!q[-dr,:l
(cont'd)
4-31
ChargingSystem
AlternatorOverhaul(cont'dl
7. Removethe four screws,then removethe rectifier
( A )a n d f o u r i n s u l a t o r (sB ) .
the frontbearingand/or
9. lf you arenot replacing
'16.
rearbearing,go to step Removethe rotorfrom
the statordriveendhousing.
o\
. l f e i t h e r t h er o t o r o r s t a t o r h o u s i n g
isdamaged,
replacethe alternator,
. lf both the rotor and the stator housingare OK,
g o t o s t e p1 1 .
'l
\"
1 . R e m o v et h e r e a rb e a r i n gu s i n ga p u l l e ra s s h o w n .
f.r,e
4-32
\1 2 . W i t h a h a m m e ra n d c o m m e r c i a l l a
yvailable
tools
shown, installa new rear bearingon the rotor shaft.
NOTE:Installthe bearingusing the inner race.
1 5 . W i t h a h a m m e ra n d t h e s p e c i a l t o o l si ,n s t a l a
l new
front bearingin the stator housing.
13. Removethe front bearingretainerplate.
sH
6
u
qE
e
s
07749-0010000
f-\
\r-:1
\s---'^/
07746-0010400
( c o n t ' d)
4-33
ChargingSystem
AlternatorOverhaul(cont'd)
Rectitier Test
1 7 . M e a s u r et h e l e n g t ho f b o t h b r u s h e s( A ) w i t ha
v e r n i e rc a l i p e r{ B ) .
. l f e i t h e rb r u s hi s s h o r t e r t h a n t h es e r v i c el i m i t ,
r e p l a c et h e b r u s ha s s e m b l y .
. lf brush length is OK, go to step '18.
Alternator Brush Length:
Standard(New): 10.5mm (0.41in.)
ServiceLimit: 1.5 mm (0.06in.)
/--:',t-L
-o \--
. -l'-=
\"
Rotor Slip Bing Test
18. Checkthat there is continuitybetweenthe slip rings
{A).
. lf there is continuity,go to step 19.
. lf there is no continuity,replacethealternator.
B P "
P,
P.
P,
P.
4-34
\r'a
Stator Test
20. Checkthatthereis continuitybetweeneach pair of
leads(A).
lf there is continuity,go to step 21.
lf there is no continuity,replacethe alternator.
'--l-- --i
2 1 .Checkfor no continuitybetweeneach lead and the
coil core (B).
. lf there is no continuity,goto step 22.
. lfthere is continuity,replacethe alternator.
4-35
GruiseControl
ComponentLocationIndex
CRUISECONTROLINDICATOR
(Builtinto gaug6assembly)
CLUTCH
PEDALPOSITION
swtTcH
Test,page4-45
ClutchPedalAdjustment,
page12-4
CRUISECONTROLUNIT
lnputTest,page4-40
BRAKEPEDALPOSITION
SWITCH
Test,page22-84
page'19-6
PedalHeightAdjustment,
t.-
CRUISE
CONTROL
ACTUATOR
Test,page4'43
page4-44
Replacement,
4-36
_,-
ACTUATORCABLE
Adjustment,page4-45
\-a
CircuitDiagram
'
fUS'/iILAY IOX
UISEF NOOD
-to
ots
No.aloAl
No.20itoAl
USAnod.l
C.md! modrl
BU/YIL
lcl H0Tii0llilll
mdSTARTlllll
1 Honilsffroi
1
uNtT
cnu6EcoNTnoL
3
l0
CTuICIIPEDAL
P0sm0swtrct
4-37
CruiseControl
Symptom TroubleshootingIndex
NOTE:
' The numbersin the table showthetroubleshootingsequence.
. Beforetroubleshooting.
- checkthe No, 10 (7.5A)and No. 4 (10A)fuses in the under-dashfuse/relaybox. and the No. 7 (15A)
fuse in the
under-hoodfuse/relaybox,
- checkthat the horn sounds.
- checkthe tachometerto see if it works properly.
- checkthe speedometerlo see if it works properly.
Symptom
Cruisecontrol cannot be
set
Diagnostic procedure
1. Checkmain switch (seepage 4-42)
2. CheckSET/RESUME/CANCEL
switch (seepage 4-42)
3. Test brakepedal positionswitch (seepage 22-84)and check
its adjustment{seepage 19,6)
4. Test clutch pedal positionswitch (seepage 4-45)and check
its adjustment(seepage 12-41
5. Checkcruisecontrol unit {seepage 4-40}
6. Checkvehiclespeed sensor(VSS)(seepage 22-65)
1. Checkcruisecontrolindicatorbulbin gaugeassembly{see
page 22-631
2. Checkcruisecontrolunit(seepage4-40)
ar, 'i.a
c^aa.l
ic
noticeablh
y i g h e ro r
lower than what was set
Excessiveovershooting
or undershootingwhen
trying to set speed
Speedfluctuationon a
flat road with cruise
control set
Vehicledoes not
decelerateor accelerate
accordinglywhen SET/
RESUME/CANCEL
button
is pushed
Set speed does not
cancel(enginerpm stays
h i g h )w h e n c l u t c hp e d a l
is pushed
Set speeddoes not
cancelwhen brakepedal
is pushed
4-38
. Poorground:
G501
. Opencircuit,
looseor
disconnected
t e r mi n a l s :
L TG R N ,
BLI(ORN.
GRY/RED,
BLU.
LTBLU,
BLUAA/HT
. Poor ground:
G501
. Open circuit,
looseor
disconnected
termrnats:
YEL,BLUA/EL
Open circuit,loose
or disconnected
terminals:
GRY/RED,
LT GRN/BLK
Shortto groundin
the LTBLUwire
'1.
2.
g ,
svmptom
Set speeddoes not
cancelwhen main switch
i s o u s h e dO F F
Set speeddoes not
c a n c ew
l henCANCEL
button is pushed
Diagnosticprocedure
1. Checkmain switch (seepage 4-42)
2. Checkcruisecontrol unit (seepage 4-40)
Opencircuit,loose
or disconnected
terminals:
GRYiRED,
LTGRN/BLK
1. CheckSET/RESU
ME/CANCELswitch (seepage 4-42)
2. Checkcruisecontrol unit {seepage 4-40)
Open circuit,loose
or disconnected
terminals:
L TG R N / B L K
4-39
CruiseGontrol
CruiseControl Unit Input Test
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-'13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
1. Disconnectthe 14Pconnectorfrom the control unit.
2. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent, loose,orcorroded, repairthem as necessary,and recheckthesystem.
. lf the terminalslook OK, go to step 3.
Wire sideof
femaleterminals
Wire
Test condition
BRN/WHT Connectbattery
power
BLU
BLK
4-40
lgnitionswitch ON
(ll),main swltch ON
and brakepedal
pressed,then
reteaseo
Test:Desiredresult
Checkthe operationof the
magneticclutch:Clutch
s h o u l dc l i c ka n d o u t p u tl i n k
should be locked.
Checkfor voltageto ground;
There should be 0 V with lhe
pedal pressedand battery
voltagewith the pedal
released.
U n d e ra l l c o n d i t i o n s Checkfor continuityto
grouno:
There should be continuitv
BLIVORN l g n i t i o ns w i t c hO N
Checkfor voltageto ground:
Thereshould be battery
flr)
vottaqe.
WHT/BLK Brakepedal pressed, Checkfor voltageto ground:
then released
There should be battery
voltagewith the pedal
pressed,and 0 V with the
pedal released.
Possiblecause
ifresuhis notobtained
Faultyactuator
P o o rg r o u n d( G 3 0 1 )
An open in the wire
Shon to ground (arcswhen
Doweris connected)
. Faultybrakepedal position
switch
. A n o p e ni n t h e w i r e
. Open in cruisecontrol main
swrtcn
. B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under/dashfuse/relavbox
. P o o rg r o u n d( G 5 0 1 )
. An open in the wire
'
.
.
.
B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under-dashf use/relaybox
An oDenin the wire
B l o w nN o . 7 { 1 5A ) f u s ei n t h e
under-hoodfuse/relaybox
Faultybrakepedal position
SWIICN
A n o D e ni n t h e w i r e
Cavity
11
10
Test condition
Wire
GRYiRED Setbuttonpushed
LT GRN/
BLK
Resumebutton
pusneo
BRN
Connectbattery
BLUIVEL
t e r m i n a la n d g r o u n d
to the BRNIVEL
termrnal
lgnitionswitch ON
0r)
12
BLU/VVHT lgnitionswitch ON
(ll) and main switch
ON; raisethe front of
the vehicle,and
rotateone wheel
s l o w l yw h i l e h o l d i n g
the other wheel
Test:Desiredresult
Checkfor voltageto ground:
Thereshould be battery
voltage,
W h e nt e s t i n gt e r m i n a lN o . 6 ,
there should be no voltageon
t e r m i n a lN o . 7 .
Checkfor voltageto ground:
Thereshould be battery
voltage.
W h e nt e s t i n gt e r m i n a lN o . 7 ,
there should be no voltageon
t e r m i n a lN o . 6 .
Checkthe operationof the
actuatormotor: You should
be able to hear the motor.
Possible
cause
il resultis notobtained
B l o w nN o . 7 ( 1 5A ) f u s e i n t h e
under-hoodfuse/relaybox
Faultyhorn relay
Faultysevresume/cancel
swrtch
Faultycable reel
An open in the wire
Shon to ground (horn sounds
when button is pressed)
. Faultyactuator
. An open in the wire
Attachto groundi
C r u i s ei n d i c a t o lri g h ti n t h e
g a u g ea s s e m b l ys h o u l dc o m e
on.
FaultyVSS
An openin thewire
Shortto ground
B l o w nN o . 4 ( 1 0A ) f u s e i n t h e
under-dashfuse/relaybox
Faultymain switch
An oDenin the wire
Faultyclutch pedal position
swtlcn
P o o rg r o u n d( G 5 0 1 )
Incorrectclutchswitch
adjustment
An open in the wire
13
LTGRN
lgnitionswitchoN
{ l l )a n dm a i ns w i t c h
ON
14
LT BLU
C l u t c hp e d a l
reteaseo
Checkfor continuityto
grouno:
T h e r es h o u l db e c o n t i n u i t y .
N O T E : T h e r se h o u l db e n o
continuitywhen the clutch
oedal is Dressed.
lf any test indicatesa problem,find and correctthe cause,then recheckthe system.lf all the input tests prove OK,
the cruisecontrol unit may be faulty. Substitutea known-goodcruisecontrol unit and retest.lf the system works
properly,replacethe cruisecontrol unit.
4-41
CruiseControl
Main Switch Test/Replacement
Set/Resume/Cancel
Switch Test/
Replacement
\-------11v1
ON
Terminal
'\
\
1
Position
OFF
(9
o @ o \J
;"itl*
sET(ONt
CF
RESUME
ION)
o
o
CANCEL{ON}
--o
--o
r\--
4-42
CruiseControlActuatorTest
1. Disconnectthe 4P connector(A) from the cruise
control actuator(B).
Output linkageposition
FULt MIDDLEFUtL
OPEN
CLOSE PO$TION
The
The
The
No.3
No,4
Terminal Terminal motor motor motor
runs. runs. stoDs,
The
The
The
No.3
N o .4
Terminal Terminal motor motor motor
sIoos. runs. runs.
OUTPUTLINKAGE
FULLCLOSE
4-43
CruiseControl
CruiseControlActuator/CableReplacement
1 . Fully open the cruisecontrol link by hand,then
removethe cruisecontrol cable{A) from link.
Loosenthe locknut(B),and removethe cablefrom
the bracket.
6x1,0mm
12 N.m (1.2kgf.m,8.7lbf.ft)
\rla
4-44
ActuatorCableAdiustment
1. Checkthat the actuatorcable{A) moves smoothly
with no binding or sticking.
ClutchPedalPositionSwitch Test
1. Disconnectthe 2P connectorfrom the clutch pedal
positionswitch (A),
SWITCH2PCONNECTOR
CLUTCHPEOALPOSITION
T e r m i n a l s i do
ef
m a l et e r m i n a l s
2. Startthe engine.
3. Measurethe amount of movementof the output
linkage(B) until the engine speedstartsto increase.
At first, the output linkageshould be locatedat the
fully closedposition(C).The free play (D)should be
3 . 7 5 1 0 . 5m m ( 0 . 1 5 1 0 . 0 2i n , ) .
4. lf the free play is not within specs,loosenthe
locknut(E).and turn the adjustingnut (F)untilthe
free play is as specified,then retightenthe locknut
PRESSED
RELEASED
4-45
EngineAssembly
EngineRemoval
Special Tools Required
FrontsubframeadapterEOS02C00001
1
NOTE:
. Usefender coversto avoid damagingpainted
surfaces.
. To avoid damage,unplug the wiring connectors
carefullywhile holdingthe connectorportion.
. Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
\,
6. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),removethe breatherhose (B)and
v a c u u mh o s e( C ) ,t h e n r e m o v et h e a i r c l e a n e r
housingcover/intakeair duct assemblv(D).
II
5-2
7 . R e m o v e t h e a i r c l e a n e rh o u s i n g .
1 1 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
1 2 . R e m o v et h ef u e ll i n e ( s e e p a g e l l - 1 4 9 ) .
13. Removethe evaporativeemission(EVAP)canister
hose {A) and brakeboostervacuum hose (B).
(cont'd)
5-3
EngineAssembly
..4,
EngineRemoval(cont'dl
1 4 . R e m o v et h e c l u t c hs l a v ec y l i n d e r{ A )a n d c l u t c h l i n e
bracketmounting bolt (B).
't7. Remove
the harnessclamps (A) and grommet (B),
t h e n p u l l t h ee n g i n ew i r e h a r n e s st h r o u g ht h e
bulkhead.
\l,
5-4
o@
2 4 . L o o s e nt h e d r a i np l u g i n t h e r a d i a t o r t od r a i nt h e
enginecoolant(seepage 10-6).
2 5 . D r a i nt h e t r a n s m i s s i ofnl u i d ( s e ep a g e1 3 ' 3 ) .
26. Drainthe engineoil {seepage8-5).
2 7 . D i s c o n n e ct h
t e s t a b i l i z el ri n k s( s e ep a g e1 8 - 1 8 ) .
28. Disconnectthe suspensionlower arm ball joints
( s e es t e p3 o n p a g e1 8 - 1 9 ) .
29. Removethe driveshafts{seepage 16-3).Coat all
precision
f i n i s h e ds u r f a c e sw i t h c l e a ne n g i n eo i l .
Tie plasticbags over the driveshaftends.
(cont'd)
5-5
EngineAssembly
EngineRemoval(cont'd)
32. Lowerthe hoist.
33. Removethe upperhose(A)andheaterhoses(B).
5-6
36. Removethetransmission
mountbracketsupport
boltandnuts.
(.g
\a
40. Removethefrontmountbracketmountinqbolt.
(cont'd)
5-7
EngineAssembly
EngineRemoval(cont'd)
43. Use a markerto make alignmentmarks on the
referencelines(A) that align with the centersof the
r e a rs u b f r a m em o u n t i n gb o l t s( B ) .
!:_- _l.=
:r
--
---.-','-
ffi4
ffit'"
5-8
Enginelnstallation
Special Tools Required
FrontsubframeadapterEOS02C00001
1
1. lnstallthe accessorybrackets,and tighten their bolts and nuts to the specifiedtorques.
ENGINEMOUNTBRACKET
1 0x 1 . 2 5m m
il4 N.m {4.5kgf.m,33lbl.ft)
A/C COMPRESSOR
BRACKET
10 x 1,25mm
44 N.m {4.5kgf.m,33lbt.ft)
(cont'dl
5-9
EngineAssembly
EngineInstallation(cont'd)
Positionlhe engine under the vehicle.Attachthe
chain hoistto the engine,then lift the engine into
p o s i t i o ni n t h e v e h i c l e .
Reinstallthe
m o u n t i n gb o l t s / s u p p o rntu t si n
the sequencegiven. Failureto follow this
sequencemay causeexcessivenoiseand
vibration,and reducebushinglife.
- - -.'.: -
--=---=--
.-..'tt-
---:- -
6r"
1 4 x 1 . 5m m
103Nm
{ 1 0 , 5k g f m .
76 rbt.ftl
Replace.
6-_-'-
l 0 x 1 . 2 5m m
59 N.m (6.0 kgf.m, 4:] lbI.ft)
5 - 10
'l '1.
' t 2 . Tighten
the front engine mount bracketmounting
bolt.
12x 1.25rnrn
64 N.m{6.5kgf.m,
47 tbt.ftl
:l
5-11
EngineAssembly
EngineInstallation{cont'dl
1 8 . Connectthe suspensionlower arm ball joints (see
s t e p6 o n p a g e1 8 - 1 9 ) .
1 9 . Connectthe stabilizerlinks (seepage 18-18).
2 3 . I n s t a l l t h es p l a s hs h i e l d .
-t-
-- -
-- --r
-d
,ry
6\
\
8 x 1.25mm
22N.m |.2.2kglm,
16tbt.ft)
v
5-12
Pushthe enginecontrolmodule(ECM)connectors
through
t h eb u l k h e a tdh, e ni n s t a l l t hger o m m e(tA ) .
3 1 .Installthe throttlecable (seepage 11-164),then
a d j u s t t h ec a b l e{ s e ep a g e1 1 - ' 1 6 3 ) .
2 9 . I n s t a l l t h eh a r n e s sc l a m p s( B ) .
3 4 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
(cont'd)
5-13
EngineAssembly
EngineInstallation{cont'dl
\"
6x1.0mm
12Nm{1.2kgt.m,
8.7rbf.ft)
"-.----->)
"------'6
I n s t a l l t h eg r o u n dc a b l e( C ) .
3 9 . I n s t a l l t h ei n t a k ea i r d u c t .
6x1.0mm
12Nm{1.2kgf.m,
8.7 tbf.ft)
I n s t a ltlh e c l u t c hs l a v ec y l i n d e r( A )a n d c l u t c hl i n e
bracketmounting bolt (B).
8 x '1.25mm
24 N.m (2.4kgl.m,
5-14
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft)
\-
4 0 . I n s t a ltlh e a i r c l e a n e rh o u s i n q .
4 3 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm
12 N m (1.2kgf.m,8.7lbt.ft)
6x1.0mm
12Nm11.2kgf.m.
8.7 tbf.ft)
4 1 . I n s t a ltl h e a i r c l e a n e rh o u s i n gc o v e r( A )a n d
connectthe intakeair temperature(lAT)sensor
connector(B),
5 0 . P e r f o r mt h e e n g i n ec o n t r o lm o d u l e( E C M )i d l el e a r n
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
5 1 . Inspectthe idle speed (seepage 11-138).
52. I n s p e ctth e i g n i t i o nt i m i n g ( s e ep a g e4 - 1 7 ) .
5 3 . C h e c kt h e w h e e la l i g n m e n {t s e ep a g e1 8 - 4 ) .
54. Enterthe anti-theftcode for the radio,then enter
the customer'sradio station presets.
55. Set the clock.
5-15
EngineMechanical
CylinderHead
SpecialTools
6-2
Comoonent
LocationIndex
6-3
EngineCompression
Inspection
b-t'
VTECRocker
Arm Test ...........
............
6-7
VTCActuatorInspection
....................
6-8
ValveClearance
Adjustment
.............
6-9
Crankshaft
PulleyRemovaland Installation..............
6-11
C a mC h a i nR e m o v a l
. . . . . . . . . . . . . . . . . . .6. -. 1
. .2. . . .
C a mC h a i nI n s t a l l a t i o n
. . . . . . . . . . . . . . . .6. .-.1. .5. .
Auto-Tensioner
Removal/1nsta11ation
.........................
6-19
ChainCaseOil SealInstallation
........6-21
CyfinderHeadCoverRemoval
..........
6-22
CylinderHeadRemoval
.....................
6-23
WC Actuator.ExhaustCamshaftSorocket
R e paf c e m e n t
.........6-24
Head
Cylinder
Inspection
for Warpage......................
6-25
Rocker
Arm AssemblyRemoval.................................
6-26
Rocker
ArmsandShafts
Disassembly/Reassembly
..............
6-27
Rocker
ArmsandShaftsInspection............................
6-28
Camshaft
Inspection
..........................
6-29
Valves,Springs,andValveSealsRemoval................
6-31
ValveInsoection......................
...........
6-32
ValveStem-to-Guide
Clearance
Insoection...............
6-32
ValveGuideReolacement
.................
6-33
ValveSeatReconditioning
................
6-35
Valves,Springs,
andValveSealsInstallation............
6-37
Rocker
Arm AssemblvInstallation
.... 6-38
C v l i n d eHr e a dI n s t a l l a t i o.n. . . . . . . . . . . . . . . . . . . . . . . . . . . .6. -. 3
. .9. . . . . . . . . .
CylinderHeadCoverInstallation
......6-41
CylinderHead
SpecialTools
O
.D
o
@
o
G)
E]
O
tro
@
(D
ozoa
I oz..rae-oot
07JAB-0010204
07NAB-0010404
07VAE-001010A
OTZAJ.PNAAlOO
OTZAJ-PNAA2OO
I 07ZAJ-PNAA300
07742-0010100
07746-001o4oo
07749-0010000
l-:
,.
''
,.-/
a:-t'"
,)
r--\
Lq-,
',..)-)--'
- 1jr-
r-
..'.,i2
.<:'':'v''
5'r'
..#
..a:-"
- -- -i
'a- ti--
,-
1
1
1
1
1
1
2
1
1
Regulator
Air Pressure
V a l v eG u i d eR e a m e r5, . 5m m
Socket,19 mm
H o l d e rH a n d l e
HolderAttachment,50 mm
Valve Spring CompressorAttachment
VTECAir Adapter
VTECAlr Stopper
Air Joint Adapter
V a l v eGu i d eD r i v e r , 5 . 5m m
Attachment,52 x 55 mm
Driver
OTAAJ.PNAA'IOO
OTHAH-PJ7O1OB
--
Oty
Description
Tool Number
Ref. No.
/":
l?
-- -'''
't'tY-,l
a,/'/'
6-2
OD
ComponentLocationlndex
IGNITIONCOIL
COVER
CYLINDER
HEAD
COVER
page6-22
Removal,
page6-41
lnstallation,
CAM CHAIN
Bemoval,page6-'12
Installation,page6-15
frn
"p
CAM CHAINGUIDEB
| ] t J,
CAM CHAINGUIDEA
VALVE
VARIABLE
TIMINGCONTROL
twc) olL soLENotD
VALVE
PULLEY
CRANKSHAFT
R e p l a c e m e npt a
, g e6 1 1
TENSIONER
ARM
AUTO.TENSIONER
page6-'lI
Replacement,
O-RING
(cont'd)
6-3
CylinderHead
ComponentLocationIndex(cont'd)
CAMSHAFT
HOLDER
Fg
Y f\
R
LI T
fr
F]
CAMSHAFTPOSITION
ICMP}SENSOR
EEI
g-----
CAMCHAIN
GUIDEB
-"-oowetew
TOPDEADCENTER
(TDC)SENSOR
EXHAUSTCAMSHAFT
SPROCKET
Removal,page6 24
page6-25
Installation,
EXHAUSTCAMSHAFT
ROCKER
ARM
ASSEMBLY
Overhaul,page6 27
Inspection,page 6-28
6-4
.\
ll"
--.i
SPRING
RETAINER
vALvE
EXHAUSTVALVE
SEAL
.""or", uo.u,
,H
>il(
d:l.\
aFl
T1
l l
l* I / uo.ur.r","o l l
\ l gg
| |
II
vALVE
-/ TNTAKE
^-'--
I I
U-
tl
Y
EI 1.U
spntruc
.--
G\-r_
9E4L
Replacement,
Page6-31
H e ,
|NTAKEVALVE
GUIDE
page6-33
Replacement,
_-/
,p
2bw
9)
\*""'RArNERcovER
wcsrRArNER
HEATSHIELD
HEAD
CYLINDER
Removal,page6'23
Inspection,page6-25
Installation,page6-39
EXHAUSTVALVE
Removal,page6-31
Installation,page6-37
INTAKEVALVE
Removal,page6 31
Installation,page6 37
CYLINDER
HEAD
GASKET
6-5
CylinderHead
EngineCompressionInspection
1 . W a r m u p t h e e n g i n et o n o r m a lo p e r a t i n g
temperature(coolingfan comes on).
\
9 . Open the throttlefully, then crankthe enginewith
the startermotor and measurethe compression.
Compression Pressure
Above 930 kpa (9.5 kgf/cm', 135 psi)
\-
V,
6-6
WEC RockerArmsTest
Special Tools Required
. Air pressureregulator07AAJ-PNAA100
. VTECair adaoter07ZAJ-PNAA100
. WEC air stoDoer07ZAJ-PNAA200
. Air joint adapter07ZAJ-PNAA300
1. Removethe cylinder headcover (seepage 6-22).
2. Set the No. 1 pistonat top dead center(TDC)(see
step 1 on page6-12).
3. Verify that the intakeprimary rockerarm (A) moves
independentlyof the intakesecondaryrockerarm
(B).
D
OTZAJ-PNAA3OO
OTZAJ.PNAAlOO
(cont'd)
6-7
CylinderHead
WEC RockerArms Test (cont'dl
'10.
VTGActuator Inspection
'11.
Removethe cylinder headcover (seepage 6-22lr.
2. Removethe auto-tensioner(seepage6-19).
3. Loosenthe rockerarm adjustingscrewslsee step 2
on page6-26).
4. Removethe camshaftholder (seestep 3 on page 6-
26t.
5. Removethe intakecamshaft.
6, Checkthat the variablevalve timing control (VTC)
actuatoris lockedby turning the VTCactuator
clockwiseand counterclockwise.
lf the VTC actuator
is not locked,replacethe VTCactuator.
7 . S e a lt h e a d v a n c eh o l e s( A ) a n dr e t a r dh o l e s( B )i n
the No. 1 camshaftjournal with tape.
1 2 .Removethe specialtools.
1 3 .Tightenthe camshaftholder mounting boltslo
22N m 12.2kgf.m, 16 lbf.ft).
1 4 . T i g h t e nt h e s e a l i n gb o l t t o 2 0 N . m ( 2 . 0k g f . m ,
14 tbf.ft).
t5.
6-8
I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
ValveGlearanceAdiustment
9. Apply air to the advancehole to releasethe lock.
{cont'd)
6-9
GylinderHead
ValveClearanceAdjustment (cont'd)
3. Selectthe correctthickness
feelergaugefor the
valvesyou'regoingto check.
Intake: 0.21 0.25mm (0.008-0.010
in.)
Exhaust; 0.28 0.32mm (0.011 0.013in.)
\.
5 . l f y o u f e e lt o o m u c h o r t o o l i t t l e d r a g ,l o o s e n t h e
locknut(A),and turn the adjustingscrew {B) until
the drag on the feelergauge is correct..
Adiustingscrew locations:
EXHAUST
No. 1
No. 1
N o .2
No.3
N o .4
No.4
s c r e w( B )a n d t h e e n d o f t h e v a l v es t e m ,a n d s l i d ei t
backand forth; you should feel a slight amount of
d rag.
t.
\-
6-10
CrankshaftPulleyRemovaland
Installation
9. Rotatethe crankshaft180"clockwise(camshaft
pullevturns 90').
Special Tools Required
. Holder handle07JAB-001020A
. Holderattachment,50 mm 07NAB-001040A
. Socket,19 mm 07JAA-001020,4
or a commercially
a v a i l a b l e1 9 m m s o c k e t
Removal
1. Removefront tires/wheels.
2. Removethe splashshield (seestep 23 on page 5-5).
3 . H o l dt h e p u l l e yw i t h h o l d e rh a n d l e( A )a n d h o l d e r
attachment(B).
B
07NAB-001040A
el
/
f
/ Srroo.oo,oroo
(or
commercially
available)
(cont'd)
6-11
CylinderHead
CrankshaftPulleyRemovaland
Installation(cont'dl
CamChainRemoval
Installation
1. Cleanthe crankshaftpulley (A),crankshaft(B),bolt
(C).and washer (D).Lubricateas shown below.
. .: Clean
O; Lubricate
ll
ll
t[] rL
-'....-----=a
(-,
5U-1J
It
t -
3 . R e m o v et h e s p l a s hs h i e l d .
- , , - - . = . - - - - - _ _ - - _
B
07NAB-0010iroA
A
07JAB-001020A
I n s t a ltl h e s p l a s hs h i e l d( s e es t e p2 0 o n p a g e5 - 1 2 ) .
5 . Install front tires/wheels.
\-
6-12
7. Disconnectthecrankshaftposition(CKP)sensor
connector{A) and variablevalvetiming control
{VTC)oil control solenoidvalve connector(B).
1 1 . R e m o v et h e s i d ee n g i n em o u n tb r a c k e t .
1 2 . R e m o v et h e c h a i nc a s e .
(cont'd)
6-13
CylinderHead
CamChainRemoval(cont'd)
Looselyinstallthe crankshaftpulley.
\
16. Removethe auto-tensioner.
1 7 . R e m o v et h e c a m c h a i ng u i d eB .
gffi
llll
t5.
U U
\-
6- 14
CamChainInstallation
1 8 . R e m o v et h e c a m c h a i ng u i d eA ( A )a n d t e n s i o n e r
a r m( B ) .
t./6. | \
{n$1J;
,o
g"'1 9 . R e m o v et h e c a m c h a i n .
(cont'd)
6-15
GylinderHead
CamChainInstallation(cont'dl
3. Installthecamchainon the crankshaft
sprocket
with thecoloredpiece(A)alignedwiththe punch
mark(B)on the crankshaft
sprocket.
5 . I n s t a l l t h ec a m c h a i ng u i d eA ( A )a n d t e n s i o n ear r m
(B).
6x1.0mm
1 2N . m
{1,2kgf.m,
8.7 tbf.ftt
'6I
8 x 1 . 2 5m m
22 N.m
12.2kgt.m,
16tbf.ft)
6. Installthe auto-tensi
a
6x1,0mm
12Nm
(1.2kgt.m,8.7 lbf ti)
a
6-16
7 , I n s t a ltlh e c a m c h a i ng u i d eB .
8 x 1.25mm
22 N.m
(2.2kgf.m,16lbt.ft)
H4
\ilt
H g
(cont'd)
6-17
GylinderHead
CamChainInstallation(cont'd)
'15.
1 6 . l n s t a l l t h es i d ee n g i n em o u n t . b r a c k e t .
rbf.ft)
',.9
6x1.0mm
1 2N . m
(1.2kgt.m.8.7lbf.ft)
6x1.0mm
12Nm
(1.2kgf.m,8.7lbf.ft)
1 2 x 1 . 2m
5m
54 N.m
(5.5 kgt m, 40 lbf.ft)
1 8 . I n s t a ltl h e g r o u n dc a b l e( B ) .
\-
6-18
Auto-TensionerRemovaU
lnstallation
1 9 . lnstallthe variablevalve timing control (VTC)oil
c o n t r o ls o l e n o i dv a l v e( s e es t e p 1 o n p a g e1 1 ' 1 2 7 ) .
Removal:
20. Connectthe crankshaftposition(CKP)sensor
connector{A) and VTC oil control solenoidvalve
connector(B).
1 . R e m o v et h e c h a i nc a s ec o v e r .
2 2 . I n s t a l l t h ec y l i n d e rh e a dc o v e r( s e ep a g e6 - 4 1 ) .
2 3 . I n s t a l l t h ed r i v eb e l t .
2 4 . I n s t a l l t h es p l a s hs h i e l d .
D@
{cont'd)
6-19
GylinderHead
Auto-TensionerRemoval/lnstallation(cont'dl
3. Align the holes on the lock (A) and the autot e n s i o n e (r B ) ,t h e n i n s e r ta 1 . 5m m ( 0 . 0 6i n . )
diameterpin (C)into the holes.Turn the crankshaft
clockwiseto securethe oin.
4. Removethe auto-tensioner.
Installation:
1. Installthe auto-tensioner.
6x1.0mm
12 N.m {1.2kgt.m,8.7 lbt.tt)
Remove the pin from the auto-tensioner.
\-
6-20
ChainCaseOil SealInstallation
Removeold liquid gasketfrom the chain casecover
mating surfaces,bolts,and bolt holes.
SpecialToolsRequired
. Driver07749-0010000
. Attachment,52 x 55 mm 07746-0010400
1 . U s et h e s p e c i atl o o l st o d r i v ea n e w o l l s e a l
squarelyinto the chain caseto the specified
i n s t a l l e dh e i g h t .
07749-0010000
6 . I n s t a l l t h ec h a i nc a s ec o v e r .
Oil Seal InstalledHeight:
3 3 . 0 - 3 3 . 7m m ( 1 . 3 0 -1 . 3 3i n . )
6x1.0mm
1 2N . m
{1.2kgt.m,
8.7 tbf.ft)
33.0 33.7mm
{ 1 . 3 0 1 . 3 3i n . l
6-21
GylinderHead
CylinderHeadCoverRemoval
1. Removethe intakemanifoldcover.
\
4, Removethe cylinder headcover
V:t :;t 1
|,'.i/
2. Removethe four ignition coils (seepage 4-'18).
3. Removethe dipstick(A) and breatherhose (B).
\-
6-22
GylinderHeadRemoval
NOTE:
. Usefendercoversto avoiddamagingpainted
surfaces.
To avoid damage,unplug the wiring connectors
carefullywhlle holdingthe connectorportion.
To avoid damagingthe cylinderhead,wait until the
enginecoolanttemperaturedrops below 100'F(38"C)
betore looseningthe cylinder head bolts.
Mark all wiring and hosesto avoid misconnection.
Also, be sure that they do not contactother wiring or
hoses,or interferewith other parts.
' 1 .Drainthe
enginecoolant(seepage 10-6).
'10.
(cont'd)
6-23
CylinderHead
CylinderHeadRemoval(cont'd)
VTCActuator,ExhaustCamshaft
SprocketReplacement
Removethe rockerarm assembly(seepage 6-26).
tJ.
Removal:
1 . R e m o v et h e c a m c h a i n( s e ep a g e6 - 1 2 ) .
2. Hold the camshaftwith an open-endwrench,then
loosenthe variablevalve timing control (VTC)
actuatormounting bolt and exhaustcamshaft
sprocketmounting bolt.
1 4 . R e m o v et h e c y l i n d e rh e a d .
I
I
6-24
Installation:
1. Installthe VTC actuatorand exhaustcamshaft
sprocket.
CylinderHeadInspectionfor
Warpage
1 , Removethe cylinder head{see page 6-23).
4 . I n s t a ltl h e c a m c h a i n{ s e ep a g e6 - 1 5 ) .
6-25
CylinderHead
RockerArm AssemblyRemoval
'1.
\-
6-26
wASHEB
Yr
rY
rffin
,ffif-
\nl I ltnrllln
IJI_J;-L,JLI
[]1_L^|l]
'rl)
70)
.;.
..1
t:l P
- l
,,_tl
,q
'l
o
INTAKE ROCKER
ARM ASSEMBLY
INTAKEROCKERSHAFT
6-27
CylinderHead
RockerArms and ShaftsInspection
1 . Removethe rockerarm assembly(seepage 6-26).
2 . Measurethe diameterof the shaft at the first rocker
location.
\
4. Measurethe insidediameterofthe rockerarm, and
checkit for an out-of-roundcondition.
Rocker Arm-to-Shaflt Clearance:
Standard lNew):
0.025 0.052 mm
lntake:
(0.0010 0.0020in.)
Exhaust:
0.018 0.056mm
(0.0007 0.0022in.)
0.08 mm (0.003in.)
Service Limit:
\.
,,,@@
6-28
GamshaftInspection
NOTE:Do not rotatethe camshaftduring inspection.
1. Removethe rockerarm assembly(seepage 6-26).
and disassembleit (seepage6-27).
2. Putthe rockershaft holders,camshaft,and
camshaftholderson the cylinderhead,then tighten
the bolts to the specifiedtorque.
Specified torque:
I mm bolis:
22 N.m {2.2kgt m, 16lbf.ft}
6 mm bolts:
12 N.m {1.2kgf.m,8.7 tbf.ftl
6 mm bolts: @, 0, @
(cont'd)
6-29
CylinderHead
CamshaftInspection(cont'dl
Unscrewthe camshaftholder boltstwo turns at a
time, in a crisscrosspattern.Then removethe
camshaftholdersfrom the cylinder head.
Lift the camshaftsout of the cylinder head,wipe
them clean.then inspectthe lift ramps.Replacethe
camshaftif any lobes are pitted,scored,or
excessivelyworn,
1 . C l e a nt h e c a m s h a fjto u r n a ls u r f a c e si n t h e c y l i n d e r
head,then set the camshaftsbackin place.Placea
plastigagestrip acrosseachjournal.
Installthe camshaftholders,then tighten the bolts
to the specifiedtorque as shown in step 2.
\,
{0.001 0.003in-)
0.060*0.099mm
{0.002 0.004in.)
0 . 1 5m m { 0 . 0 0i6n . )
1 1 . M e a s u r ec a m l o b eh e i g h t .
Cam Lobe HeiohtStandard(New
INTAKE
PRI
3 3 . 9 2 5m m
(1.3356
in.)
2 9 . 6 3m
8m
( 1 . 1 6 6i n8 . )
P R IP
: rimary
C/C:CamChain
EXHAUST
34.092mm
\1.3422in.l
SEC
SEC:Secondary
\-
6-30
Valves,Springs,and ValveSealsRemoval
Special Tools Bequired
Valvespring compressorattachment07VAE-001010A
4 . I n s t a l l t h ev a l v eg u i d es e a lr e m o v e r .
5 . Removet h e v a l v es e a l .
\
6-31
GylinderHead
ValveInspection
ValveStem-to-GuideClearance
Inspection
1 . R e m o v et h e v a l v e s( s e ep a g e6 - 3 1 ) ,
.<
4,.
6-32
t-
ValveGuideReplacement
SpecialToolsRequired
. Valveguidedriver,5.5mm 07742-0010100
. Valveguidereamer,5.5mm 07HAH-PJ7o108
1 . Inspectvalve stem-to-guideclearance(seepage 6-
32t.
As illustratedbelow, use a commerciallyavailable
air-impactvalve guide driver (A) modifiedto fit the
diameterof the valve guides.In most cases,the
same procedurecan be done usingthe specialtool
and a conventionalhammer.
tT
-_|Jfillr-.-4fi'11.,
10.8mm
{0.,|2in.)
(cont'd)
6-33
CylinderHead
ValveGuideReplacement(cont'dl
Apply a thin coat of clean engineoil to the outside
of the new valve guide. Installthe guide from the
camshaftside of the head;usethe specialtool to
drive the guide in to the specifiedinstalledheight
( A )o { t h e g u i d e( B ) .l f y o u h a v ea l l 1 6 g u i d e s t od o ,
you may have to reheatthe head.
\
1 0 .Coat both reamerand valve guide with cutting oil.
1 1 .Rotatethe reamerclockwisethe full length of the
v a l v eg u i d eb o r e .
O7HAH.PJ7O1OB
' - \
6-34
ValveSeat Reconditioning
1. Inspectvalve stem-to-guideclearance(seepage 632).lf the valve guidesare worn, replacethem (see
page6-33)beforecuttingthe valve seats.
2 . R e n e wt h e v a l v es e a t si n t h e c y l i n d e rh e a du s i n ga
valve seat cutter.
3 , C a r e f u l l yc u t a 4 5 ' s e a t ,r e m o v i n go n l y e n o u g h
materialto ensurea smooth and concentricseat.
4 . Bevelthe upper and lower edgesat the angles
shown in the illustration.
Checkthe width of the seat and adjustaccordingly.
INTAKE:35"
EXHAUST:30'
- 45'
, { 67.5'
(cont'd)
6-35
CylinderHead
ValveSeat Reconditioning(cont'dl
\-
\-
6-36
l n s t a l l t h ev a l v es p r i n g .P l a c et h e e n d o f t h e v a l v e
spring with closelywound coils toward the cylinder
ne a o .
6 . Installthe valve retainer.
7 . Installthevalve spring compressor,Compressthe
spring, and installthe valve keepers.Removethe
valve spring compressor.
6-37
CylinderHead
RockerArm AssemblyInstallation
:,ean and dry the No. 5 rockershaft holder mating
surfaces.
\
5 . Removethe bolts from the rockershaft holder.
6 . M a k es u r et h e D U n c hm a r k so n t h e v a r i a b l ev a l v e
fl
c
6-38
l-
CylinderHeadInstallation
Installthe cylinder head in the reverseorder of
removat:
)>-
A '15mm {'1.8in.)
" < > .
l f e i t h e rd i a m e t e ri s l e s st h a n 1 0 . 6m m { 0 . 4 2i n . ) ,
replacethe cvlinder head bolt.
Set the crankshaftto top dead center{TDC).Align
the TDC mark (A) on the crankshaftsprocketwith
the pointer(B)on the cylinderblock.
( c o n td )
6-39
CylinderHead
CylinderHeadlnstallation(cont'd)
7 . Apply engine oil to the bolt threadsand under the
b o l t h e a d so f a l l t h e c y l i n d e rh e a db o l t s .
---l.-.
B
6
x1.0mm
'r2
N.m
c
(1.2kgl.m,8.7lbf.ftl
6
x
l
.
0
m
m
'12N,m(1.2kgt.m,8.7
lbf.ft)
9 . After torquing,tighten all cylinderhead bolts in two
steps(90" per step).lf you are using a new cylinder
head bolt,tighten the bolt an extra 90..
't3. Installthe
(B).
FIRSTSTEP
SECOND
STEP
6-40
GylinderHeadCoverlnstallation
1 4 . I n s t a l l t h ew a t e rb v p a s sh o s e .
1 5 . I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 6 . I n s t a l l t h ei n t a k em a n i f o l d( s e ep a g e9 - 5 ) .
1 7 . I n s t a l l t h ee x h a u s tm a n i f o l d( s e ep a g e9 - 7 ) .
'18.
I n s t a l l t h ec a m c h a i n ( s e ep a g e6 - 1 5 ) .
on the chain
Apply liquid gasket.P/N 08718-0009,
caseand the No.5 rockershaft holder mating areas.
1 9 . A d j u s tt h e v a l v ec l e a r a n c e( s e e p a g e 6 - 9 ) .
2 0 . I n s t a l l t h ed r i v eb e l t( s e ep a g e4 - 2 6 ) .
(cont'd)
6-41
GylinderHead
CylinderHeadGoverInstallation(cont'd)
Set the spark plug seals(A) on the spark plug tubes.
O n c et h e c y l i n d e rh e a dc o v e r( B )i s o n t h e c y l i n d e r
head,slide the cover slightly backand forth to seat
the head cover gasket.
8 . I n s t a ltlh e d i p s t i c k( A )a n d b r e a t h e hr o s ei B ) .
\l
6-42
6-43
EngineMechanical
EngineBlock
. . . . . . . . . .7.-.2.
S o e c i aTl o o l s
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .-.3. . . . . . . . . . .
EndPlay
RodandCrankshaft
Connecting
7-5
..............
InsDection
7-6
......................
Replacement
Main
Bearing
Crankshaft
7-8
RodBearingReplacement......................
Connecting
. . . . . . . .7. .- 1 1
O i lP a nR e m o v a .l . . . . . . . . . . . . . . . . . . . . . .
........7-12
Piston
Removal
and
Crankshaft
7-14
........................
Inspection
Crankshaft
. . . . . . . . . . . . . . . . . . . . . . . . . . .7.-. 1. .5. . . . . . . . .
B l o c ka n dP i s t o nI n s o e c t i o n
. " . . . . . . . . . . . . .7. -. .' 1. .7. .
C y f i n d eHr o n i n g. . . . . . . . . . . .
7-18
..........
RodReplacement
Piston,PinandConnecting
7 -21
...................
PistonRingReplacement
7-23
...........
Pistonlnstallation....................
7 -24
.......'
Inspection
Rod
Bolt
Connecting
7-24
.....................'.
lnstallation
Crankshaft
. . . . . . . . .7.-.2 7
O i lP a nl n s t a l l a t i o .n. . . . . . . . . . . . . . . . .
Seal
EndCrankshaft
Transmission
........'7-28
Car ...................
lnstallation-ln
EngineBlock
SpecialTools
Ref.No.
6
@
Tool Number
OTZAD-PNAAlOO
07746-0010700
07749,0010000
Description
Oil Seal DriverAttachment96
Attachment,24 x 26 mm
Driver
Oty
1
1
1
I
o
7-2
ComponentLocationIndex
BAFFLEPLATE
LOWERBLOCK
fr
"
fi E
-4
MAINBEARINGS
O i l c l e a r a n cpea,g e7 - 6
page7-6
Selection,
FLYWHEEL
CRANKSHAFT
OILSEAL.
END
TRANSMISSION
Installation,
step21on page7-26
THRUSTWASHERS
CRANKSHAFT
End play,page7-5
R u n o u t p, a g e7 - 1 4
page7-14
Out-of-Round,
Removal,page7-12
lnstallation,page7-24
(cont'd)
7-3
EngineBlock
ComponentLocationIndex(cont'd)
/^.,
D-><
Y1
rkrej,
ffil
|
l-"t
nrrucs
_,-ersroru
Benlacement. 7-21
rG\ AalQ
[=l
^oJ
PISTON
Removal,page7-'12
Measurement,page7-15
CONNECTINGROD
End play, page7-5
Small end measurement,page7-19
Page
f,
PISTONPIN
Removal,page7-18
I n s p e c t i o np ,a g e7 - 1 9
Installation,page7,20
ENGINEBLOCK
Cylinderbore inspection,page7-'15
Warpageinspection,page7-15
C y l i n d e br o r eh o n i n g ,p a g e1 - 1 1
Ridgeremovai,step 13 on page7-13
CONNECTINGROD
CONNECTINGROD BOLT
page7 24
lnspectaon,
7- 4
replacethe thrust
lf the end play is out-of-tolerance,
washersand recheck.lf it is still out-of-tolerance,
replacethe crankshaft.
7-5
EngineBlock
CrankshaftMain BearingReplacement
MainBearingClearance
Inspection
1. To checkmain bearing-to-journaI oil clearance.
removethe lower block and bearinghalves(see
page 1 -12)..
2 , C l e a ne a c hm a i nj o u r n a la n d b e a r i n gh a l fw i t h a
cleanshop towel.
3. Placeone strip of plastigageacrosseach main
l o ur n a l .
4. Reinstallthe
b e a r i n g sa n d l o w e rb l o c k t, h e nt o r q u e
the bolts to 29 N.m {3.0kgf.m,22 lbf.ft) + 56'.
10.0007 0.0016in.l
0.050mm {0.0020
in.)
Standard{Newl:0.025- 0.049mm
(0.0010 0.0019in.)
ServiceLimit: 0.055mm (0.0022
in.l
\.
7-6
Main BearingSelection
No. 1 JOURNAL
IPULLEYEND}
No. 1 JOURNAL
No. 5 JOURNAL
(cont'd)
7-7
EngineBlock
CrankshaftMain Bearing
Replacement(cont'd)
ConnectingRodBearing
Replacement
Main
iournsl
cooe
1
Crank ---=->
bore | 1or
code IAorl
--
2ot
Borll
Lalgercrankbore
3or
c oi__-l
C o r l l l D o r t t t It
v"no*c,""" $;;fl
f111f;,,"
cr""n $ffi
ero-n
ffi#Tr,.*"
i.,""*
'---l-'o"*,
;;lT]*Brown
Black 6il;
Brack !l;kr
RodBearingClearance
lnspection
1 . R e m o v et h e o i l p u m p ( s e ep a g e8 - 9 ) .
2. Bemovethe baffle plates(seestep 6 on page7-12).
3. Removethe connectingrod cap and bearinghalf.
4 . C l e a nt h e c r a n k s h a frto d j o u r n a la n d b e a r i n g h a l f
with a clean shop towel.
5. Placeplastigageacrossthe rod journal.
6 . R e i n s t a l l t hb
e e a r i n gh a l fa n d c a p ,a n dt o r q u et h e
b o l t st o 2 0 N . m ( 2 . 0k g f . m ,1 4 l b f . f t )- l 9 0 " .
NOTE:Do not rotatethe crankshaftduring
inspection.
7 . R e m o v et h e r o d c a pa n d b e a r i n gh a l f ,a n d m e a s u r e
the widest part of the plastigage.
ConnectingRod Bearing-to-Journal
Oil
Clearance:
Standard{Newl: 0.020 0.050mm
(0.0008--0.0020in.l
ServiceLimit:
0.060mm (0.0024in.)
\-
ar*
(Thicker)
7-8
RodBearingSelection
1. Inspecteach connectingrod for cracksand heat
damage.
Connecting Rod Big End Eore Code Locations
2 . E a c hr o d h a sa t o l e r a n c er a n g ef r o m 0 0 . 0 2 4m m
(0.0009in.),in 0.006mm (0.0002in.) increments,
dependingon the sizeof its big end bore. lt's then
s t a m p e dw i t h a n u m b e ro r b a r ( 1 ,2 , 3 o r 4 / 1 l,l , l l l ,o l
l l l l )i n d i c a t i n g
t h e r a n g e .Y o u m a y f i n d a n y
c o m b i n a t i o no f n u m b e r sa n d b a r si n a n y e n g i n e .
( H a l ft h e n u m b e ro r b a r i s s t a m p e do n t h e b e a r i n g
cap,the other half on the rod.)
lf you can't readthe code becauseof an
accumulationof oil and varnish.do not scrub it
with a wire brush or scraper.Cleanit only with
solventor detergent.
Normal Bore Size: 48.0 mm 11.89in.l
(cont'd)
7-9
EngineBlock
ConnectingRod BearingReplacement(cont'dl
Connecting Rod Journal Code Location
3. The connectingrod journalcodesare stampedon
the crankshaft.
Connecting Rod Journal Code Location (Letters or
Bars)
Rod
2oJll
3 ol lll
4 orllll
Pink/ Yollow/
Yellow Grecn
Green
Green/ Brown
Brown
Yellow Yellow/
Green
Green
Green/ Erown/
Brown Black
Black
Brown
Brown/
Black
Blue
Black/
Blue
(Thicker)
7-10
OilPanRemoval
1 . Drainthe engineoil (seepage8-5).
5 . C u tt h eo i l p a n s e abl y s t r i k i n g t h e s i d e o f t h e c u t t e r
to slidethecutteralongthe oil pan.
7-11
EngineBlock
Crankshaftand PistonRemoval
1 . R e m o v et h e e n g i n ea s s e m b l y( s e ep a g e5 - 2 ) .
2 . R e m o v et h e t r a n s m i s s i o (ns e ep a g e1 3 - 4 ) .
3 . R e m o v et h e o i l p a n ( s e ep a g e7 - 11 ) .
4. Removethe oil pump {seepage8-9).
5. Removethe cylinderhead (seepage 6-23).
6. Removethe baffle plates.
E
7. Removethe 8 mm bolts.
7-12
R e i n s t a l l t h ce o n n e c t i n gr o d b e a r i n g sa n d c a p s
after removingeach piston/connectingrod
assembly.
7-13
EngineBlock
Crankshaftlnspection
\
Straightness
. o t a t et h e
9 . M e a s u r er u n o u to n a l l m a i nj o u r n a l sR
crankshafttwo completerevolutlons.The
differencebetweenmeasurementson eachjournal
must not be more than the servicelimit.
Crankshaft Total Runout
Standard(New):0.03mm 10.0012
in.l max.
ServiceLimit: 0.04mm (0.0016in.l
I_JJ
fl
5. Measuretaper at the edgesof each rod and main
journal.The differencebetweenmeasurementson
eachjournal must not be more than the service
limit.
JournalTaper
StandardlNewl: 0.005mm (0.0002in.) max.
ServiceLimit: 0.010mm {0.0004in.)
7- 14
Blockand PistonInspection
1 . Removethe crankshaftand pistons(see pageT -121.
Checkthe pistonfor distortionor cracks,
M e a s u r et h e p i s t o nd i a m e t e ra t a p o i n t I 1 m m { 0 . 4
in.)from the bottom of the skirt.There are two
pistons(No Letteror A, and B).The
standard-size
letteris stampedon the top of the piston.Letters
are also stampedon the blockas cylinder bore
stzes.
Piston Diameter:
Standard(Newl:
No Letter {or A): 85.980 85.990 mm
(3.3850 3.3854in.)
B:
85.970-85.980mm
(3.3846-3.3850in.)
Service Limit:
No Lefter lor A): 85.930mm (3.3831in.)
B:
85.920mm 13.3827in.)
Bore Taper:
Limit: (Differencebetween first and third
measurement)0.05mm (0.002in.)
6 mm {0.2in.}
First
Measurement
Second
Measutement
Third
Measurement
6 mm {0.2in.}
(cont'd)
7-15
EngineBlock
Blockand PistonInspection(cont'd)
Scoredor scratchedcylinderbores must be honed.
Checkthe top of the blockfor warpage.Measure
along the edgesand acrossthe centeras shown.
Engine Block Warpage
StandardlNew): 0.07mm (0.003in.) max.
ServiceLimit: 0.10mm (0.004in.l
\
7. Calculatethe differencebetweenthe cylinder bore
diameterand the plstondiameter.lf the clearance
is near or exceedsthe servicelimit, inspectthe
pistonand cvlinder blockfor excessivewear.
Piston-to-Cylinder Clearance
StandardlNew): 0.020 0.040mm
{0.0008 0.0016in.)
ServiceLimit: 0.05mm (0.002in.l
++
PISTON-TO-CYLINDER
CLEARANCE
PRECISION
STRAIGHT
EDGE
7-16
CylinderHoning
Only a scoredor scratchedcylinderbore should be
noneo.
'L
M e a s u r et h e c y l i n d e rb o r e s{ s e ep a g e7 - 1 5 ) .
lf the block is to be reused,hone the cylindersand
remeasurethe bores.
H o n et h e c y l i n d e rb o r e sw i t h h o n i n go i l a n d a f i n e
(400grit) stone in a 60 degreecross-hatchpattern
(A).Use only a rigid hone with 400 grit or finer
stone such as Sunnen,Ammco, or equivalent.Do
not use stonesthat are worn or broken.
3 . W h e n h o n i n gi s c o m p l e t et,h o r o u g h l yc l e a nt h e
engine blockof all metal particles.Wash the
cylinder boreswith hot soapywater,then dry and
oil them immediatelyto preventrusting.Never use
solvent,it will only redistributethe grit on the
c y l i n d e rw a l l s .
lf scoringor scratchesare still presentin the
cylinderboresafter honing to the servicelimit,
reborethe cylinder block.Some light vertical
scoringand scratchingis acceptableif it is not deep
enoughto catchyour fingernailand does not run
the full length of the bore.
7-17
EngineBlock
Piston,Pin,and ConnectingRod Replacement
Disassembly
\
Removeboth snap rings (A).Start at the cutout in
t h e p i s t o np i n b o r e .R e m o v et h e s n a pr i n g s
carefullyso they do not go flying or get lost.Wear
eve protection.
\"
7-18
Inspection
NOTE:Inspectthe piston,piston pin, and connecting
rod when they are at room temperature.
1. Measurethe diameterof the piston pin.
v
(cont'd)
7-19
EngineBlock
(cont'd)
Piston,Pin,and ConnectingRodReplacement
Reassembly
1 . I n s t a l al p i s t o np i n s n a pr i n g ( A ) .
5 . I n s t a ltlh e r e m a i n i n gs n a pr i n g ( F ) .
6 . T u r nt h e s n a pr i n g si n t h e r i n gg r o o v e su n t i l t h e
end gaps are positionedat the bottom of the piston.
7 -20
PistonRing Replacement
1. Removethe piston{rom the cylinder block(see
page 7 -121.
I
B
3. Cleanall ring groovesthoroughlywith a squaredoff brokenring or ring groovecleanerwith a blade
to fit the pislon grooves.The top and 2nd ring
g r o o v e sa r e 1 . 2m m ( 0 . 0 5i n , ) w i d e T
. h eo i l r i n g
groove is 2.0 mm (0.08in.) wide. Filedown a blade
lf necessary.Do not use a wire brush to cleanthe
ring grooves,or cut the ring groovesdeeperwith
t h e c l e a n i n gt o o l s .
NOTE:lf the piston is to be separatedfrom the
connectingrod, do not installnew rings yet.
(cont'd)
7-21
EngineBlock
PistonRing Replacement(cont'd)
6. Installthe top ring and secondring as shown.The
t o p r i n g ( A )h a sa 1 R m a r ko r n o m a r ka n dt h e
s e c o n dr i n g ( B )h a sa 2 R m a r ko r 2 N D m a r k .T h e
marks must be facing upward.
OIL RINGGAP
About 90'
SECONDRINGGAP
About 45"
TOP RINGGAP
and SPACER
RINGGAP
\5
=:-=2
V"
12-)
V
P'ffi+a
\aq*-pogd
.ZR,
V
PistonRingoimensions:
|
|
|
|
A-
t
J
o
-
ToPRing{Standardl:
A :3 . 1m m { 0 . 1 2
in.l
in.)
B : 1 . 2m m { 0 . 0 5
SocondRing{Standard):
A : 3 . 4m m { 0 . 1 3
in.}
B:'1.2mm (0.05in.i
7-22
PISTONPIN
o\,"16.
s
OIL RINGGAP
Top RingClearance
Standard {New}:
mm {0.0014-0.0024
in.)
0.035-0.060
ServiceLimit:
0.13mm (0.005in.)
SecondRing Clearance
StandardlNew):
REKENmanutactured ring
in.)
0.030-0.055
mm (0.0012-0.0022
FEDERALMOGUL manulactured ring
0.025-0.060mm (0.0010-0.0024in.)
0.13 mm (0.005in.)
ServiceLimit:
PistonInstallation
lf the crankshaftis alreadyinstalled
1. Setthe crankshafttobottom dead center(BDC)for
e a c hc y l i n d e r .
2. Removethe connectingrod caps,then installthe
ring compressor,and checkthat the bearingis
securelyin place,
2. P o s i t i o nt h e a r r o w( A ) f a c i n gt h e c a m c h a i ns i d eo f
Ineengrne.
\--lno
^ un\-.--l.
>-*/zi
.,.'_\pf{
wr
(( 'V,/:
7-23
EngineBlock
ConnectingRod Bolt Inspection
1 . Measurethe diameterof each connectinqrod bolt
at DointA and ooint B.
35 mm
mm
CrankshaftInstallation
07749-0010000
07746-00'l
\-
\-
7-24
5 . I n s t a l l t h eb e a r i n gh a l v e si n t h e c y l i n d e rb l o c ka n d
conneclrngrods.
6 . A p p l ya c o a to f e n g i n eo i l t o t h e m a i n b e a r i n g sa n d
rod bearings.
7 . H o l dt h e c r a n k s h a fsto r o d j o u r n a lN o . 2 a n d r o d
journal No. 3 are straightup, and lower the
crankshaftinto the block.
8 . l n s t a l l t h et h r u s tw a s h e r s( A )i n t h e N o . 4 j o u r n a lo f
the cylinder block.
.\
,i,
\-1
(cont'd)
7-25
EngineBlock
CrankshaftInstallation(cont'd)
'17
. Putthe lower blockon lhe cylinderblock.
1 8 . Tightenthe bearingcap bolts in sequenceto
29 N.m (3.0kgf m, 22 lbf.ft).
{
2'1. Use the specialtoolsto drive a new oil seal
squarelyinto the blockto the specifiedinstalled
height.
07749-0010000
07zAo-PNAA100
Measurethe distancebetweenthe crankshaft(A)
a n d o i l s e a l( B ) .
Oil Seal InsialledHeight:
7-26
5.5 6.5 mm
|10.22 0.26 in.l
5.5-6.5 mm
{0.22 0.26in.l
OilPanlnstallation
23. Installthe baffle plates.
6x1.0mm
1 2N . m
(1.2ksf m, 8.7lbf ft)
2 4 . I n s t a l l t h eo i l p u m p ( s e ep a g e8 - 1 4 ) .
25. Installtheoil pan (seepage7-27).
Apply liquid gasket
alongthe brokenline.
4. I n s t a l l t h eo i l p a n .
s t e p ,t i g h t e na l l b o l t s ,i n s e q u e n c et ,o 1 2 N . m ( 1 . 2
kgf m, 8.7 lbf.ft).
( } @
(cont'd)
7-27
EngineBlock
Oil PanInstallation(cont'dl
TransmissionEndGrankshaftSeal
Installation- In Car
6 . l f t h e e n g i n ei s s t i l l i n t h e v e h i c l e i,n s t a l tl h e
subframe,
- 1 I n s t a l l t h es u b f r a m eA. l i g nt h e r e f e r e n c e
lines
on the subframewith the bolt head center,then
tighten the bolts (seestep 5 on page 5-10).
-2 Tightenthe front mounting bolt (seestep 6 on
p a g e5 - 1 0 ) .
-3 Tightenthe rear mount mounting bolts (see
s t e p7 o n p a g e5 - 1 1 ) .
-4 Connectthe suspensionlower arm ball joints
(seestep 6 on page 18-19).
7. After assembly,wait at least30 minutes before
f i l l i n gt h e e n g i n ew i t h o i l .
D r y t h e c r a n k s h a fot i l s e a lh o u s i n g .
/$rRfr4T
tr*W(r
-]t fl\
OTZAD.PNAAlOO
v
7-28
EngineMechanical
t--l
r_::::-l
EngineLubrication
SpecialTools
Ref. No.
Tool Number
07HAA-PJ70100
\
Descriotion
Otv
Oil FilterWrench
I
\-
8-2
ComponentLocationIndex
WASHER
DRAINBOLT
OILPAN
R e m o v apl ,a g e7 1 1
page7-27
Installataon,
OILPUMP
page8-8
OverhaLrl,
HL]
BAFFLEPLATE
OILPUMP
CHAINTENSIONER
OILCONTROL
ORIFICE
-&\JrI
--t
ksrarr
cKEr
OIL FILTERFEEDPIPE
Replacement,page8-7
N\
lN-?
dczt$)
# 1
\
OIL PUMP
CHAINGUIDE
OILFILTER
page8-6
Replacement,
OIL PRESSURESWITCH
SwitchTest,page8 4
Oil Pressuretest, page8'4
R e p l a c e m e npt a, g e8 1 6
8-3
EngineLubrication
Oil PressureSwitch Test
1 . R e m o v et h e Y E U R E Dw i r e ( A ) f r o mt h e e n g i n eo i l
pressureswitch (B).
Oil PressureTest
Connecta tachometer.
Removethe engine oil pressureswitch,and install
a n o i l p r e s s u r eg a u g e{ A ) .
\.
I
8-4
EngineOil Replacement
1 . Warm up the engine.
2 . R e m o v et h e d r a i nb o l t ( A ) ,a n d d r a i nt h e e n g i n eo i l .
A
44 N.m {i1.5kgf.m,33lbf.ft)
Donotovertighten.
8-5
EngineLubrication
EngineOil FilterReplacement
Special Tool Fequired
Oil filter wrench 07HAA-PJ70100
EngineOil Filter(3/4-turntype)
1 . R e m o v et h e o i l f i l t e r w i t h t h e s D e c i at ol o l .
2. Inspectthe threads{A) and rubber seal (B)on the
new filter. Wipe off the seat on the engine block,
then apply a light coat of oil to the filter rubber seal.
Use only filterswith a built-inbypasssystem.
Number aftertightening.
\..
I n s t a l l t h eo i l f i l t e rb y h a n d .
After the rubberseal seats,tightenthe oil filter
clockwisewith the specialtool.
Tighten:
Tighteningtorque:
N u m b eor r
M a r kw h e n
r u b b esr e a li s
1
or
V
N u m b e ro r
Mark after
tightening
2
or
VV
3
or
VVV
4
or
VVVV
or
or
2
or
VV
3
or
VVV
vvvv. v
6 . A f t e ri n s t a l l a t i o nf i,l l t h e e n g i n e w i t ho i l u p t o t h e
specifiedlevel,run the enginefor more than 3
m i n u t e st,h e n c h e c kf o r o i l l e a k a g e .
07HAA-PJ70100
\,
8-6
Oil FilterFeedPipeReplacement
1 . Removethe oilfilter (seepage8-6).
Removethe oil filter feed pipe.
3 . l n s t a l l t h e t w o 2 x0 1 . 5 m m n u t s ( Ao) n t o t h e n e w
oil filter feed pipe. Holdthe nut with a wrench,then
tighten the other nut.
4 . T i g h t e n t hoei lf i l t e r f e e p
d i p e t o t h eb l o c k t o4 9N .
m {5.0kgf.m,36 lbf ft),thenremovethe nutsfrom
the oil filterfeedoiDe.
8-7
EngineLubrication
OilPumpOverhaul
ExplodedView
6x1.0mm
1 2N . m
{1.2kgfm,8.7lbf.ft)
BAFFLEPLATE
x 1 . 2 5m m
27 N.m
6x1.0mm
12 N.m
11.2kgf.m,8.7 lbt ft)
Ptr
P UI" I
EU
UPPERBALANCER
SHAFTHOLDER
$--."Dowetem
BALANCERSHAFT
BEARINGS
DOWELPIN
REAR
BALANCER
SHAFT
-
/=.---'n
fs/
t w
SEALINGBOLT
39 N.m
{4.0kgf.m,29lbf.ftl
FRONT
BALANCER
SHAFT
LOWERBALANCER
SHAFTHOLDER
\-
8-8
Oil PumpRemoval
(cont'd)
8-9
EngineLubrication
Oil PumpOverhaul{cont'dl
Oil PumpInspection
1 . R e m o v et h e p u m p h o u s i n g .
{
3. Checkth e h ousing-to-roto
r axiaI clearancebetween
t h e r o t o r( A )a n d p u m p h o u s i n g( B ) .l f t h e h o u s i n g to-rotoraxial clearanceexceedsthe servicelimit.
r e p l a c et h e o i l p u m p .
Housing"to-Rotor Axial Clearance
Standard(New):0.02 0.07 mm (0.001-0.003 in.l
ServiceLimit: 0.12mm (0.005in.l
4 . Checkthe housing-to-outer
rotor radialclearance
\,
1'[1e-\1.-,-2
1
'a :.:
,-'r'
\-
8- 10
BalancerShaft Inspection
1 . Seatthe balancershaft by pushingit away from the
o i l p u m p s p r o c k eet n d o f t h e o i l p u m p .
.r
''/
j/
L=]
Rfl|]
3B eI ]U U
+-
(cont'd)
8-11
EngineLubrication
Oil PumpOverhaul(cont'dl
4. Measure
the innerdiameterof the No. 1 bearingfor
thefrontbalancer
shaftholeandthe rearbalancer
shafthole.
BearingInnerDiameier:
Front:
Standard(New):20.000-20.020
mm
(0.7874 0.7882in.)
ServiceLimit; 20.03mm (0.789in.)
Rear:
Standard(New):24.000-24.020mm
in.)
10.9/t49-0.9457
ServiceLimit: 24.03mm (0.946in.)
(
5 . Measurethe diametersof the No. 1 journalson the
front balancershaft and rear balancershaft.
NO.1Journal Diameter:
Front:
StandardlNew): 19.938 19.950mm
(0.7850 0.7854in.)
ServiceLimit: 19.92mm {0.784in.)
Rear:
StandardlNewl: 23.938 23.950mm
in.)
{0.9424-0.9/129
ServiceLimit: 23.92mm (0.942in.)
Front:
Front:
a
Rear:
8-12
1 0 . A l i g nt h e p u n c hm a r ko n t h e r e a rb a l a n c esr h a f t
with the centerof the two punch marks on the front
balancershaft,then install'thebalancershaftsin
the lower balancershaft holder
(0.0024 0.0047in.l
0.15mm {0.006in.)
1 1 .Apply engine oil to the threads of the 8 mm bolts
(A).
6
x1.0mm
'12
N.m
(1.2kgt.m,8.7 lbt ft)
1 2 . I n s t a l l t h eu p p e rb a l a n c esr h a f th o l d e r( B )a n d
bafile plate (C).
(cont'd)
8-13
EngineLubrication
Oil PumpOverhaul(cont'd)
1 3 . l n s t a l l t h ep u m p h o u s i n g .
Oil PumpInstallation
1. Make sure the No. 1 piston is at TDC (seestep 1 on
p a g e6 - 1 2 ) .
2. Align the dowel pin{A} on the rear balancershaft
with the mark (B)on the oil pump.
9%ttrc
6x1,0mm
1 2N . m
(1.2kgt.m,8.7lbf.ft)
+:.:4.4
o/.-lY\
t\
\,-
-rrdv
:aa:'
f,o-;
8- 14
A
10x 1.25mm
{4 N.m
(a.5kg{ m,
33 rbf.ftl
1 0 x1 . 2 5m m
,l,t N.m {4.5kgf.m,
33 tbt.ftl
8 x 1 , 2 5m m
22N m l2.2kot m.
r6 tbt.fti
5 . L o o s e l yi n s t a l l t h eo i l p u m p( B ) t, h e ni n s t a l l t hoei l
pump sprocket(C).
Removethe pin driver (D).
7 . Tightenlhe oil pump mounting bolts.
(cont'd)
8-15
I
EngineLubrication
Oil PumpOverhaul(cont'dl
I
Oif PressureSwitch Replacement
1 0 . R e m o v et h e s e tc l i pf r o m t h e o i l p u m p c h a i n
tensioner.
1 1 . I n s t a ltl h e o i l p a n ( s e ep a g e T - 2 7 ) .
8-16
EngineMechanical
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation.................
9-2
ExhaustManifoldRemovalandInstallation..............
9-7
ExhaustPipeand MufflerReplacement
.....................
9-8
r-!i!1
IntakeManifoldand ExhaustSystem
lntakeManifoldRemovaland Installation
Exploded View:
8 x 1 , 2 5m m
22 N.m {2.2kgf.m, 16 lbf ft}
I
INTAKEMANIFOLD
Replaceif crackedor
if mating surfaceis
GASKET
Replace.
'e)
w)
INTAKE MANIFOLDPLATE
Replaceif crackedor
if matingsurfaceis
damaged.
'!
\-
t9
\
8 xx1.25
. 2 5mm
222 N' mm
2
kgf.m, 1 6
12.2ksf
6x1.0mm
1 2N . m
{1.2kgf.m,8.7lbf.ft)
8 x 1 . 2 5m m
22 N.m
(2.2kgf m. 16 lbt.ft)
9-2
Removal:
'1.
Removethe intakemanifoldcover.
3. Disconnecttheintakeairtemperature(lAT)sensor
connector(A),and removethe breatherhose (B),
then removethe air cleanerhousingcover/intake
a i r d u c ta s s e m b l y( C ) .
2 . Removethe evaporativeemission(EVAP)canister
hose (A),brakeboostervacuum hose (B),and
vacuum hoses{C).
(cont'd)
9-3
IntakeManifoldand ExhaustSystem
IntakeManifoldRemovaland Installation(cont'dl
5. Be preparedto catch and clean up spilledcoolant.
Removethe water bypasshoses,then plug the
water bypasshoses.
Four injectorconnectors
ldle air control (lAC)valve connector
Throttleposition(TP)sensorconnector
fvlanifoldabsolutepressure{lvlAP)sensor
connector
. Evaporativeemission(EVAP)canister
purge
valve connector
6 . R e l i e v e f u epl r e s s u r e( s e ep a g e1 1 - ' 1 4 4 ) .
7 . R e m o v et h e f u e l l i n e ( s e e p a g e l l - 1 4 9 ) .
8. Removethe positivecrankcaseventilation(PCV)
hose (A),harnessholder mounting bolt (B)and
h a r n e s sc l a m pm o u n t i n gb o l t ( C ) .
1'>
\-
9-4
e-li*h,r
*&
\
8 x 1.25mm
22 N.m
|.2.2k91.m.
16 tbt.ft)
8 x 1.25mm
22 N.rn
(2.2kgf m. 16 lbf.ttl
8 x 1.25mm
22 N.m (2.2ksf m, 16lbf.ft)
6x1.0mm
12N.m(1.2kgf.m,8.7lbf.ft)
5 . I n s t a l l t h ef u e l l i n e ( s e ep a g e1 1 - 1 5 0 ) .
6 . Installthewater bypasshoses.
7 . I n s t a ltl h e t h r o t t l ec a b l e( s e ep a g e11 - 1 6 4 )t ,h e n
a d j u s t h e c a b l e( s e ep a g e1 1 - 1 6 3 ) .
8 . Installthe cruisecontrol cable (seepage 4-44).then
adjustthe cable (seepage 4-45).
(cont'd)
9-5
1 2 . I n s t a l l t h ei n t a k em a n i f o l dc o v e r .
6x1.0mm
1 2N . m
l.1.2k91.m,
8.7 tbf.ftl
C l e a nu p a n y s p i l l e de n g i n ec o o l a n t .
1 0 .Installthebreatherhose(C).
After installation,checkthat all tubes,hoses,and
connectorsare installedcorrectly.
1 1 .lnstalltheEVAPcanisterhose(A),brakebooster
, n dv a c u u mh o s e s{ C ) .
v a c u u mh o s e( B ) a
Inspectfor fuel leaks.Turn the ignition switch ON
(ll) (do not operatethe starter)so that the fuel pump
runs for about 2 secondsand pressurizesthe fuel
line. Repeatthis operationtwo or three times,then
checkfor fuel leakageat any point in the fuel line.
to.
\-
9-6
ExhaustManifoldRemovaland Installation
1 . Removethe VTECsolenoidvalve (seepage 1'1-128).
2 . Removethe driveshaftheat shield(seepage 16-19).
3 . Removethe cover and exhaustmanifold bracket,then removethe exhaustmanifold.
8 x 1 . 2 5m m
22 N.m
(2.2kgf.m, 16lbt.ftl
SELF-LOCKING
NUT
10x 1.25mm
44 N.m {4.5ksf.m, 33lbt.ftl
Beplace.
#'-.-
1 0x 1 . 2 5m m
44 N.m
(4.5kgt.m, 33 lbl ftl
Replace.
GASKET
Replace.
WASHEB
10x 1.25mm
14 N.m
{4.5kgl.rn, 33lbf.ft)
8 x 1-25mm
22 N.m (2.2kgI m, 16lbf.ft)
Replace.
Tightenthe boltsin steps,
alternating
sideto side.
9-7
8 x 1 . 2 5m m
22 N.m (2.2kst.m. 16lbf.ftl
Replace.
Tightenthe bolts in steps,
alternatingside'to side.
EXHAUSTPIPEB
HEATSHIELD
\,
6x1.0mm
9.8 N.m
{1.0kgt.m,7.2 lbf ft}
GASKET
Replace.
SECONDARY
HEATED
OXYGEN
SENSOR
HO2SI
{SECONDARY
NUT
SELF-LOCKING
1 0x 1 . 2 5m m
33N.m{3.4kgf.m,
25 rbf.ft)
Beplace.
8 x 1.25mm
22 N.m {2.2kgf m, 16lbf.ft)
Replace.
Tightenthe bolts in steps,
alternatingside to-side.
il4Nm
(4.5 ksf.m,33 lbf.ftl
\-.
9-8
EngineCooling
CoolingSystem
Component
Location
Index .........................................
10-2
Radiator
CapTest .....................
..........
10-3
RadiatorTest
.............
10-3
FanMotorTest
..........l0-4
Thermostat
Test ......................
...........
10-4
WaterPumpInspection
.....................
10-5
WaterPumpReplacement
.................
10-5
C o o l a nCt h e c k. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . .1. .0. .- .6. .
CoolantReplacement
.........................
10-6
Thermostat
Replacement
..................
10-8
WaterPassage
Installation
................
10-9
WaterOutletInstallation
....................
10-9
Radiator
andFanReplacement
...................................
10-10
FanControls
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .0. .-.1. .1. . . . . . .
SymptomTroubleshooting
Index ...............................
10-12
CircuitDiagram
.........10-13
Radiator
FanCircuitTroubleshooting
........................
10-14
Radiator
FanSwitchCircuitTroubleshooting
( O p e n ). . . . . . . . . . . .
. . . . . . .1. 0 - 1 6
Radiator
FanSwitchCircuitTroubleshooting
( S h o r t ). . . . . . . . . . . .
. . . . . . .1. 0 - 1 6
Radiator
FanSwitchTest
...................
10-17
Radiator
FanSwitchReolacement
..............................
10-17
CoolingSystem
ComponentLocationIndex
WATER
OUTLET,
I n s t a l l a t i opna,g e ' 1 0 - g
\\f
WATERPUMP
page10-5
Inspection,
page10-5
Replacement.
PIPE
CONNECTING
RESERVE
TANK
WATERPASSAGE
page10-9
Installation,
THERMOSTAT
Test,page10 4
page108
Replacement,
RADIATOR
CAP
RAOIATORFAN SWITCH
Test,page 10-17
page 10'17
Replacement,
RADIATOR
page 10-'l0
Replacement,
A/C CONDENSER
FAN ASSEMBLY
Replacement,page 10'10-4
10
Fan Motor Test,page
RADIATORFAN
ASSEMgLY
R e p l a c e m e npta, g e1 0 - 1 0
Fan MotorTest,page 10 4
\J
10-2
RadiatorCapTest
RadiatorTest
Apply a pressureof 93
kgf/cm', l4 18 psi).
'123
kPa{0.95 1.25
'14
18 psi).
4 . I n s p e cfto r e n g i n ec o o l a n tl e a k sa n d a d r o p i n
pressure.
Removethe tester,and reinstallthe radiatorcap.
10-3
CoolingSystem
FanMotor Test
1. Disconnectthe 2P connectorsfrom the radiatorfan
motor and condenserfan motor.
ThermostatTest
\.
10- 4
2 . D r a i nt h e e n g i n ec o o l a n t{ s e ep a g e1 0 - 6 ) .
3 . R e m o v et h e c r a n k s h a fpt u l l e y( s e ep a g e6 - 1 1 ) .
6x1.0mm
1 2 N m { 1 . 2k g t m ,
8.7 rbf.ft)
10-5
CoolingSystem
GoolantCheck
1. Look at the coolantlevel in the reservetank. Make
sure it is betweenthe MAX mark (A) and MIN mark
(B),
CoolantReplacement
\
Removethe reservetank drain cap (A),and drain
the coolant.
\-
10-6
Type 2
8. Pour HondaAll SeasonAntifreeze/Coolant
into the radiatorup to the baseof the filler neck.
NOTE:
. Always use HondaAll SeasonAntifreeze/Coolant
Type 2 {P/N01999-9001).Using a non-Honda
c o o l a n tc a n r e s u l ti n c o r r o s i o nc, a u s i n gt h e
cooling systemto malfunctionor fail.
. HondaAll SeasonAntifreeze/Coolant
Type 2 is a
mixture of 50% antifreezeand 507owater. Prem i x i n gi s n o t r e q u i r e d .
L I n s t a l l t h er a d i a t o cr a p l o o s e l y .
10-7
GoolingSystem
ThermostatReplacement
1 . D r a i nt h e e n g i n ec o o l a n t( s e ep a g e1 0 - 6 ) .
2. Removethe splashshield (seestep 23 on page 5-5).
3. Removethe lower hose,then removethe thermostat.
6 x 1 . 0m m
9.8N.m
( 1 . 0k g f . m , 7 . 2 l bf ft )
i*
-
THERMOSTAT
LOWERHOSE
\_
10-8
Water PassageInstallation
I n s t a l l t hw
e a t e ro u t l e (t A ) w i t ha n e wO - r i n g{ B ) ,
1 2 N m ( 1 . 2k g t m , 8 , 7 l b ff t )
3 . I n s t a l l t h ew a t e rp a s s a g e( A ) w i t ha n e w O - r i n g( B ) .
.t':.:
1 0x 1 . 2 5m m
44N m {4.5kgtm.33 lbf.ft}
4. After assembly,wait at least30 minutes before
f i l l i n gt h e e n g i n ew i t h o i l .
10-9
CoolingSystem
Radiatorand FansReplacement
O.RING
RADIATOR
CAP
UPPERBADIATORHOSE
BADIATOB
BAOIATOAFAN
ASSEMBLY
\LOWERCUSHION
RADIATOR FAN
swtTcH
24Nm
{ 2 . 1kt g l m . 1 7 l b l h l
LOWERFADIATOR
HOSE
RESERVETANK
A/C CONDENSER
FANASSEMBLY
9 . 8N m { 1 . 0k g f m , 7 . 2l b ff t )
CONNECTORS
RADIATOBFANSWITCH
CONNECTOB
5. Disconnectthe fan motor connectorsand radiatorfan switch connector,then pull the radiatorup and out.
6. Removethe fan shroud assembliesand other partsfrom the radiator.
7 . I n s t a l l t h er a d i a t o ri n t h e r e v e r s eo r d e ro f r e m o v a l M
. a k es u r et h e u p p e ra n d l o w e rc u s h i o n sa r e s e t s e c u r e l V .
8 . I n s t a ltlh e b u l k h e a di n t h e r e v e r s eo r d e ro f r e m o v a l A
. p p l y b o d y p a i n tt o t h e b u l k h e a dm o u n t i n gb o l t s .
9 . F i l lt h e r a d i a t o w
r i t h e n g i n ec o o l a n ta n d b l e e dt h e a i r ( s e ep a g e1 0 - 6 ) .
10-10
\.
FanControls
ComponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
RADIATORFAN RELAY
RADIATOBFAN SWITCH
Test,page 10'17
R e p l a c e m e npt a, g e ' 1 0 - 1 7
RADIATORFAN ASSEMBLY
Motor Test,page 10 4
CONDENSER
FAN ASSEMBLY
Motor Test,page 10-4
10-11
FanControls
Symptom TroubleshootingIndex
Beforeperformingany troubleshootingprocedurescheck:
. Fuses
. Grounds
. Cleanlinessand tightnessof all connectors
SYMPTOM
PROCEDURE
RadiatorFanCircuilTroubleshooting(seepage 1O-14).
\ , 4
\-
10-12
CircuitDiagram
'
No.20loA): USA
modd
: Cm.de
mod.l
No.20l50A)
UNDEN
DASX
FUSE/RELAY
BOX
BOX
UIIDEFHOOD
FJSE/NILAY
lG2H0TiiAClill,
0N{lllrndSTABI
llll)
10-13
FanGontrols
RadiatorFanCircuitTroubleshooting
1. Checkthe No. 4 (20A)fuse in the under-hood
fuse/relaybox, and the No. 14 (10A)fuse in the
under-dashfuse/relaybox.
ls the tuse (s) OK?
(
4 . C o n n e ct th e N o . l a n d N o . 2 t e r m i n a l s o f t h e
radiatorfan relay 4P socketwith a jumper wire.
YES-Go to step 2.
NO- Replacethe fuse (s) and recheck.l
JUMPER
WIRE
T e r m i n asli d eo f I e m a l tee r m i n a l s
YES Go to step 5.
NO Go to step 6.
RADIATORFAN RELAY4PSOCKET
\-
BADIATOB
FANRELAY4PSOCKET
Terminalside of femaleterminals
ls therebatteryvoltage?
YES Goto step4.
NO Replace
the under-hood
fuse/relay
box.I
Termlnalsideof femaleterminals
\-
10-14
RAOIATOR
FANREI-AY
4PSOCKET
5\-'fl \
\r--
Terminalsideof
femaleterminals
f-;
IJUMPER
I wrRE
Wiresideof femaleterminals
RADIATORFAN MOTOR2P CONNECTOR
ls thete continuity?
YES- Replacethe radiatorfan switch.l
YES-Go to step8.
N O - G o t o s t e p1 2 .
rftr
T-
ls there continuity?
YES Replacethe radiatorfan motor.l
NO Checkfor an open in the wire between
radiatorfan motor 2P connectorterminal No. 1 and
body ground. lf the wire is OK, checkfor a poor
g r o u n da t G 3 0 1 . 1
10-15
FanControls
RadiatorFanSwitch Circuit
Troubleshooting(Openl
1. Disconnectthe radiatorfan switch 2P connector.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
3 . M e a s u r ev o l t a g eb e t w e e nt h e N o . 2 t e r m i n a lo f t h e
radiatorfan switch 2P connectorand body ground.
RADIATORFAN SWITCH2P
CONNECTOR
RadiatorFanSwitch Circuit
Troubleshooting(Short)
NO
YES-Go to step 4.
ls there continuity?
lstnere continuity?
10-16
NO Replacethe under-hoodfuse/relaybox.t
\-
RadiatorFanSwitch Replacement
RadiatorFanSwitch Test
NOTE:Bleedair from the cooling system after installing
the radiatorfan switch (seepage 10-6).
1, Removethe radiatorfan switchfrom the radiator
( s e ep a g e1 0 - 1 7 ) .
2 . S u s p e n dt h e r a d i a t ofra n s w i t c h( A )i n a c o n t a i n e r
of water as shown.
\
Operation
lTemperature
203'F
ON 196"
(91" gs"C)
swtTcH
5' 15'F {3' 8'C) lowel
OFF than the temoerature
when it goes on
10-17
Fueland Emissions
Fueland EmissionsSystems
SpecialTools
1't-2
General
Troubleshooting
Information
I I-J
DTCTroubleshooting
lndex .... 11-7
SymptomTroubleshooting
1ndex...............
11 - 1 0
SystemDescriptions
................
11-12
Howto SetReadiness
Codes.. 11-46
PGM-FlSystem
Component
Location
Index .... 11-49
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .11-52
...
MILCircuitTroubleshooting
... 11-97
DLCCircuitTroubleshooting
.. 1 1 - 1 0 9
InjectorReplacement
...............
11-111
A,/FSensorReplacement
.........1 1 - 1 1 3
HO2S
Secondary
Replacement
11-113
ECTSensorReolacement.......1 1 - 1 1 4
CMPSensorB {TDCSensor)
Replacement
11-114
I A TS e n s oR
r e p l a c e m e.n. t. . . . . 1. .1 - 1 1 5
KnockSensorReplacement
.... 1 1 - 1 1 5
CKPSensorReolacement
.......1 1 - 1 1 6
VTEC/VTC
LocationIndex .... 11-117
Comoonent
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 11 8
VTCOil ControlSolenoid
ValveRemoval/Test
.............
11-127
CMPSensorA Replacement
... 11-128
VTECSolenoid
Valve
R e m o v a l / l n s o e c t.i .o. n. . . . . . .11-128
...
ldle ControlSystem
Location
Index
Component
11-129
. . . . . . . . . . .1. .I.- 1 3 0
D T CT r o u b l e s h o o t i n g
A,/CSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .I .t.-. t.5 5
AlternatorFRSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1. 1. .-. 1 3 4
EPSSignalCircuit
T r o u b l e s h o o t i n.S. . . . . . . . . . . . . .1.1. .-1. 3 5
Brake
PedalPosition
SwitchSignal
Troubleshooting
.............
Circuit
11 - 1 3 7
ldle SpeedInspection
11 - 1 3 8
E C Ml d l el e a r nP r o c e d u r e. . . . . . .11 - 1 3 9
FuelSupplySystem
ComponentLocationIndex
11 - 1 4 0
FuelPump
Circuit
Troubleshooting 1 1 - 1 4 1
F u e lP r e s s rue R e l i e v i n g. . . . . . . . .1. .1 - 1 4 4
F u eP
l r e s s u r e T e s. .t. . . . . . . . . . . .1. 1. .-.1. 4 5
FueL
l i n e sI n s p e c t i o.n. . . . . . . . . .1. .1. .- 1 4 6
FuelLine/Ouick-Connect
FittingsPrecautions.............
11-148
FuelLine/Ou
ick-Con
nect
F i t t i n gR
s e m o v a l. . . . . . . . . . . . .1. 1. .-.1. 4 9
FuelLine/Ou
ick-Con
nect
F i t t i n glsn s t a l l a t i o.n. . . . . . . . . .1. .1. .- 1 5 0
FuelPressure
Regulator
R e p l a c e m e .n.t. . . . . . . . . . . . . . . 1
. .1. .-.1. .5. 2
FuelFifterReplacement
...........
11-152
FuelPump/Fuel
GaugeSending
. .1. .-.1 5 3
U n i t R e D l a c e m e. .n. t. . . . . . . . . 1
F u eP
l u l s a t i oDna m o e r
R e p 1 a c e m e. n
. .t. . . . . . . . . . . . . . 1
. .1. .-.1. .5. 4
F u eT
l a n kR e o l a c e m e n
. .t. . . . . . .1. 1. - 1 5 5
F u eGl a u g e S e n dUi n igt T e s. .t . . . .1. 1 - 1 5 6
11-158
LowFuellndicatorTest
.................
IntakeAir System
C o m o o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 5 9
T h r o t t l eB o d y T e s t . . . . . . . . . . . . . . 1
. .1. .-.1 6 0
IntakeAir BypassControl
T h e r m aV
l a l v eT e s t . . . . . . . . . . .1. .1. - 1 6 1
A i r C l e a n eR
r e o l a c e m e n .t . . . . . .1. 1 - 1 6 2
A i r C l e a n eE
r lement
R e o l a c e m e n.t. . . . . . . . . . . . . . . . . 1
. .1. .-.1. .6 2
ThrottleCableAdjustment ...... 11-163
ThrottleCable
Removal/lnstallation
............
11-164
Th rottleBody Removal/
Installation
.. 11-165
Th rottleBody Disassembly/
R e a s s e m b l v. . . . . . . . . . . . . . . . . . .1. .1. .- .1. 6. 6
CatalyticConverterSystem
D T CT r o u b l e s h o o t i n. .g. . . . . . . . .1.1. .- 1 6 7
PCVSystem
D T CT r o u b l e s h o o t i n g. . . . . . . . . . .1. .1.- 1 6 8
PCVValveInsDection
a n dT e s t
. . . . . .11 -1 6 9
P C VV a l v eR e o l a c e m e n.t. . . . . . . .1.1 - 1 6 9
EVAPSystem
C o m p o n e nLt o c a t i o nI n d e x . . . . 1 1 - 1 7 0
D T C T r o u b l e s h o o t i n.g. . . . . . . . . .1. .1. - 1 7 1
EVAPTwo Way ValveTest ......11-186
FuelTank VaoorControl
ValveTest
... 11-187
E V A PC a n i s t eR
r e p l a c e m e n.t. . 1 1 - 1 8 9
FuelTank VaoorControl
V a l v eR e o l a c e m e n.t. . . . . . . . . .1. .1.- 1 8 9
Fueland EmissionsSystems
SpecialTools
Rel. No.
(L)
@
@
@
@
@-t
@-2
O-3
@-4
@
(iD
Tool Number
ffi
1
1
1
/6\
l\r
)l
\-,/
\7
@
-'-,---=---1,-'.
ut/t
'jt'
o
(i)
/'r';-:'-;--'
At-''
UtB
o
\-
1
1
--1
a=:t=' (F
otv
Description
V a c u u mP u m p / G a u g e0, 3 0 i n . H g
Vacuum/Pressure
Gauge.0 4 in.Hg
BackprobeSet
Fuel PressureGaugeAdapter
PressureGaugeAdapter
FuelSenderWrench
Hose,Oil Pressure
A,/TPressureHose
A,/TLow PressureGaugeW/Panel
A,/TPressureHose,2,210 mm
A,/TPressureHoseAdapter
F u e lP r e s s u r eG a u g e
FuelPressureGauoeSet
A973X-041-XXXXX
07JAZ-0010008
07sAz-001000A
07vAJ-0040100
07NAJ-P07010A
07xAA-001010A
07zAJ-S5AA200
07406-0020201
07406-0070300
OTMAJ-PY4O11A
07MAJ-PY40120
07406-004000A
07zAJ-S5A0100
\,
i-==.
*==-.2'l
-1,40-2, -3,@-4
\\h
*.'l)
\\:
\\d
o
\-
11-2
GeneralTroubleshooting
Information
IntermittentFailures
The term "intermittentfailure" means a svstem mav
have had a failure.but it checksOK now. lf the
MalfunctionIndicatorLamp (MlL)on the dash does not
come on, checkfor Doorconnectionsor looseterminals
at all connectorsrelatedto the circuitthat Vou are
troubleshooting.
Opensand Shorts
"Ooen" and "Short" are common
electricalterms.An
open is a breakin a wire or at a connection.A short is
an accidentalconnectionof a wire to ground or to
anotherwire. In simple electronics,this usuallymeans
somethingwon't work at all. With complex electronics
( s u c ha s E C M s ) t h i sc a n s o m e t i m e sm e a ns o m e t h i n g
works, but not the way it's supposedto.
w:ix&K#
(cont'd)
11-3
Fueland EmissionsSystems
GeneralTroubleshootingInformation(cont'dl
How to Resetthe ECM
You can resetthe ECM in eitherof two ways:
. U s et h e O B Dl l s c a n t o o lo r H o n d aP G M T e s t e r t o
resetthe ECM memory.
Seethe OBD ll scantool or HondaPGI\4Testeruser's
manualsfor specificinstructions.
' Turn the ignition switch OFF,and removethe No. 6
ECU{ECM}(15A)fuse (A)from the under-hoodfuse/
r e l a vb o x ( B l f o r 1 0 s e c o n d s .
(c),
9.8 N.m
{1.0kgf.m,7.2lbt.ft}
3 . R e m o v et h e E C M ( B ) .
\- ta
11-4
2 . U s i n gt h e w i r e i n s u l a t i o n
a s a g u i d ef o r t h e
contouredtip ofthe backprobeadapter,gently slide
the tip into the connectorfrom the wire side until it
touchesthe end of the wire terminal.
3. lf you cannot get to the wire side of the connector
or the wire side is sealed(A),disconnectthe
connectorand probe the terminals(B)from the
terminal side. Do not force the Drobeinto the
connector.
07sAz-001000A
(cont'd)
11-5
Fueland EmissionsSystems
Information(cont'd)
GeneralTroubleshooting
ECMUpdatingand Substitutionfor Testing
Special Tools Bequired
HondaInterfaceModule (HlM) EOS05435570
3 . R e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e E C M
replacementprocedurefrom the Honda PGM
Tester.lt allows you to startthe engine.
4. After completingyour tests,reinstallthe original
E C Ma n d r e w r i t et h e i m m o b i l i z ecr o d ew i t h t h e
E C Mr e p l a c e m e nptr o c e d u r e
o n t h e H o n d aP G M
T e s t e ra g a i n .
EOS05A35570
\-
11-6
DTCTroubleshootingIndex
DTC
Temporary
DTC
Detection ltem
{MlLindication*)
P 0 0 1 (05 6 )
VariableValveTiming Control{VTC)Oil Control
P 0 0 1 (15 6 )
P0011
P 0 1 0 (73 )
P 0 1 0 (83 )
P 0 1 1 2( 1 0 )
(10)
P01r3
P 0 1 1 6{ 8 6 )
P0116
S o l e n o i dV a l v eM a l f u n c t i o n
VariableValveTiming Control(WC) System
Malfunction
Note
{ s e ep a g e11 ' 11 8 )
( s e ep a g e1 1 -11 9 )
(MAP)SensorCircuit
ManifoldAbsolutePressure
LowVoltaqe
(MAP)SensorCircuit
ManifoldAbsolutePressure
HiqhVoltaqe
( s e ep a g e1 ' l - 5 2 1
IntakeAir Temperature(lAT)SensorCircuitLow
Voltaoe
IntakeAir Temperature(lAT)SensorCircuitHigh
Voltaoe
EnglneCoolantTemperature(ECT)Sensor Range/
PerformanceProblem
(seepage 11-55)
( s e ep a g e1 1 - 5 3 )
(seepage '11-56)
{ s e ep a g e1 1 - 5 7 )
P0117
{6)
(ECT)SensorCircuit
EngineCoolantTemperature
LowVoltaqe
( s e ep a g e1 1 - 5 8 )
P 0 1 1{86 )
EngineCoolantTemperature(ECT)SensorCircuit
Hiqh Voltaqe
Throttle Position(TP)SensorCircuitLow Voltaqe
Throttle Posltion(TP)SensorCircuitHiqh Voltaoe
CoolinqSVStemMalfunction
Air Fuel Ratio(Ay'F)
Sensor(Sensor1) No Activity
Detected
SecondaryHeatedOxygen Sensor (SecondaryHO2S)
(Sensor2) CircuitLow Voltaqe
SecondaryHeatedOxygen Sensor (SecondaryHO2S)
( S e n s o2
r ) C i r c u i tH i q hV o l t a q e
SecondaryHeatedOxygen Sensor (SecondaryH02S)
( S e n s o2
r )SlowResDonse
SecondaryHeatedOxygen Sensor(SecondaryH02S)
(Sensor2) HeaterCircuitMalfunction
{ s e ep a g e1 1 - 5 9 )
P 0 1 2 t27 \
P 0 1 2 {37 )
P 0 1 2 8( 8 7 )
P 0 1 3 4( 4 1 )
P0128
P 0 1 3 (76 3 )
P0137
P 0 1 3 8( 6 3 )
P0138
P 0 1 3 (96 3 )
P0139
P 0 1 4 1( 6 5 )
P 0 1 7 1( 4 5 )
PO112l'45)
PO\11
PO\l2
P0300andany
of
P 0 3 0 (17 1 )
(721
PO302
P0303(73)
P0304(74)
P0301(7'1)
P0300andany
of
P0301
P0302
P0303
P0304
P0301
No. 1 Cyl n d e rM i s f i r e
P0302
No.2 Cvl n d e rM i s f i r e
P0303
N o . 3 C v l nder Misfire
FuelSvstemToo Lean
FuelSystemToo Rich
R a n d o mM i s f i r e
( s e eD a q e1 1 - 6 0 )
( s e ep a q e1 1 - 6 2 )
( s e eD a q e1 1 - 6 4 )
( s e ep a g e1 1 - 6 5 )
( s e ep a g e1 1 - 6 5 )
( s e ep a g e1 1 - 6 6 )
( s e ep a g e1 1 - 6 7 )
( s e ep a g e1 1 - 6 8 )
( s e ep a q e1 1 - 7 0 )
( s e eo a o e1 1 - 7 0 )
( s e ep a g e1 1 - 7 1 )
{ s e ep a g e1 1 - 7 2 )
{ s e ep a q e11 - 7 2 )
( s e eo a q e1 1 - 7 2 )
P0303(73)
P0304{74)
P0304
N o . 4 C v l nder Misfire
{seeDaqe11-72)
" ; T h e s e D T C sa r e i n d i c a t e db y a b l i n k i n gm a l f u n c t i o ni n d i c a t o lra m p ( M l L ) w h e nt h e S C Ss e r v i c es i g n a l i n e i s
jumped with the Honda PGM Tester.
P0302(721
{cont'd)
11-7
Fueland EmissionsSystems
DTCTroubleshootingIndex(cont'd)
KnockSensorCircuitN4alfunction
PO4i{
P 0 4 5 1( 9 1 )
TU45I
P0452
CrankshaftPosition(CKP)SensorIntermittent
( s e ep a g e1 1 - 7 8 )
CamshaftPosition(CMP)SensorA No
CamshaftPosition(CMP)SensorA Intermiftent
( s e eo a q e1 1 - 1 2 1
i s e ep a g e1 1 - 1 2 1 )
Phqse
G
Yetrgb-le
VelyeTiTing_controlll/T!)
s e eo a o e1 1 - 1 2 2
CqJalystSystemElficie-ncy
Below Threshold
s e eo a q e11 -1 6 7
( F T PS
) e n s o rR a n g e / P e r f o r m a n c e( s e e p a g e l l 1 7 1 )
F u e lT a n kP r e s s u r e
SensorCircuitLow V
FuelTank Pressure(FTP)SensorCircuitHigh V
V e h i c l eS D e e dS e n s o r
C i r c u i tM a l fu n c t i o n
E n g i n eC o n t r o M
l o d u l e( E C N 4P)o w e rS o u r c eC i r c u i l
11-172
s e eD a q e1 1 - 1 3 0 )
( s e ep a g e11 - 8 1 )
SeriaC
l o m m u n i c a t i o Ln i n kM a l f u n c t i o n
P 1 1 0(61 3 )
(BARO)
Barometric
Pressure
SensorRange/
PerformanP
c er o b l e m
( s e ep a g e11 - 8 3 )
P 1 1 0(?1 3
( B A R OS
) e n s o rC i r c u i tL o w
BarometriP
c ressure
( s e ep a S e11 ' 8 3 )
P 11 0 8( t s '
( B A R OS
) e n s o rC i r c u i tH i g h
BarometriP
c ressure
{ s e ep a g e1 1 - 8 3 )
P112111)
P't121
T h r o t t l eP o s i t i o n{ T P iS e n s o rS i g n a lL o w e rT h a n
( s e ep a g e1 1 - 6 3 )
P1122ll J
Pl122
T h r o t t l eP o s i t i o n( T P )S e n s o rS i g n a lH i g h e rT h a n
i j 1 1 2 8( 5 )
P11f,.8
Pr 158 (48)
(l\,4AP
M a n i { o l dA b s o l u t eP r e s s u r e
S }e n s o rS i g n a l
G;tp"s" 1154)
Loqer Than Expected
( * " p a S e11 5 4 )
ManifoldAbsolutePreisure (MAP)SeiiioiSgnul
H i q h e rT h a nE x
( s e ep a g e1 1 - 8 4 )
A i r F u e lR a t i o( A V FS) e n s o r( S e n s o r1 ) R a n g e /
R e r f o r m a n cP
eroblem
A i r F u e lR a t i o { A " FS) e n s o r{ S e n s o 1
r ) A F S T e r m i n a l ( s e ep a g e11 - 8 5 )
P 11 5 9( 4 8 )
'l)
A i r F u e lR a t i o1 A V FS)e n s o ri s e n s o r A F S+ T e r m i n a l ( s e ep a g e11 - 8 6 )
P 1 1 6 3( 6 1
P 1 1 6 4( 6 1 )
P 11 2 9( 5 )
P 1 1 5 7( 4 8 )
l\."
P 11 6 6( 4 1 )
( s e ep a g e1 1 - 8 9 )
Air Fuel Ratio(4,/F)Sensor(Sensor1) HeaterCircuit
Malfunction
Air Fuel Ratio(A,/F)Sensor(Sensor1) HeaterSystem ( s e ep a g e1 1 - 9 1 )
P 11 6 7( 4 1 )'
Malfunction
" : T h e s eD T C Sa r e i n d i c a t e db y a b l i n k i n gM I L w h e n t h e S C Ss e r v l c es i g n a l i n e i s j u m p e dw i t h t h e H o n d aP G M
Tester.
* 1 r' 0 2 m o d e l
\.
11-8
DTC
Temporary
DTC
Detectionltem
{MlLindication*l
P1259t22J
VTECSystem l\4alfunction
P1291t20\
ElectricalLoad Detector(ELD)CircuitLow Voltaqe
P1298(20)
ElectricalLoad Detector(ELD)CircuitHiqh Voltaqe
P 1 3 6 1( 8 )
P 1 3 6 (28 )
P'r456(90)
P1456
(90)
P14s7
P1457
P 1 5 0 (51 0 9 )
P1505
(14)
P1519
P 1 6 0 7( )
EnginC
e o n t r oM
l o d u l e( E C MI)n t e r n aCl i r c u i t
Malfunction
Page
( s e eD a q e1 1 - 1 2 3 )
( s e eD a q el 1 - 9 2 )
( s e eo a o e1 1 - 9 3 )
( s e ep a g e1 1 - 9 5 )
( s e ep a g e1 1 - 9 5 )
( s e ep a g e1 1 - 1 7 5 )
( s e ep a g e1 ' l - 1 8 0 )
( s e eo a q e1 1 - 1 6 8 1
{ s e ep a q e1 1 - 1 3 1 )
( s e ep a g e11 - 9 6 )
" : TheseDTCSare indicatedby a blinking MIL when the SCSservicesignal line is jumped with the Honda PGM
Tester.
11-9
Fueland EmissionsSystems
Symptom TroubleshootingIndex
When the vehiclehas one of these symptoms,checkthe diagnostictrouble code (DTC)with the scantool. lf there is no
DTC,do the diagnosticprocedurefor the symptom, in the sequencelisted,until you find the cause.
Svmotom
E n g i n ew i l l n o t s t ar t
(MlL works OK, no DTCSset)
Diaqnostic procedure
1. Testthe battery{seepage 22-50).
2. Testthe starter(seepage 4-8).
3. Troubleshootthe fuel pump circult(seepage 11
141).
E n g i n ew i l l n o t s t a r t( M l L
comes on and stayson, or
n e v e rc o m e so n a t a l l ,n o
DTCSset)
Enginewill not start
(immobilizerindicatorstays
on or flashs)
Troubleshootthe l\4lLcircuit(seepage 1
Hardstarting
(MlLworksOK,no DTCS
set)
1. Testthe battery(seepage22-50).
2 . C h e c k t h ef u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
2 . C h e c k t h ei d l e s D e e d( s e ep a q e1 1 - 1 3 8 ) .
' ] D o t h e E C I \ 4i d l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) .
2. C h e c k t h ei d l es p e e d{ s e ep a g e1 1 - 1 3 8 ) .
'1-'163).
the throttlecable (seepage 1
3 . Inspect/adjust
Inspectand test the throttle body {seepage 11-160}.
( s e ep a g e1 1 - ' 1 3 9 ) .I n t a k ea i r l e a k s
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e
2 . C h e c kt h e i d l es p e e d( s e ep a g e1 1 - 1 3 8 ) .
3, Inspecvadjustth e throttlecable (seepage 11''163).
4. Insoectand test the throttle bodv (seepaqe 11-160)
1 . D o t h e E C I Vi d
I l e l e a r np r o c e d u r e( s e ep a g e11 -1 3 9 ) . Vacuum hose clogged/
cracked/poor
2. TroubleshootthealternatorFRsignalcircuit (see
p a g e1 1 - ' 1 3 4 ) .
connectron
3. InsDectand test the throttle bodv {seepaqe 11-160).
1 . D o t h e E C Mi d l e l e a r np r o c e d u r e
{ s e ep a g e1 ' j - 1 3 9 ) .
t e a l t e r n a t oFr Rs i g n a lc i r c u i t ( s e e
2 . T r o u b l e s h o ot h
p a g e1 1 - 1 3 4 ) .
ldle speedfluctuates
(MlL works OK, no DTCSset)
E n g i n es t a l l s
(MlL works OK. no DTCSset)
'1-97).
1 . C h e c kt h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 5 ) .
2. Inspectand test the th roftle body (seepage 11-160).
3 . I n s p e c v a d j u tsht e t h r o t t l ec a b l e( s e ep a g e1 1 - ' 1 6 3 ) .
1.
2.
3.
4.
D o t h e E C Mi d l el e a r np r o c e d u r e( s e ep a g e1 ' l ' 1 3 9 ) .
C h e c kt h e f u e l p r e s s u r e { s e e p a g e l l - 1 4 5 ) .
C h e c kt h e i d l es p e e d( s e ep a g eI 1 - 1 3 8 ) .
Troubleshootthebrakepedal positionswitch signal
c i r c u i t( s e ep a q e1 1 - 1 3 7 ) .
Low compression
I n t a k ea i r l e a k s
Contaminatedfuel
\-
Low compressron
C a m s h a ftti m i n g
problem
E n g i n eo i l l e v e l
prootem
l n t a k ea i r l e a k s
F a u l t yh a r n e s sa n d
sensorconnections
\-
11-10
Symptom
Difficultto refuel
(MlL works OK. no DTCSset)
Fueloverflowsduring
refueling
(No DTCSset)
Diagnosticprocedure
1 . T e s t t h e f u e lt a n kv a p o rc o n t r o lv a l v e { s e e p a g e1 ' l 2. 1471.
I n s p e ctth e f u e lt a n kv a p o rc o n t r o ls i g n a lt u b e
3. betweenthe fuel pipe and the fuel tank vapor
control valve.
4. Inspectthe fuel tank vapor vent tube betweenthe
EVAPcanisterand the fuel tank vapor control valve.
Checkthe EVAPcanister.
Replacethe fuel tank vapor control valve (seepage '11
189).
Also checktor
M a l f u n c t i o n i ngga s
s t a t i o nf i l l i n gn o z z l e .
Malfunctioninggas
stationfilling nozzle.
11-11
Fueland EmissionsSystems
SystemDescriptions
ElectronicControl System
The functionsof the fuel and emlssioncontrol systemsare managedby the enginecontrol module (ECM).
Fail-safeFunction
When an abnormalityoccursin the signalfrom a sensor,the ECI\4ignoresthat signaland assumesa pre-programmed
value for that sensorthat allowsthe enqineto continueto run.
Back-up Function
When an abnormalityoccursin the ECM,the injectorsare controlledby a back-upcircuitindependentof the systemto
p e r m i tm i n i m a ld r i v i n g .
Self-diagnosis
When an abnormalityoccursin the signalfrom a sensor,the ECM suppliesground for the malfunctionindicatorlamp
{MlL) and storesthe diagnostictrouble code {DTC)in erasablememory.When the ignition is first turned on, the EClvl
suppliesground to the l\4lLfor 15 to 20 secondsto checkthe M lL bulb condition.
Two Driving Cycle Detection Method
"two driving cycle detectionmethod" is usedfor some self-diagnostic
functions.
To preventfalse indications,the
When an abnormalityoccurs,the ECM storesit in its memory. When the same abnormalityrecursafterthe ignition
s w i t c hi s t u r n e dO F Fa n d O N ( l l )a g a i n ,t h e E C Mt u r n so n t h e M l L .
\.
11-12
ECMData
You can retrievedata from the ECI\4by connectingthe OBD ll scantool or the Honda PGM Testerto the data link
connector(DLC).The items listedin the table below conform to SAE recommendedpractice.The HondaPGM Tester
also readsdata beyondthat recommendedby SAEto help you find the causesof intermittentproblems.
The "operatingvalues" listedare approximateand may vary dependingon the environmentand the individual
vehicle.
Unlessnoted otherwise,"at idle speed" means idling with the enginecompletelywarmed up in the neutralposition,
and the A,/Cand all
Diagnostic
Trouble Code
(DTC}
l f n o p r o b l e mi s
detected,there is no
ourpul.
YES
TheECI\4
computesenginespeedfromthe signalssent
N e a r l yt h e s a m ea s
position(CKP)sensor.Thisdatais
fromthe crankshaft
tachometerindication
usedfor determining
thetimeandamountof injectedfuel. At idle speed;
Manifold
Absolute
Pressure
(MAP)
N e a r l yt h e s a m ea s
speedometer
indication
Withenginestopped:
YES
Nearlythe same as
almospnencpressure.
At idle speed:about
20 4'1kPa
( 1 5 0 3 1 0m m H g ,
6 - 1 2 i n . H q ) . 0 . 71 . 3V
The ECTsensorconvertscoolanttemperatureinto voltage W i t h c o l d e n g i n e :
and signalsthe ECM.The sensor is a thermistorwhose
S a m ea s a m b i e n t
internalresistancechangeswith coolanttempetature.The temperatureand IAT
ECM usesthe voltagesignalsfrom the ECTsensorto
With enginewarmed
determinethe amount of injectedfuel.
u p ; a b o u t1 1 6 2 ' 1 2 " F
1 0 0 ' c ) . 0 . 5 - 0 .v8
Secondary
Heated
Oxygen
Sensor
(Secondary
H02S,
Sensor2)
NO
(cont'd)
11-13
Fueland EmissionsSystems
r a
SystemDescriptions(cont'd)
ECMData(cont'd)
Description
"open" or "closed".
Fuelsystem statusis indicatedas
Closed:Basedon the A,/FSensoroutput,the ECM
determinesthe airlfuel ratio and controlsthe amount of
injectedfuel.
Open: lgnoringAy'FSensoroutput,the ECM refersto
signalsfrom the throttle position{TP),manifoldabsolute
pressure(MAP),intakeair temperature(lAT),barometric
pressure(BARO),and enginecoolanttemperature(ECT))
sensorsto controlthe amount of iniectedfuel.
The airlfuel ratio correctioncoefficientfor correctingthe
Short Term
amount of injectedfuel when the fuel system status
FuelTrim
is "closed." When the ratio is leanerthan the
sloichiometricratio,the ECM increasesshort term fuel
trim gradually,and the amount of iniectedfuel increases.
The airlfuel ratio graduallygets richer,causinga lower
oxygen content in the exhaustgas. Consequently,the
short term fuel trim is lowered,and the ECM reducesthe
amount of injectedfuel.
This cvcle keepsthe airlfuelratio closeto the
stoichiometricratio when in closed loop status.
Long term fuel trim is computedfrom short term fuel trim
LongTerm
and indicateschangesoccurringin the fuel supply system
F u eT
l rim
over a long period.
l f l o n gt e r m f u e lt r l m i s h i g h e rt h a n 1 . 0 0t,h e a m o u n lo f
injectedfuel must be increased.lf it is lower than 1.00,the
amount of injectedfuel must be reduced.
The IAT sensorconvertsintakeair temperatureinto
IntakeAir
Temperature v o l t a g ea n d s i g n a l st h e E C M .W h e n i n t a k ea i r
temperatureis low, the internalresistanceofthe sensor
{IAT)
increases,and the voltagesignal is higher.
Basedon the acceleratorpedal position,the opening
Throttle
anole of the throttlevalve is indicated.
Position
lgnitiontiming is the ignition advanceangle set by the
lgnition
ECM.The ECM matchesignitiontiming to driving
Timing
conditions.
Data
FuelSystem
Status
Calculated
L o a dV a l u e
(cLV)
Opera'tingValue
At idle speed:closed
FreezeData
YES
o.7 1.5
YES
0.8 1.2
YES
w
W i t h c o l de n g i n e :
S a m ea s a m b i e n t
a n dE C T
temperature
YES
At idle speed:
a b o u t1 0%
At idle speed:8" t 5"
| ' t u L w n e nr n e > L )
s e r v i c es i g n a l i n e i s
jumped with the Honda
PGM Tester
At idle speed:
12 34%
At 2.500rpm with no
toao:
't4- 34%
YES
NO
YES
\.,
11-14
J/-\
-1\_/
BEIAY2
A/C CLUTCHRELAY
I
)
RAOIATOR
T
UNDER.HOOD
FUSE/RELAY
BOX:
(8oA)
ONo. 19BATTERY
ONo.6 ECU(ECM)(15A1
(3)No.20lG
{40A1
{Canada:50A}
ONo.l4 OPTION
{40A1
)No.9 BACKuP (7.5A1
lo)No.7 HORN,STOP{15A}
UNDER.DASH
FUSE/RELAY
BOX:
ONo. 17FUELPUMP
{15A}
@No.,t ACG{10A)
ONo.1 IGNCOIL(1sA)
q)No.10METER
(7.5A)
0)No.14A/C CLUTCH
RELAY
IlOA)
@No.2+B LAF(A/F)
(2OA)
HEATER
(cont'd)
11-15
Fueland EmissionsSystems
SystemDescriptions(cont'dl
ECMElectricalConnections
MAPSENSON
No. INJECTOR
No,2INJECTOR
TPSENSOR
No.3 INJEC]OB
No./tINJECTOF
IATSENSOR
ECTSENSOB
\'
CMP SENSORB
(TDCSENSOSJ
CKPSENSOR
FVERSELOCK
SOLENOIDVAIVE
\-
11-16
A/FSENSOR
EVAPCANISTE6
PURGEVAIVE
EVAPCANISTER
VENTSHUTVATVE
A/FSENSOR
(sENSOn 1)
sotENotovAtvE
CMP SENSOFA
wEcorl
N o . 2 l G N l l l O NC O I L
No. 3 IGNITIONCOIL
PRESSUSESWTICH
VTEC SOLENOID
No. a IGNITIONCOIL
{cont'd)
11-17
Fueland EmissionsSystems
SystemDescriptions(cont'd)
ECMElectricalConnections
ARAKEPEDAL
POStTtONSWTTCH
GAUGEASSEMBLY
IMMOBILPENUN|T
EPSCONTROTUNIT
TERMINALLOCATIONS
\-
11-18
2
1
AFS]TC ]GP2
'10
SG2
t1
3
IGPl
^:^ I -:,
12
ACV
22
23
HTC+ LG2
6
AFS+
15 T6
TPS AFS_
26
25 CMPB
CMPA(rDc)
I
KS
1
CKP
18
1 9 2A
V S S IVAP vcc2
21
vccl
27
28
29
30
tGPts,lrcPts3tGPts2GPLS
1
forminal name
YEUBLK
AFSHTC(AIRFUELRATIO
(4./F)SENSOR
HEATER
CONTROL}
IGP2(POWEB
SOURCE)
YEUBLK
IGPl {POWER
SOURCE)
4
5
6
1
9
10
12
18
PG2(POWER
GROUND
PG1(POWER
GROUND
AFS+ (AIRFUELRATIO
(A,/F}SENSOR,
SENSOR1
+ stDE)
8LU
CKP(CRANKSHAFT
POSITION
SENSOR)
BED/BLU
) KS E N S O B )
YEL
2 {SENSOR; R O U N D )
;ROUND)
G 1{ S E N S O R
BLIVRED IACV(IDLEAIRCONTROL
(IAC)VALVE)
RED/BLK TPS(THROTTLE
POSITION
SENSOR)
REDI/EL AFS (AIRFUELRATIO
(4,/F)SENSOR,
SENSOB1
SIDE)
WHT/GRN V S S ( V E H I C L ES P E E D
BLK
BLK
RED
SENSOR)
Description
Signal
DrivesAy'Fsensorheater
Withignit'onswitchON {ll):batteryvoltage
Withfullywarmedup enginerunnang:
0V
Groundforthe ECMcircuit
Groundforthe ECMcircuit
DetectsAy'Fsensor
{sensor1)signal
Detects
CKPsensorsignal
Withenginerunning:pulses
Detectsknocksensorsiqnal
Sensorqrounr
Sensorqroun(
DrivesIACvalve
pulses
Withenqineknocking:
Lessthan1.0Vat elltimes
L e s s t h a 1n . 0 Va t a l l t i m e s
Withenginerunningrdutycontrolled
Detects
TPsensorsignal
Withthrottlefullyopen:about4.8V
Withthronlefullvclosed:ahout0-5V
Detects!y'Fsensor
( s e n s o1r) s i g n a l
Detects
VSSsignal
(cont'd)
11-19
Fueland EmissionsSystems
\. il
SystemDescriptions{cont'd)
ECMInputsand Outputsat ConnectorA (31P)
1
AFS]TC
2
GP2
3
IGPl
4
PG2
12
10
11
SG2 sG1 IACV
22
23
AFS LG2
HTC+
5
6
PG.1 AFS+
'15 1 6
TPS AFS_
26
25 CMPB
Ct\.4PA
(rDc)
I
KS
1
CKP
18
1 9 20
V S S IVAP vcc2
21
vccl
29
30
27
28
IGPLS,I
IGPLS4
IGPLS3
IGPLS2
21
YEURED VCC](SENSOB
VOLTAGE) Provides
sensorvoltage
22
AFSHTC- (AIRFUEL
Detectsa,/Fsensorheater
RATIO(A"iFiSENSOR
voltage
+ SIDE)
HEATER
CONTROL
BRN?ryE
L
LG2(LOGIC
GROUND
roundfor the ECMcircu
1(L
roundfor the ECMcircu
BRN?ryE
L
(CAMSHAFT
D e t e c t sC M P s e n s o r A
BLU,^/VHT CMPA
A)
stonal
POSITION
SENSOR
Detects
CMPsensor8 (TDc
GRN
CMPB CAMSHAFT
(CMP)SENSOB sensor)
POSITION
B (TDC(TOPDEADCENTER
SENSORi)
I G P L S 4{ N o .4 I G N I T I O N
DrivesNo, 4 ignitioncoi
BRN
23
24
25
26
27
COILPULSE)
I G P L S 3{ N o . 3 I G N I T I O N
COILPULSE)
28
WHT/BLU
29
GNITION
BLU/RED l G P L S 2 l N o .I 2
COILPTJLSE)
YEUGRN IGPLSI(No.1 IGNITION
co PlltsF)
30
Signal
With ignitionswitchON (ll):about3 V
A t i d l e : a b o u t 1 . 0V ( d e p e n d i n go n e n g i n e s p e e d )
\.
Lessthan1.0V at alltimes
L e s st h a n
'1.0
V at alltimes
Withenginerunning:pulses
Withenginerunning:pulses
WithignitionswitchON (ll)rabout0 v
Withenginerunning:pulses
O r i v e s N o . 3 r g n i t i o nc o i
DrivesNo.2 ignitioncoil
DrivesNo. I ignitioncoil
\.
11-20
NOTE:Standardbafteryvoltageis 12V.
Terminal
numot
Wirecolor
[erminal name
Description
10
'17
18
21
23
VALVE+SIDE)
SOLENOID
lNJa{No.4INJECTOR)
Jo.3INJECTORI
BL
)TOR)
R1
lNJl 1No.I INJECTOR)
BRN
FAN
FANC(RAOIATOR
GRN
CONTROL)
LOCK
GRN/vVHT RVS(REVERSE
VALVE)
SOLENOID
Drives o. 4 iniector
Drives o.3 iniector
Drives o . 2 i n i e c t o r
DrivesNo. 1 iniector
Drivesradiatorfan relay
Signal
WithignitionswitchON (ll):0 V
At idle:dutycontrolled
IAT(INTAKE
AIR
TEMPERATURE
SENSOR)
WHT/GRN ALTC(ALTERNATOR
CONTROL)
YEUBLU PCS{EVAPORATIVE
EMISSION
CANISTER
PURGE
VALVE)
REDI/EL
DetectsIATsensorsignal
(confd)
11-21
Fueland EmissionsSystems
L
SystemDescriptions(cont'dl
ECMlnputsand Outputsat ConnectorE (31P}
1
iMo
FPR
sr-{]zsLG3
22
23
24
BKSWK-LINESEFMJ
6
1
$1025 MRLY
HTC
16
14
15
18
FTP ELD EPS
ACC
LD
21
26
rMo
NEP
CD
8
AFS
HTCR
4
SG3
20
21
Z/VBS VSV
29
scs
30
31
WEN MIL
3
4
5
6
(SECONDARY Drivessecondary
BLKATr'HT SO25HTC
HO2S
HEATED
OXYGENSENSOR heater
(SECONDARY
H02S)
HEATER
CONTROL)
REDA/EL MRLY(PGM.FI
MAIN
DrivesPGM-Flmain
relay1
RELAY}
Powersourceforthe DTC
ORN
YEUBLK
'18
Description
IMOFPR(IMMOBILIZER D r i v e s P G M F l m a i n r e l a y 2
FLJEL
PUMPRELAYI
WHT/RED SHO2S(SECONDARY
DetectssecondaryHO2S
HEATED
OXYGENSENSOR {sensor2) signal
(SECONDARY
HO2S),
SENSOR
2r
BRN/YEL LG3(LOGIC
GROUND)
cround forthe ECM/PCM
controlcircuit
PNK
SG3{SENSOR
GBOUND) Sensororound
YEUELU VCC3{SENSOR
VOLTAGE) Providessensorvoltage
't4
ferminal name
LT GRN
0Vfor2 secondsafterturningignitionswitchON
{ll).then battervvoltaoe
WiththrottleJullyopenedfrom idlewith fully
warmedup engine:above0.6V
Withthrottlequicklyclosed:below0.4V
Lessthan1.0V at all times
Lessthan 1.0V at all times
With ignitionswitchON (ll):about5 V
With ionitionswitchOFF:about0 V
With ignitionswitch ON (ll):bafteryvoltage
Wilh fullvwarmedup enginerunning:dul,
controlled
WithignitionswirchON {ll):0 V
IGl (IGNITION
SIGNAL)
D e t e c r si g n i t i o n s i g n a l
WithignitionswitchON (ll):about0 V
With ignitionswitchOFF:batteryvoltage
AFSHTCR
{AIRFUELBATIO Drivesairfuel ratiosensor
(Iy'F)SENSOR
HEATER
heaterrelay
CONTROLRELAY)
FIP lFUELTANK
(FTP)SENSOR)
PRESSURE
GRN/RED ELD(ELECTRICAL
LOAD
DETECTOF)
LTGRN/8LK EPSLD(ELECIRICAL
POWEBSTEEBING
LOAD
DETECT)
RED
Signal
ACC(Ay'C
CLUTCH
RELAY) DrivesP,/Cclutch relay
Withcompressor
ON:about0 V
With comoressorOFF:battervvoltaoe
\-
11-22
2
t M o $.c2s
FPR
14
FTP
22
23
24
BKSWK LINESEFMJ
I
AFS
HTCR
6
1
SFIO2S
IV
RLY
HTC
15
ELD
16
EPS
LD
26
NEP
21
20
2,4/BS VSV
t8
21
lvo
CD
9
tGl
29
scs
30
31
WEN MIL
NOTE:Standardbatteryvoltageis 12V.
Terminal Wire color
20
21
22
23
21
29
Description
BLU/RED 2WBS(EVAPORATIVE
DrivesEVAPbypass
(EVAP)BYPASSsolenoidvalve
EMISSION
SOLENOID
VALVE)
DrivesEVAPcanistervent
LT GRN/RED VSV (EVAPORATIVE
shutvalve
EI\4ISSION
iEVAP)
VENTSHUT
CANISTEB
VALVE)
Detects brake pedal
WHT/BLK BKSWlBRAKEPEDAL
POSITION
SWITCH)
o o s i t i o ns w i t c h s i o n a l
scan
LT BLU
K-LIN E
Sendsand receives
YEL
26
Terminalname
SEFMJ
N E P( E N G I NSEP E E D
PULSE)
RED/BLU \40CDfl\4MOBTLTZER
CODE)
BRN
S C S ( S E R V I C EC H E C K
BLU
ENABLE
RED,A/VHT WEN(WRITE
SIGNALi
GRN/ORN MIL(MALFUNCTION
LAMP)
INDICATOR
WithignitionswitchON (ll):bafteryvoltage
W i t h i g n i l i o n s w i t c h O N ( l l ) :b a t t e r y v o l t a g e
With brakepedalreleased:
about0 V
With hrake nedal nresse.l: batterv voltaoe
C o m m u n i c a t e sw i t h
mrltinleYeontrolunit
D e t e c t si m r n o b i l i z e rs i g n a l
SIGNAL)
30
Signal
D e t e c t sw r i t e e n a b l e s i g n a l
W i t h i g n i t i o n s w i t c h O N ( l l ) :a b o u t 0 V
DrivesN4lL
WithMILturnedON:about0 V
WithMILturnedOFF:battervvoltaqe
(cont'd)
11-23
Fueland EmissionsSystems
!
SystemDescriptions(cont'dl
VacuumHoseRouting
INTAKEAIR
BYPASSCONTROL
THERMALVALVE
\*
FRONTOF
VEHICLE
EVAPORATIVEEMISSION
{EVAP}CANISTERPURGEVALVE
\,
11-24
VacuumHoseRouting
1}
{SENSOR
O AIRFUELRATIOIA/F)SENSOR
HEATED
OXYGENSENSOR
O SECONDARY
2}
HO2S}{SENSOR
ISECONDARY
(MAPISENSOR
PRESSURE
ABSOLUTE
O MANIFOLD
{ECT)SENSOR
O ENGINECOOLANTTEMPERATURE
(IAT)SENSOR
O INTAKEAIRTEMPERATURE
(CKP)SENSOR
POSITION
O CRANKSHAFT
O KNOCKSENSOR
(CMPISENSOR
B
POSITION
O CAMSHAFT
ITDC)SENSOR)
ITOPDEADCENTER
A
POSITION
O CAMSHAFT
ICMPISENSOR
(IACIVALVE
@ IDLEAIRCONTROL
O THRONLEBODY
.OINJECTOR
OAMPER
@ FUELPULSATION
[I FUELFILTER
REGULATOR
@ FUELPRESSURE
@ FUELPUMP
@ FUELTANK
@ RESONATOR
(9 AIRCLEANER
VENTILATION{PCVIVALVE
@ POSITIVECRANKCASE
CONVERTER
WAYCATALYTIC
@ THREE
EMISSION
{EVAPICANISTER
@ EVAPORATIVE
EMISSION
{EVAP)CANISTER
@ EVAPORATIVE
PURGE
VALVE
(EVAPICANISTER
EMISSION
{} EVAPORATIVE
VENTSHUTVALVE
EMISSION
{EVAP)TWOWAYVALVE
{' EVAPORATIVE
EMISSION
IEVAPIBYPASS
@ EVAPORATIVE
VALVE
SOLENOID
(FTP)SENSOR
@ FUELTANKPRESSURE
EMISSION
IEVAP}VALVE
@ EVAPORATIVE
VALVE
@ FUELTANKVAPORCONTROL
VALVE
60)FUELTANKVAPORRECIRCULATION
VALVE
THERMAL
CONTROL
O INTAKEAIRBYPASS
(cont'd)
11-25
Fueland EmissionsSystems
SystemDescriptions(cont'd)
PGM-FISystem
The ProgrammedFuel Injection(PGM-Fl)system is a
sequentialmultiport fuel injectionsystem.
CamshaftPosition(CMPISensorB (TopDeadCenter
(TDCISensor)
TheCMPsensorB (TDCsensor)detectsthe positionof
the No.1 cylinderasa reference
for sequential
fuel
injectionto eachcylinder.
ztRcoNta
ELEMENT
HEATER
MAGNET
SENSOR
TERMINALS
HEATER
TERMINALS
\,
11-26
Knock Sensor
The knockcontrol system adjuststhe ignitiontiming to
minimizeknock.
PIEZO
CERAMIC
(cont'd)
11-27
Fueland EmissionsSystems
SystemDescriptions(cont'dl
Secondary Heated Oxygen Sensor (Secondary HO2S)
The secondaryHO2Sdetectsthe oxygen content in the
exhaustgas downstreamof the three way catalytic
converter(TWC)and sendssignalsto the ECMwhich
checksthe efficiencyof the TWC.To stabilizeits output,
the sensorhas an internalheater.The secondarvHO2S
i s i n s t a l l e di n t h e T W C .
(
Vehicle Speed Sensor (VSS)
The VSS is driven by the differential.lt generatesa
pulsedsignalfrom an input of 5 volts.The number of
pulsesper minute increases/decreases
with the speed
of the vehicle.
BEARING
SENSOR
TERMINALS
ztRcoNta
ELEMENT
HEATER
TERMINALS
Starting Control
When the engine is started,the ECM providesa rich
mixture by increasinginjectorduration.
(
Throttle Position ITP)Sensor
The TP sensoris a potentiometerconnectedto the
throttlevalve shaft.As the throttle positionchanges,the
sensorvariesthe signalvoltageto the ECM.The TP
sensoris not replaceableapart from the throftle body.
ELEMENT
BRUSHHOLDER
gRUSH
11-28
wEc/wc
The i-WEC has a VTC (VariableValveTiming Control)mechanismon the intakecamshaftin additionto the usual
VTEC.
This mechanismimprovesfuel efficiencyand reducesexhaustemissionsat all Ievelsof engine speed,vehiclespeed.
a n d e n g i n el o a d .
The VTECmechanismchangesthe valve lift and timing by using more than one cam profile.
The VTCchangesthe phaseof the intakecamshaftvia oil pressure.lt changesthe intakevalve timing continuously.
HIGH
LOW<-
ENGINESPEED
DrivinoCondition
Qr Light-load
VTC Control
B a s eP o s i t i o n
?l M edium/high-load
AdvanceControl
) High speed
Advance-BasePosition
DescriDtion
Cam angle is retardedto reducethe entry of exhaust
gas into the intakeport and to achievestablefuel
c o n s u m D t i o dn u r i n ql e a nb ur n .
Cam angle is advancedfor EGReffectand to reduce
this pumping loss.The intakevalve is closedquickly
to help reducethe entry of airlfuel mixture into the
intakeport and improve the chargingeffect.
C a m p h a s ea n g l ei s c o n t r o l l e df o r o p t i m u mv a l v e
t i m i n qa n d m a x i m u me n o i n eo o w e r .
{cont'd)
11-29
Fueland EmissionsSystems
SystemDescriptions(cont'dl
VTC system
. The VTC system makescontinuousintakevalvetiming changesbasedon operatingconditions.
. Intakevalve timing is optimizedto allow the engineto producemaximum power.
'CamangleisadvancedtoobtaintheEGReffectandreducethepumpingloss.Theintakevalveisclosedquicklyto
reducethe entry of the airlfuel mixture into the intakeport and improvethe chargingeffect.
. Cam angle is reducedat idle to stabilizecombustionand reducesenginespeed.
' l f a m a l f u n c t i o n o c c u r s , t h e V T C s y s t e m c o n t r iosl d i s a b l e da n dt h e v a l v et i m i n g i s f i x e da t t h e f u l l y r e t a r d e dp o s i t i o n .
TDC
MAXIMUM VTCADVANCE50'
l(-4
'+-|l
sHoRToVERLAP
LoNGoVERLAP
VTEC system
' The VTECsystemchangesthe cam profileto correspondto enginespeed.lt maximizestorque at low enginespeed
and output at high engine speed.
. The low lift cam is used at low engine speeds,and the high lift cam is used at high enginespeeds.
LOWSPEEDVALVETIMING
11-30
HIGHSPEEDVALVETIMING
System Diagram
CMPSENSORA
From No. il
ACC{10A)fuse
INTAKE
CAMSHAFT
BRN/YEL
-:-
BLU/WHT
BLU/WHT
VARIOUS
SENSORS
BLK/WHT
GRN/YEL
BLU/BLK
BLK
It
:5i.T,""
{cont'd}
11-31
Fueland EmissionsSystems
(
SystemDescriptions(cont'd)
ldle Control System
FuelSupply System
IAC VALVE
11-32
To INTAKE
MANIFOLD
IntakeAir System
Referto the SystemDiagramto seethe functional
layout of the system.
Throttle Body
The throttle body is a single-barrelside draft type. lt
housesthe TP senserand the IACvalve.The lower
portion of the IAC valve is heatedby enginecoolant
f r o m t h e c y l i n d e rh e a d .
IACVALVE
INJECTOR
{cont'd)
11-33
Fueland EmissionsSystems
SystemDescriptions(cont'dl
GatalyticConverterSystem
PositiveCrankcaseVentilation (PCVISystem
ThreeWay CatalyticConverter(TWC)
(HC),carbon
TheTWCconvertshydrocarbons
monoxide{CO),andoxidesof nitrogen(NOx)in the
exhaustgasto carbondioxide(C02),dinitrogen(N2),
andwatervaDor.
BREATHERPIPE
THREEWAY
CATALYST
FRONTOF
VEHICLE
::
:
BLOW-BY
VAPOR
FRESH
AIR
11-34
Evaporative
Emission(EVAPIControl
System
Referto the SystemDiagramto see the functional
layout of the system.
EVAPCanister
The EVAPcanistertemporarilystoresfuel vapor from
the fuel tank until it can be purged back into the engine
a n db u r n e d .
EVAP Canister Purge Valve
When the enginecoolanttemperature is below 149'F
(65'C),the ECMturns off the EVAPcanisterpurge valve
which cuts vacuum to the EVAPcanister.
VALVE
SENSOR
UNIT
To FUELTANK
(cont'd)
11-35
Fueland EmissionsSystems
SystemDescriptions(cont'dl
IACVALVE
AKEAIR DUCT
CLEANER
YEL/BLK ---<
From
PGM.FI
MAIN
RELAY
BLK/
REO
THROTTLEAODY
VARIOUS
SENSOnS
BLK
IntakeAir SystemDiagram
This systemsuppliesair for engine needs.A resonatorin the intakeair pipe providesadditionalsilencingas air is
drawn into the svstem.
THROTTLEAODY
VARIOUS
SENSORS
BLK
11-36
Evaporative
Emission(EVAPIControlDiagram
The EVAPcontrolsminimizethe amount of fuel vapor escapingto the atmosphere.Vapor from the fuel tanKrs
temporarilystoredin the EVAPcanisteruntil it can be purgedfrom the canisterinto the engine and burneo.
. The EVAPcanisteris purged by drawing fresh air through it and into a port on the intakemanifold.
The purgingvacuum is controlledby the EVAPcanisterpurge valve,which operateswheneverengine cootant
temperatureis above 149'F(65"C).
'WhenvaporpressureinthefueltankishigherthanthesetvalueoftheEVAPtwowayvalve,thevalveopensan
regulatesthe flow of fuel vapor to the EVAPcanister.
' D u r i n g r e f u e l i n g , t h e f u e l t a n k v a p o r c o n t rvoal l v eo p e n sw i t h t h e p r e s s u r ei n t h e f u e lt a n k ,a n d f e e d st h e f u e lv a D o r
to the EVAPcanister.
FUELTANK
VAPOR
RECIRCULATION
VALVE
FUELTANK
VAPOR
SIGNAL
TUBE
BLU/RED
BLK
FUELFILLCAP
FUELTANK
VAPOR
RECIRCULATION
TUBE
EVAP
+
CANISTER
VENTSHUT
VALVE
From
BLK/YEL --<No. 4 Acc
FUELTANK
{ 1 0A } f u s e
EVAP
CANISTER
EVAPTWOWAY
VALVE
(cont'd)
11-37
Fueland EmissionsSystems
SystemDescriptions(cont'd)
ECM Circuit Diagram
CONNECTOi
mrrrrn
CMP SENSORB
(TDCSENSOn)
I-BRN/YEr-
\,
11-38
wEc solENorD
_YEL/aLU
-RED/aLK
|-GFN/YEL
I
__f
-----l
_l
F=-1
Hi
I
t_r
I
I?SCNSOn
L!l
I
I
I
croz
ff:l_l
*'*"_-ll-t
-KnocK
lSENSOn
l
I
-l-
Ll]
wcoLcoNTnoL
SoLENO|OVAIVE
(cont'd)
11-39
Fueland EmissionsSystems
SystemDescriptions(cont'dl
ECMCircuitDiagram{cont'd)
-{ffi]
---1t-|
IATSENSOR
-{El
------l
ECTSENSOS
T_""",,..
I-BFN/YEL
CMPSENSOAA
L-
IJUNCTION
I CONNECTOR
ft^--l
, " , " . , J | t -' :
I
I
I
+
t!j]]
11-40
REVERSE
LocK
soleloto
vaLvE
_1ffi1
-'----1 | |Fahdl
G8N
'--r-
'8r-K-L-|
l -r l
l
HcoNNEcroR
BLU/
-l
J.L9l
.lurcrroru
EVAPCANISTEB
ALK/YEL
WHT/ALU
WHT/NED
WHI/GRN
JUNCTION
CONNECTOR
rrrn
tcM
PLUG
N o . 2 I G N I T I O NC O l t
PLUG
No.3IGNITION COIL
(cont'd)
11-41
Fueland EmissionsSystems
SystemDescriptions(cont'd)
ECMCircuitDiagramlcont'dl
YEI/BLK
IGP2
VET/BLK
---rF-rl
-lF-forl
--JliD\l
--t-l
MAIN BETAV2
t_,",
:t
l-,r'l r,
-,u-
f-"'*'o""
I SENSOS
tr
IMMOAIL|zERUNIT
a
11-42
SECONDAFY
H02S
(sNsoR2l
m
tlil
TPSNSOR
'--{=l
-{r
CANISTERVEAIT
SHUTVALVE
t-_]
--lti l
EVAP EYPASS
solENorD
ToPS
CONTROLUNIT
CPU
GAUGE ASSEMBTY
(cont'd)
11-43
Fueland EmissionsSystems
SystemDescriptions(cont'dl
ECMCircuitDiagram(cont'd)
UNDER.HOOD
FUSE/RELAY9OX
CONNCTOF
CONNECTOi
WHI/NED
BLK/YET
lalLREllY_ _l
a
11-44
CONNECTOR
E
""rr"a*J
r''lHr/cnN
1
CONNECTOiK
IGNITIONSWITCH
lG2
' I
CONNECTOFJ
/GRN
TEST
TACHOMETER
CONNECTO8
UNDER.HOOD
UNDER.DASH
FUSE/FELAYBOX
UNDER.DASH
FUSE/RELAY
BOX:
4 ACG (1oAt
1 tGN CO|Lt15A)
2 A/F HEATER{2OA)
17 FUELPUMPI15A}
1OMETER{7.5AI
14 A/C CLUTCHRELAY{1OA}
POStTtONSWTTCH
,or"-9J3{51
"_.rl
re* _{F
Brake pedal pressed: closed
Brake pedal releasedropen
11-45
Fueland EmissionsSystems
How to Set ReadinessCodes
MalfunctionlndicatorLamp(MlL)Indication
(ln relationto Readiness
Codesl
CatalyticConverterMonitorand Readiness
Code
NOTE:
. Do not turn the ignition switch off during the
procedure.
. All readinesscodes are clearedwhen the batteryis
disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGlvlTester.
. Low ambienttemperaturesor excessiveslop-and-go
traffic may increasethe drive time neededto switch
the readinesscode from incompleteto complete.
' The readinesscode will not switchto com Dleteuntil
a l l t h e e n a b l ec r i t e r i aa r e m e t .
. lf a fault in the secondaryHO2Ssystemcausedthe
MIL to come on. the readinesscode cannot be set to
comDleteuntil vou correctthe fault.
EnableCriteria
. E C Ta t 1 5 8 " F( 7 0 ' C )o r h i g h e r .
. I n t a k ea i r t e m p e r a t u r e
( l A T )a t 2 0 " F( - 7 ' C ) o r h i g h e r .
. Vehiclespeed is steady,and vehiclespeedsensor
( V S S )r e a d sm o r et h e n 2 5 m p h ( 1 3 k m / h ) .
Procedure
1 . C o n n e ctth e s c a nt o o l t o t h e v e h i c l e ' sd a t al i n k
c o n n e c t o(rD L C i a, n d b r i n gu p t h e t o o l ' sg e n e r i c
O B Dl l m o d e .
2 . Startthe engine.
3 . Test-drivethe vehicleunder stop-and-goconditions
with short periodsof steadycruise.After about
5 miles (3 km),the readinesscode should switch
from incompleteto complete.
lf the readinesscode is still set to incomplete,check
for a temporary DTC.lf there is no DTC,one or
more of the enablecrlteriawere probablynot met;
11-46
\
\"
EvaporativeEmissions(EVAP)Control
SystemMonitor and Readinesscode
Air FuelRatio(A/FlSensorMonitorand
Readiness
Code
NOTE:
NOTE:
. Do not turn the ignitionswitch off during the
orocedure.
. All readinesscodesare clearedwhen the bafteryis
disconnectedor when the ECM is clearedwith the
OBD ll scantool or Honda PGM Tester.
EnableCriteria
At enginestart up, ECTand IAT are higherthan 32'F
(0"C), but lower than 95'F (35"C).
At enginestart up, the ECTand IAT are within 12'F
(7'C)of each other.
Procedure
1. Connectthe scantool to the vehicle'sdata link
connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Startthe engine.
3. Test-drivethe vehicleunder stop-and-goconditions
with short periodsof steadycruise.After about
2 . 5m i l e s( 1 . 6k m ) ,t h e r e a d i n e scso d es h o u l d
switchf rom incompleteto complete.
4. lf the readinesscodeisstill setto incomplete,check
for a temporaryDTC.lf there is no DTC,one or
more of the enablecriteriawere probably not met;
repeatthe procedure.
EnableCriteria
ECTat 140'F(60"C)or higher.
Procedure
1. Connectthe scantoolto the vehicle'sdata link
connector(DLC),and bring up the tool's generic
O B Dl l m o d e .
2. Start the engine.
3. Test-drivethe vehicle under stop-and-goconditions
with short periodsof steadycruise.Duringthe
drive, decelerate(wirh the throttlefully closed)for
5 seconds.After about 3.5 miles (2.2km).the
readinesscode should switch from incomDleteto
complete.
4 . l f t h e r e a d i n e s s c o d e i s s t isl le tt o i n c o m p l e t ec,h e c k
for a temporary DTC.lfthere is no DTC,the enable
criteriawas probablynot meU repeatthe procedure.
Air/FuelRatio(A/FlSensorHeaterMonitor
Readiness
Code
NOTE;All readinesscodes are clearedwhen the battery
is disconnectedor when the ECM is clearedwith the
OBD ll scantool or HondaPGM Tester,
Procedure
'1.
(cont'd)
11-47
Fueland EmissionsSystems
How to Set ReadinessCodes(cont'd)
\-
Code
MisfireMonitorand Readiness
. This readinesscode is alwaysset to available
becausemisfiring is continuouslymonitored.
. l\4onitoringpauses,and the misfirecounterresets,if
the vehicleis driven over a rough road.
. Monitoringalso pauses,and the misfire counter
holds at its currentvalue.if the throttle position
changesmore than a predeterminedvalue,or if
driving conditionsfall outsidethe rangeof any
relatedenablecriteria,
Code
FuelSystemMonitorand Readiness
. This readinesscode is always setto available
becausethe fuel system is continuouslymonitored
during closedloop operation.
. Monitoringpauseswhen the catalyticconverter,
EVAPcontrol system,and Ay'Fsensor monitorsare
active.
. Monitoringalso pauseswhen any relatedenable
criteriaare not being met. Monitoring resumeswhen
lhe enablecriteriais again being met.
ComponentMonitorand
Comprehensive
Readiness
Code
This readinesscode is always set to availablebecause
the comprehensivecomponentmonitor is continuously
r u n n i n gw h e n e v e tr h e e n g i n ei s c r a n k i n go r r u n n i n g .
a
11-48
PGM-FISystem
ComponentLocationIndex
CAMSHAFTPOS]TION{CMP)SENSORB
(TOPDEAD CENTER(TDC}
SENSORI
Troubleshootina.
oaoe 11-95
p;ge 1-1.1
Replacement,
14
ii'- r'1
ELECTRICAL
LOAD
DETECTOR
{ELDI
Troubleshooting,
page1'l-92
.I11---:,I
''.!,i(..,.?:fir-J-
.....,..:--.
INTAKEAIRTEMPERATURE
{IATISENSOR
Troubleshooting,
page'l'l-55
page11-'l15
Replacement,
f -
ENGINECOOLANTTEMPERATURE
(ECTISENSOR
page11-57
Troubleshooting,
R e p l a c e m epnat ,g e1 11 1 4
MANIFOLD
ABSOLUTE
PRESSURE
(MAP)SENSOR
page11-52
Troubleshooting,
CRANKSHAFTPOSITION
ICKPISENSOR
page'l1-78
Troubleshooting,
page 11-'l16
Beplacement,
THROTTLE
POSITION
ITP}SENSOR
page11-60
Troubleshooting,
KNOCKSENSOR
page11-77
Troubleshooting,
B e p l a c e m epnat ,g e1 11 1 5
AIR FUELRATIO{A/F)
SENSORISENSOR1}
page 11-84
Trorrbleshooting,
page 11-113
Replacement,
{cont'd)
11-49
PGM-FlSystem
ComponentLocationIndex(cont'd)
\.,
v
11-50
'}
DATALINKCONNECTOR
IDLCI
GeneralTroubleshooting
Information,page 1l 3
PGM.FIMAINRELAY1
page11-97
Troubleshooting,
ENGINECONTROLMODULE
g Information,
GeneralTroubleshootin
p a g e1 1 3
page I 1-96
Troubleshooting,
11-51
PGM-FISystem
DTCTroubleshooting
DTCP0107:
MAPSensorCircuitLowVoltage
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
ls there about 5 V?
YES-Repair open in the wire betweenthe Eclvl
( A 2 1 ) a n dt h e M A P s e n s o r . l
N O - G o t o s t e p3 .
3. Turn the ignition switch OFF.
YES-Go to step 9.
4. Disconnectthe MAP sensor3P connector.
NO Replacethe lvlAPsensor.l
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l l .
'10.Disconnect
ECMconnectorA (31P).
sGl
{GRN/WHTI
Wires de of femaleterminais
ls there about 5 V?
YES Go to step8.
ls therc continuity?
N O - G o t o s t e p7 .
1 . Measurevoltage betweenEClvlconnector
t e r m i n a l s4 1 1 a n d 4 2 ' 1 .
ECM CONNECTOR
A 13'IP}
vccr
{YEL/BED)
sGr
{GRN/WHT}
11-52
DTCP0108:MAPSensorCircuitHighVoltage
'1.
9. Measure
voltagebetweenMAPsensor3P
connector
terminalsNo.1 andNo.3.
MAP SENSOR3PCONNECTOF
vccl
{ Y E L / Rl E
, lD
o)
cl
l . l . r l
I
lsct
d)
l{GRN/wHrr
YES Go to step 3.
W i r es i d eo f f e m a l el e r m i n a l s
ls there about 5 V?
1 2 3
MAP
{GRN/REO}
A {31PI
ECMCONNECTOR
SG1(GRN/WHTI
JUMPER
WIRE
J U M P E RW I A E
Wiresideof femaleterminals
YES-Go to step 8.
NO Replacethe MAP sensor.I
8 . R e m o v et h e j u m p e rw i r e .
11-53
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCPl128:MAPSensorSignalLowerThan
Expected
1. Turn the ignition switch ON (ll).
2. Checkthe MAP with the scantool.
ls 54.1 kPa(406mmHg, 16.0in.Hg),1.6 V, or
higher indicated?
YES- Intermittentfailure.system is OK at this
time.I
NO Replacethe MAP sensor.l
DTCPl129:MAPSensorSignalHigherThan
Expected
1. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
then Iet it idle.
2. Checkthe MAP with the scantoot.
ls 36.9 kPa (277 mmHg, 10.9 in.Hg),1.1 V , or less
indicated?
YES- lntermittentfailure,system is OK at this
time.l
NO Replacethe MAP sensor.l
11-54
DTCP0112:
IATSensorCircuitLowVoltage
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
2. Checkthe IAT with the scantool.
ls 302'F (150'C) or highet (or H-Limit in Honda
node of PGM Tester),ot 0 V indicated?
VES-Go to step 3.
NO Go to step 8.
,^\
,
l r 2 l
t
-----Tr---
l
IAT
_t{RED/YELI
II
W i r es i d eo f f e m a l et e r m i n a i s
ls there continuity?
YES Repairshon in the wire betweenthe ECM
( B ' 1 7a) n d t h e I A Ts e n s o r . l
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-55
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0113:
IATSensorCircuitHighVoltage
1. Turnthe ignitionswitchON (ll).
\"
YES-Go to step 3.
9 . R e m o v et h e j u m p e rw i r e .
1 0 . C o n n e cE
t C Mc o n n e c t otre r m i n a l sA 1 0 a n d 8 1 7
w i t h a j u m p e rw i r e .
A (31 P)
B {24 P)
IATSENSOR
2PCONNECTOR
rJ--
:---
JUMPERWIRE
l ' l L l
-'_-l--_----r--_
sG2
rAT
I
{GRN/YEL)
IRED/YEL)
I
L ]
WIRE
JUMPER
Wiresideof femaleterminals
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
12. Checkthe IAT with the scantool.
Wiresideof femaleterminals
6 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
YES Updatethe ECMif it does not have the latest
software,or substitutea known-goodECI\4then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM.replacethe
originaE
l C M !.
NO Repairopen in the wire betweenthe ECM
( A 1 0 ,8 1 7 )a n dt h e I A Ts e n s o r . I
11-56
DTCP0116:ECTSensorRange/Performance
Problem
NOTE:lf DTCP0117and/or P0118are storedat the
same time as DTCP0116,troubleshootthose DTCSfirst,
then recheckfor DTCP0116,
1. Stanthe engine.Hold the engineat 3,000rpm with
no load {in neutral)until the radiatorfan comes on,
then let it idle.
2. Checkthe ECTwith the scantool.
ls 176- 212'F (80
indicated?
100"C)or0.5 0.8V
11-57
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0117:ECTSensorCircuitLow Voltage
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
2. Checkthe ECTwith the scantool.
ls there continuity?
YES-Go to step 5.
NO
Replacethe ECTsensor.!
6. DisconnectECMconnectorB (24P).
11-58
DTCP0118:
ECTSensorCircuitHighVoltage
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NO Replace
t h e E C Ts e n s o r . I
YES Go to step 3.
9 . R e m o v et h e j u m p e rw i r e .
a {31P}
B {24P)
ECTSENSOR2P CONNECTOR
JUMPERWIRE
lt tt .l t l l
-I-l*,
Ecr
(RED/WHT)
Wiresideof femaleterminals
{GRN/YEL)
t
l
WIRE
JUMPER
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 2 . Checkthe ECTwith the scantool.
11-59
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0122:TP SensorCircuitLowVoltage
1 . T u r nt h e i g n i t i o ns w i t c ho N ( 1 1 1 .
2. Checkthe throttle positionwith the scantool.
T e r m i n as li d eo f m a l et e r m i n a l s
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
YES Go to step 9.
6. Measurevoltagebetweenthe TP sensor3P
connectorterminals No. 1 and No. 3.
TP SENSOR3P CONNECTOR
9 . Measureresistancebetweenthe TP sensor3P
connectorterminalsNo. 2 and No. 3 with the
throttlefully closed.
TPSENSOR
3PCONNECTOB
ls thereabout5 V?
Terminalsideof maleterminals
YES-Go to step7.
N O G ot o s t e p1 4 .
1 . Turnthe ignitionswitchOFF.
11-60
11 2 1 3
1 2 3
TPS
(RED/BLX}
'PS
REO/BLKI
ls there continuity?
ls thetecontinuity?
YES-Repairshortin the wire betweenthe ECM
{ A 1 5a) n dt h eT Ps e n s o r . l l
N O - G o t o s t e p1 2 .
terminalA15to body
12. ConnectECMconnector
groundwith a jumperwire.
A 131P)
ECMCONNECTOR
9
1 1 2 1 34 5 6 7
19
t
c
6
10 1 1 1 1 2
8 t2021
23124
28129130
wrne
,tf$,rr*, ];uueen
vcc2
(YEL/8LU)
ls there about 5 V?
YES Repairopen in the wire betlveenthe ECM
( A 2 0 )a n d t h e T P s e n s o r . I
NO Updatethe ECM if it does nor have the latest
software,or substilutea known-goodECM,then
r e c h e c k( s e ep a g e11 - 6 ) l.f t h e s y m p l o m i n d i c a t i o n
goes away with a known-goodECM.replacelhe
originaE
l CM.I
11-61
PGM-FISystem
DTCTroubleshooting(cont'd)
DTCP0123:
TPSensorCircuitHighVoltage
1 . T u r nt h e i g n i t i o ns w i t c ho N ( l l )
2. Checkthe throttle positionwith the scantool.
(
7. Measurevoltage betweenECMconnector
terminalsA10 and A20.
ECMCONNECTOR
A 131PI
Wiresideof femaleterminals
W;resideof femaleterminals
ls thete about 5 V?
YES-Replace the throttle body (theTP sensor is
not availableseparately).
I
NO Go to step 7.
11-62
DTCPl121:TPSensorSignalLowerThan
Expected
DTCP1122:.fP
SensorSignalHigherThan
Expected
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
11-63
PGM-FISystem
(cont'dl
DTGTroubleshootang
DTCP0128:CoolingSystemMalfunction
\
3. Checkthe radiatorfan.
Does the tadiator fan keep running?
11-64
DTCP0134:Ay'FSensor(Sensor1) No Activity
Detected
1. Checkthe attachmentstateof the A,/Fsensor
( S e n s o r1 ) .
DTCP0137:
Secondary
HO2S(Sensor
2)
CircuitLowVoltage
1 . R e s e t h e E C M( s e ep a g eI 1 - 4 )
NO-Go to step 2.
2 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
YES Go to step 4.
3 . S t a nt h e e n g i n e H
. o l dt h e e n g i n es p e e da t
3,000rpmwith no load (in neutral)until the radiator
fan comes on, then let it idle for 2 minute.
4. T u r nt h e i g n i t i o ns w i t c hO F F .
5 . Disconnectthe secondaryHO2S(Sensor2) 4P
connector.
icont'd)
11-65
PGM-FISystem
DTCTroubleshooting(cont'dl
10. Checkfor continuitybetweenthe secondaryHO2S
(Sensor2) 4P connectorterminal No. 2 and body
ground.
SECONDARY
H02S
2) 4PCONNECTOR
ISENSOR
DTCP0138:
Secondary
HO2S(Sensor
2)
CircuitHighVoltage
1 . R e s e t t h eE C M{ s e ep a g e ' 1 1 - 4 ) .
2. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
3. Checkthe secondaryHO2S(Sensor2) output
voltageat 3,000rpm with the scantool.
ls thete 1.0 V or morc?
YES Go to step 4.
ls there continuity?
4. Turn the ignition switch OFF.
YES-Repair shon in the wire betweenthe ECM
(E2)and the secondaryHO2S(Sensor2).t
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I|
5. Disconnectthe secondaryHO2S(Sensor2) 4P
connector.
ConnectsecondaryH02S (Sensor2) 4P connector
t e r m i n a l sN o . 1 a n d N o . 2 w i t h a j u m p e rw i r e .
SECONDARY
HO2S
{SENSOR2) 4P CONNECTOR
JUMPERWIRE
SG3 (PNKI
SHO25(WHT/RED)
T e r m i n asl i d eo Jm a l et e r m i n a l s
7. Turn the ignitionswitch ON (ll).
11-66
DTCP0139:SecondaryHO2S(Sensor2l Slow
Response
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
Start the engine.Holdthe engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
NO Replacethe secondaryHO2S(Sensor2).1
JUMPERWIRE
Wiresideof femaleterminals
1 1 .Turn the ignition switch ON (ll).
1 2 . Checkthe secondaryHO2S(Sensor2) output
voltagewith the scantool.
ls there 1.0 V or more?
YES Updatethe ECM if it does not have the latest
soflware,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM.replacethe
originaE
l CM.I
NO Repairopen in the wire betweenthe ECM (E2,
E4)and the secondaryHO2S{Sensor2).I
11-67
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCP0141:
Secondary
HO2S(Sensor
2l
HeaterCircuitMalfunction
1. Resetthe ECM(seepage 1 l-4)
2. Startthe engine.
ls DTC P0141indicated?
YES-Go to step 3.
NO-lntermittent failure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the secondaryHO2S(Sensor2) and at the ECM.I
ls therecontinuity?
YES- Replace
the secondary
HO2S(Sensor2).1
NO-Go to step7.
7 . Turnthe ignitionswitchON (ll).
HO2S(SENSOR
214PCONNECTOR
SECONDARY
voltagebetweensecondary
H02S4P
8 . Measure
connector
terminalsNo.3 andNo.4,
SECONDARYHO2S (SENSOR2l ilP CONNECTOR
s02sHTc
{BLK/WHTI
IG1(BLK/ORN}
ls thereabout3.3 Q ?
T e r m i n asli d eo f m a l et e r m i n a l s
11-68
DisconnectECMconnectorE (31P).
to.
1 7 . Measurevoltage betweenECMconnectorterminal
E 6a n d A 5 .
ECMCONNECTORS
Wire side o{fIemaleterminals
A (31 P)
ls therc continuity?
YES-Repair short in the wire betweenthe ECM
r ).1
( E 6 )a n d t h e s e c o n d a r yH O 2 S( S e n s o 2
NO-Update the ECM if it does not have the latest
soflware,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
MeasurevoltagebetweensecondaryHO2S
(Sensor2) 4P connectorterminal No. 4 and body
g round.
HO2S{SENSOR
2I 4PCONNECTOR
SECONDARY
tFff I
E {31P}
l[faJl--ro'
14
|
IBLK/OFN)
Y
I
Terminal
sideof maleterminals
ls there battety voltage?
YES Go to step 13.
N O - C h e c k t h e N o . 4 A C G ( 1 0 A )f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repair open in
the wire betweenthe secondaryHO2S(Sensor2)
a n d N o . 4 A C G ( 1 0 A )f u s e . l
11-69
PGM-FISystem
DTCTroubleshooting(cont'dl
FuelSystemToo Lean
DTCP0171:
DTCP0172:FuelSystemToo Rich
'
ls luel pressure OK?
A973AX-041-XXXXX
YES Go to step 2.
Does it hold vacuum?
NO Checkthese items:
. lf the pressureis too high, replacethe fuel
p r e s s u r er e g u l a t o(rs e ep a g e1 1 - 1 5 2 ) . 1
. l f t h e p r e s s u r ei s t o o l o w . c h e c k t h e f u epl u m p ,
the fuel feed pipe,the fuel filter, and replacethe
f u e l p r e s s u r er e g u l a t o (r s e ep a g e1 1 - 1 5 2 ) . I
2. Startthe engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
11-70
DTCP0300:
RandomMisfireandAny Combination
of the Following:
DTCP0301:
No.1 CylinderMisfire
DTCP0302:No.2 CvlinderMisfire
DTCP0303:
No,3 CvlinderMisfire
DTCP0304:No. 4 CvlinderMisfire
NOTE:
. lfthe misfiring is frequentenoughto trigger detectionof increasedemissionsduring two consecutivedriving cycles.
the MIL will come on, and DTCP0300(and some comlrinationof P0301through P0304)will be stored.
. lf the misfiring is frequentenoughto damagethe catalyst,the MIL will blink wheneverthe misfiring occurs,and OTC
P0300(and some combinationof P0301through P0304)will be stored.When the misfirlng stops,the MIL will remain
on.
1. Troubleshootthe following DTCsfirst if any of them were stored along with the random misfire DTC(s):
P 0 ' 1 0 7P,0 1 0 8P, 1 1 2 8P
, 1 1 2 9N
r 4 a n i f o ladb s o l u t ep r e s s u r e( M A P )s e n s o r
P0111.P0'172t
Fuelsvstem
P0335.P0336:Crankshaftposition(CKP)sensor
P0505:ldle control system
sensor
P1149,Pl 162,P1163,P1164,P 1165:Air fuel ratio (Ay'F)
P1259:VTECsystem
P1361,P1362:Camshaftposition(CMP)sensorB {Top dead center(TDC)sensor)
P 1 5 1 9l:d l ea i r c o n t r o l( l A C )v a l v e
2. Test-drivethe vehicleto verify the symptom.
3. Findthesymptom inthechart below, and dothe relatedproceduresin the order listeduntil you find the cause.
Symptom
R a n d o mm i s f i r eo n l y
at low RPMand
under load
R a n d o mm i s f i r eo n l y
du ring acceleration
Randommisfire at
h i g h R P M ,u n d e r
l o a d ,o r u n d e r
random conditions
Procedure(sl
. Lowcompressron.
. Lowqualityfuel.
in the
Malfunction
VTECsystem(seepage
1' t-123).
C h e c kf u e l p r e s s u r e( s e ep a g e1 1 - 1 4 5 ) .
Correctenginevalve
clearances(seepage 691.
11-71
PGM-FISystem
DTCTroubleshooting(cont'dl
No.1 CylinderMisfire
DTCP0301:
DTCP0302:No.2 CylinderMisfire
DTCP0303:No.3 CylinderMisfire
YES Replacethe faulty ignitioncoil.!
DTCP0304:No. 4 CylinderMisfire
NO-Go to step 8.
1. After checkingand recordingthe freezedata,reset
the ECM (seepage 11-4).lf there is no freezedata of
the misfire,just clearthe DTC.
2. Startthe engine,and listenfor a clickingsound
from the injectorat the problemcylinder.
Determine
w h i c h c y l i n d e r ( sh)a dt h e m i s f i r e .
Does the misl ire occur in the cylinder where the
spark plug was exchanged?
YES Replace
t h e f a u l t ys p a r kp l u g . l
ls DTC or Tempotaty DTC P0301, P0302, P0303
or P0304 ind icated?
NO Go to step 13.
YES Go to step 7.
11-72
L e tt h e e n g i n ei d l ef o r 2 m i n u t e s .
't7.
Checkfor a DTCor a TemporaryDTCwith the scan
Tool.
ls DTC or TemporaryDTC P0301,P0302, P0303
or P0304 indicated?
YES Go to step 18.
NO lntermittentmisfire due to bad contactat the
injectorconnector(no misfireat this time). Make
surethe injectorconnectionis secure.Checkfor
poor connectionsor looseterminalsat the
injector.l
problemcylinder.
Turn the ignition switch ON (ll).
ls there continuity?
YES Go to step 25.
NO Repairopen in the wire betweenthe ignition
c o i l a n dG 1 0 1 . 1
DisconnectECMconnectorA {31P)
(cont'd)
11-73
PGM-FISystem
DTCTroubleshooting(cont'dl
26. Checkfor continuitybetweenbody ground and
ECMconnectorterminal (seetable).
ECMCONNECTOR
A {31PI
PROBLEIVI
CYLINDER
DTC
ECM
WIRE
TERMINAL COLOR
N o .1
No.2
No.3
No,4
P0301
P0302
P0303
P0304
430
A.29
428
421
YEUGRN
BLU/RED
WHT/BLU
BRN
ECMCONNECTOR
A {31P}
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
DTC
P0301
P0302
P0303
P0304
ls there continuity?
ls there continuity?
ECM
WIRE
TERI\4INAL COLOR
A30
YEL/GRN
429
BLU/RED
A.28
WHT/BLU
A.21
BRN
Wire s de of femaleterminals
3 0 . DisconnectECMconnectorB (24P).
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
11-74
DTC
WIRECOLOR
P0301
P0302
P0303
P0304
YEUGRN
BLU/RED
WHT/BLU
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
BRN
32. fvleasure
voltagebetweenbodygroundandECM
connector
terminal(seetable).
ECMCONNECTOR
B (24P)
3 7 . L e t t h ee n g i n ei d l ef o r 2 m i n u t e s .
3 8 . Test-drivethe vehiclefor severalminutes in the
r a n g eo I t h e l r e e z ed a t ao r u n d e rv a r i o u s
condilionsif there was no freezedata.
DTC
P0301
P0302
P0303
P0304
ECt\4
TERMINAL
B5
B4
B3
WIRE
COLOR
BRN
RED
BLU
YEL
NO Intermittentmisfiredue to injector
malfunction,etc. Make sure the injector
connectionsare secure.Checkfor poor connections
or looseterminalsat the injectorconnector.l
D e t e r m i n ew h i c hc y l i n d e r { sh}a d t h e m i s f i r e .
N O G o t o s t e p4 1 .
3 5 , Measurethe resistancebetweeninjector2P
c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
l s t h e r e 1 0Q
13A?
11-75
PGM-FISystem
DTCTroubleshooting(cont'dl
45. Measure
voltagebetweeninjector2Pconnector
t e r m i n aNl o .1 a n db o d yg r o u n d .
48. Connectinjector2PconnectorterminalNo.2to
bodygroundwith a jumperwire {seetable).
INJECTOR
2P CONNECTOR
INJECTOR2P CONNECTOR
tll-z]
-lt,o,,"=rrrr*,
oI
tll-Z-l
-]_r-l_rNJ
IJUMPER
IwrBE
Wiresideof femaleterminals
Wire side of {emaleterminals
PROBLEM
CYLINDER
No.1
No.2
N o .3
N o .4
DTC
WIRECOLOR
P0301
P0302
P0303
P0304
BRN
RED
BLU
YEL
ECMconnectorterminal (seetable).
B {24P)
ECMCONNECTOR
PROBLEM
CYLINDER
N o .1
No.2
No.3
N o .4
ECM
TERMINAL
P030'1
B5
B4
P0302
P0303
B3
P0304
82
DTC
WIRE
COLOR
BRN
RED
BLU
YEL
PROBLEM
CYLINDER
No.1
N o .2
N o .3
N o .4
DTC
P0301
P0302
P0303
P0304
ECM
TERMINAL
B5
B4
B3
82
WIRE
COLOR
BRN
RED
BLU
YEL
ls therc continuity?
ls there continuity?
YES Replacethe injector,then recheck.l
YES-Repair short in the wire betweenthe ECM
a n dt h e ; n j e c t o r . I
N O - G o t o s t e p4 8 .
11-76
DTGP0325:Malfunctionin KnockSensor
Circuit
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
7. Connectstanersubharness
6Pconnector
terminal
r ire.
N o .5 t o b o d yg r o u n dw i t ha j u m p e w
STARTER
SUAHARNESS
6P CONNECTOR
l1l213l
l._, / l 5 l 6 l
KS
IJUMPER
|RED/BLU)
IW|RE
I
YES-Go to step 4.
NO Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the knocksensorand at the ECM.I
8 . Checkfor continuitybetweenbodygroundand
ECMconnector
terminalA9.
ECMCONNECTOR
A {31PI
ls there continuity?
YES-Go to step 9.
NO Repairopen in the wire betweenthe ECM (A9)
and the startersubharness6P connector.l
Wire side of lemaleterminals
9 . Checkthe startersubharnessbetweenthe 6P
ls therecontinuity?
YES-Repairshortin thewire betweenthe ECM
(A9)andthe startersubharness
6Pconnector.l
NO Goto step7.
11-77
PGM-FISystem
DTCTroubleshooting(cont'd)
DTCP0335:CKPSensorNo Signal
DTCP0336:CKPSensorIntermittent
Interruption
'1-4).
'1. Reset
the ECM (seepage 1
2. Start the engine.
ls DTC P0335 and/or P0336 indicated?
YES Go to step 3.
Wire side of female tefminals
ls thereabout5 V?
N O G ot o s t e p1 0 .
voltagebetweenCKPsensor3Pconnector
8. Measure
t e r m i n a lN
s o . 2a n dN o .3 .
CKPSENSOR3PCONNECTOR
CKPSENSOR3PCONNECTOF
,llYtL
IGP
1 2 3
(YEL/BLK}
L " l
LGl
{BRN/YELI
W i r e s i d eo f f e m a l et e r m i n a l s
Wiresadeof femaleterminals
Is therebattery voltage?
YES- Goto step7.
NO Repairopenln thewire betweenPGM-Flmain
r e l a y1 a n dt h eC K Ps e n s o r . !
11-78
'10.l\4easure
voltagebetweenECMconnector
terminal
A7 andbodyground,
ECMCONNECTOR
A 13lPI
Wiresideot femaleterminals
ls there about 5 V?
YES-Repair open in the wire betweenthe ECM
(A7)and the CKPsensor.t
N O - G o t o s t e p1 1 .
1 1 .Turn the ignitionswitch OFF.
DisconnectECMconnectorA (31P)
1 3 . Checkfor continuitybetweenECMconnector
terminal 47 and body ground.
ECMCONNEfiORA (31P)
Wiresideof femaleterminals
ls there continuity?
YES-Repair short in the wire betweenthe ECM
(A7)and the CKPsensor.t
NO Updatethe ECM if it does not have the latest
software.or substitutea known-goodECI\4,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.t
11-79
PGM-FlSystem
DTCTroubleshooting(cont'dl
DTCP0500:VSSCircuitMalfunction
1. Test-drivethe vehicle.
11 . T u r nt h e i g n i t i o ns w i t c hO N { l l } .
lMeasurevoltage betweenECMconnector
t e r m i n a l sA 1 8 a n d A 2 4 .
A I31PI
ECMCONNECTOR
Wiresideof femaleterminals
Wiresideof femaleterminals
11-80
DTCP0563:ECMPowerSourceCircuit
Unexpected
Voltage
1 . R e s e t h e E C I \ {4s e ep a g el 1 - 4 } .
2. Turn the ignitionswitch OFF.
3. Wait 5 seconds.
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l l .
ls DTC P0563 indicated?
YES Go to step 5.
NO-lntermiltent failure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
t h e N o . 6 E C U( E C M ){ 1 5A ) f u s e i n t h e u n d e r - h o o d
fuse/relaybox and at the ECM.I
1 1 .Checkfor continuitybetweenECMconnector
terminal E7 and body ground.
6 . DisconnectECI\4connectorE {31P).
MRLY
{RED/YEL)
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
8 . lvleasurevoltagebetweenECMconnectorterminal
E7 and body ground.
ECMCONNECTOR
E {31P}
MRLY
Wiresideof {emaleterminals
ls there continuity?
YES-Repair short in the wire betweenthe ECM
l a i n r e l a y1, I
{ E 7 )a n d t h e P G M - Fm
Wiresideol remaleterminals
NO Replace
t h e P G M - Fm
l a i n r e l a y1 . 1
tt.
'13.R e c o n n e cEt C M
c o n n e c t oE
r (31P).
(conl'd)
11-81
PGM-FISystem
DTCTroubleshooting(cont'dl
14. Measurevoltage betweenECMconnectorterminal
E7 and body ground.
ECMCONNECTORE 13lPI
MRLY
IBEO/YEL)
W i r es i d eo f f e m a l et e r m i n a l s
IGP1
(YEL/BLK)
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
IGP1
(YEL/BLKI
Wiresideof femaleterminals
11-82
N O R e p l a c e t h eP G M F l m a i n r e l a y1 . !
DTGPl106:BAROSensorRange/Perfomance
Problem
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.Holdthe engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
then let it idle.
DTCPl107:BAROSensorCircuitLowVoltage
DTCPl108:BAROSensorCircuitHigh
Voltage
1 . R e s e t h e E C M{ s e ep a g e11 - 4 ) .
2. Turn the ignition switch ON (ll).
l s D T C P 1 1 0 7o r P 1 1 0 8i n d i c a t e d ?
NO Intermittentfailure,system is OK at this
time.I
11-83
PGM-FISystem
DTGTroubleshooting(cont'dl
DTCPl157:Ay'F
Sensor(Sensor1)Range/
Performance
Problem
1 . R e s e t t h eE C I M( s e ep a g e1 1 - 4 ) .
L
6. Checkfor continuitybetweenECMconnector
t e r m i n a l4s6 a n dA 1 6 .
ECMCONNECTOR
A {3IP)
2. Startthe engine.
ls DTC Pl157 indicated?
YES-Go to step 3.
NO Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the Ay'Fsensor(Sensor1) and at the ECN4.I
Wire side of femaleterminals
ls therecontinuity?
YES Goto step9.
NO Goto step7.
(SENSOR
A/F SENSOR
1) 4PCONNECTOR
7 . Connect
A/Fsensor(Sensor1)4Pconnecror
r ire.
t e r m i n aNl o .1 t o b o d yg r o u n dw i t ha j u m p e w
AFS+ {BLU)
JUMPERWIRE
11-84
8. Checkfor continuitybetweenECMconnector
terminals46 andbodyground.
A 131P}
ECMCONNECTOR
DTCPl158:Ay'F
Sensor(Sensor1)AFSTerminalLowVoltage
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
ls DTC P1158 indicated?
YES Go to step 3.
NO-lntermittent failure,system is OK at this time
Checkfor poor connectionsor loosetermanalsat
the Ay'Fsensor(Sensor1) and at the ECIMI
4, DisconnecttheAy'Fsensor(Sensor1) 4P connector,
r (31P).
a n d E C Mc o n n e c t oA
5. Checkfor continuitybetweenECMconnector
termina4
l 1 6 a n d b o d yg r o u n d .
A (31P)
ECMCONNECTOR
' c o n td )
11-85
PGM-FISystem
DTCTroubleshooting(cont'd)
6. Substitutea known-goodAy'Fsensor(Sensor1)and
recheck.
DTCPl159:A,/FSensor(Sensor1)AFS +
TerminalLowVoltage
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
ls therecontinuity?
YES-Repairshortin thewire between
the Ay'F
s e n s o(rS e n s o1r )a n dt h eE C M( A O ) . I
NO Goto step6.
11-86
11-87
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCPl163:Ay'FSensor(Sensor1) Slow
Response
NOTE:lf DTCP1162is storedat the same time as DTC
P1163.troubleshootDTCP1162first, then recheckfor
D T CP 1 1 6 3 .
1 . R e s e t h e E C M( s e ep a g e11 - 4 ) .
2. Startthe engine.Hold the engine at 3,000rpm with
no load (in neutral)until the radiatorfan comes on.
3. Test-driveunderthe following conditions:
. 55 mph (89 km/h) steadyspeed
' Transmissionin sth gear
' Until the Ay'Fsensorreadinesscode or
TemporaryDTCPl163 comes on
4. Checkfor a TemporaryDTCwith the scantool.
ls Temporary DTC P 1163indicated?
YES Replacethe Ay'Fsensor(Sensor1).I
NO Intermittentfailure, system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the A'lFsensor (Sensor1) and at the ECM.t
11-88
DTCPl164:A,/FSensor(Sensor1)Circuit
Range/Performance
Problem
( s e ep a g e1 t - 4 ) .
1 . R e s e t t h eE C I \ 4
2 . S t a r tt h e e n g i n e .H o l d t h e e n g i n e a t 3 , 0 0r0p m w i t h
no load (in neutral)until the radiatorfan comes on,
3. Test-drivein 3rd gear.Startingat 1,600rpm,
accelerateusing wide open throttlefor at least
5 seconds.Then deceleratefor at least5 seconds
with the throttle completelycloseduntil the A,/F
sensorreadinesscode is set to completeor
TemporaryDTCP1164comes on.
4. Checkfor a TemporaryDTCwith the scantool.
ls TemporaryDTC P1164indicated?
YES- Replacethe A,,/F
sensor(Sensor1).I
NO Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the Ay'Fsensor relay,at the Ay'Fsensor(Sensor1),
a n da t t h e E c M . l
Sensor(Sensor1)Heater
DTCPl166:Ay'F
CircuitMalfunction
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
ls DTC P1166indicated?
NO-Go to step 5.
YES-Go to step 3.
NO-lntermittent failure,system is OK at this lime.
Checkfor poor connectionsor looseterminalsat
the Ay'Fsensorrelay,the A,/Fsensor(Sensor1),and
t h e E c M .!
5. MeasurevoltagebetweenECMconnector
terminalsA22 and A24.
A {31P}
ECMCONNECTOR
ls therebattery voltage?
NO Go to step 4.
4. MeasurevoltagebetweenECMconnector
terminalsA1 and A24. 30 secondsafter the ignition
s w i t c hi s t u r n e dO N ( l l ) .
A I31P)
ECMCONNECTOR
N O - G o t o s t e p1 0 .
6. Turnthe ignitionswitchOFF.
E (31P).
7. Disconnect
ECMconnector
s w i t c hO N{ l l ) .
8 . T u r nt h ei g n i t i o n
W i r es r d eo f l e m a l et e r m i n a l s
(cont'd)
11-89
PGM-FISystem
DTCTroubleshooting(cont'dl
9. ConnectECMconnectorterminal EStobody
ground with a jumper wire, then measurevoltage
betweenECMconnectorterminalsA1 and 424.
ls there continuity?
YES Repairshort in the wire betweenthe A|/F
sensorrelay,A,/Fsensor{Sensor1) and ECM
lA22J.a
ECMCONNECTORS
NO Go to step 13.
t5.
1 4 . Measurevoltage betweenECMconnector
terminalsE8 and A24.
ECM CONNECTORS
E {31P)
a {31P)
Wiresideof femaleterminals
NO Repairopen in the wire betweenthe Ay'F
r ) a n d E C M( A 1 ) t.
s e n s o r( S e n s o 1
(SENSOR
A/F SENSOR
1)4PCONNECTOR
11-90
Sensor(Sensor1)Heater
DTCPl167:Ay'F
CircuitMalfunction
NOTE:lf DTCP1162is storedat the same time as DTC
P1167,troubleshootDTCP1162first, then troubleshoot
D T CP 1 1 6 7 .
1 . R e s e t t h eE C I \ (4s e ep a g e1 1 - 4 )
6. Checkfor continuitybetweenECMconnector
t e r m i n a l s, 4 6a n d 4 1 6 .
A {31P)
ECMCONNECTOR
AFS- {RED)
trTzTil,ilsl l t
t8
9
2C21
l?rlzsIels
AFS
IRED/YEL)
YES Go to step 3.
Wire side of lemale terminals
ls thetecontinuity?
h eA / Fs e n s o(rS e n s o1r ) . 1
Y E S - R e p l a ct e
NO-Repairopenin thewire betweenthe Ay'F
s e n s o(rS e n s o1r) a n dt h eE C M( 4 6o r A 1 6 ) . I
Wire side of
f e m a l et e r m i n a l s
11-91
PGM-FISystem
DTCTroubleshooting(cont'dl
DTCPl297:ELDCircuitLowVoltage
1 . R e s e t h e E C M{ s e ep a g e1 1 - 4 ) .
2. Startthe engine.
3 . T u r no n t h e h e a d l i g h t s .
ECMCONNECTOR
E 131PI
I l 2 l 34 5 6 1 7
YES Go to step 4.
to
,2 2al2/
tA
7\'
td
8 I
/ 12021
31
ELD
(GRN/RED}
ELD{GRN/REDI
ls thereabout5 V?
YES Replace
the ELD.t
N O - G o t o s t e p8 .
11-92
DTCPl298:ELDCircuitHighVoltage
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 )
8. T u r nt h e i g n i t i o ns w i t c hO F F .
9 . ConnectELD3P connectorterminal No. 3 to body
g r o u n dw i t h a j u m p e rw i r e .
---F-------
l 1 l 2: r l
ELD
(GRN/RED)
YES-Go to step 4.
wrRE
IJUMPER
1 0 .DisconnectECMconnectorE (31P).
ECMconnectorterminal E15.
E 131PI
ECMCONNECTOR
1 2 1 34 5
IG1IBLK/ORNI
14
L C
22123
24
I I
6 l / 1 8 2C 21
21./ 2Q 30 J
o t /
ELD
i1' IGRN/RED)
Is thetecontinuity?
ls there battery voltage?
Y E S - G ot o s t e p1 2 .
YES-Go to step 8.
N O - C h e c k t h e N o . 4 A C G ( 1 0 A ) f u s ei n t h e u n d e r dash fuse/relaybox. lf the fuse is OK, repairopen in
the wire betweenthe No. 4 ACG (10A)fuse and the
ELD.I
(cont'd)
11-93
PGM-FISystem
DTCTroubleshooting(cont'dl
12, Checkfor continuitybetweenELD3P connector
t e r m i n a lN o . 2 a n d b o d y g r o u n d .
E L D 3 PC O N N E C T O R
W i r e s i d eo f f e m a l et e r m i n a l s
ls there continuity?
YES Go to step 13.
NO- Repairopen in the wire betweenthe ELDand
G 2 0 1I.
Reconnectthe ELD3P connectorand ECM
connectorE (31P).
1 4 . Startthe engineand let it idle.
t5_
W i . e s i d eo f f e m a l et e r m i n a l s
11-94
DTCPl361:CamshaftPosition(CMP)Sensor
B (TDCSensor)Intermittent
Interruption
DTCPl362:CamshaftPosition(CMP)Sensor
B (TDCSensor)No Signal
7. l\4easure
voltage betweenCMP sensorB {TDC
sensor)3P connectorterminal No. 1 and body
ground.
CMP SNSOR 8 ITDCSENSOR)3P CONNECTOR
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.
ls DTC P1361and/or P1362 indicated?
YES Go to step 3.
Wlres de ollemaleterminals
ls thereabout5 V?
YES-Go to step8.
voltagebetweenCl\ilPsensorB (TDC
8. Measure
s e n s o r3)Pc o n n e c t ot er r m i n a lN
s o .2 a n dN o ,3 .
connector.
1 2 3
{YEL/BLK}
Wiresideol temaleterminals
YES Go to step7.
NO Replace
theoriginaC
l MPsensorB(TDC
sensor).1
(cont'd)
11-95
PGM-FISystem
(cont'd)
DTCTroubleshooting
10. MeasurevoltagebetweenECI\4
connectorterminal
A26andbodyground.
ECMCONNECTOR
A (31P)
1 2 3 4 5 6 1 7
I
0 1 11 2 1 . /
61,/18 I 2C2l
2324
21m 30
TDC {GRN}
ls thereabout5 V ?
YES- Repairopenin thewire betweenthe ECM
(426)and CMPsensorB (TDCsensor).1
DTCPl607:Malfunction
in ECMInternal
Circuit
1. ResettheEC|\illsee page 11-4).
2 , T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r
40 seconds.
ls DTC P 1607 indicated?
YES Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11 6). lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
NO Intermittentfailure,system is OK at this time.
A low batterycan causethis problem . Ask the
customerif there has been any recenttrouble
s t a r t i n gt h e e n g i n e . l
N O - G o t o s t e p1 1 .
1 1 .Turnthe ignitionswitchOFF.
ECIM
A (31P)
1 2 . Disconnect
connector
Checkfor continuitybetweenECMconnector
terminal426 andbodyground.
ECMCONNECTOR
A {31PI
Wiresideof femaleterminals
ls there continuity?
YES Repairshort in the wire betweenthe ECM
(426)and the CMP sensor B (TDCsensor).1
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-96
MIL CircuitTroubleshooting
1. Connectan OBD ll scantool/HondaPGM Tester
( s e ep a g e1 1 - 3 ) .
2. Turn the ignition switch ON (ll) and readthe OBD ll
scantool/HondaPGM Tester.
Does the OBD ll scan tool/Honda PGM Tester
communicatewith the ECM?
YES Go to step 3.
"
NO Go to troubleshooting DLCCircuit
T r o u b l e s h o o t i n g (" s e ep a g e1 1 - 1 0 9 ) .
. A l o o s eN o . 1 7 F U E LP U M P( 1 5 A ) f u s ei n t h e
under-dashfuse/relaybox.
. A p o o rc o n n e c t i o n
l 31.
a t E C Mt e r m i n a E
. An intermittentopen in the GRN/ORNwire
) n d t h e g a u g ea s s e m b l y .
b e t w e e nt h e E C M( E 3 1 a
. An intermittentshort in the wire betweenthe
ECM(A21)and the manifold absolutepressure
( M A P )s e n s o r .
. An intermittentshort in the wire betweenthe
ECI\4(A20)and the throttle posilion (TPisensor.
. An intermittentshort in the wire betweenthe
ECM (E5)and the fuel tank pressure(FTP)sensor.
6. Turn the ignition switch OFF.
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NO-Go to step 4.
N O - G o t o s t e p8 .
YES Go to step L
oN (tr)?
N O R e p a i rs h o n i n t h e w i r e b e t w e e nN o . 1 0
M E T E R( 7 . 5 A ) f u s e
a n d t h e g a u g ea s s e m b l yA. l s o
r e p l a c e t h eN o . 1 0 M E T E R{ 7 . 5 A f) u s e . l
(conr'd)
11-97
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
1 0 .Tryto startthe engine.
to.
Doesthe enginestart?
1 7 . Removethe glove box (seepage 20-63)and the
P G M ' F Im a i n r e l a y1 .
Y E S - G ot o s t e p1 1 .
N O - G o t o s t e p1 4 .
1 1 .Turnthe ignitionswitchOFF.
12. ConnectECMconnector
terminalE31to body
groundwith a jumperwire.
ECMCONNECTOR
E 13lPI
l l 2 l 34 5 6 1 7 l1 8I
4 1 5161,/118 2( 2t
2' 23 24
z7l/ 129 31
JUMPER MIL
(GRN/ORN}
WIRE
't4. Turn
the ignltion switch OFF,
f V (wHr/
B
v)
BLK)(
IA
W r r es r d eo l l e m a l et e r m r n a l s
ls there continuity?
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e N o . 6
) 5 A )f u s ea n d t h e P G M - Fm
E C U( E C l \ 4( 1
l a i n r e l a y1 .
A l s o r e p l a c et h e N o . 6 E C U( E C M )( 1 5 A )f u s e . l
N O - G o t o s t e p1 9 .
(15A)fuse in the
1 5 . Inspectthe No. 6 ECU (ECIM)
under-hoodfuse/relaybox.
ls the f use OK?
YES-Go to step 22.
N O - G o t o s t e p1 6 .
11-98
.
.
.
.
.
PGfvl-Flmain relay 2
ECMconnectorA (31P)
Eachinjector2P connector
ldle air control (lAC)valve3P connector
CamshaftPosition(CMP)sensorB (Topdead
center(TDC)sensor)3P connector
. Crankshaftposition(CKP)sensor3P connector
PGM-FIMAIN RELAY1
4PCONNECTOR
Wire side of femaleterminals
ls there continuity?
YES Repairshort in the wire betweenthe PGM-Fl
main relay 1 and each item. Also replacethe No. 6
E C U{ E C M )( 1 5 A )f u s e . l
l a i n r e l a y1 .A l s o r e p l a c e
N O - R e p l a c et h e P G M - Fm
t h e N o 6 E C U{ E C I M()1 5 A )f u s e .I
Wire side of femaleterminals
( 1 5 A ) f u s ei n t h e
22. I n s p e c t t h eN o . 1 7 F U E LP U I \ 4 P
ls thete continuity?
under-dashf use/relaybox.
23. R e m o v et h e b l o w nN o , 1 7 F UE LP U M P( 1 5 A )f u s e
from the under-dashfuse/relaybox.
2 4 . DisconnectECfvlconnectorE (31P).
P G M - Fm
l a i n r e l a y2
E C Mc o n n e c t oA
r (31P)
lnjectors
l d l ea i r c o n t r o l( l A C ) v a l v e
CamshaftPosition{CMP)sensorB (Top dead
center(TDC)sensor)
. Crankshaftposition(CKP)sensor
(conr'd)
11-99
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
25. Checkfor continuitybetweenECMconnector
terminal E9 and body ground.
ECMCONNECTOR
E (31P)
ECMCONNECTOR
E 131P)
ls therc continuity?
ls there continuity?
N O R e p l a cteh e N o . l T F U E L P U M P ( 1 5 A ) f u s e ,
and updatethe ECM if it does not have the latest
software.or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM.replacethe
originaE
l CM.I
NO Go to step 28.
11-100
=
Wire side ol lemal rerminals
ls there continuity?
ls therc continuity?
YES Repairshortin thewire betweenthefuel
p u m pa n dt h eP G M - Fml a i nr e l a y2 .A l s or e p l a c e
t h EN O .1 7F U E LP U M P( 1 5 Af)U S E . T
NO-Go to step32.
32. Reinstallthe
PGM-Flmainrelay2 (A).
(cont'd)
11-101
PGM-FISystem
(cont'dl
MIL CircuitTroubleshooting
37. lvleasure
voltagebetweenECM/PCM
connector
t e r m i n aEl 7a n db o d yg r o u n d .
Y E S - G o t o s t e p4 1 .
NO Go to step38.
MRLY(RED/YEL)
ECMCONNECTOR
E 131PI
MRLY(RED/YEL)
ls there continuity?
YES-Testthe PGM-Flmain relay 1 (seepage2251). lf the relay is OK, updatethe ECM if it does not
have the latestsoftware,or substitutea knowngood ECM,then recheck{seepage 11'6).lf the
symptom/indicationgoes away with a known-good
E C M ,r e p l a c et h e o r i g i n a E
l CM.I
NO*Repair open in the wire betweenthe PGM-FI
m a i n r e l a y1 a n d t h e E C M( E 7 ) . 1
11-102
48. MeasurevoltagebetweenPGM-FI
mainrelay1 4P
connector
terminalNo.2 andbodyground.
4 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
PGM.FIMAIN RELAY1
4PCONNECTOR
N O R e p a i ro p e ni n t h e w i r e b e t w e e nt h e N o . 6
E C U{ E C M )( 1 5 A } f u s ea n d t h e P G M - Fm
l ain
r e l a y1. !
4 9 . T u r nt h e i g n i t i o ns w i t c hO F F .
4 5 . T u r nt h e i g n i t i o ns w i t c hO F F .
46. R e m o v et h e P G M ' F lm a i n r e l a y1 {A)
,A
IGPl (YEL/BLK)
W i r es i d eo f f e m a l et e r m i n a l s
4 7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls there continuity?
YES Replace
t h e P G M - Fm
l a i n r e l a y1 . 1
NO Repairopen in the wire betweenthe PGM-FI
'1
m a i n r e l a y a n d t h e E C M( A 2 ,A 3 ) . 1
{cont'd}
11-103
PGM-FISystem
MIL CircuitTroubleshooting(cont'dl
51. MeasurevoltagebetweenbodygroundandECM
connector
terminals44, A5,423,and424
individuallv.
ECMCONNECTOR
A 131P)
PG2(BLK)
PG1IBLKI
W i r es i d eo f f e m a l et e r m i n a l s
Wiresideof femaleterminals
ls there about 5 V?
YES Replacethe MAP sensor.l
NO Go to step 57.
5 7 . Turn the ignition switch OFF.
5 8 . D i s c o n n e cEt C Mc o n n e c t oA
r (31P).
Wiresideof femaleterminals
ls there about 5 V?
YES-Go to step 60.
N O - G o t o s t e p5 3 .
11-104
t t,
6 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
64. Measurevoltage betweenbody ground and ECM
connectorterminal 420,
ECMCONNECTOR
A 131P)
ls there continuity?
YES*Repair short in the wire betweenthe ECM
( 4 2 1 )a n d t h e M A P s e n s o r . l
NO Updatethe ECM it it does not have the latest
soflware,or substitutea known-goodECM,then
recheck(seepage 1'l-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
Wiresideof femaleterminals
ls there about 5 V?
YES Replacethe thronle body (theTP sensoris
not availableseparately).
I
NO Go to step 65.
ECMCONNECTOR
A {3TP}
1 1 2 1 43 5 o t /
I
1 0 11112
5 6 / 1189 2t 21
2' 231?4 ? q
Tln 29
vcc2
IYEL/
BLU)
W i r es i d eo t f e m a l tee r m i n a l s
ls there about 5 V?
YES-Go to step 68.
N O - G o t o s t e p6 1 .
conlo
11-105
PGM-FISystem
MIL CircuitTroubleshooting(cont'd)
6 7 . Checkfor continuitybetweenECIM
connector
t e r m i n aAl 2 0a n db o d yg r o u n d .
ECMCONNECTOR
A (31P)
r l 2 l 3 1 54
o t /
10 t1 121,/1,/ 1516
22 '3 241 12526
ECMCONNECTOR
E (31PI
ta,
9 2A21
vcc2
{YEL/
BLU}
ls there continuity?
Is there about 5 V?
11-106
72. MeasurevoltagebetweenbodygroundandECM
connector
terminalE5.
7 6 . T u r nt h e i g n i t i o ns w i t c hO F F .
7 7 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ECMCONNECTOR
E 131P}
7 8 . Measurevoltage betweenECMconnectorterminal
E 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E (31P)
r l 2 l 3 1 4
5 6 1
15 6
,/1,/114
22
23 241 l,/
8 9
2A21
2930
scstBRN)
ls there about 5 V?
Wiresideof femaleterminals
YES Replacethe FTPsensor.t
NO Go to step 73.
7 4 . DisconnectECMconnectorE (3'lP).
NO Go to step 79.
7 5 .Checkfor continuitybetweenECMconnector
t e r m i n a lE 5 a n d b o d y g r o u n d .
8 0 . DisconnectECMconnectorE (31P).
ECMCONNECTOR
E {31PI
Is there continuity?
YES Repairshort in the wire betweenthe ECM
( E 5 )a n dt h e F T Ps e n s o r . l
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
(cont'd)
11-107
PGM-FISystem
MIL GircuitTroubleshooting(cont'd)
81. Checkfor continuitybetweenECMconnector
t e r m i n a lE 2 9a n d b o d y g r o u n d .
ECMCONNECTOR
E 131P}
r l 2 l 34 5
14 t c
22123124
61,/118 2A21
271./ 3031
scs(BRN)
ls there continuity?
YES-Repair short in the wire betweenthe data link
connector(DLC)and the ECM(E29).1
NO Updatethe ECM if it does not havethe latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CI\4,I
Turn the ignition switch OFF.
DisconnectECMconnectorE (31P).
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the MIL stay on?
YES-Repair short in the wire betweenthe gauge
a s s e m b l ya n dt h e E C M( E 3 1) . l f t h e w i r e i s O K ,
r e p l a c et h e g a u g ea s s e m b l y . l
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-108
DLCCircuitTroubleshooting
lf the ECMdoes not communicatewith the OBD ll scan
tool, HondaPGfMTester,or l/M test equipment,do this
troubleshootingprocedure.
1. Measurevoltage betweenDLCterminal No. 16 and
body ground.
DATALINKCONNECTOR
{DLCI
(WHT/RED)
Terminalside of femaleterminals
YES-Go to step 2.
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
NO-Repair open in the wire betweenDLCterminal
N o . 1 6 a n d t h e N o . 9 B A C KU P ( 7 . 5A ) f u s ei n t h e
under-hoodf use/relaybox.I
Measurevoltage betweenDLCterminalsNo. 4 and
No.16.
5 . M e a s u r ev o l t a g eb e t w e e nD L Ct e r m i n a l sN o . 5 a n d
No.7.
DATA LINKCONNECTOR
{DLCI
T e r m i n asli d eo f l e m a l et e r m i n a l s
Terminalsideof Jemale
terminals
(cont'd)
11-109
PGM-FISystem
DLCCircuitTroubleshooting
{cont'dl
7. DisconnectEClvlconnectorE (31P).Make sure the
O B Dl l s c a nt o o l o r H o n d aP G MT e s t e ri s
disconnectedfrom the DLC.
ls there continuity?
YES U pdatethe ECMif it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CI\4.I
1 0 .T u r nt h e i g n i t i o ns w i t c hO F F .
1
' I.
ls there continuity?
tJ.
NO Go to step 9.
K-LINE{LTBLU)
DATA LINK CONNECTOR
Is there 0 V?
YES Updatethe ECMif it does not havethe latest
then
software,or substitutea known-goodECI\4,
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
Terminalside of femaleterminals
11-110
InjectorReplacement
(seepage1l-144).
fuel pressure
1 . Relieve
2 . Disconnect
the connectors
fromthe injectors(A),disconnect
the groundcable(B),andremovethe bracket(C).
ffi\t\
*\
(cont'd)
11-111
PGM-FISystem
InjectorReplacement(cont'd)
7 . C o a t t h e n e w o - r i n g s ( A ) w i t h c l e a n e n g i n e o l l , a n d i n s e r t t h e i n j e c t o risn(tBo)t h e f u e lr a i l( C ) .
8 , l n s t a ltl h e i n j e c t o cr l i p { D ) .
9. Coatthe injectoro-rings(E)with cleanengine oil.
1 0 . I n s t a l l t h ei n j e c t o r si n t o t h e f u e lr a i l ,t h e n i n s t a l tl h e f u e l r a i li n t o t h e i n t a k e m a n i f o l d ( G ) .
1'1. Installthe fuel rail mounting nuts,ground cable.and bracket.
12. Connectthe connectorsto the injectors.
13. Connectthe quick-connectfittings.
1 4 . T u r n t h ei g n i t i o ns w i t c hO N ( l l ) ,b u t d o n o t o p e r a t e t h es t a r t e rA. f t e r t h e f u e lp u m p r u n sf o r a b o u t2 s e c o n d st,h e
fuel pressurein the fuel line rises.Repeatthis two or three times. then checkfor fuel leakage.
11-112
A/F SensorReplacement
SecondaryHO2SReplacement
ffi
B
44N.m
11-113
PGM-FlSystem
ECTSensorReplacement
'1.
CMPSensorB (TDCSensorl
Replacement
R e m o v et h e a i r c l e a n e r{ s e ep a g e1 1 - 1 6 2 ) .
' t . R e m o v et h e a i r c l e a n e r( s e ep a g e1 1 - 1 6 2 ) .
3. Removethe ECTsensor(A).
11-114
8.7tbf.ftl
IAT SensorReplacement
1, Dlsconnectthe IAT sensor2P connector.
KnockSensorReplacement
1. Removethe intakemanifold bracket(A).
24Nm
(2.4kgt.m,17lbt.ftl
11-115
PGM-FISystem
GKPSensorReplacement
1. Disconnect
the CKPsensor3Pconnector.
2. RemovetheCKPsensor{A).
12 N.m (1.2kgt m.
8.7 tbf.ftl
11-116
VTEC/VTC
ComponentLocationIndex
-gl
:1
i-
ia
r-:
@'-;'
--tl
;'l--i
lt i..,,
',..
VTCOILCONTROL
VALVE
SOLENOID
page11-118
Troubleshooting,
11-'l27
Test,page
-'
tt
'--'-
CAMSHAFTPOSITION
ICMPISENSORA
Troubleshooting,page 11-121
Replacement,
Pagel'!-128
VALVE
VTCSOLENOID
page11-123
Troubleshooting,
page11-128
Removal/lnspection,
11-117
VTEC/VTC
DTGTroubleshooting
DTCP0010:WC Oil ControlSolenoidValve
Malfunction
8. MeasureresistancebetweenVTCoil control
s o l e n o i dv a l v e2 Pt e r m i n a l sN o . 1 a n d N o . 2 .
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
T e r m i n a s i d 6 o t m a t e t e r m i n as
YES Go to step 4.
YES-Go to step L
-4t 1 t
ECMCONNECTOR
B I24P)
wc
2 l
lwc*
tBr-K/wHT) |
liELU/WHT)
JUMPER
WTREI IJUMPEnW|RE
W i r e s i d eo f 1 6 m a l et e . m i n a t s
ls there continuity?
Y E S G o t o s t e p1 1 .
NO- Repairopen in the wire betweenthe ECM (B1,
B23)and the VTCoil control solenoidvalve.I
11-118
DTCP0011:VTCSystemMalfunction
1. Resetthe EClvl(seepage 11-4).
2 . S t a r tt h e e n g i n e .H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h
n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n .
VTC
(BtK/WHT)
YES-Go to step 5.
1 3 .Checkfor continuitybetweenECMconnector
N O - G o t o s t e p6 .
t e r m i n a l sB 1 a n d 8 2 3 a n d b o d y g r o u n di n d i v i d u a l l y .
6 . Turn the ignition switch OFF.
7 . Removethe auto-tensioner(seepage 4-28).
vfc
(8LK/WHT)
W i r e s i d eo f f e m a l er e r m i n as
ls there continuity?
Y E S - R e p a i rs h o r ti n t h e w i r e b e t w e e nt h e E C M( B 1 ,
B23)and the VTCoil control solenoidvalve.l
NO Replacethe VTC oil control solenoidvalve
(seepage 11-1211.a
(cont'd)
11-119
VTEC/VTC
DTCTroubleshooting(cont'dl
Removethe VTC strainer(A).Checkthe WC
s t r a i n e fro r c l o g g i n g .
YES Go to step g.
NO-Clean the VTC strainer,then replacethe
e n g i n eo i l f i l t e ra n d t h e e n g i n eo i l . l
9. Checkthe VTCoil control solenoidvalve{seepage
11-127
).
ls the VTC oilcontrol solenoid valve OK?
YES Go to step 10.
NO Cleanthe ports of the WC oil control solenoid
valve,or replacethe VTCoil control solenoidvalve
{seepage 11-127).a
213415
8
1
e l1a,/1,/
6 7
15
181./l l./ 21
23
vTc
JUMPER
(BLK/WHT} WIRE
11-120
DTCP0340:
CMPSensorA No Signal
DTGP0344:CMPSensorA Intermittent
Interruption
7. MeasurevoltagebetweenCMPsensorA 3P
terminalNo. 1 andbodyground.
connector
CMP SENSORA 3P CONNECTOR
'11-4).
1 . R e s e t h e E C M( s e ep a g e
2. Startthe engine.
ls DTC P0340and/or P0344indicated?
YES-Go to step 3.
W i r e s i d eo l f e m a l e t e r m i n as
ls thercabout5 V?
YES-Go to step8.
NO-Go to step10.
4. Disconnectthe CMPsensorA 3P connector.
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
6. Measurevoltage betweenCMPsensorA 3P
connectorterminal No. 3 and body ground.
CMPSENSORA 3P CONNECTOR
tG1
1 2 3
voltagebetweenCMPsensorA 3P
8. Measure
s o .2 a n dN o .3 .
c o n n e c t ot er r m i n a lN
CMP SENSORA 3P CONNECTOF
;f-;-1 J ,o,,r.*,"r.,
I l1
l-t
,-or---T--I
{8RN/YEL)
ni-
(BLK/YEL}
11-121
VTEC/VTC
DTCTroubleshooting(cont'd)
1 0 .Measurevoltage betweenECMconnectorterminal
A25 and body ground.
ECMCONNECTORA 131P)
DTCP0341:WC PhaseGap
1 . R e s e t t h eE C M{ s e ep a g e1 1 - 4 ) .
2. Startthe engine.
ls DTC P0341indicated?
YES Go to step 3.
NO Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
t h e C M Ps e n s o rA a n d a t t h e E C M . I
Wiresideof femalete.minals
ls there about 5 V?
YES-Repair open in the wire betweenthe ECM
( A 2 5 )a n d C M Ps e n s o rA . I
N O - G o t o s t e p1 1 .
DisconnectECMconnectorA (31P)
Checkfor continuitybetweenECMconnecror
terminal A25 and body ground.
ECMCONNECTONA 131P}
Wiresideof femaleterminals
ls tnere continuity?
YES-Repair short in the wire betweenthe ECM
(A25)and the CMP sensorA. t
NO Updatethe ECt\4if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-122
DTCPl259:WEC SystemMalfunction
SpecialToolsRequired
. Pressuregaugeadapter07NAJ P07010A
. A/T low pressuregaugew/panel 07406-0070300
. A/T pressurehose 07406-0020201
. Av/Tpressurehose,2,210mm 07IMAJ-PY4o11A
. l"/T pressureadapter07MAJ-PY40120
. Oil pressurehose 07ZAJ-S54,4200
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2 . C h e c kt h e e n g i n eo i l l e v e l ,a n d r e f i l li f n e c e s s a r y .
3. Startthe engine.Hold the engineat 3,000rpm with
no load {in neutral)until the radiatorfan comes on.
4. Roadtestthe vehicle:
Acceleratein the 1stgear to an engine speedover
4.000rpm. Holdthe speedfor at least2 seconds.lf
DTCP1259is not repeatedduring the first road test,
repeatthe test two more times.
ls DTC P1259 indicated?
YES Go to step 5.
NO-lntermittent failure,system is OK at this time
Checkthe oil consumptionif oil was added in step
2. Checkfor poor connectionsor looseterminalsat
the VTECsolenoidvalve,the VTECoil pressure
I
switch,and at the ECI\4.
5, Turn the ignitjon switch OFF.
T e r m i n asl i d eo f m a l et e r m i n a l s
Is therecontinuity?
YES-Go to step8.
switch.l
theVTECoil pressure
NO Replace
s w i t c hO N( l l ) .
8 . T u r nt h ei g n i t i o n
switch
voltagebetweenVTECoil pressure
9. Measure
terminalNo.1 andbodyground
2Pconnector
SWITCH
VTECOILPRESSURE
2PCONNECTOR
VTPSW
/T\ {BLU/BLK}
{.--rr-l'--.l
\rJ
II
oI
W i r es i d eo f f e m a l et e r m i n a l s
(cont'd)
11-123
VTEC/VTC
DTCTroubleshooting(cont'd)
10. Measurevoltage betweenECMconnectorterminal
89 and body ground.
14. fMeasure
voltagebetweenVTECoil pressure
switch
2 Pc o n n e c t ot er r m i n a lN
s o .1 a n dN o .2 ,
ECMCONNECTOR
B (24P)
VTECOILPRESSURE
SWITCH
2P CONNECTOR
VTPSW
(BLU/BLK)
213415
o 1
8 I a t / t / n 3 15
(BRN/YELI
WPSW {BLU/BLK}
WiresideofIemale
terminals
Y E S - G o t o s t e p1 5 .
N O - G o t o s t e p1 1 .
Checkfor continuitybetweenECMconnector
t e r m i n a lB g a n d b o d y g r o u n d .
ECMCONNECTOR
B {24P)
2 3 415
I 9 ol./ ./ 13
6 7
15
1 7 . Checkfor resistancebetweenVTECsolenoidvalve
2 Pc o n n e c t otre r m i n a l sN o , 1 a n d N o . 2 .
VTECSOLENOIDVALVE
2PCONNECTOR
VTPSW{BLU/BLK}
T e r m i n as li d eo f m a l et e r m i n a l s
ls there continuity?
YES Repairshort in the wire betweenthe VTECoil
pressureswitch and the ECM (89).I
ls there 14- 30 Sl ?
YES Go to step 18.
11-124
07406-0070300
07406-0020201
ot
07MAJ-PY,lo11A
and
07MAJ-PY40120
\lsl
t:={
A
22 N.m
l2.2kgt.m,
16rbf.ft)
07NAJ-P07010A
t e r m i n a l t oV T E Cs o l e n o i dv a l v e2 P c o n n e c t o r
t e r m i n a lN o . 1 , a n d c h e c kt h e o i l p r e s s u r ea t a n
engine speedof 3,000rpm.
ls the oil pressure above 390 kPa (4.0 kgt/crtf ,
57 psi)?
YES Go to step 27.
NO InspecttheVTECsolenoidvalve (seepage I112Al.a
(cont'd)
11-125
WEC/VTC
DTCTroubleshooting(cont'd)
30. DisconnectECMconnector B (24P)
Checkfor continuitybetweenECMconnector
t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ECM CONNECTORB {24P)
r-.'-r.---.1
t 1 t 2 l
JUMPERI VtS
WIRE I IGRN/YEL)
Wiresideof femaleterminals
Checkfor continuitybetweenECMconnector
t e r m i n a l8 1 5 a n d b o d y g r o u n d .
ls therecontinuity?
ECM CONNECTORB {24PI
Wiresideof femaleterminals
ls thete continuity?
YES Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
NO Repairopen in the wire betweenthe VTEC
s o l e n o i dv a l v ea n dt h e E C M( 8 1 5 ) . I
11-126
WC OilControlSolenoidValveRemoval/Test
1 . R e m o v et h e W C o i l c o n t r o ls o l e n o i dv a l v e( A ) .
NOTE:lnstallthe valve in the reverseorder of
removalwith a new o-ring (B),then checkthese
tlems:
Terminalside oJ
m a l et e r m i n a l s
BATTERY
Connectthe batterynegativeterminalto VTC oil
c o n t r o ls o l e n o i dv a l v e2 Pc o n n e c t otre r m i n a lN o . 1 ,
t h e n m a k es u r et h e v a l v e( A )o p e n sf u l l y .
11-127
VTEC/WC
CMPSensorA Replacement
WEC SolenoidValveRemoval/
Inspection
1 . R e m o v et h e a i r c l e a n e r( s e ep a g e11 - 1 6 2 ) .
Disconnectthe CMP sensorA 3P connector.
MeasureresistancebetweenVTECsolenoidvalve
c o n n e c t otre r m i n a l sN o . 1 a n d N o . 2 .
Resistance:14-30 Q
B-'-----'-l:,",14*
Installthe sensorin the reverseorder of removal
with a new o-ring (B).
3. lf the resistanceis within specifications,removethe
VTECsolenoidvalve assemblv(A)from the
cylinder head,and checkthe VTECsolenoidvalve
f i l t e r( B ) f o rc l o g g i n g l.f i t i s c l o g g e d r, e p l a c et h e
solenoidvalve filter,the engine oilfilter, and the
e n g i n eo i l .
6x1.0mm
9.8 N.m (1.0kgf.m, 7,2 lbf.ftl
11-128
ldleGontrolSystem
ComponentLocationIndex
TE'
IDLEAIRCONTROL{IAC)VALVE
page11-'131
Troubleshooting,
11-129
ldle ControlSystem
(
DTCTroubleshooting
DTCP0505:ldle ControlSystemMalfunction
7 . P u ty o u r f i n g e r so n t h e l o w e rp o n ( A )i n t h e t h r o t t l e
oooy.
Y E S C h e c k t h ei d l es p e e d( s e ep a g e1 1 - 1 3 8 )l f. i t ' s
out of specification,replacethe IACvalve.l
3 . D i s c o n n e ct h
t e i d l e a i r c o n t r o l{ l A C )v a l v e 3 P
connector.
Does the engine speed increase or fluctuate?
YES- Checkthe idle speed{seepage 1 1-138).lf the
idle will not adjust properly,cleanthe passagein
the throttle body, and then adjustthe idle.I
NO- Replace
t h e I A Cv a l v e . I
4. Turn the ignition switch OFF.
5. Removethe intakeair duct from the throttle body.
6. Startthe engine,and let it idle.
11-130
DTCPl519:IACValveCircuitMalfunction
1 . R e s e t t h eE C M( s e ep a g e1 1 - 4 ) .
YES Go to step 3.
PG1{BLK}
a.
Wire side of lemaleterminals
IGP{YEL/BLK)
s
r l 2 l 3 l 45 6 1 7
/ 115 6 ./118192C21
da 25126 l27ln2930
r0 1l 12./
Wire side of femaleterminals
ls therebattery voltage?
IACV{BLK/RED}
1,)
terminals
WiresideoJJemale
ls there continuity?
7 . Turnthe ignitionswitchOFF.
YES-Repair short in the wire betweenthe IAC
v a l v ea n dt h e E C M( A 1 2 ) . 1
N O G o t o s t e p 11 .
LCOnIOl
11-131
ldle ControlSystem
(
DTCTroubleshooting(cont'd)
11. ConnectIACvalve3Pconnector
terminalNo.3to
bodygroundwith a jumperwire.
IACVALVE3PCONNCTOR
ECMCONNECTOR
A 131P}
r l 2 l 3 1 54 6 1 7
IACVIBLK/REO}
JUMPERWIRE
t 0 1tl12l,/l/
22
tc
231?4l|
12.
9
6 ,/ 118 2C21
zil28 30
IACVIBLK/RED)
Checkfor continuitybetweenECMconnector
t e r m i n a l A l 2 a n d b o d yg r o u n d .
ECMCONNECTOR
A 131P)
ls therecontinuity?
YES Goto step13.
NO-Repairopenin thewire betweenthe IACvalve
a n dr h eE c M( A 1 2 ) . r
1 3 .Reconnect
the IACvalve3Pconnector.
1 4 .Turnthe ignitionswitchON (ll).
11-132
A/G SignalCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll).
2 . MomentarilyconnectECMconnectorterminals424
and E18with a jumper wire severaltimes.
6. Momentarilyconnectunder-hoodtuse/relaybox
14Pconnectorterminal No. 10 to body ground with
a jumper wire severaltimes.
UNDER.HOOD
FUSE/RELAY
BOX
I4P CONNECTOR
1 2 3
1 8 9 10 11
5 6
I J
14
ACC (RED)
JUMPERWIRE
Wiresideof femaleterminals
Wire side of femaleterminals
YES Go to step 3.
NO-Go to step 6.
11-133
ldle GontrolSystem
AlternatorFRSignalCircuitTroubleshooting
' t . Disconnectthe alternator4P
connectorfrom the
alternalor.
2. T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
'11.
Connectalternator4P connector term inal No.4 to
body ground with a jumper wire.
ALTERNATOR4P CONNECTOR
3 . Measurevoltage betweenECMconnector
t e r m i n a l s4 2 4 a n d 8 1 3 .
ECM CONNECTORS
A l31Pl
ALTFIWHT/RED)
1 2 1 3 4 5 6 1 1| 1 . , 'I
10 1 1 1 1 2 , / 5 6 , / r8119l2C21
23124
28129130
L
JUMPERWIRE
(BRN/Y EL)
ALTF
(WHT/REDI
213 4t5
8
9ltal,/l/
6 1
15
Wiresideof femaleterminals
ECMCONNECTOB
B (24PI
ls there about 5 V?
YES Go to step 4.
N O - G o t o s t e p1 3 .
4. Turn the ignition switch OFF.
5. Reconnectthe alternator4P connector.
6. Slan the engine.Hold the engineat 3,000rpm with
no load (in neutral)until the radiatorfan comes on,
then let it idle.
7. lvleasurevoltagebetweenECMconnector
t e r m i n a l sA 2 4 a n d B 1 3 .
Does the voltage decrease when the headlights
and rear window defogger arc tutned on?
ls there continuity?
YES-Testthe alternator(seepage 4-22).1
NO Repairopen in the wire betweenthe ECM
( B1 3 )a n dt h e a l t e r n a t o r . l
11-134
ElectricalPowerSteering(EPSI
SignalCircuitTroubleshooting
15. Checkfor continuitybetweenbody ground and
ECIMconnectorterminal 813.
ECM CONNECTORB I24P}
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
2 . l\4easure
voltage betweenECMconnector
t e r m i n a l s4 2 4 a n d E 1 6 .
ls there continuity?
Wire side of femaleterminals
3 . Startthe engine.
4 . Turn the steeringwheel lo the full lock position.
5 . l\4easurevoltage betweenECMconnector
t e r m i n a l sA 2 4 a n d E 1 6 .
ls there momentatybattery voltage?
Y E S T h e E P Ss i g n a li s O K . t
N O G o t o s t e p1 0 .
6 . T u r nt h e i g n i t i o ns w i t c hO F F .
7. Disconnectthe EPScontrol unit 20Pconnector.
8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
11-135
ldle ControlSystem
ElectricalPowerSteering(EPSISignalCircuitTroubleshooting(cont'd)
9. Measure
voltagebetweenEPScontrolunitterminal
N o . l 7a n db o d yg r o u n d .
'13.
l\4easure
voltagebetweenEPScontrol unitterminal
N o . 1 7a n d t h e b o d y g r o u n d .
EPSCONTROLUNIT2OPCONNECTOR
EPSCONTROLUNIT2OPCONNECTOR
N O - G o t o s t e p1 4 ,
1 4 . Turn the ignition switch OFF.
t5_
D i s c o n n e c t t hE
e C Mc o n n e c t oE
r {31P).
a,
Wiresideot Iemaleterminals
lsthere continuity?
YES Repairshort in the wire betweenthe ECN4
( E1 6 )a n d t h e E P Sc o n t r o lu n i t . l
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-136
BrakePedalPositionSwitch SignalCircuitTroubleshooting
1. Checkthe brakelights.
Are the brake lights on without pressing the brake
pedal?
YES Inspectthebrakepedal positionswitch
( s e ep a g e1 9 - 6 ) . I
NO Go to step 2.
2. Pressthe brakepedal.
Do the brake lights come on?
4 . I n s p e ctth e N o . 7 H O R N S
, T O P( 1 5 A )f u s el n t h e
under-hoodfuse/relaybox.
ls the tuse OK?
YES- Repairopen in the wire betweenthe brake
pedal positionswitch and the No.7 HORN,STOP
( l5A) fuse, Inspectthe brakepedal positionswitch
( s e ep a g e1 9 - 1 0 ) . 1
NO Repairshort in the wire betweenthe ECM
( E 2 2 )a n dt h e N o . 7 H O R N ,S T O P( 1 5 A ) f u s e .
Replace
the No.7 HORNS
, T O P( 1 5 A ) f u s e . t
YES-Go to step 3.
NO Go to step 4.
3. MeasurevoltagebetweenECMconnector
terminalsA24 and E22with the brakepedal
presseo.
oK,I
NO Repairopen in the wire betweenthe Eclvl
(E22)and the brakepedal positionswitch.l
11-137
ldle ControlSystem
ldle Speedlnspection
NOTE:
' Leavethe idle air control (lAC)valve connecled.
. Beforecheckingthe idle speed,checkthese items:
- T h em a l f u n c t i o n
i n d i c a t o lra m p ( M l L )h a s n o t b e e n
reportedon.
- l g n i t i o nt i m i n g
- S p a r kp l u g s
- Aircleaner
- PCVsystem
. P u l l t h ep a r k i n gb r a k el e v e ru p . S t a r tt h e e n g i n e a
, nd
make sure the headlightsare off.
1. Disconnectthe evaporativeemission(EVAP)
canisterpurge valve 2P connector.
11-138
ECMldle LearnProcedure
The idle learn proceduremust be done so the ECMcan
learnthe engine idle characteristics.
Do the idle learn procedurewheneveryou do any of
these actions:
. Disconnectthe battery.
Replacethe ECMor disconnectits connector.
Resetthe ECM.
NOTE:ErasingDTCSwith the HondaPGM Tester
does not requireyou to do the idle learn procedure.
Removethe No.6 ECU{ECM)( 15A)fuse from the
under-hoodfuse/relaybox.
Removethe No.19baftery(80A)fuse from the underhood fuse/relaybox.
R e m o v eP G M - Fm
I a i n r e l a y1 .
Removeany of the wires from the under-hoodfuse/
retayDox.
Disconnectany of the connectorsfrom the under
hood fuse/relaybox.
Disconnectthe connectorbetweenthe engine
compartmentwire harnessand ECMwire harness.
Disconnectthe G2 terminal from the transmission
h ous r n g .
DisconnecttheG'l terminal from the body.
D i s c o n n e c t t hG
e 1 0 1t e r m i n a fl r o m t h e c y l i n d e rh e a d
cover.
Procedure:
To completethe idle learn procedure,do this:
1. Make sure all electricalitems (Ay'C,
audio, rear
defogger,l:ghts,etc.,)are off.
2. Startthe engine,and hold it at 3,000rpm with no
l o a d{ i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n , o r
u n t i lt h e e n g i n ec o o l a n t t e m p e r a t u r e a c h e s1 9 4 " F
(90'c).
11-139
FuelSupplySystem
ComponentLocationIndex
PUMP
T e s t ,p a g e1 1 - 1 4 1
page 11'153
Fleplacement,
FUELFILTER
page 11-152
Replacement,
FUELGAUGESENDINGUNIT
T e s t ,p a g e1 1 - 1 5 6
page 11-153
Replacement,
FUELPRESSUN
REGULATOR
page'11-'152
Replacement,
FUELFILLCAP
FUELTANK
R e p l a c e m epnat ,g e '1l - 1 5 5
FUELTUBE/OUICK.CONNECT
FITTINGS
page 11-148
Precautions,
p
a
g
e
Removal,
11-'149
Installation,page 11-'l50
FUELFEEDLINE
FUELVAPORLINE
FUELPULSATIONDAMPER
page11'154
Replacement,
PGM.FIMAIN RELAY1
PGM.FIMAINRELAY2
T r o u b l e s h o o t ipnagg, e ' l ' l - 1 4 1
11-140
FuelPumpCircuitTroubleshooting
lf you suspecta problemwith the fuel pump, checkthat
the fuel pump actuallyruns;when it is on, you will hear
some noise if you listento the fuel fill port with the fuel
fill cap removed.The fuel pump should run for 2
secondswhen the ignition switch is first turned on. lf
the fuel pump does not make noise,checkas follows:
5. N4easure
voltage betweenPGM-Flmain relay 2 5P
connectorterminal No. 1 and body ground.
PGM.FI MAIN RELAY2
5P CONNECTOR
7. DisconnectECMconnectorE (31P).
8. Checkfor continuitybetweenPGM-FImainrelay2
5P connectorterminal No. 3 and ECMconnector
t e r m i n a lE 1 .
PGM-FIMAIN RELAY2 5PCONNECTOB
E
t 2
Ftxm
IGPl
(YEL/BLK}
7 -
z
IMOFPR
(GBN/
YEL)
ECMCONNECTOR
E 131P}
Wiresideof femaleterminals
Wire side of femaleterminals
ls therecontinuity?
YES-Go to step 5.
YES-Go to step9.
NO Repairopen in the wire betweenthe PGM'Fl
m a i n r e l a y1 a n dt h e P G M - Fm
l a i n r e l a y2 . t
(cont'd)
11-141
FuelSupplySystem
FuelPumpCircuitTroubleshooting(cont'dl
l a i n r e l a y2 .
L R e i n s t a l l t hP
e G M - Fm
1 0 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
connector
1 ' ] .Measurevoltage betweenECI\4/PCM
t e r m i n a lE 1a n d b o d y g r o u n d .
ECMCONNECTOB
E {31P)
NO Go to step 15.
t5.
to.
Wiresideof femaleterminals
(
Turn the ignition switch OFF.
1 3 .ReconneclECMconnectorE (31P).
1 4 .Turn the ignitionswitch ON (ll),and measure
voltagebetweenECMconnectorterminal E1 and
body ground within the first 2 secondsafterthe
i g n i t i o ns w i t c hw a s t u r n e dO N ( l l ) .
Wiresideof femaleterminals
11-142
FUEL
PUMP
(YEL/
GRN)
JUMPER
WIRE
FNI
tri
rcr
fv
{YEL/BLK)
A
dffi
Wiresideof {emaleterminals
ls therecontinuity?
Y E S R e p l a cteh ef u e lp u m p . l
Wiresideol femaleterminals
11-143
FuelSupplySystem
FuelPressureRelieving
Beforedisconnectingfuel lines or hoses,relieve
pressurefrom the system by disconnectingthe fuel
tube/quickconnectfitting in the enginecompartment.
1 . T u r nt h e i g n i t i o ns w i t c hO F F ,
2 . R e m o v et h e P G M - Fm
l a i n r e l a y2 ( A ) .
3 . S t a r t t h ee n g i n e a, n d l e t i t i d l e u n t i li t i s s t a l l s .
NOTE:The DTCSor TemporaryDTCSP0301.P0302,
P0303,P0304may come on during this procedure.
lf any DTCSare stored,ignorethem.
4 . Turn the ignitionswitch OFF.
NOTE:
. P r e v e ntth e r e m a i n i n gf u e l i n t h e f u e lf e e d l i n e o r
hosefrom flowing out with a rag or shop towel.
. Be carefulnotto damagethe line (E)or other
parts.
. Do not use tools.
. l f t h e c o n n e c t o r d o e ns o t m o v e ,k e e p t h er e t a i n e r
tabs presseddown, and alternatelypull and push
the connectoruntil it comes off easily.
. Do not removethe retainerfrom the line; once
removed,the retainermust be replacedwith a
new one.
11-144
FuelPressureTest
Special Tools Required
. Fuel pressuregauge 07406-0040004
. Fuel pressuregaugesel 07ZAJ-S5A0100
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 ' 1 - 1 4 4 ) .
2. Disconnectthe quick-connectfitting (A).Aftachthe
fuel pressuregaugeset and fuel pressuregauge.
11-145
FuelSupply System
FuelLineInspection
Checkthe fuel system lines,hoses,and fuel filter for damage,leaks,and deterioration.Replaceany damagedparts.
11-146
Settheboltflange
T h e r es h o u l d b e n o
W.W
C l a m pi n t h e m i d d l e .
Setthispart
C l a m pi n t h e m i d d l e .
t h e f u e l { i l lt u b e ,
a l i g nt h e m a r k s
on the tubeand
t h el i n e .
11-147
FuelSupply System
FuelLine/Ouick-Connect
FittingsPrecaution
The fuel tube/quick-connect
fittings connectthe fuel rail
(A)to fuel feed hose (B),the fuel feed hose (B)to the
f u e l l i n e( C ) ,a n dt h e f u e l t u b e( D )t o t h e f u e l p u m p
a s s e m b l y( E ) .W h e n r e m o v i n go r i n s t a l l i n g
t h ef u e l f e e d
hose,fuel pump assembly,or fuel tank, it is necessary
to disconnector connectthe quick-connectfittings.
Pay attentionto the following:
. T h e f u e lf e e dh o s e( B ) ,f u e lt u b e ( D ) ,a n d q u i c k be careful
connectfittings (F)are not heat-resistanU
not to damagethem during welding or other heatgeneralrngproceoures.
. T h ef u e l f e e dh o s e( B ) ,f u e l t u b e( D )a n d q u i c k connectfittings (F)are not acid-proof;do not touch
them with a shop towel which was used for wiping
batteryelectrolyte.Replacethem if they came into
contactwith electrolyteor somethingsimilar.
. When connectingor disconnectingthe fuel feed hose
(B),fuel tube (D),and quick'connectfittings (F).be
carefulnot to bend or twist them excessivelv.ReDlace
them it they are damaged.
A disconnectedquick-connectfitting can be
reconnected,but the retaineron the mating line cannot
be reusedonce it has been removedfrom the line.
Replacethe retainerwhen
.
.
.
.
.
.
.
PART
I\4ANUFACTUREB RETAINER
COLOR
EN GI N E
TOKAI
GREEN
COI\4PARTMENT
( F U EF
LEED
H O S EF; UE L
L I N ES I D E )
E NGI N E
TOKAI
BLU
COIVIPARTMENT
( F U EF
LEED
H O S EF: U E L
R A I LS I D E )
WHITE
FUELTANK
SANOH
UNIT
11-148
FittingsRemoval
FuelLine/Ouick-Gonnect
1 . R e l i e v ef u e l p r e s s u r e( s e ep a g e1 ' l - 1 4 4 ) .
=k
To preventdamagedand keepforeign matter out,
cover the disconnectedconnectorand line end with
plasticbags (A).
NOTE:
. The retainercannot be reusedonce it has been
r e m o v e df r o m t h e l i n e .
Replacedthe retainerwhen
- replacing
t h e f u e lr a i l .
- r e p l a c i n gt h e f u e lf e e dI i n e .
- r e p l a c i n gt h e f u e l p u m P .
- replacingthe fuel filter.
- replacing
t h e f u e l g a u g es e n d i n gu n i t
- it has been removedfrom the line.
- it is damaged.
11-149
FuelSupply System
FuelLine/Ouick-Connect
Fittingslnstallation
1. Checkthe contacta rea (A) of the line (B)for dirt and
damage,and clean if necessary.
11-150
N O T E ;l f i t i s h a r dt o c o n n e c tp, u t a s m a l la m o u n to f
n e w e n g i n eo i l o n t h e l i n ee n d .
Connectionwith new retainer:
11-151
FuelSupply System
FuelPressureRegulator
Replacement
1 . R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 ) .
2 . Removethe fuel pressureregulator(A).
FuelFilterReplacement
The fuel filter should be replacedwheneverthe fuel
pressuredrops belowthe specifiedvalue {270 320 kpa,
2.8 3.3 kgflcm', 40 47 psi),after makingsure that the
fuel pump and the fuel pressureregulatorare OK.
1 . R e m o v et h e f u e l p u m p ( s e e p a g e l l - ' 1 5 3 ) .
2. Removethe fuel filter (A).
@-to
Re
IJ
e"^
^e
g s
AR
...\
@n-)
s g
Installthe part in the reverseorder of removalwith
a n e w o - r i n g( B ) .
11-152
FuelPump/FuelGaugeSendingUnit Replacement
SpecialToolsRequired
F u e ls e n d e rw r e n c h0 7 X A A - 0 0 1 0 1 0 A
8 . R e m o v et h e l o c k n u (t A )a n d t h e f u e lt a n k u n i t .
1 . R e l i e v et h e f u e l p r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
Removethe fuel fill cap.
Removethe seat cushion(seepage 20-80).
Removethe accesspanel (A)from the floor.
5 . D i s c o n n e ct h
t e f u e l p u m p 5 Pc o n n e c t o(rB ) .
Disconnectthe quick-connectfitting {C)from the
f u e lt a n ku n i t .
7 . U s i n gt h e s p e c i atlo o l ,l o o s e nt h e f u e lt a n ku n i t
locknut(A).
t h e h o o k ( P )a n d
9 . R e m o v et h e s t o p p e r{ O ) .R e l e a s e
r e m o v et h e f u e lf i l t e r( B ) ,t h e f u e l g a u g es e n d i n g
u n i t ( C ) .t h e c a s e( D ) ,t h e w i r e h a r n e s s( E ) ,a n d t h e
fuel pressureregulator(F).
t h e f u e lt a n ku n i t ,m a k es u r et h e
1 0 . W h e nc o n n e c t i n g
i s s e c u r ea n d t h e s u c t i o nf i l t e r( G )i s
connection
t o t h e f u e lp u m p ( H ) .
f i r m l yc o n n e c t e d
1 1 . I n s t a ltl h e f u e lt a n ku n i t i n t h e r e v e r s eo r d e ro f
r e m o v aw
l i t h a n e w b a s eg a s k e t( l ) a n dn e w o - r i n g s
( J ) ,t h e nc h e c kt h e s ei t e m s :
93 N.m
19.5kgf.m,69 lbf.ftl
. W h e nc o n n e c t i n tgh e w i r e h a r n e s sm
, a k es u r e
t h e c o n n e c t i o ni s s e c u r ea n d t h e c o n n e c t o(rK )i s
f i r m l y l o c k e di n t ot h e p l a c e .
. W h e n i n s t a l l i n gt h e f u e l g a u g es e n d i n gu n i t ,
make sure the connectionis secureand the
c o n n e c t oirs f i r m l y l o c k e di n t o p l a c e .B e c a r e f u l
not to bend or twist the connectorexcessively.
. W h e ni n s t a l l i n g
t h e f u e l t a n ku n i t ,a l i g nt h e m a r k s
( L )o n t h e f u e lt a n k ( M ) a n d t h e f u e lt a n ku n i t( N i
11-153
FuelSupply System
FuelPulsationDamperReplacement
1 . R e l i e v et h e f u e l p r e s s u r e ( s e e p a g e l l - 1 4 4 ) .
2. Removethe enginecover.
3. Removethe fuel rail mounting nuts from the fuel
rail.
4 . R e m o v et h e g r o u n dc a b l e( G1 0 1 .
5 . R a i s et h e f u e l r a i l .
6 . P l a c ea w r e n c h( A )o n t h e f u e l r a i l( B ) .
7 . P l a c ea w r e n c h( C )o n t h e f u e l p u l s a t i o nd a m p e r( D ) .
8. Removethe pulsationdamper.
9. Installthefuel pulsationdamper in lhe reverse
order of removalwith new washers.
NOTE:
. Replaceall washerswhenever the fuel pulsation
damper is loosenedor removed,
. l f t h e d r a i nh o l e( A )o f t h e f u e l p u l s a t i o n d a m p e r
cover does not face bottom, reinstallit as shown.
11-154
FuelTank Replacement
1 . R e l i e v e t h e f u epl r e s s u r e( s e ep a g e1 1 - 1 4 4 ) .
2 . D r a i nt h e f u e lt a n k :R e m o v et h e f u e l p u m p ( s e ep a g e11 - 1 5 3 )U. s i n ga h a n dp u m p ,h o s e ,a n d c o n t a i n esr u i t a b l ef o r
gasoline.draw the fuel from the fuel tank.
(}
38N.m
(3.9ksf.m,28lbfft)
11-155
FuelSupply System
FuelGaugeSendingUnit Test
Special Tools Required
Fuelsenderwrench 07XAA-001010A
NOTE;For the fuel gauge system circuitdiagram,refer
to the GaugesCircuitDiagram(see page 22-58||.
1 . C h e c k t h eN o . 1 0 f U E T E R
{ 7 . 5 A ) f u s ei n t h e u n d e r dash fuse/relaybox beforetesting.
FUELPUMP5PCONNECTOR
3 . T u r nt h e i g n i t i o ns w i t c hO F F .
4. Removethe rear seat cushion{seepage 20-80).
Wiresideof femaleterminals
-ztr
-VVV{Y
{YEL/BLK)
2 9 RESISTOR,
=-a
\
(elrt \
\ 4
//,
5 /
11-156
1 0 . C h e c k t h a t t h ep o i n t e r o ft h e f u e lg a u g ei n d i c a t e s
"F".
. lf the pointerdoes not indicate"F", replacethe
g au g e .
. lf the pointerindicates"F", inspectthe fuel
gauge sendingunit.
NOTE:The pointerof the fuel gauge returns to the
bottom of the gaugedial when the ignition switch
is OFF,regardlessof the fuel level.11. Relievethe fuel pressure(seepage 11-144\.
1 2 . R e m o v et h e f u e l f i l l c a p .
1 5 . M e a s u r er e s i s t a n cbee t w e e nt h e N o . 1 a n d N o . 2
'l12
terminalswith the float at E (EN4PTY), \HALF
F U L L )a, n d F { F U L L p
) ositions.
lf you do not get the following readings,replacethe
f u e l g a u g es e n d i n gu n i t{ s e ep a g e1 ' 1 - 1 6 3 ) .
F
Float
Position
Resistance 1 1
{0)
to 13
'U2
68,5
to 74.5
LOW
114.4
130
to 126.6 to 132
A
93Nm
{9.5ksf.m,69 lbf.ft}
11-157
FuelSupply System
Low FuelIndicatorTest
1 . Do the fuel gauge sendingunit test (seepage 11,
rcol.
. lf the system is OK, go to step 2.
. lf the system has any malfunction,repair it.
Turn the ignition switch OFF.Removethe No. 9
BACKUP (10A)fuse from the under-hoodfuse/
relay box for at least30 seconds,then reinstallit.
Turn the ignition switch ON (ll)with the float at the
E (EMPry) position.
. lf the low fuel indicatoris on, go to step 4.
. lf the low fuel indicatoris not on, referto the low
fuel indicatorCircuitDiagram(seepage 22-58)
and checkthe circuit.
4, Turn the ignition switch OFF.Removethe No. 9
11-158
\,
IntakeAir System
ComponentLocationIndex
THROTTLEBODY
Test,page l'l-160
page 11-165
Removal/lnstallation,
page 11 166
Disassembly/Reassembly,
l .
AIR CLEANER
R e p l a c e m e npt a, g e11 ' 1 6 2
AIR CLEANERELEMENT
R e p l a c e m e npta, g e11 - 1 6 2
THROTTLE
CABLE
page11-163
Adjustment,
R e m o v a l / l n s t a l l apt a
i ogne1, 1 - 1 6 4
11-159
IntakeAir System
Throttle BodyTest
NOTE:
. Do not adjustthe throttlestop screw. lt is presetat the
factory.
. lfthe malfunction
i n d i c a t o lra m p ( M l L )h a sb e e n
reportedon, checkfor diagnostictrouble codes
( D L C S()s e ep a g e1 1 3 ) .
1. With the engine off, checkthe throttle cable
movement.The cableshould move without binding
or sticking.
. lf lhe cable moves OK, goto step 2.
. lf the cable binds or sticks,checkit and its routing.
. l f t h e c a b l ei s f a u l t y ,r e r o u t ei t o r r e p l a c ei t a n d
a d j u s ti t ( s e ep a g e1 1 - 1 6 3 )t h
, e ng o t o s t e p2 .
2. l\4ovethe throttle lever by hand to see if the throftle
valve and/or shaft are too looseor too tight.
. lf there is excessiveplay in the throttlevalve
shaft,or any binding in the throttlevalve at the
fully closedposition,replacethe throttle body.
. l f t h e t h r o t t l e v a l v ea n d s h a f ta r e O K ,g o t o s t e p 3 .
3. Connectthe scantoolto the DLC.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
5 . Checkthe throttle positionwith the scantool. The
readingshould be about 10%when the throttle is
fully closedand about 90% when the throttle is fully
openeo.
. lf the throttle positionis correct,the throttle body
is OK.
. lf thethrottle positionis notcorrect,replacethe
throttle body.
11-160
Test
IntakeAir BypassGontrolThermalValve
Special Tools Required
Vacuum Pump/Gauge,0 30 in. Hg A973X-041-XXXXX
, n d m a k es u r e
5 . R a i s ea n d l o w e rt h e e n g i n es p e e d a
the vacuum gauge readingdoes not changeas the
rpm cnanges.
1 . S t a nt h e e n g i n e T
. h e nl e t i t i d l .
NOTE:The enginecoolanttemperaturemust be
b e l o w1 4 9 ' F ( 6 5 ' C ) .
2 . R e m o v et h e v a c u u mh o s e( A ) f r o mt h e i n t a k ea i r
duct, and connecta vacuum pump/gaugeto the
nose.
. n d m a k es u r e
3 . R a i s ea n d l o w e r t h ee n g i n es p e e d a
t h e v a c u u mg a u g er e a d i n gc h a n g e sa s t h e e n g i n e
speeocnanges.
lf the vacuum readingdoes not change,checkfor
these problems:
. M i s r o u t e dl,e a k i n gb, r o k e n o, r c l o g g e di n t a k ea i r
bypasscontrol system vacuum lines.
. A crackedor damagedintakeair bypasscontrol
t h e r m a lv a l v e .
4 . H o l dt h e e n g i n ea t 3 , 0 0 0r p m w i t h n o l o a d( i n
neutral)until the radiatorfan comes on, then let it
i dl e .
11-161
IntakeAir System
Air CleanerReplacement
1. Removethe nuts (A) and the stud (B).
Air CleanerElementReplacement
1 . D i s c o n n e ct h
t e P C Vh o s e1 A ) .
{0.3kgf m,2lbf.ft)
2 . O p e nt h e a i r c l e a n e rh o u s i n gc o v e r( B ) .
3 . R e m o v et h e a i r c l e a n e r( C )f r o m t h e a i r c l e a n e r
h o u s i n g( D ) .
4 . Installin the reverseorder of removal.
11-162
\,
Throttle CableAdjustment
1 . Checkcablefree play at the throttle linkage.Cable
f r e e p fa v ( A )s h o u l db e 1 0 1 2 m m ( 3 / 8 1 / 2i n . ) .
11-163
IntakeAir System
Throttle CableRemoval/lnstallation
1. Fully open the throttlevalve,then removethe
throttle cable (A)from the throttle link (B).
(P/N08?98-9002)
2 . R e m o v et h e c a b l eh o u s i n g( C ) f r o mt h e c a b l e
bracket(D).
('1.0kgf.m,
7.2 tbf.ftl
SILICONE
GREASE B
(P/N08798-9002)
11-164
THROTTLE
LEVER
Thereshould be
noclearance
THROTTLECABLE
MANIFOLD
ABSOLUTEPRESSURE
{MAP}SENSOR
22Nm
(2.2 kgt.m, 16 lbf.ft)
EVAPORATIVEEMISSION{EVAPI
CANISTERPURGEVALVE
IDLEAIR CONTROL
{IACI VALVE
11-165
IntakeAir System
Throttle Body Disassembly/Reassembly
2 N.m
{0.2 kgt m, 1 lbf.ft)
V
MAPSENSOR
EMISSION
EVAPORATIVE
{EVAP)
PURGE
VALVE
CANISTER
L
TPSENSOR
THROTTLEBODY
3.5 N.m
(0.35kgf m.2.5lbf ft)
11-166
CatalyticConverterSystem
DTCTroubleshooting
DTCP0420:CatalyticSystemEfficiency
BelowThreshold
NOTE:lf some of the DTCSlistedbelow are storedat
the same time as DTCP0420,troubleshootthose DTCS
first, then recheckfor DTCP0420.
P 0 1 3 7P, 0 1 3 8S: e c o n d a r yH e a t e dO x y g e nS e n s o r
(secondaryHO2S)(Sensor2)
r )heater
P 0 1 4 1S: e c o n d a r yH O 2 S( S e n s o 2
1 . R e s e t h e E C M{ s e ep a g e1 ' l - 4 }t,h e nc o n t i n u et o
step 2 through 5 to resetthe readinesscode.
2. Startthe engine.Hold the engineat 3,000rpm with
n o l o a d( i n n e u t r a lu) n t i l t h er a d i a t o fr a n c o m e so n .
D r i v ef o r a b o u t l 0 m i n u t e sw i t h o u ts t o p p i n gY. o u r
speeocan vary.
4 . With the transmissionin 4th gear,drive at a steady
speed between50 62 mph (80-'100 km/h)for
30 seconds.
Repeatstep 4 three times. Betweeneach repetition,
closethe throttlecompletelyfor 1 2 seconds.lf
the engine is stoppedduring this part of the
procedure,repeatsteps3, 4 and 5.
Checkfor a TemporaryDTCwith the scantool.
Does the scan tool indicate Temporaty DTC
P0420?
YES Checkthe TWC. lf necessary,replacethe
TWC.I
N O C h e c kf o r r e a d i n e s cs o d ec o m p l e t i o nl.f t h e
readinessis complete,it was a interminentfailure,
and the system is OK at this time. lf the readiness
code is incomplete,repeatsteps2 through 5.1
11-167
PCVSystem
DTCTroubleshooting
DTCP1505:PCVAir Leakage
1 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
2. Startthe engine.Hold the engineat 3,000rpm with
n o l o a d( i n n e u t r a l u) n t i lt h e r a d i a t o fra n c o m e so n
3. Letthe engineidle tor al least40 secondswith the
throttlefully closed.
4. Checkfor a DTCP1505with the scantool
ls DTC P1505 indicated?
YES-Check these partsfor vacuum leaks l
.
.
.
.
.
PCVvalve
PCVhose
EVAPcanisterpurge valve
Throttlebody
Brakeboosterhose
NO - Intermittentfailure,system is OK at this
time.l
11-168
PCVValve Replacement
'L
Disconnectthe PCVhose.
Removethe PCVvalve (A).
(4.5kgf.m,33lbf.ft)
l parts in the reverseorder of removal
3 . I n s t a lthe
with a n e w g a s k e t( B ) .
11-169
EVAPSystem
ComponentLocationIndex
EVAPORATIVEEMISSIONIEVAPI
CANISTERPURGEVALVE
Troubleshooting,
'l1-175,
step 3 on page
s t e p1 o n p a g e1 1 - 1 8 0
FUELTANK VAPORCONTROLVALVE
Test,page 11'187
R e p l a c e m e npt a, g e1 1 1 8 9
EVAPORATIVEEMISSION{EVAPI
CANISTER
Troubleshooting,
step 28 on page 11'183
page 11-189
Replacement,
SENSOR
FUELTANKPRESSURE
T r o u b l e s h o o t ipnagg, e11 - 1 7 1
EVAPORATIVEEMISSION{EVAP}
BYPASSSOLENOIDVALVE
Troubleshooting,
p a g e' 1 1 ' 1 7 6 ,
s t e p1
' 120o n
s t e p o n p a g e1 1 1 8 1
EVAPORATIVEEMISSION{EVAP)
CANISTERVENT SHUT VALVE
Troubleshooting,
step 23 on page 1'l 178,
s t e p1 go n p a g el 1 - 1 8 2
11-170
EVAPOBATIVEEMISSON{EVAP)
VALVE
TWO WAY 'l1-'186
Test,page
DTCTroubleshooting
DTCP0451:FTPSensorRange/Performa
nce
Problem
SpecialTools Required
Vacuum Pump/Gauge,0-30 in. Hg A973X-041-XXXXX
1 . R e m o v et h e f u e lf i l l c a p .
2. Turn the ignition switch ON (ll)
3. l\4onitorfuel tank pressure(FTP)sensorvoltage
with the HondaPGM Tester,or medsurevoltage
betweenECMconnectorterminalsE4 and E14.
ECMCONNECTOR
E 131P)
W i r es i d eo f f e m a l tee r m i n a l s
Replacethe FTPsensor.!
11-171
EVAPSystem
DTCTroubleshooting(cont'd)
DTCP0452:FTPSensorCircuitLow Voltage
1. Checkthe vacuum lines at the FTPsensorfor
misrouting,leakage.breakage,or clogging.
2 . R e s e t h e E C M( s e ep a g e1 1 - 4 ) .
3 . R e m o v et h e f u e l f i l lc a p .
VCgl {YEL/BLU}
1 2 t 3 t 45
8 9
. / . / 1 1 4 t c 61./18 2C 21
22123241 t 26 271/ 29 31
o
Wiresideof femaleterminals
TP (LTGRN)
ls there about 5 V?
'1.
YES Go to step 1
NO-Repair open in the wire betweenthe FTP
s e n s o ra n dt h e E C M{ E 5 ) . 1
ls thete about2.5 V?
YES- Intermittentfailure,system is OK at this time.
Checkfor poor connectionsor looseterminalsat
the FTPsensorand at the ECrM.l
NO Go to step 6.
11-172
FTP(LT GBN)
DTCP0453:FTPSensorCircuitHighVoltage
1. Checkthe vacuum lines at the FTPsensorfor
misrouting,leakage,breakage,or clogging.
Are the vacuumlines OK?
Y E S - G o t o s t e p2 .
N O R e p a i ro r r e p l a c ev a c u u ml i n e sa s
necessary.I
W i r e s i d eo f f e m a l e t e r m i n a l s
2 . R e s e t h e E C M{ s e ep a g e1 1 ' 4 ) .
3. Removethe fuel fill cap.
ls there about 5 V?
YES- Replacethe FTPsensor.t
N O - G o t o s t e p1 2 .
' t 2 .Turn
4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
5. lvlonitorFTPsensorvoltagewith the Honda PGM
Tester,or measurevoltage betweenbody ground
a n d E C Mc o n n e c t otre r m i n a lE ' 1 4 .
1 3 .DisconnectECMconnectorE (31P),
1 4 .Checkfor continuitybetweenFTPsensor3P
connectorterminal No. 3 and body ground.
ECMCONNECTOR
E 131PI
1 1 2 1 34 5 6 7
I 9
5 6 / t18 2C 21
24
2il./ 29 30 31
TP {LTGRN}
FTPSENSOR3P CONNECTOB
W i r es i d eo f f e m a l e l e r m i n a t s
ls there continuity?
{cont'd)
11-173
EVAPSystem
DTCTroubleshooting(cont'dl
6. Turn the ignitionswitch OFF.
7 . R e i n s t al h
l e f u e lf i l l c a p .
FTPILT GRN}
'10.
l\4easure
voltage betweenFTPsensor3P connector
t e r m i n a l sN o . 1 a n d N o . 2 .
FTPSENSOR3P CONNECTOR
VCC3(YEL/BLU)
Wiresideof femaleterminals
ls there about 5 V?
YES Replacethe FTPsensor.l
NO Go to step 12.
l\4easure
voltage betweenECMconnector
t e r m i n a l sE 4 a n d E1 4 ,
ls there about 5 V?
Y E S G o t o s t e p1 1 .
ECMCONNECTOR
E (31P)
W i r es i d eo f f e m a l tee r m i n a l s
ls there about 5 V?
YES Repairopen in the wire betweenthe FTP
s e n s o ra n d t h e E C M( E 1 4 ) . I
NO Updatethe ECM if it does not have the latest
then
software,or substitutea known-goodECN4.
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-174
DTCPl456:EVAPControlSystemLeakage
(FuelTankSvstem)
The fuel system is designedto allow specified
maximum vacuum and pressureconditions.Do not
deviatefrom the vacuum and pressuretests as
indicatedin these procedures.Excessivepressure/
vacuum would damagethe EVAPcomponentsor cause
eventualfuel tank failure.
A973X-041-XXXXX
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Follow thesetroubleshootingprocedurescarefullyto
ensurethe integrityof the system and to confirm the
causeof the problemor code.
{cont'd)
11-175
EVAPSystem
DTCTroubleshooting(cont'd)
8. Checkfor continuitybetweenEVAPcanisterpurge
valve2Pconnenctor
terminalNo.2 andbody
grouno.
EVAP CANISTERPURGE
VALVE 2P CONNECTOR
F-
A973X-041-XXXXX
Wire side of femaleterminals
ls therecontinuity?
YES Goto step9.
NO Replace
the EVAPcanisterpurgevalve.l
B (24P).
ECMconnector
9 . Disconnect
1 0 . Checkfor continuitybetweenEVAPcanisterpurge
terminalNo.2 andbodyground.
valve2Pconnector
EVAPCANISTERPURGE
VALVE2PCONNECTOR
1 2 3 4 5 6 1 7 l1 8 9
4 5 6 / 118 2C21
2 2 t 2 ? 24
z7l./29
2WBS
(BLU/RED}
JUMPER
WIRE
1 2
PCS
{YEL/BLU)
Wiresideof femaleterminals
'.\'
ls there continuity?
Y E S - G o t o s t e p1 5 ,
YES Repairshort in the wire betweenthe EVAP
canistep
r u r g ev a l v ea n dt h e E C I \ {48 2 1 ) . 1
NO Updatethe ECM if it does not have the latest
software,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
originaE
l CM.I
11-176
NO Go to step 20.
Disconnectthe EVAPbypasssolenoidvalve 2P
connecror.
'19.
Measurevoltage betweenEVAPbypasssolenoid
valve 2P connectorterminal No. 1 and body ground.
EVAPBYPASSSOLENOID
VALVE2PCONNECTOR
1 7 . Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
EVAP BYPASSSOLENOID
VALVE 2P CONNECTOR
2
tG'l
{BLK/ORN)
ls there continuity?
YES Go to step 18.
NO-Repair open in the wire bet\iveen
the EVAP
bypasssolenoidvalve and the ECM (E20).1
'18.T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls there battery voltage?
YES Replacethe EVAPtwo way/bypasssolenoid
v a l v e( A ) . 1
NO-Repair open in the wire betweenthe EVAP
bypasssolenoidvalve and the No. 4 ACG (10A)
fuse.l
{cont'd)
11-177
EVAPSystem
(cont'dl
DTCTroubleshooting
2 0 . P l u gt h e f u e l t a n kp o r t ( A )o f t h e E V A P t w o w a y
valve,
T u r nt h e i g n i t l o ns w i t c hO N ( l l ) .
Apply vacuum to the hosewith five strokesof the
pump.
Does the valve hold vacuum?
25. T u r nt h e i g n i t i o ns w i t c hO F F .
26. Disconnectthe EVAPcanistervent shut valve 2P
Wiresideof femaleterminals
conneclor.
2 1 . Checkfor continuitybetweenEVAPcanistervent
s h u tv a l v e2 Pc o n n e c t otre r m i n a lN o . 2 a n d b o d y
ground.
EVAPCANISTEBVENTSHUT
VALVE2PCONNECTOR
N O R e p a i rt h e l e a kf r o m t h e E V A Pb y p a s s
solenoidvalve, EVAPtwo way valve.or
F T Ps e n s o r . l
{LTGRN/REOI
W i r es i d eo f f e m a l et e r m i n a l s
11-178
VacuumHosesand ConnectionsTest
3 0 . Do the fuel tank vapor control valve test (seepage
11 - 1 8 7 ) .
ls the fuel tank vapot control valve OK?
Y E S - G o t o s t e p3 1 .
NO Replace
t h e f u e l t a n kv a p o rc o n t r o lv a l v e . l
5 t .
ls thete continuity?
Checkthe FTPsensor readings.
YES-Go to step 28.
NO-Replace the EVAPcanistervent shut valve (A)
a n d o - r i n g( B ) . 1
ls there continuity?
YES-Repair short in the wire betweenthe EVAP
c a n i s t e vr e n ts h u tv a l v ea n dt h e E C M( E 2 1 ) . 1
NO Updatethe ECM if it does not have the latest
soflware,or substitutea known-goodECM,then
recheck(seepage 11-6).lf the symptom/indication
goes away with a known-goodECM,replacethe
o r i g i n aE
l CM.I
.
.
.
.
.
.
.
.
.
F u e l t a n k( A )
F u e lf i l l c a p ( B )
F u e lf i l l p i p e( C )
F u e l t a n kv a p o rc o n t r o lv a l v e ( D )
F u e l t a n kv a p o rr e c i r c u l a t i ovna l v e( E )
F u e l t a n kv a p o rr e c i r c u l a t i otnu b e ( F )
F u e l t a n kv a p o rs i g n a l t u b e( G )
F u e l t a n kv a p o rc o n t r o lv e n t t u b e ( H )
FTPsensor(J)
- R e p a i ro r r e p l a c ea n y l e a k i n gp a r t s .
11-179
EVAPSystem
DTCTroubleshooting(cont'd)
DTCPl457:EVAPControlSystemLeakage
(EVAPCanisterSystem)
ECMCONNECTOR
A I24P'
SpecialToolsRequired
Vacuum pump/gauge,0-30 in.HgA973X-041-XXXXX
W i r e s i d eo f l e m a l et e r m i n a l s
'^6
rh6
^^.16
YES-Go to step 5.
NO-The EVAPcanisterpurge valve is OK. Go to
step 10.
Turn the ignition switch OFF.
b.
7 . Checkfor continuitybetweenEVAPcanisterpurge
valve 2P connectorterminal No. 2 and body ground.
EVAPCANISTEN
PURG
VALVE2PCONNECTOR
-4l-fircs
ll2l
IYEL/8Lu)
(f])
I
W i r e s i d eo f f e m a l e l e r m i n a l s
ls therecontinuity?
YES-Goto step8.
4973X-041-XXXXX
11-180
voltagebetweenEVAPcanisterpurge
9. Measure
terminalNo. 1 andbodyground.
valve2Pconnector
EVAPCANISTERPURGE
VALVE2PCONNECTOR
ls thetebatteryvoltage?
the EVAPcanisterpurgevalve.l
YES- Replace
NO Repairopenin thewire betweenthe EVAP
canisterpurgevalveandthe No.4 ACG(10A)
fuse.I
1 1 .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
'It
1 4 . Disconnectthe EVAPbypasssolenoidvalve 2P
connector.
Checkfor continuitybetweenEVAPbypass
s o l e n o i dv a l v e2 P c o n n e c t otre r m i n a lN o . 2 a n d
b o d yg r o u n d .
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
(cont'd)
11-181
EVAPSystem
DTCTroubleshooting(cont'd)
EVAP Canisler Vent Shut Valve Test
18. Disconnectthe vacuum hosefrom the EVAP
canistervent filter (A),and connecta vacuum pump
to the hose.
ls there continuity?
YES Go to step 16.
NO- Replacethe EVAPtwo waylbypasssolenoid
valve (A).1
DisconnectECMconnectorE {31P).
to.
't7.
Checkfor continuitybetweenEVAPbypass
solenoidvalve 2P connectorterminal No. 2 and
body ground.
EVAPBYPASSSOLENOID
VALVE2P CONNECTOR
\ ,
lI l tl - 2l l
1 1 2 1 34 5
1/
1 5tal/la
z3lz4
zil./
2WBS
JUMPER
WIRE
-[BLU/REo)
())
8 9 vsv(
{LTGBN/RED)
2A21
m 31
Wiresideol lemaleterminals
11-182
-4l-T_*u
r 2l
ILTGFN/REDI
@
wn s de ol lma1e terminals
ls therc continuity?
YES Go to step 25.
NO Repairopen in the wire betweenthe EVAP
c a n i s t e vr e n ts h u tv a l v ea n dt h e E C I V(IE 2 1 ) . 1
25. T u r nt h e i g n i t i o ns w i t c ho N ( l l ) .
26. Measurevoltage betweenEVAPcanistervent shut
v a l v e2 P c o n n e c t otre r m i n a lN o . 1 a n d b o d yg r o u n d .
VENTSHUT
EVAPCANISTER
VALVE2PCONNECTOR
3 0 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
11-183
EVAPSystem
DTCTroubleshooting(cont'dl
31. While monitoring FTPsensorvoltagewith the
Honda PGM Tester,or measuringvoltage between
ECMconnectorterminalsE4 and E14,slowly pump
the vacuum oumD.
ECMCONNECTOR
E 13lPI
Wiresideof lemaleterminals
40. T u r nt h e i g n i t i o ns w i t c hO F F .
34. Turn the ignition switch OFF.
35. Disconnectthe quick-connectfitting (A) fromthe
EVAPcanister,and plug the canisterport {B).
3 6 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
11-184
4 2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Wiresideof femaleterminals
11-185
EVAPSystem
EVAPTwo Way ValveTest
Special Tools Required
. V a c u u mp u m p / G a u g e , 0 - 3 0i n . H g
A973X-041-XXXXX
. Vacuum/Pressure
cauge.0-4 in. Hg 07JAZ-0010008
1 . R e m o v et h e f u e l f i l l c a p .
2. Disconnectthe vapor line from the EVAPtwo way
valve (A).Connectit to a T-fitting(B)from the
v a c u u mg a u g ea n d t h e v a c u u mp u m p a s s h o w n ,
07JAZ-0010008
11-186
. lfthe pressuremomentarilystabilizes(valve
o p e n s )a b o v e1 . 0k P a( 8 m m H g , 0 . 3i n . H g )t,h e
v a l v ei s O K .
. lf the pressurestabilizesbelow 1.0 kPa(8 mmHg,
0.3 in.Hg),installa new valve and retest.
FuelTankVaporControlValveTest
SpecialToolsRequired
0-30 in. HgA973X-041-XXXXX
VacuumPump/Gauge,
FloatTest
1 . M a k es u r et h e f u e lt a n ki s l e s st h a n h a l ff u l l .
ValveTest
1 . N 4 a kseu r et h e f u e lt a n k i s l e s st h a n h a l ff u l l
2 . R e m o v et h e f u e l f i l l c a p .
3. Disconnectthe fuel tank vapor signaltube (A).
A973X-041-XXXXX
P l u gt h e l i n e( B ) .
5 . Apply vacuum to the fuel tank vapor recirculation
tuDe.
lf the vacuum holds, replacethe fuel tank vapor
c o n t r o lv a l v e( s e ep a g e1 1 - 1 8 9 ) .
lf the vacuum does not hold, the float is OK. Do
the valve test.
A973X-O41-XXXXX
5. Disconnectthe vacuum hose (D)from the EVAP
canistervent shut valve (E),and connecta vacuum
pump to the vacuum hose.
6 . P u m pt h e v a c u u mp u m p 8 0 t i m e s .
. l f t h e v a c u u mh o l d s ,g o t o s t e P7 .
. l f t h e v a c u u md o e sn o 1h o l d ,g o t o s t e p 1 0 .
(cont'd)
11-187
EVAPSystem
FuelTankVaporControlValveTest (cont'd)
7. Connecta secondvacuum pump to the fuel tank
v a p o rs i g n a l t u b e( A ) .
Fill the fuel tank with fuel, then checkfor fuel in the
EVAPtwo way valve (A),and fuel tank vapor
recirculationhose (B).
NOTE:At either location,tiny dropletsof fuel are
normal.
. lf fuel runs out of th e hosesat either location,
replacethe fuel tank vapor control valve.
. l f t h e f u e l d o e sn o t r u n o u t o f t h e h o s e s t, h e f u e l
tank vapor systemfunction is normal.
11-188
EVAPCanisterReplacement
FuelTankVapor ControlValve
Replacement
'l
4 , Installthe fuel tank (seepage 1 -155).
11-189
Clutch
.........12-2
Tools
Special
I
n
d
e
x
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
. . . . . , .1. .2.-. 3
........
L
o
c
a
t
i
o
n
Comoonent
Switch,and
ClutchPedal,ClutchPedalPosition
12-4
SwitchAdiustment....................
ClutchInterlock
12-5
.....................
CfutchMasterCylinderRep|acement
12-7
.'........
SlaveCylinderReplacement
.....12-9
...................
ClutchReplacement
Clutch
SpecialTools
Ref. No.
(1,
@
Tool Number
OTJAF-PM7O11A
07LAB-PV001
00 or 07924-PD20003
07zAF-PR8A100
07936-3710100
Description
C l u t c hA l i g n m e n tD i s c
R i n gG e a rH o l d e r
C l u t c hA l i g n m e n tS h a f t
R e m o v e rH a n d l e
Oty
,l
1
1
1
l .
l _ l
'l-r
o
o
.{\
.tt./
'\-'/
12-2
ComponentLocationIndex
""*--/
\,L_.Ei
/i
(,'.'
_,___-,-s\
SWITCH
CLUTCHINTERLOCK
page12-4
Adjustment,
PEDAL
CLUTCH
POSTTTON
SWITCH
A d j u s t m e npta, g e ' 1 2 - 4
RETAININGCLIP
Replace.
UTCHPEDAL
A d j u s t m e n tP, a g e1 2 4
O-RING
Replace.
CLUTCHMASTERCYLINDER
pagel2-5
Replacement,
CLUTCHDISC
Bemoval,page 12-9
I n s t a l l a t i op
na
, ge'12-12
PRESSURE
PLATE
page'12-9
Removal,
l n s t a l l a t i opna,g e1 2 - 1 2
RELEASE
BEARING
B e p l a c e m epnat ,g e1 2 - 1 3
FLYWHEEL
page'12-1
1
Inspection,
page12-11
Replacement,
CLUTCHHOSE
CLIP
SLAVECYLINDER
page 12-7
Replacement,
\".rr"*"o*
12-3
Clutch
ClutchPedal,ClutchPedalPositionSwitch, and ClutchInterlockSwitch
Adjustment
NOTE:
. To checkthe clutch pedal positionswitch
(seepage 4-45).
. To checkthe clutch interlockswitch (seepage 4-6).
. Removethe driver's side floor mat beforeadjusting
the clutch pedal.
. The clutch is self-adjustingto compensatefor wear.
. lf there is no clearancebetweenthe mastercylinder
pistonand push rod, the releasebearingwill be held
againstthe diaphragmspring.which can resultin
clutchslippageor other clutch problems.
1. Loosenthe clutch pedal positionswitch locknut(A),
and backoff the clutch pedal positionswitch (B)
until it no longertouchesthe clutch pedal (C).
J
9.8 N.m
(1.0kgf.m,7.2lbf.ft)
A
9.8 N.m
11.0kgf.m,7.2 lbf.ft)
18 N.m
{1.8kgf.m,
13 tbf.ftl
130 140 mm
( 5 . 1 2 5 . 5 1i n . l
Clutch PedalFreePlay: l0 16 mm (0.39-0.63 in.)
Clutch PedalHeight: 193 mm (7.60in.)
Disengagement
Height:
115 mm (4.53in.)
Between Floor And
Carpet Height
(ApproximateValuel: 38 mm {1.50in.l
12-4
ClutchMasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may
damagethe paint; if brakefluid does contactthe paint,
wash it off immediatelVwith water.
1 . P r yo u t t h e l o c kp i n ( A ) ,a n d p u l l t h e p e d a lp i n ( B )
out of the yoke. Removethe mastercylinder
mounting nuts (C).
UP
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
cleanerhousing (seestep 6 on page 5-2).
g-E
(cont'd)
12-5
Clutch
ClutchMasterCylinderReplacement(cont'd)
10. To preventthe retainingclip (A)from coming off,
pry open the tip of the retainingclip (B)with a
screwdriver,
12-6
SlaveCylinderReplacement
NOTE:
. U s ef e n d e rc o v e r st o a v o i dd a m a g i n gp a i n t e d
surfaces.
. D o n o t s p i l lb r a k ef l u i d o n t h e v e h i c l e i; t m a y d a m a g e
the paint; if brakefluid does contactthe paint,wash it
off immediatelywith water.
R e m o v et h e a i r c l e a n e rh o u s i n gc o v e ra n dt h e a i r
c l e a n e rh o u s i n g( s e es t e p6 o n p a g e5 - 2 ) .
4 . Removethe intakeair duct (seestep 8 on page 5-3).
,,6NJ'
=-#.q!4sEn
(P/N08798-90021
(Brak6Assembly
Lube)
9 . P u l l t h eb o o t ( B )b a c k ,a n d a p p l yb r a k ea s s e m b l y
l u b et o t h e b o o ta n d s l a v ec y l i n d e r o d ( C ) .R e i n s t a l l
the boot.
(cont'd)
12-7
Clutch
SlaveCylinderReplacement(cont'd)
11. Bleedthe clutch hydraulicsystem.
. Aftach a hoseto the bleederscrew (A),and
suspendthe hose in a containerof brakefluid.
. M a k es u r et h e r ei s a n a d e q u a t es u p p l yo f f l u i d i n
the clutch mastercylinder,then slowly pump the
clutch pedal until no more bubblesappearatthe
bleederhose.
. lt may be necessaryto llmit the movement of the
releasefork (B)with a blockof wood to remove
all the air from the system.
. Tightenthe bleedscrewto I N.m (0.8kgf.m,6 lbf
ft); do not ovenightenit,
. Refillthe clutch mastercylinderwith fluid when
done.
. Always use only Honda DOT3 brakefluid.
L
12. Installthe intakeair duct (seestep 36 on page 5-14).
1 3 .I n s t a l l t h ea i r c l e a n e rh o u s i n g( s e es t e p3 7 o n p a g e
5-15).
1 4 . Installthe batterytray.
t5.
12-8
ClutchReplacement
Spscial Tools Required
. Clutchalignmentdisc 07JAF-PM701
1A
. Ringgear holder07LAB-PV00100
or
07924-PD20003
. Clutchalignmentshaft 07ZAF-PR8A100
. Removerhandle07936-3710100
2 . I n s t a l l t h es p e c i atl o o l s .
A
\-
PressurePlateand GlutchDiscRemoval
1 . C h e c kt h e d i a p h r a g ms p r i n gf i n g e r sf o r h e i g h t
using lhe speciallool and feelergauge.lf the height
is more than the servicelimit, replacethe pressure
ptate.
A-.-
nl I
\ffim
9fra-I
StandardlNewl:
ServiceLimit:
07zAF-PR8A100
07936-3710100
OTJAF-PM7O11A
|-
tP
07LAB-PV00100
or
07924-PD20003
plate
To preventwarping,unscrewthe pressure
patternin several
mountingbolts(A)in a crisscross
plate(B).
steps,then removethe pressure
Inspectthefingersof the diaphragmspring(A)for
wearat the releasebearingcontactarea.
(cont'd)
12-9
Clutch
ClutchReplacement(cont'd)
6. Inspeclfor warpage using a straightedge (A) and
feeler gauge (B).l\4easureacrossthe pressureplate
(C).lf the warpage is more than the servicelimit,
replacethe pressureplate.
Standard{New):
ServiceLimit:
8.3 8.9 mm
(0.33 0.35in.)
6.0 mm {0.24in.)
1 d
I n s p e c t t h el i n i n go f t h e c l u t c hd i s cf o r s i g n so f
s l i p p i n go r o i l . l f t h e c l u t c hd i s ci s b u r n e db l a c ko r
oil soaked.reolaceit.
12-10
1.65 2.25 mm
(0.065 0.089in.)
0.7 mm (0.03in.)
FlywheelInspection
1. Inspectthe ring gear teeth for wear and damage.
FlywheelReplacement
1 . I n s t a l l t h es p e c i atlo o l .
1 2 x 1 . 0m m
103 N.m
(10,skst.m. 76 lbf ftl
(cont'd)
12-11
Glutch
ClutchReplacement(cont'dl
ClutchDiscand PressurePlateInstallation
'L
T e m p o r a r i l yi n s t a ltl h e c l u t c hd i s co n t o t h e s p l i n e s
of the transmissionmainshaft,Make sure the clutch
disc slidesfreely on the mainshaft.
2 . l n s t a l l t h er i n g g e a rh o l d e r .
pattern,
5. Torquethe mountingboltsin a crisscross
Tightenthe boltsin severalstepsto prevent
warping
spring.
t h ed i a p h r a g m
PRESSURE
PLATE
MOUNTING
BOLTTOROUE:
25 N.m{2.6kgt.m,19lbt.ft)
O?ZAF.PRSAIOO
\---,
/v
07936-3710100
{P/N08798-9002)
07LAB-PVo0'100
or
0792,1-PD20003
3 . Apply super high temp urea grease(P/N087989002)to lhe splines(A) of the clutch disc (B),then
installthe clutchdisc usingthe specialtools.
Removethe specialtools.
Installthe pressureplate (A) and the mounting
bolts (B)finger-tight.
12-12
ReleaseBearingReplacement
'L
4 . Apply super high temp urea grease{P/N087989002)to the releasefork (A),the releasefork bolt
( B ) ,t h e r e l e a s eb e a r i n g( C ) ,a n d t h e r e l e a s eb e a r i n g
g ui d e ( D )i n t h e s h a d e da r e a s .
1 . 0 1 . 6g
10.04 0.06oz)
l-'..\
\\
\\
!ac
\ ) ) /
/-/
Xrl-Rl
It\'1
f-l\-._
-A
{re\
I L!),l-*E
0 . 4 1 . 0g
10.01 0.04o
"
12-13
ManualTransmission
SpecialTools
13-2
Transmission
FluidInspection
a n dR e o 1 a c e m e. n. .t. . . . . . . . . . . .|.5-J
...-.
Back-Up
LightSwitchTest ..........t J - 5
Transmission
Removal
13-4
Transmission
Installation...........
I J-at
Transmission
Disassemblv........1 3 - 1 4
Reverse
ShiftForkClearance
lnsoection
13-19
ChangeLeverClearance
lnsoection
13-19
ChangeLeverAssembly
Disassembly/Reassembly
.......13-20
ShiftForksClearance
Inspection
13-21
ShiftForks
Disassembly/Reassembly
.......13-22
Mainshaft
Assemblv
Clearance
Inspection
13-23
't3-25
Mainshaft
Disassembly
Mainshaft
lnsoection
13-26
Mainshaft
Reassembly
| 5-2.5
Countershaft
Assemblv
Clearance
Inspection
13-31
Disassembly
Countershaft
.........13-32
Inspection.............
Countershaft
13-33
Reassembly..........
Countershaft
13-34
SynchroSleeveand Hub
Inspection
andReassembly
.... 13-39
SynchroRingandGear
Insoection
.......13-39
Mainshaft
BearingandOilSeal
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.4, .1. .
Countershaft
Bearing
ReDlacement
.. 13-42
Mainshaft
ThrustClearance
Adiustment
.....13-43
Transmission
Reassemblv.........13-46
Gearshift
Mechanism
R e p l a c e m e n. .t. . . . . . . . . . . . . . . . .1. .3. .-.5. .1. .
M/T Differential
Comoonent
LocationIndex ........13-52
Backlash
Inspection.....................
13-53
FinalDrivenGear/Carrier
Replacement
.. 13-53
... 13-54
CarrierBearings
Replacement
Oil SealReplacement
13-55
..................
Differential
ThrustClearance
Adiustment
.....13-56
ManualTransmission
SpecialTools
ToolNumber
Ref.No.
Description
E n g i n eH a n g e rA d a p t e r ,2 . 0t o 2 . 4 L i t e r
E n g i n eH a n g e r
ral
M a i n s h a fH
t older
07GAJ-PG20' ]10
M a i n s h a fB
t ase
07GAJ-PG20130
@
O i l S e a lD r i v e r
07JAD-P190100
Oil Seal DriverAftachment
07NAD-P20A100
AdjustableBearingPuller,20-40mm
07736-A01000B
ri)
Attachment,42 x 47 mm
07746-0010300
Driver,40 mm LD.
07746-0030100
@
Driver,30 mm LD.
07746-0030300
@
Driver
07749-0010000
@
of Mainshaft Inspection
on T
o o lS
e t .0 7 G A J - P G 2 0 1 0 2 .
Tool
Set,
'16
S l i d eH a m m e r .
M u s t b e u s e dw i t h c o m m e r c i a l lay v a i l a b l e3 / 8 "
(!l
ar\
o
o
Z-'
-4
I
rS'D
A nDr f ;
\".,i'i
\'---''
IN
@
-4
-a ,/
Q)-''
o
13-2
Oty
vs802c000015
vs802c000018
l
l
,l
Transmission
FluidInspectionand
Replacement
'1.
2 . R e m o v et h e o i l f i l l e rp l u g ( A )a n d w a s h e r( B ) ,c h e c k
the conditionof the fluid, and make sure the fluid is
at the proper level (C).
A
44 N.m{4.5kgt.m,
33rbr.ftl
R e i n s t a tl lh e d r a i np l u gw i t h a n e w w a s h e r ,a n d
refillthe transmissionfluid to the proper level.
Oil Capacity
1.50 (1.6US (F) at tluid change
1.70 {1.8US qt) at overhaul
Always use Honda ManualTransmissionFluid
(MTF).Using motor oil can causestiffer shifting
and noise becauseit does not containthe proper
additives.
5 . R e i n s t a tl lh e o i l f i l l e rp l u gw i t h a n e w w a s h e r .
13-3
ManualTransmission
Transmission
Removal
SpecialToolsRequired
. E n g i n eh a n g e ra d a p t e r . 2 . t0o 2 . 4l i t e rV S B 0 2 C 0 0 0 0 1 5
. E n g i n eh a n g e rV S B 0 2 C 0 0 0 0 1 8
. Enginesupport hanger,A & RedsAAR'T 12566'
'
. SubframeadaDterEOS02C000011
* A v a i l a b l et h r o u g ht h e H o n d aT o o l a n d E q u i p m e n t
Program888-424-6857
A
i
@
l
D i s c o n n e ct h
t e t r a n s m i s s i o gn r o u n dc a b l e( B ) .
7 . Disconnectthe back-uplight switch connector(A)
a n dv e h i c l es p e e ds e n s o r( V S S )c o n n e c t o(rB ) .
13-4
vsB02c00001s
tJ.
I n s t a l l t h ee n g i n eh a n g e r( A ) a n d t h e e n g i n es u p p o r t
hanger {B) to the vehicle,then attachthe hook to the
sDeciaitool.
vs802c000015
(cont'd)
13-5
ManualTransmission
Removal(cont'd)
Transmission
15. Removethe transmissionmount bracket(A) and
t r a n s m i s s i om
n o u n t i n gb o l t ( B ) .
to.
R e m o v et h e a i r c l e a n e rb r a c k e {t C ) .
1 7 . R a i s et h e v e h i c l e a, n d m a k es u r ei t i s s e c u r e l y
supponed.
1 8 . D r a i nt h e t r a n s m i s s i o fnl u i d .R e i n s t a tl lh e d r a i nb o l t
w i t h a n e w w a s h e r( s e ep a g e1 3 - 3 ) .
1 9 . R e m o v et h e s p l a s hs h i e l d .
r e a rm o u n I .
db-qF
Ds
13- 6
---
EOS02C000011
2 8 . R e m o v et h e f r o n t e n g i n em o u n t .
29. P l a c et h e t r a n s m i s s i oina c ku n d e rt h e t r a n s m i s s i o n ,
and removethe transmissionmounting bolts.
(cont'd)
13-7
ManualTransmission
TransmissionRemoval(cont'd)
TransmissionInstallation
1 2 x 1 . 2 5m m
64 N.m
{6.5 ksf.m,
47 tbf.ft)
P l a c et h e t r a n s m i s s i o o
n n t h e t r a n s m i s s i o ina c k .
and raiseit to the engine level.
13-8
5 . I n s t a l lt h e t r a n s m i s s i o nm o u n t i n g bolts.
1 2 x 1 . 2 5m m
64 N.m 16.5kgf m.47 lbt ft)
1 2 x 1 . 2 5m m
64 N.m (6.5kgf.m,47 lbf.ft)
6 . I n s t a l l t h ef r o n t e n g i n e m o u n t .
9 . I n s t a l l t h ef r o n t s u s p e n s i o sn u b f r a m e( A )i n i t s
originap
l o s i t i o nb y a l i g n i n gt h e m a r k s( B )y o u
made in the removal procedure,
12 x 1.25ftrn
64 N.m
(6.5 kgf m. 47 lbf.ft)
12x 1.25mm
64 N.m
(6.5kst.m,47 lbf ft)
7 . l n s t a l l t h e c l u t c hc o v e r .
1 4x 1 . 5m m
6x1.0mm
12 N.m {1.2kgI.m,9 lbf ftl
(cont'd)
13-9
ManualTransmission
Transmission
Installation(cont'dl
'10.
1 2 x 1 . 2 5m m
54 N.m {5.5ksf.m, 40lbf.ft)
12x 1.25nn
54 N.m
(5.5kgf.m,
40 tbt.ft)
/t':::=
-)
12 x 1.25 mm
54 N.m
(5.5kgf.m,
40 tbf.ftl
59 N.m(6.0kgf.m,43tbf.ft)
12x 1.25mrn
64 N.m(6.5kgt.m,47lbf.ftl
Installthedrivershafts(seepage 16-17).
13-10
1 8 . R e m o v et h e e n g i n eh a n g e ra n d s p e c i atlo o l f r o m
engrne.
2 0 . I n s t a ltl h e s p l a s hs h i e l d .
22N.m
l2.2kglm,
16rbt.ft)
%,
9.8Nm
(1.0kgf m.
'B
7.2tbl{rl
22Nm
{2.2kgf m, 16 lbf ft)
22. I n s t a l l t h ee n g i n eh a r n e s sc o v e r .
(cont'd)
13-11
ManualTransmission
Transmission
Installation(cont'dl
Applysuperhightemp ureagrease(P/N087989002)to the endof the slavecylinderrod.Installthe
slavecylinderandthe clutchlinebracket.
Takecare
2 5 . I n s t a l l t h ec a b l eb r a c k e (t A )a n d c a b l e s( B ) .
BWZ[i:i'u'T!'*n'-'
a^_
#._gEEa9En
(P/N08798-9002)
6x1.0mm
9.8 N.m
(1.0kgf.m,
7.2 tbt.ftl
lPlN 08798-9002)
2 4 . I n s t a l l t h eh a r n e s sc l i p .
13-12
[---.-.---e
e
6x1,0mm
9.8 N.m
{1.0kgl m. 7 lbf ftl
8x125mm
22Nm
12.2kgt m, 16lbf ft)
34. R e f l l l t h et r a n s m i s s i ofnl u i d ( s e ep a g e1 3 - 3 ) .
35. Test-drivethe vehicle.
36. Checkthe clutchoperation.
3 1 .Checkthe front wheel alignment(seepage 18-4).
38. Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets.
39. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - 1 3 9 ) .
13-13
ManualTransmission
Transmission
Disassembly
ExplodedView-ClutchHousing
,.Y
/ ,, tl
' r'<__J'.@t
j=-X ri ,1.-6
'-==-Yh,_-9
n""
-',ot/u
,tA'
v
i6
\?
q'/V^
-1
t3l
t4
.!) DIFFERENTTAL
ASSEMBLY
r2lSHIFTFORKASSEMBLY
a9l6 mm FLANGEBOLT
1 2 N . m ( 1 . 2k g f m , 9 l b f f t l
..4]BEARINGsET PLATE
G, COUNTERSHAFTASSEMBLY
O NEEDLEBEARING
3 OIL GUIDEPLATEC
e 14 x 20 mm DOWELPIN
.9-iMAGNET
i.!! MAINSHAFTASSEMBLY
U 28 mm WASHER
13-14
i[, 28 mm SPRINGWASHER
iO BALLBEARING
(l 28 x 43 x 7 mm OIL SEAL
Replace.
.D REVERSE
GEARSHAFT
IDLERGEAR
1' REVERSE
f lr 6 mm SPECIALBOLT
15 N.m (1.5kgt.m, 11 lbf.ft)
(!I REVERSESHIFTFORK
.4' REVERSELOCKCAM
Q-t35 x 58 x 8 mm OIL SEAL
Replace.
?]] BACK-UPLIGHTSWITCH
29 N m (3.0kgf.m,22 lbf ftl
.?1O.RING
Replace.
(Vss)
SPEEo
sENsoR
1!)VEHICLE
.O 8 mm FLANGEBOLT
22 N.m (2.2kgf m, 16lbf.ftl
.' CLUTCHHOUSING
iI6)TRANSMISSIONHANGER
tl 10 mm FLANGEBOLT
44 N.m {4.5kgt.m,33 lbf.ft}
Housing
ExplodedView-Transmission
tt-P
@
"=-@
'\b e
P \ Bo,.
@\
rai
\:/
z-W :
iq
f /
"
O=-rl
dd
@------
F,z
,-1 _\
(g/----------__"^\
\-/r*---------..-,
HOUSING
O TRANSMISSION
O 10 mm WASHER
Replace.
@ 10 mm FLANGEBOLT
44 N.m {4.5kgf.m,33lbf.ft)
O 8 mm FLANGEBOLT
27 N.m 12.8kgf m,20lbl.ft)
.' TRANSMISSIONHANGERA
O INTERLOCKBOLT
39N m (4.0ksf.m,29lbf.ft)
O OILGUIOEPLATEM
.172 mm SHIM
.' OIL GUTTEBPLATE
{i) 80 mm SHIM
PIN
0 8 x 14mm DOWEL
[A CHANGELEVERASSEMBLY
a06 mm FLANGEBOLT
12N m {1.2kgf.m,9lbfft}
BOLT
O DETENT
22 N.m{2.2kgf.m,16lbf.ft)
O 12mm waSHER
ReDlace.
(D SPRING
[I STEELBALL
(D TRANSMISSION
HANGERB
(9 CLUTCHLINE CLIPBRACKET
@)20 mm WASHER
Replace.
q,]FILLERPLUG
44 N m {4.5kgf.m,33 lbf.ft)
@ 40 x 56 x 8 mm OILSEAL
Replace.
qO14 mm WASHER
Replace.
q' DRAIN PLUG
39 N.m (4.0kgf.m,29 lbf.ftl
@ 32 mm SEALINGCAP
34 N m (3.5 kgf.m, 25 lbf.ft)
(cont'd)
13-15
ManualTransmission
TransmissionDisassembly(cont'd)
NOTE:Placethe clutch housingon two piecesof wood
thick enoughto keepthe mainshaftfrom hittingthe
workbench.
R e m o v et h e d r a i np l u g( A ) ,f i l l e rp l u g( B ) ,a n d
1 0 m m f l a n g eb o l t ( C ) .
Removethe vehiclespeedsensor(VSS)(A) and
O - r i n g( B ) .
13-16
g
t.l
(,
Y
g
^A
7 . R e m o v et h e 3 2 m m s e a l i n gc a p ( A ) .
E x p a n dt h e 7 2 m m s n a pr i n g ( B )o n t h e
countershaftball bearing,and remove it from the
groove using a pair of snap ring pliers.
L R e m o v et h e t r a n s m i s s i o h
n o u s i n g( C )a n d
1 4 x 2 0 m m d o w e l p i n s( D ) .
(cont'd)
13-17
ManualTransmission
TransmissionDisassembly(cont'd)
15. Removethe differentialassembly(A) and magnet
( B) .
t7
t1
I
1 4 . R e m o v et h e 2 8 m m s p r i n gw a s h e r( E )a n d 2 8 m m
w a s h e r( F ) .
13-18
ReverseShift ForkClearance
Inspection
1. Measurethe clearancebetweenthe reverseidler
gear {A) and the reverseshift fork (B)with a feeler
gauge (C).lf the clearanceis more than the service
limit, go to step 2.
ChangeLeverClearanceInspection
1 . Measurethe clearancebetweenchangelever (Al
and the selectlever (B)with a feelergauge (Cf.lf
i s m o r et h a nt h e s e r v i c el i m i t ,g o r o
theclearance
step 2.
0.05 0.25 mm (0.002-0.010in.)
Standard:
ServiceLimit: 0.50mm {0.020in.)
,tl
qI
13-19
ManualTransmission
ChangeLeverAssemblyDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactsurface.
@).1
l L
r rrl
BREATHER
CAP
Turnthe arrowtowardthe{ront
andinstallit.
o{ thevehicle,
LEVER
SELECT
Becarefulnotto damagethedustseal
w h e ni n s t a l l i ni tg.
I
l
DUSTCOVEB
a^^
7 Fr"irr6-rooa
SHIFTARM COVER
ROLLER
(P/N 08798-9002)
6x1.0mm
12 N.m
(1.2kgl.m,8.7 lbf.ft)
\op
(g)'
WASHER
\r'
'^
E-='1sr/2No
!-d
Fl
q
)-=^l
-z:-=:l-':
tr7
-, OILSEAL
ReDlace.
sELEcr
sPntruc
(A)
,.*
tace.ix#,,l
H\
lV
/-r,s
\__/
,/
INTERLOCK
SHIFTARM
srx
SELECT
SPRING
,/u
/
SELECTSTOP
PLATE
9.8Nm
{1.0kgf.m,7.2 lbf.ft)
LOCKCAM
REVERSE
STRIKER
13-20
Shift ForksGlearanceInspection
NOTE:The synchrosleeveand synchrohub should be
replacedas a set.
1. Measure the clearancebetweeneach shift fork (A)
and its matchingsynchrosleeve(B).lf the
clearanceexceedsthe servicelimit, go to step 2.
Standard:
0.35 0.65 mm {0.014 0.026in.1
ServiceLimit: 1.0 mm 10.039in.l
. l f t h e w i d t h o f t h e s h i f t a r mi s n o t w i t h i n t h e
standard,replacethe shift arm with a new one.
. l f t h e w i d t h o f t h e s h i f ta r m i s w i t h i n t h es t a n d a r d ,
replacethe shift fork and shift piecewith a new
one.
Standard: 16.9-17.0 mm (0.665-0.669in.)
13-21
ManualTransmission
Shift ForksDisassembly/Reassembly
Priorto reassembling,clean all the parts in solvent,dry them, and apply lubricantto any contactparts.
sTH SHIFTFORK
PINDRIVER,
5 mm
13-22
MainshaftAssemblyClearanceInspection
NOTE:lf replacementis required,always replacethe
synchrosleeveand hub as a set.
1. Supportthe bearinginner racewith an appropriate
sizedsocket(A).and push down on the mainshaft
(B).
0.06 0.16mm
{0.002 0.006in.l
0.25 mm (0.010in.l
24.03 24.08mm
{0.946-0.9/uin.}
23.92-23.97 mm
(0.941 0.944in.)
23.80mm (0.937in.)
(cont'd)
13-23
ManualTransmission
MainshaftAssemblyClearanceInspection(cont'd)
6. Measurethe thlcknessof 4th gear.
. lf thethickneso
s f 4 t h g e a ri s l e s s t h a n t h e s e r v i c e
limit, replace4th gear with a new one.
. l f t h e t h i c k n e s s o4f t h g e a r i s w i t h i nt h e s e r v i c e
limit. replacethe 3rd/4thsynchrohub with a new
one.
Standard:
ServiceLimit:
24.03 24.08mm
(0.946 0.947in.)
23.92 23.97mm
(0.941 0.944in.)
23.80mm (0.937in.)
7. l\4easure
the clearancebetweenthe distancecollar
( A )a n d s t h g e a r( B )w i t h a d i a l i n d i c a t o (r C ) .l f t h e
clearanceis more than the servicelimit. go to step
i s w i t hi n t h e s e r v i c el i m i t ,g o t o
8.lf theclearance
steD10.
Standard:
ServiceLimit:
13-24
0.06 0.16mm
(0.002-0.006in.)
0.25 mm (0.010in.)
. l f t h e t h i c k n e s s o5f t h g e a r i s l e s s t h a n t h e s e r v i c e
limit, replace5th gear with a new one.
. lf the thicknessof sth gear iswithin the service
limit. replacethe 5th synchrohub with a new one.
Standard:
Service Limit:
23-92 23.97mm
10.9410.944in.l
23.80mm (0.937in.l
MainshaftDisassembly
'10.
M e a s u r et h e t h i c k n e s so f t h e M B S d i s t a n c ec o l l a r .
. l f t h et h i c k n e so
s f M B S d i s t a n c ec o l l a ri s l e s s
than the standard,replacethe MBS distance
c o l l a rw i t h a n e w o n e .
Standard:
1 . R e m o v et h e a n g u l a rb a l l b e a r i n g( A )a n d t h e
taperedcone ring using a commerciallyavailable
b e a r i n gs e p a r a t o{rB )a n d a c o m m e r c i a l l a
yvailable
b e a r i n gp u l l e r{ C ) .B e s u r et h e b e a r i n gs e p a r a t oirs
u n d e rt h e t a p e r e dc o n er i n g .
23.95 24.05mm
{0.9(3 0.947in.)
E-f
Support5th gear (A) on steel blocks,and pressthe
mainshaftout of the sth synchrohub (B).Use of a
jaw-typepuller can damagethe gear teeth.
(cont'd)
13-25
ManualTransmission
MainshaftDisassembly(cont'dl
3. Supportthe 3rd gear (A) on steel blocks,and press
the mainshaftout of the 3rd/4thsynchrohub (B).
Use of a jaw-type puller can damagethe gear teeth.
MainshaftInspection
1. Inspectthe gear surfaceand bearingsurfacefor
w e a r a n d d a m a g et,h e n m e a s u r et h e m a i n s h a fat t
pointsA, B, C, D, and E. lf any part of the mainshaft
is lessthan the servicelimit, reDlaceit with a new
on e .
Standard:
A Ball bearingsurface(transmissionhousingside):
2 7 . 9 8 7 2 8 . 0 0 0m m ( 1 . 1 0 1 9 1 . 1 0 2 4 i n . )
B Distance collar surtace:
31.984 32.000mm {1.2594 1.2598in.)
C Needle bearing surlace:
38.984-39.000mm (1.53/t8 1.5354in.)
D Ball bearingsurface(clutchhousingside):
2 7. 9 7 7- 2 7 . 9 9 0m m ( 1 . 1 0 1 5 1 . 1 0 2 0 i n . )
E Bushing surface:
20.80 20.85mm (0.819 0.821in.)
ServiceLimit;
A : 2 7 . 9 3m m 1 1 . 1 0 i0n . l
B: 31.93 mm |.1.257in.l
C: 38.93mm 11.533in.l
Di 27.92mm {1.099in.l
E: 20.75mm 10.817in.l
13-26
13-27
ManualTransmission
MainshaftReassembly
ExplodedView
QJ'
frfl
Y7
3RD/4TH
SYNCHRO
SLEEVE
3RD/4TH
SYNCHROHUB
SYNCHRO
SPRING
SYNCHROSLEEVE
SYNCHRORING
NEEDLE
BEARING
Checkfor wearandoperation.
MAINSHAFT
NEEDLEBEARING
GEAR
4TH/5TH GEAB DISTANCECOLLAR
SYNCHRORING
SYNCHROSPRING
a
13-28
SpecialTools Required
. D r i v e r , 4 0m m 1 . D . 0 7 7 4 6 - 0 0 3 0 1 0 0
. Attachment,30mm l.D.07746-0030300
6. Installthe3rd/4thsynchrosleeve(A) by aligning
the stops (B)with the 3rd/4thsynchrosleeveand
hub. After installing,checkthe operationof the 3rd/
4th synchrohub set.
@--
2. I n s t a l l t h en e e d l eb e a r i n ga n d 3 r d g e a ro n t h e
mainshaft.
I n s t a l l t h es y n c h r or i n g a n dt h e s y n c h r os p r i n g .
4 . I n s t a l l t h e3 r d / 4 t hs y n c h r oh u b ( A ) b y a l i g n i n gt h e
7 . I n s t a l l t h es y n c h r os p r i n g( A ) .
I n s t a l l t h es y n c h r or i n g ( B )b y a l i g i n gt h e s y n c h r o
cone fingers (C)with 3rd/4thsynchrohub grooves
(D).
9 . I n s t a l l t h e4 t h g e a r ,n e e d l eb e a r i n gd, i s t a n c ec o l l a r ,
n e e d l eb e a r i n ga, n d s t h g e a r .
07746-0030100
(cont'd)
13-29
ManualTransmission
MainshaftReassembly(cont'dl
1 0 . I n s t a l l t h es y n c h r or i n g a n d t h e s y n c h r os p r i n g .
1
\
1 4 . I n s t a l l t h es y n c h r os p r i n g( A ) .
'1.
I n s t a l l t h es t h s y n c h r oh u b ( A )b y a l i g n i n gt h e
synchrocone fingers (B)with sth synchrohub
grooves(C).
t5.
12. I n s t a l l t h e5 t h s y n c h r oh u b ( A )u s i n gt h e s p e c i a l
tools.
I n s t a l l t h es y n c h r or i n g ( B )b y a l i g n i n gt h e s y n c h r o
cone fingers (C)with sth synchrohub grooves(D).
1 6 . I n s t a l l t h eM B S d i s t a n c ec o l l a ra n dt h e t a p e r e d
c o n er i n g .
1 1 . I n s t a l l t h en e w b a l l b e a r i n g{ A ) u s i n gt h e s p e c i a l
t o o l sa n d a p r e s s( B ) .
U
07746-0030100
07746-0030300
07746-0030100
1 3 . I n s t a l l t h e5 t h s y n c h r os l e e v e .
\.
13-30
CountershaftAssemblyClearancelnspection
1 . Measurethe clearancebetweenthe 1st gear (A)
a n dt h e d i s t a n c ec o l l a r( B ) w i t ha f e e l e rg a u g e( C ) .
. lftheclearance
i s m o r et h a nt h e s e r v i c el i m i t ,g o
to step 2.
. lftheclearance
i s w i t h i nt h e s e r v i c el i m i t .g o t o
step 4.
. l f t h e t h i c k n e s s o lfs t g e a r i s l e s s t h a n t h es e r v i c e
l i m i t ,r e p l a c el s t g e a r w i t h a n e w o n e .
. lf the thicknessof '1stgear is within the service
limit, replacethe lst/2nd synchro hub with a new
one.
Standard:
0.06 0.16mm 10.002 0.006in.l
ServiceLimit: 0.25 mm (0.010in.l
Standard:
a n d 3 r d g e a r( B )w i t h a f e e l e rg a u g e( C ) .l f t h e
clearanceis more than the servicelimit, go to
steD5.
Standard:
0.06 0.16 mm (0.002 0.006in.)
ServiceLimit: 0.25mm {0.010in.l
(cont'd)
13-31
ManualTransmission
CountershaftAssemblyClearance
Inspection(cont'd)
CountershaftDisassembly
1 . Securelyclamp the countershaftassemblyin a
benchvlse with wood blocks.
4 . R e m o v et h e 3 5 m m s h i m a n d d i s t a n c ec o l l a r .
I
13-32
Countershaftlnspection
5. Support4thgear(A)on steelblocks,thenusea
(B)to pressthe
pressandan attachment
(C)
countershaft out ofthe 5thgear.
13-33
ManualTransmission
CountershaftReassembly
ExplodedView
SPECIAL
BOLT
Eeplace.
(
1 1 8N . m 1 2k g fm ,8 7l b ff t )
REVERSE
GEAR
BALL BEARING
Checkfor wear and
operation.
Note the directionof installation.
1ST/2ND
SYNCHRO
HUB
35 mm SHIM
SPRING
TRIPLECONESYNCHRO
ANCE COLLAR
GEAR
4THGEAR
1STGEAR
NEEDLE
BEARING
Checkfor wear
anoopera!on.
DISTANCECOLLAR
(
COUNTERSHAFT
TRIPLECONESYNCHRO
SYNCHROSPRING
13-34
SpecialToolsRequired
. Driver,40 mm l.D.07746-0030100
. Aftachment.30
mm 07746-0030300
6 . I n s t a l l t h es y n c h r os p r i n g( A ) .
'lst gear
aligningthe synchrocone fingers (B)with
grooves(C),then installthe synchrospring {D).
1 . lnstallthe triple cone synchroassembly(B) by
aligningthe synchrocone fingers (C)with the
1sv2ndsynchro hub grooves(D).
8 . Installthedistancecollar (A) and friction damper
(B) by aligningthe friction damper fingers (C)with
the 1sv2ndsynchro hub grooves(D).
'1st/2nd
Installthe
s y n c h r oh u b ( A ) b y a l i g n i n gt h e
synchrocone fingers (B)with 1sV2ndsynchrohub
grooves(C).
5 . I n s t a l l t h er e v e r s eg e a r .
(cont'd)
13-35
ManualTransmission
L,
CountershaftReassembly(cont'dl
1 2 . I n s t a ltlh e 4 t h g e a r( A )u s i n gt h e s p e c i a l t o oal n d a
press(B).Do not exceedthe maximum pressure.
9 . I n s t a ltl h e n e e d l eb e a r i n g .
1 0 .I n s t a l l t h e2 n d g e a r( A )b y a l i g n i n gt h e s y n c h r o
cone fingers (B)with znd gear grooves(C).
B
14,700
N {1,500
kgt,
3,307lbf) max.
07746-0030100
'l
07746-0030100
13-36
I n s t a l l t h e5 t h g e a r( A )u s i n gt h e s p e c i atl o o l a n d a
press(B).Do not exceedthe maximum pressure.
14,700N (1.500kgl,
3.307lbf) max.
07746-0030100
1 4 . I n s t a ltlh e d i s t a n c ec o l l a r( A ) ,3 5 m m s h i m ,a n d o l d
ball bearing(B)using the specialtools and a press
(c).
D
E
F
11
K
L
M
N
R
t5.
T
U
PartNumber
Thickness
23981-PPP-0000.87mm (0.0343n .
23981-PPP-9000 . 9 1m m { 0 . 0 3 5 8
n,
23982-PPP-0000 . 9 5m m ( 0 . 0 3 7 4
n.
23982-PPP-9000.99mm (0.0390n ,
23983-PPP-0001 . 0 3m m 1 0 . 0 4 0n6,
23983-PPP-9001 . 0 7m m ( 0 . 0 4 2 1n .
23984-PPP-0001 . 11 m m ( 0 . 0 4 3 7
n.
23984-PPP-9001 . 1 5m m ( 0 . 0 4 5 3
n.
23985-PPP-0001 . ' 1 9m m ( 0 . 0 4 6 9n .
n
23985-PPP-9001 . 2 3m m ( 0 . 0 4 8 4
n.
23986-PPP-0001 . 2 7m m ( 0 . 0 5 0 0
23986-PPP-9001 . 3 1m m ( 0 . 0 5 1 6i n .
23987-PPP-0001 . 3 5m m ( 0 . 0 5 3 1i n .
23987-PPP-9001 . 3 9m m ( 0 . 0 5 4 7n .
23988-PPP-0001 . 4 3m m ( 0 . 0 5 6 3i n .
23988-PPP-9001 . 4 7m m ( 0 . 0 5 7 9i n
in
23989-PPP-000 1 . 5 1m m ( 0 . 0 5 9 4
in
23989-PPP-900 1 . 5 5m m ( 0 . 0 6 1 0
23990-PPP-0001 . 5 9m m { 0 . 0 6 2i6n .
23990-PPP-9001 . 6 3m m { 0 , 0 6 4i2n .
23991-PPP-0001 . 6 7m m ( 0 , 0 6 5 7i n
23991-PPP-900 1 . 7 1m m { 0 . 0 6 7 3i n
23992-PPP-0001 . 7 5m m ( 0 . 0 6 8 9i n
23992-PPP-9001 . 7 9m m ( 0 . 0 7 0 5i n
AB
23993-PPP-0001 . 8 3m m ( 0 . 0 7 2i0n
23993-PPP-9001 . 8 7m m ( 0 . 0 7 3 6i n
23994-PPP-000' 1 . 9 1m m ( 0 . 0 7 5 2i n
AC
AD
AE
AF
in.
23994'PPP-900 1 . 9 5m m ( 0 . 0 7 6 8
in.
23995PPP-000 1 . 9 9m m ( 0 . 0 7 8 3
{cont'd)
13-37
ManualTransmission
CountershaftReassembly(cont'd)
1 1 . Supportballbearing(A)on steelblocks(B),then
(D)to pressthe
usea press(C)andan attachment
(E)out of the ballbearing.
countershaft
1 8 . l f n e c e s s a r yi n, s t a l l t h e3 5 m m s h i m s e l e c t e di n
step 16,then recheckthe clearance,
1 9 . Installthe distancecollar (A).35 mm shim, and new
b a l l b e a r i n g( B )u s i n gt h e s p e c i a l t o o l a
s n da p r e s s
(c).
46-0030r00
13-38
SynchroRingand GearInspection
1 . Inspectthe insideof each synchroring (A) for wear.
Inspectthe teeth (Bi on each synchro ring for wear
(roundedoff).
WORN
GOOD
t
GOOD
WORN
\
(cont'd)
13-39
ManualTransmission
SynchroRing and GearInspection(cont'dl
3. Inspectthe thrust surface{D)on each gear hub for
wear.
13-40
07749-0010000
07746-0010300
1. Removethe differentialassembly,
2 . R e m o v et h e b a l l b e a r i n g( A ) f r o mt h e c l u t c h
h o u s i n g( B )u s i n gt h e s p e c i a l t o oal n d a
c o m m e r c i a l lay v a i l a b l e3 / 8 " - l 6 s l i d eh a m m e r( C ) .
13-41
ManualTransmission
CountershaftBearingReplacement
Special Tools Required
. Adiustablebearingpuller,20-40 mm 07736-A0tOOOB
. Oil seal driver 07JAD-AP190100
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
I n s t a l l t h en e e d l eb e a r i n gu s i n gt h e s p e c i a l t o o l .
Installthe bearingset plate (A)wirh bolts (B).
Removethe needlebearing(A) usingthe special
tool and a commerciallyavailable3/8" - 16 slide
hammer (B),then removethe oil guide plate C.
B
6 x 1 . 0n n
12N.m{1.2kgt m,
8.7 tbf.ft)
07736-A010008
13-42
MainshaftThrust ClearanceAdiustment
Special Tools Required
. Mainshaftbase07GAJ-PG20130
. M a i n s h a fht o l d e r0 7 G A J - P G 2 0 1 1 0
1 . R e m o v et h e 7 2 m m s h i m ( A )a n d o i l g u i d ep l a t eM
from the transmissionhousing(B).
,5---o
v/
T a k et h e m i d d l ev a l u eo f t h e m i n i m u mv a l u ea n d
t h e m a x i m u mv a l u e ,a n d s e l e c t h e 1 . 5 3m m
( 0 . 0 6 0i n . )s h i m .
{cont'd)
13-/li|
ManualTransmission
MainshaftThrust ClearanceAdjustment (cont'dl
72 mm Shim
AN
PartNumber
Thickness
2 3 9 3 1 - P 2 1 - 0 0 00 . 6 0m m { 0 . 0 2 3i6n . )
23932-P21-000 0.63mm (0.0248
in.
2 3 9 3 3 - P 2 1 - 0 0 00 . 6 6m m ( 0 . 0 2 6i0n .
2 3 9 3 4 - P 2 1 - 0 0 00 . 6 9m m ( 0 . 0 2 7 1i n .
23935-P21-000 0 . 7 2m m ( 0 . 0 2 8i3n .
23936-P21-000 0 . 7 5m m ( 0 . 0 2 9i5n .
23931-P21-000 0 . 7 8m m ( 0 . 0 3 0i7n .
23938-P2'l-000 0 . 8 1m m ( 0 . 0 3 1i9n
23939-P21-000 0 . 8 4m m ( 0 . 0 3 3i1n
23940-P21-000 0 . 8 7m m { 0 . 0 3 4 3i n ,
23941-P21-000 0.90 mm (0.0354in.
23942.P21-000 0.93mm (0.0366in.
23943-P21-000 0 . 9 6m m ( 0 . 0 3 7i8n .
23944-P21.000
0 . 9 9m m ( 0 . 0 3 9i0n .
23945-P21-000 1 . 0 2m m ( 0 . 0 4 0i2n .
23946-P21-000 1 . 0 5m m ( 0 . 0 4 1 3i n .
23941-P2't-000 'l.08mm (0.0425
in
23948-P2'l-000 ' 1. 11 m m { 0 . 0 4 3i7n
23949-P21-000 ' 1 . 1 4m m ( 0 . 0 4 4 9i n
23950-P21-000 1 . 1 7m m { 0 . 0 4 6 1n .
23951-P21-000 1.20mm 10.0472
n.
23952-P21-000 1.23mm (0.0484n .
23953-P21-000 1 . 2 6m m { 0 . 0 4 9 6
n.
23954-P21-000 1 . 2 9m m ( 0 . 0 5 0 8n .
23955-P21-000 1 . 3 2m m ( 0 . 0 5 2 0
n.
23956-P21,000 1 . 3 5m m ( 0 . 0 5 3i1n
23957-P21-000 1 . 3 8m m ( 0 . 0 5 4i3n
23958-P21-000 1 . 4 1m m ( 0 . 0 5 5 5n
23959-P21-000 1 . 4 4m m ( 0 . 0 5 6 7
n.
23960-P21-000 1.47mm (0.0579n .
2 3 9 6 1 - P 2 1 - 0 0 01 . 5 0m m ( 0 . 0 5 9 1n .
23962-P21-OOO 1 . 5 3m m ( 0 . 0 6 0 2
n.
23963-P21-000 1 5 6 m m ( 0 . 0 6 1 4n .
23964-P21-000 1 . 5 9m m ( 0 . 0 6 2 6n .
23965-P21-000 1 . 6 2m m ( 0 . 0 6 3 8i n
23966-P21-000 1 . 6 5m m ( 0 . 0 6 5i0n
23967-P21-000 1 . 6 8m m ( 0 . 0 6 6i1n
-000 1 . 7 1m m ( 0 . 0 6 7i3n .
23968-P2r
23969-P21-000 1 . 7 4m m ( 0 . 0 6 8i5n .
23970-P21-000 1 . 7 7m m ( 0 . 0 6 9i7n .
AO
2 3 9 7 1 - P 2 ' t - O O O1 . 8 0m m ( 0 . 0 7 0 9
in.
D
E
F
L
M
N
o
P
o
R
T
U
X
z
AB
AC
AD
AE
AF
AG
AH
AI
AJ
AK
AL
AM
7 . I n s t a l l t h e7 2 m m s h i m ( A )s e l e c t e da n d o i l g u i d e
p l a t eM i n t h e t r a n s m i s s i o h
n o u s i n g( B ) .
,6,,-o
V
9 . l n s t a l l t h em a i n s h a fitn t h e c l u t c hh o u s i n g .
13-44
1 6 . Z e r oa d i a l g a u g e{ A )o n t h e e n d o f t h e m a i n s h a f t .
. B a c k - o ut th e m a i n s h a fht o l d e rb o l t{ A )a n d l o o s e n
the two hex bolts (B).
. Fit the holderover the mainshaftso its lip is
towards the transmission.
. Align the mainshaftholder'slip aroundthe
groove at the insideof the mainshaftsplines,
then tightenthe hex bolts.
07GAJ-PG20130
07GAJ-PG20130
13-45
ManualTransmission
Transmission
Reassembly
N O T E :P r i o r t or e a s s e m b l i n gc ,l e a na l l t h e p a r t si n
solvent,dry them, and apply lubricantto any contact
surfaces.
\
4. Installthe reverseshift fork.
6x1.0mm
15 N.m (1.5kgf.m,11 lbf.ft)
n-",-o
l;-D
f.)
Installthe reverseidler gear (A) and reversegear
s h a f t( B )b y a l i g n i n gt h e m a r k{ C ) w i t ht h e r e v e r s e
g e a rs h a f th o l e ( D ) .
13-46
6 , l n s t a l l t h er e v e r s el o c kc a m .
z/
--'
t
- 2 6 x 1 , 0m m
/ 15 N.m
/ {1 5 kgf m,
11 tbf.ft)
I
Fl g
- -
-Liquid gasket
{cont'd)
13-47
ManualTransmission
TransmissionReassembly(cont'dl
9 . I n s t a ltlh e 1 4x 2 0 m m d o w e lp i n s( A ) .
34 N.m
(3.5 kgf.m,
25 rbf.ft)
(
11. Lowerthe transmissionhousingthe rest of the way
as you expandthe 72 mm snap ring {C).Release
the snap ring so it seatsin the groove of the
countershaftbearing.
12. Checkthat the 52 mm snap ring is securelyseated
in the groove of the countershaftbearing.
DimensionO as instalted: 3.3 6.0 mm
{ 0 . 1 3 0 . 2 4i n . l
't4.
I n s t a ltl h e t r a n s m i s s i o h
n a n g e r sA . a n d B , a n d t h e
8 mm flange bolts finger-tight.
\A
e./
./
(t
13-48
16. Removethe dirt and oil from the shift iever cover
s e a l i n gs u r f a c eA. p p l y l i q u i dg a s k e t( P / N0 8 7 1 8 0001)to the sealingsurface.
1 9 . I n s t a l l t h ed r a i np l u g( A ) ,f i l l e rp l u g ( B ) ,a n d 1 0 m m
f l a n g eb o l t ( C )w i t h n e w w a s h e r s .
/..l-.=,'-B
g
^
44N.m
@ Ut !?iJl'.'l,''
R\-: \
-.-t
A
39Nm
(4.0 kgf m,
33 tbl.ft)
?0,,.ru^
44 N m {4.5kgt m,33lbf.ft}
-Liquidgasket
1 7 . I n s t a l l t h e8 x 1 4 m m d o w e lp i n s( A ) .c l u t c hl i n ec l i p
b r a c k e (t B ) ,a n d c h a n g el e v e ra s s e m b l y( C ) .
{3.0kgf.m.22lbf.ft)
2 1 . A p p l y l i q u i dg a s k e t{ P / N0 8 7 1 8 - 0 0 0 1 } t oh e t h r e a d s
o i t h e b a c k - u pl i g h ts w i t c h( B ) ,a n d i n s t a l il t i n t h e
transmissioh
nousing.
6x1.0mm
12N.m(1.2kgf.m,9lbtft)
1 8 . A p p l y l i q u i dg a s k e t( P iN 0 8 7 1 8 - 0 0 0 t1o) t h e t h r e a d s
of the interlockbolt (D),and installit on the
transmissioh
nousing.
(cont'd)
13-49
ManualTransmission
TransmissionReassembly(cont'dl
22. Installthevehiclespeedsensor(VSS){A)and
O - r i n g( B ) .
13-50
GearshiftMechanismReplacement
8 x 1.25mm
22 N.m (2.2 kgf.m, 16 lbt ftl
,.-,'-'
KNOB
--SHIFT LEVER
8 N m {0.8ksr.m.5.8lbf.ft}
l'/
SHIFTLEVERHOUSING
{P/N 08798-9002}
SHIFTCABLECLIP
Replace.
6x1.0mm
9.8Nm
(1.0kgf.m,
7.2 tbf.fr)
COTTERPINS
{P/N 08798-9002)
13-51
M/T Differential
ComponentLocationIndex
DRIVENGEAR
Beplacement,page 13-53
\
BacklashInsoection.oaoe 13-53
Feplacemeni,paoe I 3-5-3
,<-=/
I \c1
\
13-52
l/
,/
,/BALL BEARING
Beplacemenl,page 13-54
Backlashlnspection
FinalDrivenGear/Carrier
Replacement
\tt
x t . om m { t o )
1 2 1N m
(12.3kgf m,
89 rbt.ft)
M e a s u r et h e b a c k l a s h
o f b o t h p i n i o ng e a r s( B )w i t h
a dial indicator(C).lf the backlashis not within the
standard,replacethe differentialcarrier.
Standard(New):0.05 0.15mm (0.002 0.006in.)
13-53
M/T Differential
CarrierBearingsReplacement
Special Tool Bequired
Driver,40 mm l.D.07746-0030100
1. Checkthe carrierbearingsfor wear and rough
rotation.lf they rotatesmoothly and their rollers
show no signs of wear, the bearingsare OK,
\
3. Installthe new bearings(A)with the specialtool
and a press.Presseach bearingon until it bottoms.
There should be no clearancebetweenthe bearinos
and the carrier.
NOTE:Turn the sealed(B)side of the bearingaway
from the differentialtoinstallit.
077i16-0030100
13-54
07746-0030100
Oil SealReplacement
Special Tools Required
. Driver07749-0010000
. Oil seal driver attachment07NAD-P20A100
4 . I n s t a l l t h en e w o i l s e a li n t h e t r a n s m i s s i o hn o u s i n q
with the specialtools.
1. Removethe differentialassembly.
2. Removethe oil seal (A) from the transmission
h o u s i n g( B ) .
5 . I n s t a l l t h en e w o i l s e a li n t h e c l u t c hh o u s i n gw i t h
the specialtools.
3 . R e m o v e t h e o i sl e a l( A )f r o m t h e c l u t c hh o u s i n g( B ) .
13-55
M/T Differential
DifferentialThrust ClearanceAdjustment
SpecialToolRequired
Driver.40 mm LD.07746-0030100
1 . I n s t a lal n 8 0 m m s h i m t h a t ' st h e s a m es i z ea s t h e
one you removeo.
00746-0030100
0.10mm l0 0.004in.)
-i.
w
.t
-- --
13-56
..1
:,- -=.
D
E
F
rt
tvl
N
P
o
R
Thickness
4 1 4 4 1P L 3 - 8 0 0 1 1 . 0m m ( 0 . 0 3 9 4
n.
41442-PL3-B001 1 mm (0.0433
n.
4 1 4 4 3 - P L 3 - 8 0 0 1 1 . 2m m ( 0 . 0 4 7 2
n.
4 1 4 4 4 - P L 3 - B 0 0 1 1 . 3m m { 0 . 0 5 1 2n .
4 1 4 4 5 - P L 3 - 8 10 0 1 . 4m m 1 0 . 0 5 5 1n .
4 1 4 4 6 - P L 3 - 8 0 0 1 1 . 5m m { 0 . 0 5 9 1n .
41447-PL3-8
1 0 0 1 . 6m m ( 0 . 0 6 3 0n .
4 1 4 4 8 - P L 3 - B 0 0 1 1 . 7m m { 0 . 0 6 6 9n .
4 1 4 4 9 - P L 3 - 8 0 0 1 . 8m m ( 0 . 0 7 0 9n .
41450-PL3-80001. 0 5m m ( 0 . 0 4 1 3n . )
4 1 4 5 1 - P L 3 - 8 0 0 01. 1 5m m ( 0 . 0 4 5 3n . l
41452-PL3-80001 . 2 5m m ( 0 . 0 4 9 2n . l
41453-PL3-8000 1 . 3 5m m ( 0 . 0 5 3 ' ln . )
41454-PL3-80001. 4 5m m ( 0 . 0 5 7 1n . l
41455-PL3-80001 . 5 5m m ( 0 . 0 6 1 0n . )
5 m ( 0 . 0 6 5i0n . )
41456-PL3-8000' 1 . 6m
41457-PL3-8000 1 . 7 5m m ( 0 . 0 6 8 9i n . )
7 . R e m o v et h e b o l t sa n dt r a n s m i s s i o h
nousing.
8 . Replacethe thrust shim selectedin step 6, then
recheckthe clearance.
9 . R e i n s t a tl h
l et r a n s m i s s i o n .
13-57
Driveline/Axle
.............
16-2
SpecialTools
.........................
16-3
Driveshaft
Inspection
Driveshafts
Removal
..........................
16-3
...................
16-5
Driveshafts
Disassembly
DynamicDamperReplacement
........16-8
....................
16-9
Driveshafts
Reassembly
......................
16-17
Driveshafts
lnstallation
..............
16-19
lntermediate
ShaftRemoval
Intermediate
.................................
16-20
ShaftDisassembly
lntermediate
..................................
16-22
ShaftReassembly
16-24
lntermediate
Shaftlnstallation....................................
Driveline/Axle
SpecialTools
Ref. No.
n]
@
@
t9
6)
(D
ToolNumber
07GAD-PH70201
07MAC-S100200
0 7N A F - S R 3 0 1 0 1
07xAc-001010A
07746-0010400
07746-0030400
07749-0010000
07947-S800100
t g[]
Orv
DescriDtion
O i l S e a lD r i v e r
B a l l J o i n tR e m o v e r2, 8 m m
Half Shaft Base
ThreadedAdapter,22 x 1.5mm
Attachment,52 x 55 mm
u f l v e r ,J 5 m m L U .
Driver
O i l S e a lD r i v e r
1
1
1
1
1
1
1
1
r\J ? )
\*
,0)
16-2
DriveshaftInspection
1. Checkthe inboardboot (A) andthe outboardboot
(B)on the driveshaft(C)for cracks,damage,leaking
grease,and loose boot bands (D).lf any damageis
found, reDlacethe boot and boot bands.
DriveshaftsRemoval
Special Tool Required
B a l l j o i n tr e m o v e r 2, 8 m m 0 7 M A C - S 1 0 0 2 0 0
1. Loosenthe wheel nuts slightly
2. Raisethe front of the vehicle,and support it with
safetystandsin the proper locations(seepage 1-8).
3. Removethe wheel nuts and front wheels.
(cont'd)
16-3
Driveline/Axle
DriveshaftsRemoval(cont'd)
7 . R e m o v et h e l o c kp i n { A ) f r o mt h e l o w e ra r m b a l l
joint castlenut (B),and removethe nut.
NOTE:
. T o a v o i dd a m a g i n gt h e b a l l j o i n t ,i n s t a l a
l hexnut
on to the threadsof the ball joint,
. Be carefulnot to damagethe balljoint boot when
installingthe remover.
\
10. Left driveshaft:Pry the inboardjoint (A)from the
differentialcasewith a prybar.Rightdriveshaft:
Drivethe inboardjoint (A) off of the intermediate
shaft with a drift and hammer. Removethe
driveshaftas an assembly.Do not pull on the
driveshaft(B),becausethe inboardjoint may come
apart.Draw the driveshaftstraightout to avoid
d a m a g i n gt h e o i l s e a l .
Left driveshaft:
t
07MAC-S100200
.."8
w^
'e
16-4
Right driveshaft:
Driveshafts
Disassembly
Special Tools Required
. T h r e a d e da d a D t e r . 2 x2 1 . 5m m 0 7 X A C - 0 0 1 0 1 0 A
. S l i d eh a m m e r ,c o m m e r c i a l l a
yvailable
. Boot band pincers,commerciallyavailable
(cont'd)
16-5
Driveline/Axle
DriveshaftsDisassembly{cont'd)
M a k ea m a r k( A )o n e a c hr o l l e r( B )a n d i n b o a r dj o i n t
(C)to identifythe locationsof rollersand grooves
i n t h e i n b o a r dj o i n t .T h e n r e m o v et h e l n b o a r dj o i n t
on the shop towel (D).Be carefulnot to drop the
rollerswhen separatingthem from the inboard
Jornt.
9 . R e m o v et h e i n b o a r db o o t .B e c a r e f u n
l ottodamaoe
the boot.
10. Removethe vinyl tape.
N4akea mark (A) on the rollers(B) and spider (C)to
identifythe locationsof rollerson the spider,then
removethe rollers.
R e m o v et h e c i r c l i p{ D ) .
16-6
OutboardJoint Side:
1 . R e m o v et h e b o o t b a n d s .B e c a r e f u n
l ottodamage
t h e b o o ta n d d y n a m i cd a m p e r .
. l f t h e b o o t b a n di s a n e a r c l a m p t y p e( A ) ,l i f t u p
the three tabs (B)with a screwdriver.
(cont'd)
16-7
Driveline/Axle
DriveshaftsDisassembly(cont'dl
8. Removethe stopringtromthe driveshaft.
DynamicDamperReplacement
1 . R e m o v et h e i n b o a r dj o i n t ( s e ep a g e1 6 - 5 ) .
2, Removethe dynamic damper bands.Be carefulnot
to damagethe dynamic damper (seepage 16-5).
. l f t h e b o o l b a n di s a w e l d e d t y p e . c u t t h eb o o t
band.
. l f t h e b o o t b a n di s a d o u b l el o o p t y p e ,l i f t u p t h e
band bend, and push it into the clip.
. lfthe boot band is a low profiletype, pinch the
b o o t b a n du s i n ga c o m m e r c i a l l a
y v a i l a b l eb o o t
band pincers.
3. Wrap the splineson the driveshaftwith vinyl tape
(A)to preventdamageto the dynamic damper.
Left driveshaft{Directionall:
296 300mm
( 1 1 . 6 -1 1 . 8i n . )
Right driveshaft(Directionall: 301 305 mm
( 1 1 . 9- 1 2 . 0i n . l
6 . I n s t a l l t h ed y n a m i cd a m p e rb a n d( s e es t e pI o n
p a g e1 6 ' 1 2 ) .
7 . I n s t a ltlh e i n b o a r dj o i n t ( s e ep a g e1 6 - 11 ) .
16-8
DriveshaftsReassembly
ExplodedView
'02 model
SETRING
Replace.
0e
//ROLLER
\)
/''"oH?"'
6)
#'g!!a$il
YJ
.?-//
"\
,I
in the
rr
Use the greaseIncluded
inboardboot
inboard
set.
boot set
// /,/7\
II t,//>\
Usethe greaseincludedin the
inboardboot set.
l>/
I
I
.''
.'(9
{\
--.-
-<
OOUBLELOOPBAND
Replace.
/'..-:'\
.-\
|
\\1lg n
r.
.^-.1
//^\l
, \ V L/ A
r\
DYNAMTC
DAMPER
,/
//
DOUBLE
LOOPBAND
Replace.
STOPRING
Replace.
JOINT
OUTBOARD
(cont'd)
16-9
Driveline/Axle
DriveshaftsReassembly(cont'dl
ExplodedView
'03 model
SET RING
/ Replace.
DOUBLE
LOOPBAND
Replace.
(Bootbandreplacement
only.)
INBOAROJOINT
ROLLEB
CIRCLIP
s l
E.
-"-,,,
@(
Usethe greaseincluded
in the nboard boot set.
(^Y \
\_,/
>
LOWPROFILE
BAND
Beplace.
Usethe greaseincluded
in the inboardboot set.
DOUBLELOOPBAND
Replace.
DYNAMICDAMPER
OUTBOARDJOINT
at-
BOOTITPI
OUTBOARD
16-10
lnboardJoint Side:
1. Wrap the splineswith vinyl tape (A)to prevent
damageto the inboardboot.
Fit the rollers (A) onto the spider {B)with their high
shouldersfacing outward,and note these items:
' Reinstalltherollers in their original positionson
the spider by aligningthe marks (C).
. Holdthe driveshaftpointed up to preventthe
rollersfrom falling off.
(u
@\
(cont'd)
16-11
Driveline/Axle
DriveshaftsReassembly(cont'd)
6 . Packthe inboardjointwith thejointgrease
16-12
P u l lu p t h e s l a c ki n t h e b a n db y h a n d
M a r ka p o s i t i o n( A )o n t h e b a n d 1 0 - 1 4 m m ( 0 . 4 0 . 6i n . )f r o m t h e c l i p { B ) .
(cont'd)
16-13
Driveline/Axle
DriveshaftsReassembly(cont'dl
18. Unwind the boot band tool, and cut off the excess
free end of the bandto leavea 5- 10 mm (0.2-0.4
in.) tail protrudingfrom the clip
16-14
{
2 ' 1 .I n s t a l l t h en e w s e t r i n g .
OutboardJoint Side:
I n s t a l l t h en e w e a r c l a m pb a n d s( B )a n d o u t b o a r d
boot,then removethe vinyl tape. Be carefulnot to
damagethe outboardboot.
1 0c m
( 4i n . )
- ..,..,1;,t,:-,;
{cont'd)
16-15
Driveline/Axle
DriveshaftsReassembly(cont'd)
Checkthe alignmentof the paint mark (A)with the
o u t b o a r dj o i n t e n d ( B ) .
{
8. Adjust the length of the driveshaftsto the figure
below,then adjustthe boots to halfwaybetween
full compressionand full extension.Make sure the
ends of the boots seat in the groovesof the
driveshaftand joint.
Leftdriveshaft:497502mm (19.6 19.8in.)
-tTfi'.D.ilTD
Rightdriveshaft:475 480 mm {18.7 1 8 . 9i n . l
/llt,)r
-*>
\{(
'.,o"o
:;,"0'A?g.fff
:l:f
16-16
DriveshaftsInstallataon
10. Closethe ear portion (A) of the band with a
commerciallyavailableboot band pincersKentMoore J-35910or equivalent(B).
1. Installa new set ring onto the set ring groove of the
driveshaft{left driveshaft).
in.)MAX
6.0mm 10.24
12. R e p e ast t e p s1 0 a n d 1 1 f o r t h e b a n do n t h e o t h e r
end of the boot.
(cont'd)
16-17
Driveline/Axle
DriveshaftsInstallation(cont'd)
Cleanthe areaswhere the driveshaftcontactsthe
differentialthoroughlywith solvent,and dry with
compressea
d i r .I n s e n t h ei n b o a r de n d { A )o f t h e
driveshaftinto the differential(B)or intermediate
shaft {C) until the set ring (D)locks in the groove (E).
{
5 . W i p e o f f t h e g r e a s ef r o m t h e b a l l i o i n ta n d l o w e r
arm taperedsurfaces.Installtheknuckle(A) onto
the lower arm {B).Be careful not to damagethe ball
joint boot.Wipe off the greasebeforetightening
the nut at the ball joint. Torquethe new castlenut
(C)to the lower torque specification,then tighten it
o n l y f a r e n o u g ht o a l i g nt h e s l o tw i t h t h e b a l lj o i n t
p i n h o l e .D o n o t a l i g nt h e n u t b y l o o s e n i n gi t .
NOTE:Make sure the ball joint boot is not damage
or cracks.
"-'t-
I n s t a l l t h en e w l o c kp i n { D )i n t ot h e b a l l j o i n tp i n
hole from the insideto the outsideof the vehicle.
7 . Connectthe front stabilizerlink {A)to the lower arm.
H o l dt h e s t a b i l i z elri n kb a l l j o i n tp i n ( B )w i t h a h e x
w r e n c h{ C ) ,a n d t i g h t e nt h e n e w f l a n g en u t { D ) .
'10x 1.25mm
39 N.m
{4.0kgf.m,29 lbf.ft)
16-18
lntermediateShaft Removal
8. Installa newspindlenut{A),thentightenthe nut.
usea driftto stakethe spindlenut
Aftertightening,
shoulder{B)againstthe driveshaft.
108N.m
(11.0kgf.m,
80 tbt.ft)
/
o
oo
e
3 . R e m o v et h e f l a n g eb o l t{ A )a n d t w o d o w e l b o l t s ( B ) .
22x 1.5 mm
1 8 1N . m
{18.5kgf.m,134lbt.ft)
.---2"
E
(cont'd)
16-19
Driveline/Axle
IntermediateShaft Removal
(cont'dl
4. Removethe intermediateshaft (A) from the
differential.Hold the intermediateshaft horizontal
until it is clear of the differentialto preventdamage
to the differentialoil seal (B).
IntermediateShaft Disassembly
16-20
07NAF-SR30101
16-21
Driveline/Axle
IntermediateShaft Reassembly
ExplodedView
INTERMEDIATE
SHAFTRING
FLANGEBOLT
10 x '1.25mm
39IVm
{4.0kgf.m,29lbt.ftl
\^
,tto", *,"o p
\--'+7\ E
BEARING
SUPPOBT
16-22
07746-0030400
I n s t a l lt,h e n s e a tt h e e x t e r n asl n a pr i n g { A ) i n t ot h e
groove of the intermediateshaft (B).
07746-0010400
3 . I n s t a l lt,h e n s e a tt h e i n t e r n asl n a pr i n g i n t ot h e
groove ofthe bearingsupPort.
(cont'd)
16-23
Driveline/Axle
IntermediateShaft Reassembly
(cont'd)
6 . l n s t a l l t h eo u t e rs e a l( A )i n t o t h e b e a r i n g s u p p o r t ( B )
usingthe specialtool and a press.
PRESS
IntermediateShaft Installation
1 . U s es o l v e n to r b r a k ec l e a n e tr o t h o r o u g h l yc l e a n
the areaswhere the intermediateshaft {A) contacts
the transmission(differential),and dry with
compressedair. Insertthe intermediateshaft
assemblyinto the differential.Hold the
intermediateshaft horizontalto preventdamageto
the differentialoil seal (B).
Packthe interior
ofthe outer seal.
7 . I n s t a l l t h es e t r i n g .
2 . I n s t a l l t h el l a n g eb o l t( A )a n d t w o d o w e lb o l t s( B l .
A
10 x 1.25mm
39Nm
(4.0kgf.m,29lbf.ft)
16-24
B
l 0 x 1 . 2 5m m
39 N.m
(4.0kgf.m,
29 tbf.ftl
12.2
4 . I n s t a l l t h er i g h td r i v e s h a f(ts e ep a g e1 6 - 1 7 ) ,
16-25
Steering
Steering
. . . . . . . . . .1. .7.- 2
S p e c i aTl o o l s
. .7. .-.3. . . . . . . . .
C o m o o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
17-4
PlayCheck.....................".
WheelRotational
Steering
17-4
..........
PowerAssistCheck..................
17-5
.................
andGearboxInspection
SteeringLinkage
...........
l e m o v a.l . . . . . . . . . . . . . . . . . . . . . . . . , . . . .1. .7. -. 6
S t e e r i nW
g h e eR
17-7
................
WheelDisassembly/Reassembly
Steering
17-8
...............
WheelInstallation
Steering
17-9
Steering
ColumnRemovalandInstallation...........'...
17-11
..............
ColumnInspection
Steering
17-'12
.......................................'.
Replacement
SteeringLock
. . . . . " . . . . . . . . '1. .7' .- .1 3
R a c kG u i d eA d i u s t m e n t
ElectricalPowerSteering(EPS)
17-15
Steering
(
SpecialTools
Ref.No.
Tool Number
07MAA-S100200
Description
LocknulWrench.43 mm
-.tt)-
---<,/
L\2 r
6Y
.Vo
1 7-2
Oty
ComponentLocationIndex
DRIVER'S
AIRBAG
ASSEMBLY
Removal/lnstallation,
p a g e2 3 - 1 1 3
STEERINGWHEEL
Removal,page 17-6
Disassembly/Reassembly,
page 17-7
Installation,page 17-8
STEERING
COLUMN
SteeringColumnRemovaland Installation,
p a g e1 7 ' 9
SteeringColumn Inspection,
p a g e1 7 - 1 ' l
SteeringLockReplacement,
page 11-12
STEERING
GEARBOX
page'17-13
RackGuideAdjustment,
17-3
Steering
SteeringWheelRotationalPlay
Check
PowerAssistCheck
1 . Startthe engine,and let it idle.
+ :
3 . l f t h e s c a l er e a d sn o m o r e t h a n2 9 N ( 3 . 0k g f , 6 . 6l b f ) ,
the power assistis OK. lf it readsmore, checkthese
items:
.
.
.
.
17-4
Fronttire pressure
Steeringlinkage(seepage 17-5)
Rackgulde adjustment(seepage 17-13)
EPSsystem (seepage 17-18)
SteeringLinkageand GearboxInspection
BOOT
Inspect
Ior damageanddeterioration.
Checkfor looseness,
a n db i n d i n g .
12 mm BOLTS
Inspectfor looseness.
STEERING
COLUMN
Inspect
for loosecolumn
mountinghardware
STEERING
JOINTS
Checkfor looseioint bolts,
andlooseor bindingioints.
TIE.RODLOCKNUTS
Checkfor looseness.
STEERING
GEARBOX
Inspectfor loosemounting hardware.
GEARBOXMOUNTING CUSHIONS
Inspectfor deterioration.
TIE.RODENOBALLJOINT
lnsoect
tor looseness,
b i n d i n ga,n dd a m a g e .
BALLJOINT
BOOT
Inspect
for damageanddeterioration.
17-5
Steering
SteeringWheelRemoval
SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage 23-13),and
precautionsand procedures(seepage 23-14)in the SRS
sectionbeforeperformingrepairsor service.
1. Align the front wheels straightahead,then remove
the driver'sairbagfrom the steeringwheel (see
p a g e2 3 - 1 1 3 ) .
2. Disconnectthe cruisecontrol sevresumeswitch
connector(A),and loosenthe steeringwheel nut
{B).
{
3. Installa commerciallyavailablesteeringwheel
puller {A) on the steeringwheel (B).Freethe
steeringwheel from the steeringcolumn shaft by
t u r n i n gt h e p r e s s u r eb o l t( C )o f t h e p u l l e r .
Note these items when removing the steering
wheel:
. Do not tap on the steeringwheel orthesteering
column shaft when removingthe steeringwheel.
. l f y o u t h r e a dt h e p u l l e rb o l t s( D )i n t o t h e w h e e l
hub more than 5 threads,the bolts will hit the
cable reel and damageit. To preventthis, install
a p a i ro f j a m n u t s5 t h r e a d su p o n e a c hp u l l e rb o l t .
D
i
Bemovethe steeringwheel puller,then removethe
steeringwheel nut and steeringwheel from the
sleerinocolumn.
17-6
SteeringWheelDisassembly/Reassembly
WHEEL
STEERING
ACCESSPANELA
CONTACTPLATE
75*-=offi
CONNECTORHOLDERS
ffi)Y
MOOULESETBRACKET
-f
STEERING
WHEELREABCOVER
,/*
accEss
PANEL
B
CRUISECONTROLSWITCH
17-7
Steering
SteeringWheelInstallation
1 . B e f o r ei n s t a l l i n g
t h e s t e e r i n gw h e e l ,m a k es u r et h e
front wheels are alignedstraightahead,then center
the cable reel (A).Do this by first rotatingthe cable
reel clockwiseuntil it stops.Then rotate it
counterclockwiseabout two and a half turns.The
a r r o w m a r k( B )o n t h e c a b l er e e ll a b e ls h o u l dp o i n t
straightup.
_
B
lr,',,t
;. _,:!
'' '1i::..'.'l
I n s t a ltlh e d r i v e r ' sa i r b a g a
, n d c o n f i r mt h a tt h e
system is operatingproperly{seepage 23-113).
C h e c kt h e h o r n ,t u r n s i g n a lc a n c e l i n g
a n dc r u i s e
control switchesfor proper operation.
7 . Reconnectthe batteryand do the following:
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 l - 1 3 9 ) ,
. Powerwindow control unit resettingprocedure
\see page 22-1281.
. Enterthe anti-theftcord for the radio,then enter
the custmer'sradio stationpresets.
. Set the clock.
17-8
SteeringColumnRemovaland Installation
SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)and precautionsand
procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
Removal
1, Recordthe radio stationpresets,and disconnectthe battery.
2 . R e m o v e t h e d r i v e r ' s a i r b a g a s s e m b l y ( s e e p a g e 2 3 -a1n1d3t)h e s t e e r i n gw h e e l( s e ep a g e1 7 - 6 ) .
p a g e2 0 - 6 0 ) .
3 . R e m o v e t h ed r i v e r ' sd a s h b o a r dl o w e r c o v e r ( s e ep a g e2 0 - 5 9 a) n d u n d e r c o v e r ( s e e
4. Removethe column covers(A:
I x 1.25mm
16 N.m (1.6kgf.m,
12 lbl.fr)
\
(cont'd)
17-9
Steering
SteeringColumnRemovaland Installation(cont'd)
lnstallation
1 . I n s t a ltl h e s t e e r i n gc o l u m n ,a n d m a k es u r et h e
wires are not caught or pinchedby any parts.
Insertthe upper end ofthe steeringjoint onto the
steeringshaft {A) (line up the bolt hole (B)with the
flat portion (C)on the shaft).
8 x 1 , 2 5m m
28 N.m
{2.9 kgf m,
21rbr.ft)
A
17-10
SteeringColumnInspection
. C h e c kt h e s t e e r i n gc o l u m nb a l l b e a r i n g ( A a
) n d t h e s t e e r i n g j o i n t b e a r i n g s ( B ) f o r p l a y a n d p r o p e r m o v e m el fnatn. y
bearingis noisy or has excessiveplay, replacethe steeringcolumn as an assembly,
' C h e c k t h e a b s o r b i n g p l a t e s ( C ) , a b s o r b i n g p l a t e g u i d e s ( D ) , s t o p ( E ) , a n d c o a t i n g p l af o
t er sd(i F
s t)o r t i o na n d
breakage.lf there is distortionor breakage,replacethe steeringcolumn as an assembly.
17-11
Steering
SteeringLockReplacement
NOTE:Do not try to re-keya replacementsteeringlock.
lf necessary,re-keythe other locks.
1 . R e m o v et h e s t e e r i n gc o l u m n( s e ep a g e1 7 - 9 ) .
2. Centerpunch each ofthe two shear bolts (A),and
drill their headsoff with a 5 mm (3i16 in.) drill bit.
Be carefulnot to damagethe switch body when
removingthe shear bolts,
:..'-":'
17-12
RackGuideAdjustment
Special Tool Required
Locknutwrench, 43 mm 07MAA-S100200
i-rrrr-,
'-.i. ''
'
9 . 8N . m ( r . 0 k g f . m , 7 . 2 l b t f t )
I
32 on page 13-8).
4il N.m
{a.5kgf.m,33lbt.ft)
17-13
ElectricalPowerSteering(EPSI
SpecialTools
. . . . . . . . . .1. .7-. 1 6
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7. .-.1. .7. . . . . . .
Troubleshooting
General
Information.......................
17-18
DTCTroubleshooting
Index
..............
17-22
SymptomTroubleshooting
Index ...............................
17-23
SystemDescription.................
...........
17-24
CircuitDiagram
.........17-26
DTCTroubleshooting
...............
..........
17-28
EPSlndicator
CircuitTroubleshooting
.......................
17-47
MotorRemoval/lnstallation
...............
17-49
Steering
GearboxRemoval
...............
17-51
Steering
GearboxOverhaul
...............
17-55
Steering
GearboxInstallation
...........
17-63
EPSControlUnitRemova
l/lnsta
llation.......................
17-67
Tie-rodBallJointBootReplacement
..........................
17-67
EPSComponents
SpecialTools
Rel.No.
Tool Number
(!)
07MAC-S100200
at'
070AD-P0A0100
07zAA-S5A0100
otv
Description
'1
B a l lJ o i n t R e m o v e r2, 8 m m
Attachment,42 mm
LocknutWrench
1
'l
-)
,.^G) C\
_---1t
h5--d-'
u_r-.c_t t )
\L-,
a
17-16
ComponentLocationIndex
GAUGE
ASSEMBLY
UNDER.DASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
-,'/.,....
'.,i,
X \ ]
TOROUE
SENSOR
STEERINGGEARBOX
SteeringGearboxRemoval,page 17-51
SteeringGearboxOverhaul,page 17-55
SteeringGearboxInstallation,page 17-63
EPSCONTROL
UNIT
EPSControlUnitRemoval/lnstallation,
page17-67
MOTOR
Removal/lnstallation,
page l7-49
17-17
EPSComponents
GeneralTroubleshooting
Information
EPSIndicator
Undernormalconditions,
the EPSindicator
comeson when
the ignitlonswitchis turnedto theON(ll)position,
thengoes
Thisindicates
off afterthe engineis started.
thatthebulband
itscircuitareoperating
correctly.
lf thereis anytroublein thesystemaftertheengineis started,
will stayon,andthe powerassistis turned
theEPSindicator
off.
WhenEPSindicator
lightcomeson,thecontrolunit
memorizes
the DTC.In thiscase,thecontrolunitwill not
activate
the EPSsystemaftertheenginestartsagain,but it
keepsthe EPSindicator
on.
WhenDTC12,16,17,18or 67 is storedin thecontrolunit,the
EPSindicator
will stayon untiltheDTCis erased.
Whena
problemis detected
andthe EPSindicator
comeson,thereare
stayson untiltheignitionswitchis
caseswhenthe indicator
goesoff
turned0FF,andcaseswhenthe indicator
whenthesystemreturnsto normal.Eventhough
automatically
thesystemis operating
normally,
the EPSindicator
will come
on underthefollowingconditions:
'1:
Condition
. Thevehiclewastraveling
at least12.4mph(20km/h),then
. A rapid changein vehiclespeedwas detected,then
. Thevehicle(orthevehiclespeedsensorsignal)stoppedfor
at least5 seconds
'l,640rpmorhigherforatleastS
. T h ee n g i n se p e e d
w a ss t i l l
seconds
C o n d i t i o n2 :
Afterthevehicle(orthevehiclespeedsensorsignal)has
yettheenginespeedwasstill
for at least10seconds,
stopped
1,640rpmor higherforat least20seconds.
C o n d i t i o n3 :
When
is280rpmor less,
andthevehicle
istraveling
theengine
speed
at
a speed
of6,2mph(10km/h)
or morefor3 seconds.
To determine
theactualcauseofthe problem,question
the
duringwhichthe problem
customer
abouttheconditions
takingtheaboveconditions
intoconsideration.
occured,
DiagnosticTroubleCode(DTCI
. lf theCPUcannotbeactivated,
or itfails,theEPSindicator
comeson,butthe DTCis notmemorized.
. Thememorycanholdanynumberof DTCS.
However,
when
thesameDTCis detected
morethanonce,the mostrecent
onlyone
DTCis writtenoverthe priorDTC,therefore
occurrence
is memorized.
. TheDTCS
areindicated
repeatedly
untiltheignitionswitchis
turnedOFF.
. lf theDTCis not memorized,the
EPSindicator
blinks.
17-18
. TheDTCS
arememorized
in theEEPRO|(non-volatile
memory)therefore
the memorized
DTCS
cannotbe erased
by disconnecting
the battery.
Perform
thespecified
procedures
to clearDTCS.
Self-diagnosis
Self-diagnosiscan be classifiedinto two categories:
. I n i t i a l d i a g n o s i sp: e r f o r m e dr i g h ta f t e rt h e e n g i n e
startsand until the EPSindicatorgoes off.
. Regulardiagnosis:performedright after the initial
d i a g n o s i su n t i lt h e i g n i t i o ns w i t c hi s t u r n e dO F F .
The EPScontrol unit performsthe following functions
when a problem is detectedby self-diagnosis;
'1.
T u r n so n t h e E P Si n d i c a t o r .
2. Memorizesthe DTC.
3. Stops power assistand manual steeringoperation
begrns.
NOTE:
. When DTC23 (a problemwith the circuitfor
enginespeedsignal)is detected,the power
a s s i sw
t i l l r e t u r nt o n o r m a lw h e n t h e v e h i c l e
s p e e di s 0 . 6 2m p h ( 1 k m / h )o r a b o v e .
. Fot DfCs 22,23, 64, or 66 the EPSindicatorgoes
off automaticallywhen the system relurnsto
n o r m a l .F o ra l l o t h e rc o d e s t, h e E P Si n d i c a t o r
goes off when the system is OK afterthe ignition
switch is turned from OFFto ON (ll).
Restrictionon PowerAssistOperation
Repeatedextremesteeringforce.such as turning the
steeringwheel continuouslyback-and-forth
with the
vehiclestopped,causesan increaseof power
consumptionin the EPSmotor. The increaseof electric
t h i sh e a t
c u r r e n tc a u s e st h e m o t o rt o h e a tu p . B e c a u s e
adverselyaffectsthe system,the control unit monitors
the electriccurrent of the motor.
When the control unit detectsheat build-upin the motor,
it reducesthe electriccurrentto the motor graduallyto
protectthe system,and it restrictsthe power assist
o p e r a t i o nT. h e E P Si n d i c a t o dr o e sn o t c o m e o n d u r i n g
t h i sf u n c t i o n .
When steeringtorque is not appliedto the steering
wheel, or when the ignition is turned off, and the motor
cools,the control unit will restorethe power assist
graduallyuntil it's fully restored(afterapproximately15
m i n u t e sm a x i m u m ) .
How to TroubleshootEPSDTCs
The troubleshootingflowchart proceduresassumethat
the causeof the problem is still presentand the EPS
indicatoris still on, Followingthe flowchartwhen the
EPSindicatordoes not come on can result in incorrect
diagnosis.
The connectoriliustrationsshow the female terminal
c o n n e c t o rw
s i t h a s i n g l eo u t l i n ea n d t h e m a l et e r m i n a l
connectorswith a double outline.
1. Ouestionthe customeraboutthe conditionswhen
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the EPSindicatorcame on, such as while
t u r n i n g .a f t e r t u r n i n gw, h e n t h e v e h i c l ew a s a t a
certain speed,etc.
2 . T u r nt h e i g n i t i o nO N ( l l ) ,a n d f o l l o wt h e p r o m p t so n
the PGM Testerto displaythe DTC(s)on the screen.
After determiningthe DTC,referto the DTC
TroubleshootingIndex.
NOTE:See the HondaPGM Testeruser's manual
for specificinstructions.
ServiceCheckSignalCircuit Method:
1 . W i t h t h e i g n i t i o ns w i t c hO F F ,c o n n e c t h e H o n d a
P G MT e s t e r( A ) t o t h e 1 6 Pd a t al i n kc o n n e c t o(rD L C )
(B) locatedunderthe dash on the driver'sside of
the vehicle.
How to RetrieveEPSDTCs
Honda PGM Tester Method:
1, With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
(B) locatedunderthe dash on the driver'sside of
thevehicle.
(cont'd)
17-19
EPSComponents
GeneralTroubleshootingInformation(cont'dl
5. The blinkingfrequencyindicatesthe DTC.DTCSare
indicatedby a seriesof long and short blinks.One
l o n g b l i n ke q u a l s1 0 s h o r tb l i n k s A
. d d t h e l o n ga n d
short blinkstogetherto determinethe DTC.After
determiningthe DTC,referto the DTC
TroubleshootingIndex.
The system will not indicatethe DTCunlessthese
conditionsare met:
. Set the front wheels in the straightaheaddriving
position.
. The ignition switch is turned ON (ll).
. The engine is stopped.
. The SCScircuit is shortedto body ground before
the ignition switch is turned ON (ll).
How to ClearEPSDTCs
Honda PGM Tesler Method:
1. With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
( B )l o c a t e du n d e rt h e d a s ho n t h e d r i v e r ' ss i d eo f
the vehicle.
Exampleof DTC23
17-20
17-21
EPSComponents
DTCTroubleshootingIndex
DTC
Detection ltem
Note
DTC;12
(seepage 17-28)
D T C1: 6
(seepage 17-29)
DTC:17
( s e ep a g e1 7 - 3 1 )
DTC:18
( s e ep a g e1 7 - 3 1 )
DfC:22
( s e ep a g e1 7 - 3 3 )
{seepage 17-33)
DTC:23
( s e ep a g e1 7 - 3 3 )
DTC:37
(seepage 17-35)
DTC:41
( s e ep a g e1 7 3 6 )
DfC: 42
(seepage '17-38)
DTC:43
( s e ep a g e1 7 - 4 1 )
DTC:45
(seepage 17-38)
DfC: 47
{ s e ep a g e1 7 - 4 2 )
DTC:50
( s e ep a g e1 7 - 4 3 )
D T C :5 1
A problemwith EEPROM
in the EPScontrolunlt
(seepage 17-43)
DTC:62
Fail-saferelay stuckON
( s e ep a g e1 7 - 4 4 )
DTC:64
(seepage 17-44)
Fail-saferelay contactfailure
(seepage 17-44)
DTC:66
{seepage 17 45)
DTC:67
( s e ep a g e1 7 ' 4 5 )
DTC:68
{seepage 17-45)
DTC:69
A p r o b l e mw i t h t h e i n t e r l o c kc i r c u i t( c u r r e n t )
( s e ep a g e1 7 - 4 6 )
17-22
Symptom TroubleshootingIndex
Symptom
Diagnostic procedure
EPSindicatordoes not
come on
EPSlndicatorCircuitTroubleshooting(seepage 17-47)
EPSindicatordoes not go
off and no DTC is stored
EPSIndicatorCircuitTroubleshooting(seepage 17-47)
17-23
EPSGomponents
SystemDescription
EPSGontrolUnit Inputsand Outputsat ConnectorA (2pl
EPSCONTROLUNIT CONNECTORA {2P)
Terminalsign
(Terminalnamel
Description
8LK
Measurement
Conditions
lqnitiqr switch ON (lll
l Ground Constant
Terminals
Powersourcefor the
actuatormotor
Groundforthe actuator
PG
Voltage
Battery voltage
2-Ground
Terminalsign
{Te.mioalname)
Description
Terminals
RED
M1
(Motor 1
Driveslhe actuatormotor
1-Ground
GRN
M2
2'Ground
17-24
Measuremenl
Conditions
lqnition switch ON llll
Voltage
Terminal
Wire color
numbel
2
Terminalsign
{Terminelname}
Descriplion
Terminals
Measuremeni
Conditions
{lqnitionswitch ON {lll)
T/SGND
Groundfor the torque
(Torquesensorqround)
3-Ground tarttheenqrne
Powersourcefortorque
ORN
vccl
(Voltaqe
common1
Detectstorque sensor
5 Ground Starttheengineand
YEUBED VT6
(Voltaqe
turnthe steerinowheel
stonal
torque6)
ON
Drivesthe EPSindicator
6 Ground E P S
YEUBLU
(Warninqlamp)
uTllidhr
tnotcatol
Raisethe vehicleoff the
Detectsthe vehiclespeed
BLUAVHT VSP
groundandspinthe
( V e h i c l es p e e d p u l s e i
inputsignalfor the speed
sensoror the ECM(4 pulse/
Voltage
PNK
BRN
10
YEL
11
GRN//EL
SCS
checksiqnal)
{Servjco
IG1
llqnition1
vcc2
Detectsservicecheck
Drivesthetorquesensor
Batteryvoltage
on switchON (ll)
on switchOFF
1'l-Ground tan the enoine
Battervvoltaqe
About5V
on switch OFF
8LU/ORN VT3
Detectstorque sensor
YEUBLK T/SIG
(TorquesensorF/S
Detectstorque sensor
srgnal
(Voltaoe
toroue3)
OV
Banervvoltaqe
Alternating
voltageabout
OV 5V OV-5V
(Voltaqe
common2)
Ba$ervvoltaqe
OV
About
1'l
LT GRN/
B IK
19
BLU
Providespower steering
PSW
iPowersteerinoswitch) switchsional
Detectsthe enginepulse
NEP
20
GRY
DIAG-H
with
Communications
HondaPGNITester
About
13-GroundStarttheengineand
trrrnthe steerinowheel 5 - 0 v
Momentarily
5V
15-GroundStarttheengine
0-12V
l7-Ground Starttheengineand
nrrnthe steerinowheel
19-GroundStarttheengine,and let
;t idte
5V
20-Ground PGMTesternot
17-25
EPSComponents
CircuitDiagram
SPEDSENSOR
3P CONNECTOR
@
GAUGEASSEMATY22PCONNECTOR
TOFOUESENSOR
6P CONNECTOR
lli2l3F
r;T;T-I
(=J_:_LvJ
Wn. !ide ot f.m.l r.fmin.ls
17-26
GAUGEASSEMBLY22PCONNECTON
EPSCOI{IFOIUNIT
cou{EcToR A (2P)
F-l
vTTrvaEvnrv
A
EPSCONTNOLUNIT
co|lNEcTofi 8 {2P}
| l l
wwzna
MOTOF
CONNECTOR
riTt
t2)
T.rmin.l.id.
oll.m.l.r.rmin.l.
17-27
EPSComponents
DTCTroubleshooting
DTC12: TorqueSensorT/SIG
1 . C l e a rt h e D T C .
2 . S t a nt h e e n g i n e .
3. Wait at least 10 seconds.
Does the EPS indicatot come on?
EPSCONTROL
UNITCONNECTOR
C (2OP)
2 3
YES Go to step 4.
5 6 1 8
T/SIG
{YEL/BLK)
ls DTC12 indicated?
I s there battery v oltage?
YES Go to slep 5.
NO-Perform the appropriatetroubleshootingfor
the code indicated.t
T/SIG
(YEL/BLK)
W i r es i d eo f f e m a l et e r m i n a l s
TOROUE
SENSOR
6PCONNECTOR
T/SIG
(YEL/BLK)
Wire side of femaleterminals
Wire side ot femaleterminals
ls therecontinuity?
ls there continuity?
NO Go to step7.
17-28
'I
1 . Substitutea known-goodEPScontrol unit, and
connectthe all disconnectedconnectors.
DTC16:TorqueSensorVT3andW6
1 . C l e a rt h e D T C .
2. Startthe engine.
3 . W a i t a t l e a s t1 0 s e c o n d s .
YES-Go to step 5.
NO Performthe appropriatetroubleshootingfor
the code indicated.t
5. Make sure the ignition switch is OFF,then
disconnectEPScontrol unit connectorC (20P)and
the torque sensor6P connector.
6, Checkfor continuitybetweenthe appropriateEPS
control unit connectorC (20P)terminal and body
ground (seetable).
Terminalname
C
EPScontrolunitconnector
terminalNo.
Vccl
Vcc2
VT3
VT6
11
13
T/S GND
5
2
EPSCONINOTUNITCONNECIOR
C (2OP)
W re s d oltemalelermi.als
ls there continuity?
YES- Repairshort to body ground in the
appropriatesensorcircuit betweenthe torque
sensorand EPScontrol unit,!
NO Go to step7.
{cont'd)
17-29
EPSComponents
DTCTroubleshooting(cont'd)
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
EPScontrol
unitconnector
C
t e r m i nN
a lo .
3
Vcc2
VT3
VT6
11
T/S GND
13
5
EPSCONTROLUNITCONNECTOR
C {2OP}
T e r m i n a l TorqueSensor EPScontrol
name
t e r m i n aNl o , unitconnector
C t e r m i n aNl o .
Vccl
2
3
Vcc2
3
11
'l
't3
VT3
VT6
6
5
6
T/S GND
2
TOROUESENSOR6PCONNECTOR
Vccz
(GRN/YELI
Wire side of
f e m a l et e r m i n a l s
VT6 {YEL/RED)
EPSCONTROLUNIT
CONNECTOR
C I2OP)
VT6{YEL/RED}
ls therecontinuty?
Y E S G ot o s t e p1 1 .
NO Repairopenin the appropriate
torquesensor
wirecircuitbetweenthe EPScontrolunitandthe
t o r q u es e n s o r . l
17-30
't2.
DTC17: TorqueSensorVccl
DTC18:TorqueSensorVcc2
NO Performthe appropriatetroubleshootingfor
the code indicated.l
Wiresideo{femaleterminals
ls there continuity?
Y E S R e p a i rs h o n t o b o d y g r o u n di n t h e w i r e
betweenthe torque sensorand EPScontrol unit.I
NO Go to step 7.
(cont'd)
17-31
EPSComponents
DTCTroubleshooting(cont'dl
7. Checkfor continultybetweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P t)e r m i n a lN o . 3 a n d t h e t o r q u e
sensor6P connectorterminal No. 2.
EPSCONTROL
UNITCONNECTOR
C I2OP)
\
9. Checkfor continuitybetweenEPScontrol unit
connectorC {20P)terminal No. 11 and the torque
sensor6P connectorterminal No. 3.
EPSCONTROL
UNITCONNECTOR
C (2OP}
Vcc2(GRN/YEL)
ls thete continuity?
ls therc continuity?
YES Go to step 8.
2 3
lvcc2
5 6 1 8
{GRN/YEL)
ls therecontinuity?
YES-Replace the steeringgearboxand recheck.l
17-32
NO Performthe appropriatetroubleshootingfor
the code indicated.l
DTC22: VehicleSpeedSensorSignal
DTC23: EngineSpeedSignal
4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
NOTE:
. lf the MIL indicatoris ON, troubleshootthe PGIVI-Fl
systemfirst.
. Eventhough the system is operatingnormally,the
EPSindicatorwill come on underthe following
conditions.
- C o n d i t i o n1 :
. The vehiclewas travelingat least '12.4mph
(20 km/h),then
. A rapld changein vehiclespeedwas detected,
then
. T h e v e h i c l e( o rt h e v e h i c l es p e e ds e n s o rs i g n a l )
stoppedfor at least5 seconds,and
. The engine speedwas still 1,640rpm or higherfor
at least5 seconds
- Condition2:
After the vehicle(or the vehiclespeedsensor
signal)has stoppedfor at least10 seconds,yetthe
e n g i n es p e e dw a s s t i l l 1 , 6 4 0r p m o r h i g h e rf o r a t
least20 seconds.
- Condition3:
W h e nt h e v e h i c l es p e e di s 1 0 k m / h ( 6 . 2m p h )o r
a b o v ea n d t h e e n g i n ei s r u n n i n ga t 2 8 0 r p m o r
below for 3 seconds.
1. Startthe engineand checkthe tachometer.
ls the tachometer working correctly?
YES- Go to step 2.
N O - G o t o s t e p9 .
2. Test-drivethe vehicleabove 15 km/h {9.3mph).
ls the speedometerworking correctly?
YES Go to step 3.
NO-Perform the speedometersystem
troubleshooting{see page22-651.a
(conr'd)
17-33
EPSGomponents
DTCTroubleshooting(cont'dl
Turn the ignition switch OFF,and disconnectEPS
control unit connectorC (20P).
7 . Startthe engine,and let it idle.
Wiresideof femaleterminals
'12.
!
17-34
'14.
Checkfor continultvbetweenEPScontrol unit
c o n n e c t oC
r ( 2 0 P ) t e r m i n aNl o . 1 9 a n d E C M
connectorE (31P)terminal No. 26.
ECMCONNECTOR
E {31PI
DTC37: EPSControlUnitInternal
Circuit
(lnputCircuitForMotorVoltage)
1 . C l e a rt h e D T C .
2. Startthe engine.
3. Turn the steeringwheel from lock-to-lockseveral
times, and wait 10 secondsor more.
Does the EPS indicator come on?
YES Go to step 4.
NO Checkfor loosewires or poor connections.lf
the connectionsare good,the system is OK at this
trme.l
ls thete continuity?
ls DTC 37 indicated?
N O - R e p a i r o p e n i n t h e w i r e b e t w e e nt h e E P S
c o n t r o lu n i ta n d E C M . I
NO Performthe appropriatetroubleshootingfor
the code indicated.l
EPSCONTROL
UNITCONNECTOR
C (2OP}
Wiresideof femaleterminals
ls there continuity?
Y E S R e p a i rs h o r t t ob o d y g r o u n di n t h e w i r e
betweenthe EPScontrol unit, the test tachometer
connector,the gaugeassembly,and the ECM.I
NO Checkfor loose ECMcontrol unit connectors.
lf necessary,substitutea known-goodECMcontrol
u n i ta n d r e c h e c k . I
17-35
EPSComponents
.l
DTCTroubleshooting(cont'dl
DTC41: VoltageForMotor
1 . C l e a rt h e D T C .
EPSCONTROLUNITCONNECTOR
B I2P)
2 . S t a r tt h e e n g i n e .
3. Turn the steeringwheel from lock-to-lockseveral
times, and wait 10 secondsor more,
Tit
M2 {GRN)FJ
-r
o)
YES-Go to step 4.
Wiresideof femaleterminals
ls there continuity?
Y E S - R e p a i rs h o r tt o b o d y g r o u n di n t h e G R Nw i r e
betweenthe EPScontrol unit and the motor,l
YES Go to step 5.
NO Go to step 8.
NO Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . l
5. Make sure the ignition switch is OFF,then
disconnectEPScontrol unit connectorB (2P)and
the motor 2P conneclor.
M1 (RED}H
F---t||
Itr
(f))
T
,L
Wiresideof femaleterminals
ls there continuity?
YES Repairshort to body ground in the REDwire
betweenthe EPScontrol unit and the motor.!
N O - G o t o s t e p7 .
17-36
Wiresideof femaleterminals
ls there continuity?
YES Repairshort betweenthe REDand GRN
wires in the motor circuit betweenthe EPScontrol
u n i t a n dt h e m o t o r . l
NO Go to step 9.
M1 IREDI
H
r-_-1 ||
,<.)\
uL,/
Y
tr
WiresideoI femaleterminals
N O - G o t o s t e p1 0 .
NO Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . l
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . 2 a n d b o d y g r o u n d .
EPSCONTROL
B (2P)
UNITCONNECTOR
razrcnrrrr
l{. I
l-t
I
(v)
Y
I
17-37
EPSComponents
DTCTroubleshooting(cont'd)
DTC42,45: MotorDrivenCurrent
{
7. Checkfor continuitybetweenEPScontrol unit
c o n n e c t oB
r ( 2 P l t e r m i n aNl o . 2 a n d b o d y g r o u n d .
1. Clearthe DTC.
EPSCONTROLUNITCONNECTOR
B I2PI
r',rz
tcnnrt
ll
-](o)
YES- Go to step 4.
Wiresideof femaleterminals
lsthere continuity?
ls DTC 42 or 45 indicated?
YES-Go to step 5.
NO Go to step 8.
NO- Performthe appropriatetroubleshootingfor
t h e c o d ei n d i c a t e d . I
M a k es u r et h e i g n i t i o ns w i t c hi s O F F ,t h e n
disconnectEPScontrol unit B connector(2P)and
the motor 2P connector.
M1 IRED}H
f2-l
W i r es i d eo f f e m a l et e r m i n a l s
(C))
ls there continuity?
YES Repairshort to body ground in the REDwire
betweenthe EPScontrol unit and the motor,I
N O - G o t o s t e p7 .
17-38
ls there continuity?
YES Repairshort betweenthe REDand GRN
wires in the motor circuit betweenthe EPScontrol
u n i ta n d t h e m o t o r . l
NO Go to step 9.
M1{RED}H
T-----l | |
(v)
MOTORCONNECTOR
{2PI
M1 IRED)
lil
M1 (RED}
Wiresideo{ Iemaleterminals
ls therecontinuity?
YES-Go to step'12.
NO-Repairopenin the REDwire betweenthe EPS
controlunitandthe motor.l
NO Go to step 10.
mzrcnrur
ll-l
A
(v)
Y
I
W i r es i d eo f f e m a l et e r m i n a l s
(cont'd)
17-39
EPSGomponents
DTGTroubleshooting(cont'd)
12. Checkfor continuitybetweenEPScontrol unit
c o n n e c t oB
r ( 2 P ) t e r m i n aNl o . 2 a n dt h e m o t o r2 P
c o n n e c t otre r m i n a lN o . 1 .
EPSCONTROLUNIT
CONNECTORB I2PI
MOTORCONNECTOR
{2P)
M2 IGRN)
ls there continuity?
Y E S - G o t o s t e p1 3 .
NO-Repair open in the GRNwire betweenthe EPS
control unit and the motor.l
Checkfor loosewires or poor connections,if the
connectionsare good. substitutea known-good
EPScontrol unit, and connectallthe disconnected
connectors.
1 4 . Startthe engine,and turn the steeringwheel from
lockto lock severaltimes.
Does the EPS indicatot come on?
YES Go to step 15.
NO Checkfor loose EPScontrol unitconnectors.lf
necessary,replacethe EPScontrol unit and
recheck.a
17-40
2. Startthe engine.
3. Turn the steeringwheel from lock-to-lockseveral
'10
times, and wait
secondsor more.
Til
M2tcRNl F-l
f---1 z I
(v)
YES Go to step 4.
NO-Check for loosewires or poor connections.lf
the connectionsare good,the system is OK at this
ttme.I
W i r es i d eo f f e m a l et e r m i n a l s
YES Go to step 5.
NO-Go to step 9.
M 1 { R E o )H
T------t
I I
Itr
(v)
T
-L
Wiresideot Iemaleterminals
ls there continuity?
YES Repairshort betweenthe GRN and RED
wires in the motor circuitbetweenthe EPScontrol
u n i ta n d t h e m o t o r . l
N O G o t o s t e p1 1 .
( c o n td )
17-41
EPSComponents
DTCTroubleshooting(cont'dl
1 1 .Substitutea known-goodEPScontrol unit, and
connectall the disconnectedconnectors.
DTC47: EPSControlUnitlnternalCircuit
(PowerRelay)
1. Clearthe DTC.
YES-Go to step 3,
NO-Check for loosewires or poor connections,lf
the connectionsare good, the system is OK at this
time.I
3. Stop the engine,and verify the DTC.
ls DTC 43 indicated?
ls DTC 47 indicated?
17-42
NO Performthe appropriatetroubleshootingfor
the code indicated.I
DTC51: EPSControlUnitInternalCircuit
(EEPROM)
1. Clearthe DTC.
1 . C l e a rt h e D T C .
YES Go to step 3.
YES-Go to step 3.
ls DTC 50 indicated?
ls DTC 51 indicated?
NO Performthe appropriatetroubleshootingfor
the code indicated.t
NO Performthe appropriatetroubleshootingfor
the code indicated.t
17-43
EPSComponents
(cont'dl
DTCTroubleshootang
DTC62: EPSControlUnit InternalCircuit
(Fail-safe
RelayStuckON)
'1.
Low
DTC64: BatteryVoltageis Excessively
(Fail-safe
RelayContactFailureandMotor
VoltageFallOff)
Clearthe DTC.
2. Startthe engine.
1 . C l e a rt h e D T C .
2. Startthe engine.
YES-Go to step 3.
YES Go to step 3.
ls DTC 62 indicated?
ls DTC 64 indicated?
YES Go to step 4.
NO Performthe appropriatetroubleshootingfor
the code indicated.
'18(604)
4. Checkthe No.
fuse in the under-hoodfuse/
relay box, and reinstallthefuse if it is OK.
Is the f use OK?
YES Go to step 5.
NO Replacethe fuse and recheck.l
5. DisconnectEPScontrol unit connectorA (2P).
6. Measurethe voltage betweenEPScontrol unit
c o n n e c t oA
r ( 2 P )t e r m i n a lN o . 1 a n d b o d y g r o u n d .
-Blwt{r/Bl.urH
l
\9
17-44
DTC66,68: EPSControlUnitlnternalCircuit
DTC67: TorqueSensorl/FCircuit
1 . C l e a rt h e D T C .
1. Clearthe DTC.
2 . S t a r tt h e e n g i n e .
YES-Go to step 4.
YES-Go to step 4.
17-45
EPSComponents
DTCTroubleshooting(cont'd)
DTC69: EPSControlUnit InternalCircuit
1 . C l e a rt h e D T C .
2. Startthe engine.
3. Turn the steeringwheel from lock-to-lockseveral
times, and wait 10 secondsor more,
Does the EPS indicator come on?
YES Go to step 4.
NO-Check for loosewires or poor connections.lf
the connectionsare good, the system is OK at this
time.l
4. Stop the engine,and verify the DTC.
ls DTC 69 indicated?
YES-Check for loose or poor connectionsat the
EPScontrol unit. lf the connectionsare good,
substitutea known-goodEPScontrol unit. lf the
symptom/indicationgoes away, replacethe
original EPScontrol unit and recheck.l
NO- Performthe appropriatetroubleshootingfor
the code indicated.l
17-46
EPSIndicatorCircuitTroubleshooting
1 . Turn the ignitionswitch ON (ll),startthe engine,
and watch the EPSindicator.
NO Go to step 2.
w i r e s d e o f t e m a l et e r m i n a l s
Wiresideof femaleterminals
ls there continuity?
Does the EPS indicator come on?
YES-Go to step 5.
N O I n s p e ctth e E P Si n d i c a t o b
r u l b ,i f t h e b u l b i s
O K , r e p l a c et h e b u l bc i r c u i tb o a r di n t h e g a u g e
assembly.l
17-47
EPSComponents
EPSIndicatorCircuitTroubleshooting(cont'dl
1 2 .Turn the ignitionswitch OFF.
EPSCONTROL
UNITCONNECTON
A (2P}
+B (WHT/BLUIH
Itr
v
-L
ls therebatteryvoltage?
EPSCONTROL
UNITCONNECTOR
C (2OP)
Y E S - G ot o s t e p1 6 .
NO-Repairopenin thewire betweenEPScontrol
unitconnector
C (20P)andthe No, 10(7.5A)fuse.t
Wiresideof femaleterminals
ls therc about 10 V?
YES Checkfor looseor poor connectionsat the
EPScontrol unit. lf the connectionsare good,
substitutea known-goodEPScontrol unit. lf the
symptom/indicationgoes away, replacethe
originalEPScontrol unit and recheck.l
NO Repairshort to ground in the BRNwire
betweenthe data link connectorand the EPS
c o n t r o lu n i t . I
17-48
Motor Removal/lnstallation
Bemoval
1. Make sure you havethe anti-theftcode for the radio,
then write down the frequenciesfor the preset
buttons.
(cont'd)
17-49
EPSComponents
(cont'dl
Motor RemovaUlnstallation
lnsiallation
7. Cleanthe mating surfaceof the motor (A) and
gearbox.
8 x '1.25
mm
20 N.m
12.0kgt.m,7.2lbl ftl
L==-
c].E@
17-5 0
SteeringGearboxRemoval
Special Tool Required
Ball ioint remover,2Smm 0TlvlAC-S100200
_t\
l,a.:
'/
--L-
r0 mm HEXNUT
07MAC-S100200
1 0 .G r a s pt h e r i g h ts i d et i e - r o d a, n d p u l lt h e r a c ka l l t h e
way to the passenger'sside,
1 1 . Removethe heat shield (A) mounting bolts from
the body stiffener,and let the heat shield lay
againstthe exhaust.
'
(cont'd)
17-51
EPSComponents
SteeringGearboxRemoval(cont'd)
12. Disconnect
the EPSwire harness6Pconnector
(A),
andremovethe EPSwire harness(B)andmountino
bracket(C).
1 4 . R e m o v et h e e n g i n ew i r e h a r n e s sc l a m p s{ A ) f r o m
the three mounting brackets.
-a--zi
i
F--_1
t5.
1 3 . Removethe groundcableterminal(A)fromthe
steeringgearboxhousing.
..(
.,/
a
bH \
ry T,-.lt'^ \
'"
_ - 1 . . 1 . - '
17-52
\--
i t1-:: .,
(cont'd)
17-53
EPSComponents
SteeringGearboxRemoval{cont'd)
22. Move the steeringgearboxand tie-rod ends as an
assemblyto the wheelwellopening on the
passenger'sside.
23. Carefullyraisethe driver'sside (pinionside)ofthe
steeringgearbox(A) and tie-rod (B) until clearsthe
mastercylinderand under-hoodfuse relay box,
then removethe steeringgearbox.Be careful not to
damagethe hoses,linesand wtre narnesses.
17-51
SteeringGearboxOverhaul
ExplodedView
mm
I x '1.25
ftl
20 N.m(2.0kgf.m,7.2lbt
O.RING
Replace.
CONNECTOR
PINION
SHAFT
GROMMET
RACKGUIDE
-@
.
. DISCWASHEB @'--g
-sPRrNG
SCREW
L)-RACKGUIDE
6
' v---\
\.oc**u.
v
\ >-*\{i#r^i
--.
i
6^:,;
BOOT BAND
Beplace.
''
-'t
'"''/
s(./t' J
-l
GUIDE \
SLTDER
SRACKET
{^il
\J"
\
@
II
\
\
\
BOOTBAND
- Replace.
LOCKWASHER
Replace.
stot *,tttc
Renrace
\
LocK
'162 scREw
N.m
l t o . sr g f m , 1 1 9 l bfft )
Beqtace.
TIE.RODEND
rtE-ROD
54 N m {5.5kgf.m,40lbf ft)
(cont'd)
17-55
EPSComponents
SteeringGearboxOverhaul(cont'dl
Special Tools Required
. Locknutwrench 07ZAA-S5A0100
. Pincers,Oetiker1098or equivalent,commercially
available.
NOTE:
. Referto the ExplodedView as neededduring this
procedure.
. Do not allow dust, dirt, or other foreign materialsto
enter into the steeringgearbox.
Eemoval
1, Removethe steeringgearbox(seepage 17-b1).
Disassembly
2. Unbendthe lock washer (A).
-,'i.
. Loosenthe locknut(A),then removethe rack guide
screw (B),sprlng (C),disc washer (D),and rack
g u i d e( E )f r o m t h e s t e e r i n gg e a r b o x .
- -.i::..:4,.-,
17- 56
:.--. '
07zAA-S5A0r00
Removethe specialtool.
(cont'd)
17-57
EPSComponents
SteeringGearboxOverhaul(cont'd)
'll.
-.---(fr--',
Il i l ( t t
f
Z,-----:-r-.--------.t.t'E-r
i @ r
25.3mm
{0.925in.}
12
/i\
,)))
15. Applymultipurpose
greaseto the indicated
part
part)
of
the
{shaded
outersurfaceof the rack
housing.Do not applyto the dentsandgrooves.
I
|
25.3 mm
{0.925in.l
Removeanddiscardthestopring{A)onthe
cylinderby expanding
it with snapringpliers.
Removeanddiscardthe lockscrew{B}.
I
17-58
16. Set the new boot bands (A) on the band installation
groovesof the boot (B) by aligningthe tabs (C)with
the holes (D)of the band.Do not closethe ear of the
boot band in this step.
(cont'd)
17-59
EPSComponents
SteeringGearboxOverhaul(cont'dl
22. Apply multipurposegreaseto the sliding surface
and circumferenceofthe rackguide (A),and install
it onto the gearboxhousing.Wipe the greaseoff
the threadedsectionofthe housrno.
'1
{
25. Centerthesteeringrackwithin its stroke,and align
t h e s l i d e rg u i d e( A ) w i t ht h e h o t e s( B )i n t h e b o o t ( C ) .
Fit the slider guide to the boot by pressingaround
the edgesof the holessecurely
- .- =-1,...'.
,. ,l
.j
2 3 . I n s t a l l t h ed i s cw a s h e r( B ) w i t hi t s c o n v e xs i d e
f a c i n gt h e r a c kg u i d e .I n s t a l l t h es p r i n g( C ) .A p p t y
sealantto the middle of the threadson the rack
guide screw (D),then installand tighten it to 25
N m (2.5kgf.m, 18 lbf.ft).Looselyinstatlrhetocknut
(E).
24. Apply multipurposegreaseto the sliding surfaceof
the slider guide (A).Keepgreaseoff of the rack-toslider guide mating surfacesand the boot-to-slider
guide mating surfaces.
Slidethe steeringrack all the way to left, and place
t h e s l i d e rg u i d eo n t h e s t e e r i n gr a c kb y a l i g n i n gt h e
bolt holes (B).
E
25 N.m 12.5kgt.m,18tbt.ft)
26. Beforeinstallingthe bracket(D),cleanthe mating
surfaceofthe 12 mm flange bolts (E)and the
bracket.Coatthe new O-rings{F)with multipurpose
g r e a s ea, n d i n s t a l l t h e mo n t h e ' 1 2m m f l a n g eb o l t s .
27. Looselyinstallthe bracketon the steeringrack by
tighteningthe 12 mm flange boltsto 25 N.m (2.5
kgf.m, 18lbf.ft).
28. Hold the gearboxhousingusing a yoke,then install
the specialtoolon the lock screw (A).Retightenthe
lock screwto the specifiedtorque values.
A
{ 1 6 . 5k g t . m , 1 1 9 l b f . f t }
17-60
3 4 . C l o s et h e e a r p o r t i o n( A )o f t h e b a n d s( B ) w i t h
, e t i k e r1 0 9 8o r
c o m m e r c i a l la
v v a i l a b l ep i n c e r sO
e q u i v a l e n(tC ) .
74 N.m (7.5kgf.m,5irlbf.ft)
5 t .
32,
3 5 . I n s t a l l t h en e w l o c kw a s h e r( A )w i t h i t s r a d i u s e d
side facing (B)the tie-rod (C),and screwthe tie-rod
on the bracket(D).Repeatthis step for the other
side of the tie-rod.Hold the bracketwith one
wrench,and tightenthe tie-rodsto the specified
torque with anotherwrench.
. .,,";=-.
, . ,
*=,,',
(cont'd)
17-61
EPSComponents
SteeringGearboxOverhaul(cont'dl
36. Bendthe lock washer againstthe flat spots on the
bracketwitha Iarge pair of pliers.
17-62
SteeringGearboxInstallation
'1.
Beforeinstallingthe steeringgearbox,slidethe
rack all the way to the passenger'sside (right
direction).
\-
--'
'.'',
:-1
. . . .
3 . I n s t a l l t h ep i n i o ns h a f tg r o m m e t( A ) .
.: --.-{
.
( c o n t ' d)
17-63
EPSComponents
SteeringGearboxInstallation(cont'd)
7. Installthebodystiffener(A),andtorquethe
mountingboltsto the specified
torque.
8 x 1.25mm
29 N.m {3.0kgf.m,22lbf.ftl
L-t
:.i.t'
9.8N.m
(1.0kgf m,
7.2tbf.ftl
17-64
' It . Under
the steeringgearbox,installthe ground
cableterminal (A) on the steeringgearboxhousing.
9 . 8N . m
{1.0kgf.m,7.2lbf.ft)
,-', ''l
:
B
10x 1.25mm
i N.m
{4.4 kgf.m.
32 tbt.ftl
1 3 . I n s t a l l t h eh e a ts h i e l d( A ) .
to.
,.!,..
''6
(cont'd)
17-65
EPSComponents
SteeringGearboxInstallation(cont'dl
1 7 . Installthe motor on the steeringgearbox(seepage
17-49).
\
8 x '1.25mm
28 N.m
{2.9kgf.m,
21 tbt.ft)
17-66
EPSControlUnit Removal/
Installation
*-4
r/\-,
d______i.l+_D
-6rA
17-67
Suspension
Frontand RearSuspension
SpecialTools
.............
18-2
Component
LocationIndex .........................................
18-3
W h e eA
l l i g n m e n .t . . . . . . . . . . . . . . . . . . . .
. . . . . . . . .1. 8. - 4
18-8
WheelBearingEndPlayInspection............................
18-9
WheelRunoutInspection
..................
... 18-10
B a l Jl o i n tR e m o v a l
FrontSuspension
Knuckle/Hu bAVheelBearingReplacement
BallJoint Boot Reolacement..................
StabilizerBar Rep|acement....................
StabilizerLink Removal/lnstallation
LowerArm Removal/lnstallation
...............
Damper/Spring
Replacement
18-1
18-16
18-17
18-18
18-19
18-20
RearSuspension
H u bB e a r i n U
g n i tR e p l a c e m e .n. t. . . . . . . . . . . . . . . . . . . 18-26
18-28
KnuckleReolacement
18-30
Stabilizer
BarReplacement
....................
18-31
Link Removal/lnstallation
Stabilizer
..........................
18-32
UpperArm Removal/lnstallation
...............
18-33
TrailingArm Removal/lnstallation
18-34
Damper/Spring
Replacement
Frontand RearSuspension
SpecialTools
Ref.No.
o
G)
Tool Number
07GAF-SE00100
07MAC-S100200
07746-0010500
07749-0010000
07965-SA50500
07965-SD90100
otv
Description
Hub Dis/AssemblyTool
B a l lJ o i n t R e m o v e r2, 8 m m
Attachment,62 x 68 mm
Driver
Front Hub Dis/AssemblyTool
Support Base
[]
18-2
a6,l
ComponentLocationIndex
FrontSuspension:
DAMPER/SPRING
page18-20
Replacement,
STABILIZER
BAR
page18-17
Replacement,
STABILIZER
LINK
page18 18
Removal/lnstallation,
KNUCKLE/HU8/WHEELBEARING
page 18-11
Replacement,
Ball Joint Boot
page'18-16
Replacement,
LOWEBARM
page 18 19
Removal/lnstallation,
RearSuspension:
STABILIZER
BAR
page18-30
Replacement.
UPPERARM
Removal/lnstallation,
page'18-32
DAMPER/SPRING
page'18-34
Replacement,
UNIT
HUBBEARING
page18'26
Replacement,
KNUCKLE
page18-28
Replacement,
TRAILINGARM
page 18 33
Removal/lnstallation,
18-3
Frontand RearSuspension
WheelAlignment
The suspensioncan be adjustedfor front camber,front
toe, and reartoe. However,each of these adjustments
are interrelatedto each other. For example,when you
adjustthe toe, the camberchanges.Therefore,you
must adjustthe front wheel alignmentwheneveryou
adjustthe camberor toe.
Front Casterlnspection
Pre-Alignment
Checks
o u rw h e e l
U s ec o m m e r c i a l l a
vvailable
c o m D u t e r i z ef d
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Follow the
eouiomentmanufacturer'sinstructions.
1"
18-4
Front CamberInspection
Front CamberAdjustment
0"30' t 45'
DamDerPinchBolt:
AdiustingBoh:
P/N 90188-55A-000
-+
+t
A
1 6 x 1 . 5m m
157 N.m
(16.0kgf.m,
116 tbf.ftl
v e hi c l et o t h e g r o u n d ,a n d b o u n c et h e v e h i c l e
s e v e r atl i m e st o s t a b i l i z teh e s u s p e n s i o n .
5 . C h e c kt h e c a m b e ra n g l e .l f i t i s w i t h i nt h e
specification,checkthe front toe. lf it is not within
the specification,go to step 6.
(cont'dl
18-5
Frontand RearSuspension
WheelAlignment (cont'd)
Raisethe front of the vehicle,and support it with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
7 . Replacethe damper pinch boltswith the adjusting
bolts (A),and adjustthe camber angle.
NOTE:The camberangle can be adjustedup to t
15' (centerof tolerance)by replacingone damper
pinch bolt with the adjustingbolt. The camber
angle can be adjustedup to a 30' by replacingboth
upper and lower damper pinch bolts with the
adjustingbolts.
RearCamberInspection
Use commercially-available
computerizedfour wheel
alignmentequipmentto measurewheel alignment
(caster,camber,toe, and turning angle).Followthe
eouiDmentmanufacturer'sinstructions.
C h e c kt h e c a m b e ra n g l e .l f l h e c a m b e ra n g l ei s n o t
within the specification,checkfor bent or damaged
susDenstoncomoonenrs.
Rearcamberangle:
0
0"55' t 45'
NOn-dEl
Do not loosenthe specialb o l t so n t h e t r a i l i n ga r m .
'rntr
1 5 x 1 . 5m m
157N.m
{16.0kgt.m,
116tbf.ft)
i,iY.a
.:r,//
18-6
RearToe Inspection/Adiustment
Use commercially-available
computerizedfour wheel
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Followthe
equipmentmanufacturer'sinstructions,
Use commercially-available
computerizedfour wheel
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster,camber,toe, and turning angle).Followthe
equipmentmanufacturer'sinstructions.
1, Release
t h e p a r k i n gb r a k e .
1,;
A
1 4 x 1 . 5m m
,14N.m
(a.5 kgt m,33 lbt.ftl
Reartoe-in {inspection):
1 1 3 mm (0.04a 0.12 in.)
3. Loosenthe self-lockingnut (A)while holdingthe
adjustingbolt (B).
( c o n t ' d)
18-7
Frontand RearSuspension
WheelAlignment (cont'dl
TurningAngleInspection
Use commercially-available
computerizedfour wheel
a l i g n m e net q u i p m e ntto m e a s u r ew h e e la l i g n m e n t
(caster.camber,toe, and turning angle).Followthe
equiDmentmanufacturer'sinstructions.
1 . T u r nt h e s t e e r i n gw h e e lf u l l y t o t h e r i g h t a n d l e f t
while applyingthe brake,and checkthe turning
anglesof both front wheels, lf the turning angle is
not within the specificationor the inward turning
anglesdiffer betweenthe right and left side,go to
steD2.
WheelBearingEnd PlayInspec'tion
1. Raiselhe vehicle,and support it with safetystands
in the proper location(seepage 1-8).Removethe
wheels.
2. Installsuitable f lat washers (A) and wheel nuts,and
tighten the nuts to the specifiedtorque to hold the
b r a k ed i s cs e c u r e l ya g a i n s t h e h u b .
Front:
Turning angle:
lnward: 34'00'+ 2'
Outward: 28'00' {reference)
108N.m
(11.0kgf.m,
80 rbf.ft)
Rear:
\
108N.m
(11.0kgf.m,80 lbf.ft)
3 . S e t u p t h e d i a lg a u g ea g a i n s t h e h u b f l a n g ea s
shown, and measurethe bearingend play moving
the brakedisc inward and outward.
Bearing end play:
Standard:
Front/rear: 0 0.05 mm {0 0.002in.}
4. lf the bearingend play is more than the standard,
replacethe wheel bearing.
18-8
WheelRunoutInspection
1 . Raisethe vehicle,and supportit with safetystands
in the proper location(seepage 1-5,.
Checkfor a bent or deformedwheel.
Set up the dial gauge as shown, and measurethe
axial runout by turning the wheel.
4 . R e s e t h e d i a l g a u g e t o t h ep o s i t i o ns h o w n ,a n d
measurethe radial runout.
Front and rear wheel radial runout:
Standard:
Aluminum wheel: 0 0.7 mm (0 0.03io.)
1.5 mm {0.06in.}
Servicelimit:
18-9
Frontand RearSuspension
BallJointRemoval
Special Tools Required
Ball ioint remover.2Smm 07MAC-SL00200
'1,
I n s t a lal h e x n u t ( A )o n t o t h e t h r e a d s o f t h e b a l l j o i n t
{ B ) .M a k es u r et h e n u t i s f l u s hw i t h t h e b a l l j o i n tp i n
end to preventdamageto the threadedend of the
b a l l i o i n to i n .
07MAC-S100200
After adjustingthe adjustingbolt, make sure the
head (C)of the adjustingbolt is in the position
shown to allow the jaw to pivot.
5 . With a wrench,tighten the pressurebolt until the
b a l li o i n t p i n p o p sl o o s ef r o m t h e s t e e r i n ga r m o r
knuckle.lf necessary.apply penetratingtype
lubricantto loosenthe ball joint pin
18-10
FrontSuspension
Knuckle/Hub/WheelBearingReplacement
ExplodedView
WHEELBEARING
Replace.
SNAPRING
5 mm SCREWS
Replace.
FLATSCREWS
6x1.0mm
9.8Nm
(1.0kgf.m,7.2lbf.ft)
KNUCKLE
Checkfor delormation
a n oo a m a g e .
SPLASHGUARD
Checkfor corrosion.delormation.
and damage.
Replaceif rusted.
BRAKEDISC
SPINDLENUT
22 x 1.5mm
1 8 1N m
(18.5kgf.m, 134 lbt.ft)
Replace.
'--7.l
'tq
I
A p p ya s m a lal m o u not f e n g i n o
eil
to theseatingsurface.
lcont'd)
18-11
FrontSuspension
Knuckle/Hub/WheelBearingReplacement{cont'dl
Special Tools Required
. Hub dis/assemblytool 07GAF-SE00100
. Balljoint remover,2Smm 0TlvlAC-S100200
. Attachment62 x 68 mm 07746-0010500
. Driver07749-0010000
. SuDDortbase07965-5D90'100
'
,
B
22x1.5mm
1 8 1N . m
('18.s
kgf.m,
134tbt.ft)
B
12 x 1.25mm
108N.m
{11.0kgf.m,
80 rbf.ftl
A
6x1.0mm
9.8 N.m
{1.0kgt.m,
7.2 tbl.ttl
18-12
07MAC-SL00200
--....-"
'R.
12x 1.25mm
59 69N m
10 x 1.25mm
39 N.m (,1.0kgf.m,29lbf.ft)
'13.Removethe driveshaftoutboardjoint
{C)fromthe
knuckle(D) by tappingthe driveshaftend (E)with a
plastichammer while drawing the knuckleoutward,
then removethe knuckle.
NOTE:Do not Dullthe driveshaftend outward.The
driveshaftjoint may come off.
(cont'd)
18-13
FrontSuspension
(cont'd)
Knuckle/Hub/Wheel
BearingReplacement
14. Separatethe hub (A)from the knuckle(B) usingthe
specialtool and a hydraulicpress.Be carefulnotto
deform the splashguard. Hold onto the hub to keep
it from falling when pressedclear.
1 6 . R e m o v et h e s n a pr i n g ( A )a n dt h e s p l a s hg u a r d( B )
f r o m t h e k n u c k l e( C ) .
07GAF-SE00100
./
.-''-
.|
a'\s
18-14
\r
Press
Pross
1 8 . W a s ht h e k n u c k l ea n d h u b t h o r o u g h l yi n h l g hf l a s h
point solventbefore reassembly.
2 2 . P r e s sa n e w h u b b e a r i n gu n i t{ A )o n t o t h e h u b ( B )
usingthe specialtools and a press.
"-t-_"*,,''
_,.' . . a-.)
../
..-.
23. I n s t a l l t h ek n u c k l e / h u b / h ubbe a r i n gu n i t i n t h e
reverseorder of removal,and notethese items:
2 0 . I n s t a ltlh e s n a pr i n g ( A )s e c u r e l yi n t h e k n u c k l e( B ) .
D
6 N.m10.6kgf.m,4lbfft)
lnstallthe splashguard (C),and tighten the screws
(D)to the specifiedtorque.
. B ec a r e f u n
l o t t o d a m a g e t h eb a l l j o i n tb o o t w h e n
installing
the knuckle.
. Tightenall mounting hardwareto the specified
l O r q u ev a l u e s .
. Torquethe castlenut to the lower torque
specification,then tighten it only far enoughto
a l i g nt h e s l o tw i t h t h e b a l lj o i n t p i n h o l e .D o n o t
align the castlenut by looseningit.
. Installa new look pin on the castlenut after
torquing.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
. B e f o r ei n s t a l l i n g
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. B e f o r ei n s t a l l l n gt h e b r a k ed i s c ,c l e a nt h e m a t i n g
surfaceof the front hub and the insideof the
b r a k ed i s c .
. B e f o r ei n s t a l l i n g
t h e w h e e l ,c l e a nt h e m a t i n g
surfaceof the brakedisc and the insideof the
wneet.
. Checkthe front wheel alignment,and adjustit if
necessary(seepage 18-4).
18-15
FrontSuspension
BallJoint Boot Replacement
Special Tools Required
Front hub dis/assemblytool 07965-5450500
1. Removethe boot.
2. Packthe interiorand lip (A) of a new boot with fresh
grease.Keepthe greaseoff of the boot-to-knuckle
mating surfaces(B).
-6r
rffi
18-16
StabilizerBar Replacement
1 . Raisethe front of the vehicle,and support it with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
Removethe self-lockingnuts (A)while holdingthe
joint pin (B)with a hex wrench (C),and disconnect
t h e s t a b i l i z el ri n k s( D ) f r o mt h e s t a b i l i z ebr a r ( E )o n
the right and left.
D
''i]
,.'i i
.
i.',.:-l
,'
\'r'j--,r'r-'1
i-ii::;i
I
_:
i :..
i'
;4-llt,-'j--;
1 0x 1 . 2 5m m
39Nm
(4.0 kgf m,
29 tbl,ft)
FORWARD
A
1 0x 1 . 2 5m m
39Nm
(4.0ksf.m, 29lbl.ftl
18-17
Front Suspension
StabilizerLink Removal/lnstallation
1 . Raisethe front of the vehicle,and support it with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
Removethe self-lockingnut (A) and flange nut {B)
while holdingthe respectivejoint pin (C)with a hex
wrench (D),and removethe stabilizerlink (E).
mri-dEl
Do not placethe jack againstthe lower arm
balljoint.
6. Tightenthe self-lockingnut (A) and flange nut (B)to
the specifiedtorque valueswhile holdingthe
respectivejoint pins (C)with a hex wrench (D).
A
10 x 1.25mm
38 N.m
(3.9kgf m,28 lbf.ft)
\
3 . l n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
and lower arm (C)with the joint pins (D)set at the
centerof their rangeof movement.
..,
B
10 x 1.25mm
39 N.m
{4.0kgf.m,29lbf.ft}
18-18
1 4x 1 . 5m m
83 N.m(8.5kgf.m,61lbf.ft)
6. Installthe lower arm in the reverseorder of
removal,and note these items:
10x 1.25mm
39 N.m
{4.0kgf m, 29 lbt.ft)
6--__
@a
oTMAc-sloo2oo
1 2x 1 . 2 5m m
59 69Nm
16.0-7.0kgt-m,
43 51 lbf.ft)
18-19
Front Suspension
Damper/SpringReplacement
ExplodedView
/.'
^a
ta
,/
,,/
./ SELF-LOCK|NGNUT
12 x 1.25inm
44 N.m {4.5kgt.m,33lbf.ftl
neDtace.
e9
-.-
1, @-:'\--""'
lF \-:-./
- ,
MOUNTINGBASE
- DAMPER
checkfor delormation
E9-
DAMPERMOUNTING
BEARING
UPPER
SPRINGMOUNTING
CUSHION
Checkfor deterioration
anooamage,
DAMPER
SPRING
Checkfor lreelength.
DAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operatron.
18-20
SpecialToolsRequired
Balljoint remover,28mm 07MAC-S100200
Removal
1. Raisethe front of the vehicle,and supportit with
safetystandsin the proper location(seepage 1-8).
Removethe front wheels.
Removethe cotterpin (A) from the tie-rod end ball
ioint, and removethe nut (B).
6x1.0mm
x 1.25nm
/.8
(cont'd)
18-21
FrontSuspension
(cont'd)
Damper/Spring
Replacement
Disassembly/lnspection
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y
availablestrut spring compressor(A) accordingto
the manufacturer'sinstructions.then removethe
s e l f - l o c k i nngu t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t
(C)with a hex wrench (D).Do not compressthe
spring more than necessaryto removethe nut,
C h e c kf o r o i l l e a k s a
, bnorman
l o i s e sa, n d b i n d i n g
during thesetests.
18-22
FrontSuspension
(cont'dl
Damper/Spring
Replacement
Installation
Right side:
9 . I n s t a l l t h e1 2 m m n u t ( A )o n t h e d a m p e rs h a f t( B ) .
Hold the damper shaft with a hex wrench (C),and
tighten the 12 mm nut to the specifiedtorque.
,1,6
Looselyinstallthe flange nuts (A) onto the top of
the damper.
1 0 .Removethe damperassembly
fromthe strutspring
compressor.
18-24
3 . P o s i t i o nt h e d a m p e ro n t h e k n u c k l ea, n d i n s t a l l t h e
new damper pinch bolts (A) and nuts (B),and
lightlytighten the nuts.
B
1 6 x 1 , 5m m
157N.m
(16.0kgt m,
116tbt.ftl
4 . P l a c et h e f l o o rj a c ku n d e rt h e l o w e ra r m b a l l j o i n t ,
and raisethe suspensionto load it with the vehicle's
weight.
22N|rl.
12.2kgI m,
16rbr,ftl
18-25
RearSuspension
Hub BearingUnit Replacement
ExplodedView
SPLASHGUARD
Checkfor deformation.
x 1.0 mm
9.8 N.m (1.0kgf.m,?1 lbf ftl
un
KNUCKLE
Checkfor delormation.
HUBBEARING
UNIT
Checkfor faultymovement
andwear.
6x1.0mm
9,8 N.m
{1.0kgf.m,7 lbf.ft}
HUB CAP
Replace.
SPINDLENUT
22 x 1.5mm
181 N.m {18.5kgt.m, 134lbf.ft}
Beplace.
-A
T
Appy a small amount oI engineoil
to the seatingsurface.
18-26
Releasethe parkingbrakelever.
5 . Removethe brakehose mounting bolt (A).
B
1 0x 1 . 2 5m m
55Nm
{5.6kgf m.41lbf.ft}
108N.m(11.0kgf.m,80lbfftl
Removethe hub cap (A), raisethe stake(B),and
r e m o v et h e s p i n d l en u t ( C ) .
(2.2kgtm, 16lbt.ftl
Removethe caliperbracketmounting bolts (B),and
hang the caliper(C)to one side.To preventdamage
to the caliperor brakehose,use a short pieceof
w i r e t o h a n gt h e c a l i p e rf r o m t h e u n d e r c a r r i a g e .
7 . Removethe brakedisc retainingscrews(A).
O
\
ap
2 2 x 1 , 5m m
1 8 1N . m
(18.5kgf.m, 134lbf.ftl
t
\
I
A
6x1.0mm
9 . 8N . m
(1.0kgf.m,?.2lbf.ftl
(cont'd)
18-27
RearSuspension
Hub BearingUnit Replacement
(cont'd)
9. Removethe hub bearingunit (A) from the spindle.
KnuckleReplacement
1 . Raisethe rear of the vehicle,and suppon it with
safetystandsin the proper location(seepage 1-8).
Removethe rear wheels.
R e m o v et h e b r a k ed i s ca n d h u b b e a r i n gu n i t( s e e
s t e p 1 o n p a g e1 8 - 2 7 ) .
Removethe flange bolts (A) and splashguard (B)
from the knuckle.
,=,,,
kgf.m,7.2lbf ft)
11.0
4. Removethe wheel sensor(A),braKenose
m o u n t i n gb r a c k e (t B ) ,a n d p a r k i n gc a b l em o u n t i n g
bracket(C)from the knuckle.Do not disconnectthe
wheel sensorconnector.
8 x 1.25mm
22 N.m
{2.2kgfm, 16lbf ftl
6x1.0mm
9.8 N,m
{I.0 kgt.m,7.2lbf ft)
18-28
tt
12x 1.25mm
59 N.m
{6.0ksf.m.43lbf.ft)
12x 1.25mm
59 N.m {6.0kgf m,43lbl.ft)
9 . I n s t a l l t h ek n u c k l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
. F i r s ti n s t a l a
l l l t h e s u s p e n s i o cno m p o n e n t sa, n d
lightlytighten the bolts and nuls,then placea
floor jack under the lower a rm, and raisethe
suspensionto load it with the vehicle'sweight
beforefully tighteningthe bolts and nutsto the
specifiedtorque values.
. Align the cam positionsof the adjustingbolt (A)
and adjustingcam (B)with the markedpositions
w h e nt i g h t e n i n g .
. Use a new self-lockingnut on reassembly.
. T i g h t e na l l t h e m o u n t i n gh a r d w a r et o t h e
specifiedtorque values.
. U s ea n e w s p i n d l en u t o n r e a s s e m b l y .
. B e f o r ei n s t a l l i n g
t h e s p i n d l en u t ,a p p l ya s m a l l
amount of engine oil to the seatingsurfaceof the
nut. After tightening,use a drift to stakethe
s p i n d l en u t s h o u l d e ra g a i n s t h e d r i v e s h a f t .
. Beforeinstallingthe brakedisc,cleanthe mating
surfaceof the hub and the insideof the brake
drsc.
. U s ea n e w h u b c a po n r e a s s e m b l y .
. Beforeinstallingthe wheel, cleanthe mating
surfaceof the brakedisc and the insideof the
wheel.
. Checkthe wheel alignment,and adjust it if
necessary{seepage 18-4).
12x 1.25mm
59Nm(6.0kgf.m,
43 tbI.ftl
18-29
RearSuspension
StabilizerBar Replacement
1 . Raisethe rear of the vehicle,and supportit with
safetystandsin the proper location(seepage 1-8).
Removethe rearwheels.
Removethe self-lockingnuts (A)while holdingthe
joint pins (B)with a hex wrench (C),and disconnect
t h e s t a b i l i z el ri n k s( D )f r o m t h e s t a b i l i z ebr a r { E )o n
the right and left.
A
1 0 x 1 . 2 5m m
38 N.m
(3.9 kgf.m,28 lbf.ft)
\....'..: .
Al
.----'';-r'--\---r-
-tt'.,'t),
18-30
StabilizerLink Removal/lnstallation
1. Raisethe rear of the vehicle,and support it with
safetystandsin the proper location(seepage 1-8).
Removethe rearwheels.
\,1 i
i'-r d
*l'',:
3 . I n s t a l l t h es t a b i l i z el ri n k( A )o n t h e s t a b i l i z ebr a r { B )
a n dt r a i l i n ga r m ( C )w i t h t h e j o i n t p i n s( D )s e ta t t h e
centerof each moving range,
18-31
RearSuspension
UpperArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and supportlt with
safetystandsin the proper location(seepage 1-8).
Removethe rearwheels.
P l a c ea f l o o rj a c ku n d e rt h e t r a i l i n ga r m , a n d
supportthe suspensron.
Removethe flange bolt (A) and wheel sensor
h a r n e s sb r a c k e (t B ) .
8 x 1 . 2 5m m
22 N.m(2.2kgf.m,
16rbf.ft)
Removethe flange bolts (A),and removethe upper
arm{B).
1 2 x 1 . 2 5m m
59 N.m {6.0kgf.m,
ir3 lbf.ft)
18-32
1 2 x 1 . 2 5m m
59 N.m 16.0kgf m,
43 tbf.ft)
TrailingArm Removal/lnstallation
1 . Raisethe rear of the vehicle,and suppon it with
safetystandsin the proper location(seepage 1,8).
Removethe rearwheels.
Removethe knuckle(seepage 18-28).
3 . P l a c et h e f l o o rj a c ku n d e rt h e t r a i l i n ga r m ( A )t o
support it.
59 N.m
-----\':,'.ttg
'.,--1..-r.':1
B
1 0x 1 . 2 5m m
38Nm
(3.9kgl.m,
28 tbf.ftl
1 2x 1 . 2 5m m
61N m (6.2kgt m.
4s tbf,ft)
, ' a ' : -r
A
12 x 1.25Jnm
108N.m {11.0kgt.m,
80 tbf.ft)
18-33
RearSuspension
Replacement
Damper/Spring
ExplodedView
9-----.---.-.
-=\
ItI
t=J
SELF-LoCK|NGNUT
10 x 1.25mm
29 N m {3.0kgf.m,22 lbf.ft}
Replace.
DAMPER
MOUNlING
COLLAR
DUSTCOVER
-tr)
qnJ/ \
9...
E
Z
n \
lt
/t
BUMP
sroP PLArE
\ BUMPSTOP
tor weakness
Check
and damage.
DAMPERSPRING
Checkfor weakened
compressionand damage.
OAMPERUNIT
Checkfor oil leaks,
gas leaks,and smooth
operation,
18-34
Removal
i
2. Removethe flange bolt {A) from the bottom of the
damper.
( c o n td )
18-35
RearSuspension
(cont'dl
Damper/Spring
Replacement
Disassembly/lnspection
1 . C o m p r e s st h e d a m p e rs p r i n gw i t h a c o m m e r c i a l l y
availablestrut compressor(A) accordingto the
manufacturer'sinstructions.then removethe selfl o c k i n gn u t ( B ) w h i l eh o l d i n gt h e d a m p e rs h a f t( C )
with a hex wrench (D).Do not compressthe spring
more than necessarvto removethe nut.
Reassembly
1 . I n s t a lal l l t h e p a r t s e x c e p t t h e
s e l f - l o c k i nngu t o n t o
the damper unit by referringto the ExplodedView.
Align the bottom of the spring {A} and the stepped
part of the lower spring seat (B),and align the
d a m p e rm o u n t i n gb a s ea s s h o w n ,
,, '161\
7fi)1,,
\3P qY/
"
I n s t a l l t h ed a m p e ra s s e m b l yo n a c o m m e r c i a l l y
availablestrut spring compressor(C).
C o m p r e s tsh e d a m p e rs p r i n gw i t h t h e s p r i n g
compressor.
Installthenew self'lockingnut (A) on the damper
shaft.
10 x 1.25mm
29Nm
(3.0kgt m,22 lbt.ft)
18-36
Installation
1 2 x1 . 2 5m m
61N m {6.2kgf.m.45lbf.ft)
A
1 0 x 1 . 2 5m m
59 N.m
16.0kgt.m, ia lbt ft)
18-37
Brakes
ConventionalBrakeComponents
Tools
Special
........... l9-2
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. .9. .-.3. . . . . . . . .
BrakeSystemInspectionand
Tests...............
..........
19-4
BrakePedaland BrakePedalPositionSwitch
Adjustment
..............
19-6
ParkingBrakeCheckand
Adjustment
..............
19-7
BrakeSystemBleeding
......................
19-8
BrakeSystemIndicatorCircuit
Diagram
. . . . . . . . . . . . . .1. 9. .-.9.
ParkingBrakeSwitchTest
.................
19-10
BrakeFluidLevelSwitchTest ......................................
19-10
FrontBrakePadslnsoection
and
Replacement
...........
19-11
FrontBrakeDiscInspection
...............
19-13
FrontBrakeCalioerOverhaul......................................
19-14
MasterCylinderReplacement
...........
19-15
MasterCylinderInspection
................
19-16
BrakeBooster
PushrodClearance
Adjustment................................
19-16
BrakeBoosterTest...................
..........
19-18
BrakeBoosterReolacement
..............
19-19
RearBrakePadsInspection
and
Reolacement
...........
19-20
RearBrakeDiscInspection
................
19-22
RearBrakeCaliperOverhaul.......................................
19-23
BrakeHosesand LinesInsoection
.... 19-24
BrakeHoseReolacement
...................
19-25
ParkingBrakeCableReplacement
..............................
19-26
ABS (Anti-lockBrakeSystem)
Gomponents
... 19-29
ConventionalBrakeComponents
SpecialTools
Ref.No.
19-2
Tool Number
07JAG-SD40100
DescriDtion
PushrodAdiustmentGauoe
Qty
1
ComponentLocationIndex
INDICATOR
BrakeSystemIndicatorCircuit
D i a g r a mp, a g e1 9 - 9
ParkingBrakeSwitch
Test,page 19 10
BrakeFluidLevelSwitch
Test,page 19-10
BRAKECABLE
P a r k i n gB r a k eC a b l e
Replacement,page 19 26
REARDISCBRAKE
RearBrakePads Inspectionand
Replacement,page l9-20
RearBrakeDisc
Inspection,page 19'22
R e a rB r a k eC a l i p e O
r verhaul,
page 19'23
FRONTBRAKES
FrontBrakePads,Inspectionand
page 19-11
Replacement,
FrontBrakeDisc
Inspection,page 19'13
FrontBrakeCaliper
O v e r h a u lp, a g e1 9 - 1 4
BRAKEBOOSTER
BrakeBooster
Test,page 19-18
BrakeEooster
page 19 19
Replacement,
PARKING
BRAKE
LEVER
Parkino
Brake
page19-7
CheckandAdjustment,
BRAKEPEDAL
BrakePedalandErakePedalPosition
Switch
pagel9-6
Adjustment,
BRAKEHOSESand LINES
BrakeHosesand Lines
Inspection,page 19 24
BrakeHoses
page 19 25
Replacement,
MASTERCYLINDER
MasterCylinder
Fl6^1.^6m6nr
^2^o
1O-18
M a s t e rC y l i n d eIrn s p e c t i o np ,a g e1 9 - 1 6
BrakeBoosterPushrodClearance
A d j u s t m e n tp, a g e ' 1 9 - 1 6
BrakeSystemBleeding,page 19-8
19-3
BrakeComponents
Gonventional
BrakeSystemInspectionand Tests
Component
l\4asterCylinder
BrakeHoses
Caliper
ABS l\ilodulator
Procedure
Look for damageor signs of fluid leakageat;
. Reservoiror reservoirgrommets
. L i n ej o i n t s
. Betweenmastercvlinderand booster
Look for damageor signs of fluid leakageat:
. Line joints and banjo bolt connections
. Hosesand lines.also inspectfor twisting or
damaqe
Lookfor damageor signs of fluid leakageat:
. Pistonseal
. Banjo bolt connections
. Bleederscrew
Lookfor damageor signs of fluid leakageat:
. Linejoints
. Modulator
S e i z e do r s t i c k i n gc a l i p e rp i n s .
BrakeSystemTest
Brake pedal sinks/fades when braking
1. Startthe engine,and let it warm up to operatingtemperature.
2. Attacha 2-inchpieceof maskingtape along the bottom of the steeringwheel, and draw a horizontalreference
mark acrossit.
3 . With the transmissionin Neutral,pressand hold the brakepedal lightly,then releasethe parkingbrake.
While still holdingthe brakepedal,hook the end of the tape measurebehind it. Then pull the tape up to the
steeringwheel, noting where the tape measurelines up with the referencemark you made on the maskingtape.
5 . Apply steadypressureto the brakepedalfor 3 minutes.
6 . Watch the tape measure.
. if it moves lessthan 10 mm, the mastercylinderis OK.
. if it moves more than 10 mm replacethe mastercylinder.
19-4
t-
2 . W i t h t h e e n g i n er u n n i n g r, a i s et h e v e h i c l eo n a l i f t ,
a n d s p i n a l l f o u r w h e e l sb y h a n d .
19-5
ConventionalBrakeComponents
BrakePedalandBrakePedalPosition
SwitchAdjustment
PedalHeight
1 . Disconnectthe brakepedal positionswitch
connector,turn the brakepedal positionswitch (A)
c o u n t e r c l o c k w i saen, d p u l l i t b a c ku n t i li t i s n o
l o n g e rt o u c h i n gt h e b r a k ep e d a l .
PedalFreePlay
4. With the engineoff, inspectthe play (A) on the
p e d a lp a d ( B )b y p u s h i n gt h e p e d a lb y h a n d .
F r e eP l a y :0 . 4 - 3 . 0 m m { 0 . 0 1 6 0 . ' l 1 8 i n . )
1 5N . m
(1.5kgl m. 11lbl ft)
19-6
7 . C h e c kt h e b r a k ep e d a lf r e e p l a ya s d e s c r i b e db e l o w .
ParkingBrakeCheckand Adiustment
Check
Leverlockedclicks: 7-8
l2okqf,a4lbl)
Adjustment
1. Releasethe parkingbrakeleverfully.
Loosenthe parkingbrakeadjustingnut, startthe
engine,and pressthe brakepedal severaltimes to
set the self-adjustingbrakebeforeadjustingthe
parkingbrake.
Blockthe front wheels,then raisethe rear of the
vehicle,and supportit with safetystandsin the
proper location(seepage 1-8).
Make sure the parkingbrakearm (A) on the rear
brakecalipercontactsthe brakecaliperpin (B),
NOTE:The parkingbrakearm will only contactthe
brakecaliperpin when the parkingbrakeadjusting
nut is loosened.
19-7
ConventionalBrakeComponents
BrakeSystemBleeding
NOTE:
. Do not spill brakefluid on the vehicle;it may damage
the painUif brakefluid does contactthe paint.wash it
off immediatelywith water.
. The reservoiron the mastercylindermust be at the
MAX (upper)level mark at the start of the bleeding
procedureand checkedafter bleedingeach brake
c a l i p e rA
. d d f l u i da s r e q u i r e d .
. Do not reusethe drainedfluid.
. Always use Honda DOT3 brakefluid. Non-Honda
brakefluid can causecorrosionand shortenthe life of
the system.
. Make sure no din or other foreign matter is allowed
to contaminatethe brakefluid.
ORe.r Right
O Front Left
ORoar Loft
1 . M a k es u r et h e b r a k ef l u i d l e v e li n t h e r e s e r v o i irs a t
t h e M A X ( u p p e r )l e v e ll i n e( A ) .
Refillthe mastercylinder reservoirto the MAX
{upper)level line.
FRONTBRAKE:
t-
19-8
REARBRAKE:
9 N m 10.9kgf.m, 7 lbf ft)
BrakeSystemIndicatorCircuitDiagram
UNDER.OASH
FUSE/FELAYBOX
A
Y
EBAKFLUID
IEVELSwlICH
BtK
GRN/ORN
,tk
,o"","o ""o*.
(b, 3s1E8,.""",,"
oPEN,Leve,down
I
-=:
csor
19-9
Conventional
BrakeComponents
ParkingBrakeSwitch Test
1. Removethe rear console,and disconnectthe
connector(A)from the switch (B).
'dFu
!UF-
BrakeFluidLevelSwitch Test
Checkfor continuitybetweenthe terminals(A) with the
float in the down positionand the up position.
. Removethe brakefluid completelyfrom the reservoir.
With the float down, there should be continuity.
. F j l l t h er e s e r v o iw
r i t h b r a k e f l u i d t oM A X ( u p p e r )l e v e l
(B).With the float up, there should be no continuity.
\!E
19-10
1 . R e m o v et h e b o l t( A ) ,a n d p i v o tt h e c a l i p e r( B )u p o u t
of the way. Checkthe hose and pin boots for
d a m a g ea n d d e t e r i o r a t i o n .
lnspection
1. Raisethe front of the vehicle,and support it with
safetystandsin the proper location{seepage 1'8).
Removethe front wheels.
2. Checkthe thicknessof the inner pad iA) and outer
p a d { B ) .D o n o t i n c l u d et h e t h i c k n e s so f t h e b r a k e
pad backingplate.
&
\
Brakepad thickness:
9.5 10.5mm (0.37 0.41 in.l
Standard:
Servicelimit: 1.6 mm (0.06in.)
A
2 . R e m o v et h e p a d s h i m i A ) a n d p a d s { B ) .
Innerpad:
' . . '
,
.a
Outer pad:
.^hv/
lf the brakeDadthicknessis lessthan the service
l i m i t ,r e p l a c ea l l t h e p a d sa s a s e t .
\v \ \."r------B
tJ I
(cont'd)
19-11
ConventionalBrakeGomponents
Front BrakePadsInspectionand Replacement(cont'dl
3. Removethe pad retainers(A),and checkthe caliper
pins for free movement.
/:-."
t-..
. .,.';i.:
i '1='
r
..a.-
8x1.0mm
34 N.m
3.5 kgt m.
25 tbf.ft)
, a .).
19-12
Front BrakeDisclnspection
Runout
Thicknessand Parallelism
2 . R e m o v et h e b r a k ep a d s( s e ep a g e1 9 - 1 1 ) .
3. Using a micrometer,measurediscthicknessat
eight points,approximately45" apart and 10 mm
{0.4 in.) in from the outer edge of the disc.
10 mm lo.itin.l
': . --'t-'"'t , .
Set up the dial gaugeagainstthe brakedisc as
shown, and measurethe runout at 10 mm (0 4 in.)
from the outer edge of the disc.
BrakeDiscRunout:
ServiceLimit: 0.10mm (0.00ttin.l
lf the disc is beyondthe servicelimit, refinishthe
brakedisc.
Max. RetinishLimit: 19.0mm (0.75in.)
NOTE:
. l f t h e b r a k e d i s ci s b e y o n d t h e s e r v i c lei m i t f o r
r e f i n i s h i n gr ,e p l a c ei t ( s e ep a g e1 8 - 11 ) .
. A new disc should be refinishedif its runout is
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .
4 . l f t h e s m a l l e sm
t e a s u r e m e ni ts l e s st h a nt h e m a x .
refinishinglimit, replacethe brakedisc (seepage
18-11).
lf the disc is beyondthe servicelimit for parallelism,
refinishthe brakedisc with an on-carbrakelathe.
The Kwik-Latheproducedby Kwik-way
"Front BrakeDisc
ManufacturingCo. and the
Lathe" offered by Snap-onTools Co. are approved
for this operation.
19-13
ConventionalBrakeComponents
Front BrakeCaliperOverhaul
Boors
3i,l'1.'"
-ffiFA
/paq\
t l
l l
,\L,.'iE/
-ffi
-ffi
\:7
\--l
CALIPER
PINA
"=;lGoXu";;;lqEt
y' >vr
3.4N.m
{3.5kef m,
/
/
\
\
25 lbf ft)
/
/
II
t
)/)
t9..-\
BRAKE
HOSE/
/
/
/
/
/
/
---=-?
.===?
^
*fL-f
(}',
isli\ii ^ zswttt
SCREW
/8LEEO
/eNm
(o.s
kgr'm.
/
| itbt.ftl
l^
/7\
!s-
*d':ffi
^/rkr)
,-o/
vlJ
Es,lry:' E*,e,a
["fif:i#l1t*"_,,.
\
.==f@
tz x t.zsmm
1 0 8N . m 1 1 1 . 0k g f . m ,
80 tbt.ft)
19-14
/caLl
/ ,,'
//'
SEAL|NG
WAStrtXS
WASHEaS
RepracF
#.'@
PADRETATNERS
\
|
(hA
\t/
ffi
ourEBpaDsHrM
MasterCylinderReplacement
NOTE:Do not spill brakefluid on the vehicle;it may
damagethe paint;if brakefluid does contactthe paint,
wash it off immediatelywith water,
r s s e m b l y( A ) .
1 , R e m o v et h e a i r c l e a n e a
3 . R e m o v et h e c l u t c hr e s e r v o i (r B )a n d e n g i n e w i r e
harnessclip (C)from the mastercylindermounting
b a s e( D ) .
4. Removethe reservoircap and brakefuid from the
reservoir.
5. Removethe reservoir(E)on the mastercylinder
m o u n t r n gD a s e .
6, Disconnectthe brakelines (F)from the master
cylinder (G).To preventspills,cover the hosejoints
with rags or shop towels.
7. Removethe mastercylinder mounting nuts {H)and
washers.
8. Removethe mastercylinderfrom the brakebooster.
Be carefulnot to bend or damagethe brakelines
when removingthe mastercylinder.
1 5N . m
{1.5kgt.m,11 lbt.ft)
19-15
ConventionalBrakeComponents
MasterCylinderInspection
NOTE:
. Beforereassembling,checkthat alI partsare f ree of
dust and other foreign particles.
. D o n o t t r y t o d i s a s s e m b l e t hm
e astercylinder
assembly.Replacethe mastercylinder assemblywith
a new part if necessary.
. Do not allow dirt or foreign matterto contaminatethe
b r a k ef l u i d .
RESERVOIB
CAP
unecKIor otocKage
of vent holes.
,--l
RESERVOIR
r ' , , . J \ +
RESERvOIRSEAL
Checklor damaoe
and deterioration.
BrakeBoosterPushrodClearance
Adjustment
SpecialToolsRequired
Pushrodadjustmentgauge07JAG-SD40100
NOTE:Brakeboosterpushrod-to-piston
clearancemust
be checkedand adjustmentsmade, if necessarV,before
installingthe mastercylinder.
1 . S e t t h e s p e c i atlo o l ( A )o n t h e m a s t e r c y l i n d ebr o d v
(B),push in the centershaft (C)until the top of it
contactsthe end of the secondarypiston {D) by
t u r n i n gt h e a d j u s t i n gn u t ( E ) .
STRAINER
Removeaccumulated
seotment.
RESERVOIR
HOSES
Inspecthosesfor
damage,leaks,and
deterioration.
MASTER
CYLINDER
Checkfor leaks,rust,anddamage
19-16
9 . C h e c kt h e p u s h r o dl e n g t h( A )a s s h o w n i f t h e
boosteris removed,lf the length is incorrect,
loosenthe pushrodlocknut(B),and turn the clevis
(C)in or out to adjust.
A
1 1 6m m { 4 . 6i n . )
1 0 x 1 . 0m m
1.5 N'm
11.5kgf.m,11 lbf.ftl
1 0 . I n s t a l l t h em a s t e rc y l i n d e r( s e ep a g el 9 - 1 5 )
07JAG-SO40100
7. Tightenthe star locknutsecurely.
8. Removethe specialtool (D).
19-17
Gonventional
BrakeComponents
BrakeBoosterTest
FunctionalTest
1. With the enginestopped,pressthe brakepedal
severaltimes to depletethe vacuum reservoir,then
pressthe pedal hard, and hold itfor 15 seconds.lf
the pedalsinks,eitherthe mastercylinderis
bypassinginternally,or the brakesystem (master
c y l i n d e rl,i n e s .m o d u l a t o ro, r c a l i p e r si)s l e a k i n g .
LeakTest
1. Pressthe brakepedalwith the engine running,then
stop the engine.lf the pedal height does not vary
while pressedfor 30 seconds,the vacuum booster
is OK. lf the pedal rises,the boosteris faulty.
2. With the engine stopped,pressthe brakepedal
severaltimes using normal pressure.When the
pedal is first pressed,it should oe row.
On consecutiveapplications,the pedal height
s h o u l dg r a d u a l l yr i s e .l f t h e p e d a lp o s i t i o nd o e s n o t
varv, checkthe boostercheckvalve.
19-18
BrakeBoosterReplacement
1 . R e m o v et h e m a s t e rc y l i n d e r( s e ep a g e1 9 - 1 5 ) .
5 . R e m o v et h e c l i p ( A )a n dt h e j o i n t p i n ( B ) .a n d
disconnecttheyoke from the brakepedal.
.,.,....
alu
i
' - /
'..
c
6x1.0mm
9.8 N.m
(1.0kgf.m,
7.2 tbf.ft)
{'l.3kgf.m,9lbf.ftl
Removethe brakeboostermounting nuts (C).
7 . Removethe brakebooster(A)from the engine
comparlmenr.
INdAdEI
19-19
Conventional
BrakeComponents
RearBrakePadsInspectionand Replacement
Replacement
Frequentinhalationof brakepad dust, regardlessof
materialcomposition,could be hazardousto your
h e ah h .
. Avoid breathingdust particles.
. Never use an air hose or brushto clean brake
assemblies,Use an OSHA-approvedvacuum
cleaner.
Inspection
'1.
3 . R e m o v et h e p a d s h i m s( A )a n d p a d s( B ) .
t {
-::--
r\
)
19-20
tI
A
8 x 1 . 2 5m m
22 N.m
l2.2kgt m,
16rbl.ttl
.
.-.
D
8 x 1.25mm
23Nm
{2.3kgf.m,
17rbf.ft)
I n s t a l l t h eb r a k ec a l i p e r( C )a n d c a l i p e rb o l t s( D ) .
and tighten the boltsto the specifiedtorque.
1 3 .I n s t a l l t h eb r a k eh o s e( E ) .
1 4 . Pressthe brakepedal severaltimes to make sure
the brakeworks, then test-drive.
NOTE:Engagementof the brakemay requirea
greeterpedal strokeimmediatelyafterthe brake
pads have been replacedas a set. Several
applicationsof the brakepedalwill restorethe
n o r m a lp e d a ls t r o k e ,
1 5 . C h e c kt h e p a r k i n gb r a k ea d j u s t m e n{ts e ep a g e1 9 - 7 ) .
1 0 . I n s t a l l t h eb r a k ep a d sa n d p a d s h i m sc o r r e c t l y .
I n s t a l l t h ep a d sw i r h t h e w e a r i n d i c a t o r {sC )o n t h e
inside.
lf you are reusingthe pads,always reinstallthe
brakepads in their originalpositionsto preventa
momentaryloss of brakingefficiency.
1 6 . A f t e ri n s t a l l a t i o nc ,h e c kf o r l e a k sa t h o s ea n d l i n e
joints or connections,and retightenif necessarY.
19-21
Conventional
BrakeComponents
RearBrakeDiscInspection
Runout
Thicknessand Parallelism
3, Using a micrometer,measurediscthicknessat
, p p r o x i m a t e l4y5 ' a p a r ta n d 1 0 m m
e i g h tp o i n t s a
{0.4 in.)from the outer edge of the disc.
BrakeDiscThickness:
Standard:9.9-10.1 mm (0.389 0.397in.l
Max. RetinishingLimit: 9.0 mm (0.35in.)
BrakeDiscParallelism: 0.016mm 10.0006in.)
max.
108N.m (11.0kgf.m,80lbf.ft)
Set up the dial gauge againstthe brakedisc as
shown. and measurethe runout at 10 mm (0.4in.)
from the outer edge of the disc.
Brake Disc Runout;
ServiceLimit: 0.10mm {0.004in.)
lf the disc is beyondthe servicelimit, refinishthe
brakedisc.
Max. RefinishLimit: 9.0 mm (0.35in.)
NOTE:
. l f t h e b r a k ed i s ci s b e y o n d t h e s e r v i c lei m i t f o r
refinishing,replaceit (seepage 18-26).
. A new disc should be refinishedif its runout is
g r e a t e rt h a n0 . 1 0m m ( 0 . 0 0 4i n . ) .
19-22
RearBrakeCaliperOverhaul
BOLT
3 4 N . m( 3 . 5k g f m , 2 5 l b t f t )
WASHERS
BRAKEHOSE
",1 ;[.,.JF
/;;;;---
ADJUSTINGBOLT
\-"o, V((rA
t H\a \l / t,i*t'*"
?,,.t/*"^.,,.:,"",
l, /"V4#
,/
i,,'IltE"
/ !!;,ff
olT-J,.o"c.
lii.'i rz.rrgr..
.ARKING
NUr
2 7 N m { 2 . 8 k g ft .mm, ,
20 tbf.ftr
Gd
ffi
PADSPRING
A,n
Na
--t\)(*ff
'(
INNEBPA'SHIM
/
CUP
Beplace.
O.RING
Beplace.
7lfl,lif,loffi',,0,n, \ ,,:,o"\
":;*" *dF
.r.:._U
i*E
fr.x{_>@
,,.-"iV
:
.:r=,9!q!q}l
''"'t!1'ry#'
l^7k
,.2>a>-
fftt **-->**^'"
,/q &'"o.,"."""o"^.,
10 MM FLANGE BOLTS
55 N m (5.6 lgf-m, 4r lbt ft)
19-23
ConventionalBrakeComponents
BrakeHosesand LinesInspection
1. Inspectthe brakehosesfordamage,deterioration,leaks,interference,andtwisting.
2. Checkthe brakelinesfor damage,rusting.and leakage.Also checkfor bent brakelines.
3. Checkfor leaksat hose and line joints or connections,and retightenif necessary.
4. Checkthe mastercylinderand ABS modulator unit for damageand leakage.
NOTE:Replacethe brakehose clip wheneverthe brakehose is serviced.
BRAKELINE-to-BRAKE
HOSE
15 N.m (1.5kgf.m, 11 lbf.ftl
BRAKEHOSE-to-CALIPER
lBANJOBOLTI
3il N.m {3.5kgf.m.25lbt'ft)
BLEEO
SCREW
9 N.m{0.9kgf.m,7lbf.ftl
ABS MODULATORUNIT-Io-BRAKELINE
15N.m{1.5kgf m.11lbf.ftl
t''
/,i'i'
,/ ,l
t
t,..
-)
MASTERCYLINDEB-to-BRAKE
LINE
15 N m {1.5kgt.m,ll lbf.ft)
BRAKEHOSE.tO-CALIPER
{BANJO BOLTI
34 N.m {3.5kgf.m,25 lbl.ft)
BLEEDSCBEW
9 N.m
10.9kgf.m, 7 lbf ft)
19-24
CONTROLVALVE-to-
BRAKELINE
15N.m11.5kgf m, 11lbf.ft)
BRAKELINE-Io-BRAKEHOSE
15 N.m (1.5kgf.m,11lbf.ftl
BrakeHoseReplacement
NOTE:
. Do not spill brakefluid on the vehicle;it may damage
the paint;if brakefluid gets on the paint,wash it off
immediatelywith water.
. To preventdripping,cover disconnectedline joints
with rags or shop towels.
. Beforereassembling,checkthat all parts are free of
dust and other foreign particles.
. Replacepartswith new ones wheneverspecifiedto
do so.
i
!
1 0 x 1 . 0m m
15 N.m
(1.5kgf.m,
1t tbt.ftl
4. R e m o v ea n d d i s c a r dt h e h o s ec l i p ( B ) .
19-25
ConventionalBrakeComponents
ParkingBrakeCableReplacement
ExplodedView
ADJUSTING
NUT
PARKINGBRAKE
swtTcH
L
e
PARKING
BRAKECABLE
for stiffness,
Check
binding,anddamage.
19-26
8 x 1.25
22 N.m
12.2kgl
NOTE:
. The parkingbrakecablesmust not be bent or
distorted.This will leadto stiff operationand
prematurefailure.
. Referto the ExplodedView as neededduring this
proceoure.
1 . R e l e a s teh e p a r k i n gb r a k el e v e rf u l l y .
7 . l n s t a l l t h en e w c a b l ei n t h e r e v e r s eo r d e ro f
removal.and note these items:
. Be careful not to bend or distortthe cable.
. M a k es u r et h e p a r k i n gb r a k ec a b l ec l i p i s f u l l y
seatedon the cable housing.
. Do the parkingbrakecable adjuslment(seepage
1 9 - 7) .
b r a k ec a b l e( B ) .
{c).
6 . Removethe parkingbrakecable mounting
hardware,then removethe cable.
19-27
Brakes
BrakeComponents................
19-1
Conventional
ABS (Anti-lockBrakeSystem)Components
C o m o o n e nLto c a t i olnn d e x . . . . . . . . . . . . . , . . . . . . . . . . . . . 1
. .9. .-.3. .0. . . . . . .
Troubleshooting
Information.......................
19-31
General
..............
19-34
DTCTroubleshooting
Index
19-35
SymptomTroubleshooting
Index ...,...........................
.................
...........
19-36
SystemDescription
.........19-42
CircuitDiagram
..........
19-45
DTCTroubleshooting
...............
19-52
ABSIndicator
......................
CircuitTroubleshooting
BrakeSystemIndicator
Circuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . . . . . . . .
. . . . . .1. 9 - 5 5
ABSModulator-Control
UnitRemovaland
.............
19-57
lnstallation
19-59
WheelSensorInsoection
...................
..............
19-59
WheelSensorReolacement
ABSGomponents
ComponentLocationIndex
RIGHT-REAR
WHEELSENSOR
page19-59
Inspection,
page19-59
Replacement,
UNDER.OASH
FUSE/RELAY
BOX
UNDER.HOOD
FUSE/RELAY
BOX
\L
LEFT.REAR
WHEELSENSOR
Inspection,page 19-59
page 19-59
Replacement,
DATA LINKCONNECTOR
I16PI
RIGHT.FRONT
WHEELSENSOR
Inspection,page 19-59
page 19-59
Replacement,
ABSMODULATOR.CONTROL
UNIT
page19'57
Removal
andInstallation,
19-30
LEFT-FRONT
WHEELSENSOR
page19-59
Inspection,
page1959
Replacement,
GeneralTroubleshootingInformation
ABS Indicator
DiagnosticTroubleCode{DTCI
Self-diagnosis
. Self-diagnosiscan be classifiedinto two categories:
- I n i t i ad
l iagnosis:
Done right after the enginestarts and until the ABS
indicatorgoes off
- R e g u l ad
r iagnosis:
D o n er i g h t a f t e r t h ei n i t i a d
l i a g n o s i su n t i lt h e
ignition switch is turned OFF
. When a problem is detectedby self-diagnosis,
the
system does the following:
- Turnsthe ABS indicatoron
- Memorizesthe DTC
- StopsABS control
Kickback
The pump motor operateswhen the ABS is functioning,
and the fluid in the reservoiris forced out to the master
k t t h e b r a k ep e d a l .
c y l i n d e rc, a u s i n gk i c k b a c a
PumpMotor
. The pump motor operateswhen the ABS is
functioning.
. The ABS control unit checksthe pump motor
operationwhen the vehicleis startedthe first time
after the ignition switch is turned ON (ll).You may
hearthe motor operateat this time, but it is normal.
(cont'd)
19-31
ABSComponents
GeneralTroubleshootingInformation(cont'd)
How to TroubleshootABS DTCs
The troubleshootingflowchartproceduresassumethat
the causeof the oroblem is still Dresentand the ABS
indicatoris still on. Followingthe flowchartwhen the
ABS indicatordoes not come on can resultin incorrect
diagnosis.
The connectorillustrationsshow the female terminal
connectorswith a singleoutline and the male terminal
connectorswith a double outline.
1. Ouestionthe customeraboutthe conditionswhen
the problem occured,and try to reproducethe
same conditionsfor troubleshooting.Find out
when the ABS indicatorcame on, such as during
ABS control,after ABS control,when the vehicle
was at a certainspeed,etc.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n df o l l o wt h e
prompts on the PGM Testerto displaythe DTC{S)
on the screen.After determiningthe DTC,referto
the DTCTroubleshootingIndex.
NOTE:Seethe HondaPGM Testeruser'smanual
for specificinstructions.
Service Check Signal (SCS)Circuit Method:
1. With the ignition switch OFF,connectthe Honda
PGM Tester(A)to the 16Pdata link connector(DLC)
(BI underthe driver'sside of the dashboard.
19-32
NOTE:
. lf the DTCis not memorized,the ABS indicator
will go off for 3.6 seconds,and then come back
on.
. lf the ABS indicatorstayson, troubleshootfor
"ABS indicator
does not go off" (seestep 1 on
page 19-53).
Th system will not indicate the DTC unless these
conditions are met:
. The brakepedal is not pressed.
. The ignitionswitch is turned ON {ll).
. The SCScircuitis shortedto body ground before
t h e i g n i t i o ns w i t c hi s t u r n e dO N ( l l ) .
Example
ot DTC15
Long blink
Short blinks
{five timesl
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c l e a r t h e
DTC(s)by following the screenprompts on the
PGM Tester.
NOTE:Seethe HondaPGl\4Testeruser's manual
for sDeclfic instructions.
Examole of DTC 22
Long blinks (two times)
19-33
ABSGomponents
DTCTroubleshootingIndex
DTC
DTC:11
DTC:12
DTC:13
DTC:14
DTC;15
DTC:16
DTC:17
DTC:18
Drc:2l
DTC:3'l
DTC:32
DTC:33
DTC:34
DTC:35
DTC;36
DTC:37
DTC:38
DTC:51
DTC:52
DTC:53
DTC:54
DTC:61
DTC:81
19-34
Detection ltem
Rioht-frontwheel sensor{ooen/shortto bodv qround/shortto power)
Faultv riqht-frontwheel sensoroulse siqnal
Left-frontwheel sensor{oDen/shortto bodv qround/shortto power)
Faultvleft-frontwheel sensorDulsesrqnal
Riqht-rearwheel sensor(oDen/shortto bodv qround/shortto power)
F a u l t vr i q h t - r e awr h e e ls e n s o ro u l s es i q n a l
Left-rearwheel sensor (open/shortto bodv qround/shortto power)
Faultvleft-rearwheel sensorDulsesiqnal
d ulser)
C o n t i n u o uo
s D e r a t i o (nc h i o D e D
Solenoid
Solenoid
Solenoid
Solenoid
Solenoid
S ol en oi d
S ol en o i d
S o l en oi d
lvlotor Iocked
lvlotor stuck off
lMotorstuckon
Main relav stuckoff
lG2 voltaqe
cPU (CentralProcessinqUnit)
Note
(seeoaoe 19-45)
{seeoaoe 19-46)
(seeoaqe 19-45)
(seepaqe 19-46)
(seeDaqe19-45)
(seepaqe 19-46)
(seeDaoe'19-45)
(seeDaqe'19-46)
(seepaqe 19-47)
(seeDaoe19-48)
{ s e eD a q e1 9 - 4 8 )
{seeDaoe19'48)
lsee oaqe 19-48)
(seepaqe 19-48)
(seeDaqe19-48)
(seeDaqe19-48)
(seeDaoe19-48)
( s e eD a q e1 9 - 4 8 )
(seeDaoe19-49)
(seeDaoe19-50)
( s e ep a q e1 9 - 5 1
{ s e eo a q e1 9 - 5 ' l
{seepaqe 19-52)
Diagnostic procedure
ABS IndicatorCircuitTroubleshooting(seepage
19-52)
ABS IndicatorCircuitTroubleshooting{seestep 1
on Daqe19-53)
BrakeSystem lndicatorCircuitTroubleshooting
(seepaqe 19-55)
BrakeSystemIndicator
CircuitTroubleshooting
(seesteo1 on Daqe19-55)
19-35
ABS Gomponents
SystemDescription
ABSControlUnit Inputsand Outputsfor 31PConnector
1 2
4 5 6 7 B I
1 6 1 1 1B 1 9
1112
1 41 5
20 ?1/t/t/l/t/
Terminal
number
Wire
color
Terminal
sign
Description
Measurement
Terminals Conditionsllgnition
Voltage
switch ON (ll))
BLU/
YEL
GRN/
YEL
BLU
RRS
GRN/
BLK
F R S( + )
BRN/
WHT
BLU/
ORN
F L S( _ )
GRY/
RED
R L SH
9
11
YEU
RED
LT BLU
DIAG K
12
BRN
DIAG L
19-36
(+)
RRS
F R S( - )
F L S{ + )
R L S( + )
Detects
righfrear
wneetsensor
srgnal
Detectsright-front
wneetsensor
srgnal
;a-_-l
S p i nw h e e l a t AC:0.053V or
I turn/second
above
Wheel
Detectsleft-front
wneet
sensor
srgnal
6-7
Detectsleft-rear
wneetsensor
srgnal
8 9
Communications
with HondaPGM
rester
DTCindication
Oscilloscope
0 . 1 5V p - po r
above
Terminal
number
Wire
color
Terminalsign
WHT/
BLK
BLV
ORN
STOP
16
BLK
M-GND
+ B-MR
18
WHT/
RED
WHT/
GRN
BLK
14
t5
'19
20
BLU/
RED
BRN/
YEL
rG2
+ B-FSR
GND
ABS
Description
Measurement
Terminals Conditions {lgnition
Detectsbrake
switchsiqnal
I 4 - GN D
Powersource
for
activating
the
svstem
Ground
forthe
motor
0umD
15-GND
Powersourcefor
the oumDmotor
Powersourcefor
thevalverelav
Groundfor the
modulator
assemDtv
17-GND
DrivesABS
indicator
EBD
Drivesbrake
(Electronic
brake systemindicator
distribution)
switch oN lll))
Brakepedal Pressed
Released
16-GND
,18-GND
Eattery
voltaoe
Baftery
voltage
Below
0.3V
Atalltimes
Battery
voltaoe
Atalltimes
Battery
voltaoe
19.GND
20-GND
Voltage
ABS
indicator
2 1 - G N D Brakesystem
indicator
Below
0.3V
ON
OFF
OFF
ONfor
bulb
cnecK
A b o u t1 1V
Below 1 V
Below
0.3V
8attery
voltage
( c o n t ' d)
19-37
ABS Gomponents
SystemDescription(cont'd)
Features
When the brakepedal is pressedduring driving,the wheels can lock beforethe vehiclecomesto a stop. In such an
event.the maneuverabilityof the vehicleis reducedif the front wheels are locked,and the stabilityof the vehicleis
reducedif the rearwheels are locked,creatingan extremelyunstablecondition.The ABS preciselycontrolsthe slip
rate of the wheelsto ensuremaximum grip force from the tires,therebyensuringthe maneuverabilityand stabilityof
thevehicle.
The ABS calculatesthe slip rate of the wheels basedon the vehiclespeedand the wheel speed,then it controlsthe
brakefluid pressureto reachthe target slip rate.
Grip Force of Tire and Road Surface
TARGETSLIPRATE
OF
COEFFICIENT
FRICTION
SLIPRATE
19-38
ABSControlUnit
Main Control
The ABS control unit detectsthe wheel speed basedon the wheel sensorsignal it received,then it calculatesthe
vehiclespeed basedon the detectedwheel speed.The control unit detectsthe vehiclespeedduring deceleration
basedon the rate of deceleration.
The ABS control unit calculatesthe slip rate of eachwheel and transmitsthe control signalto the modulatorunit
solenoidvalve when the slip rate is high.
The pressurereductioncontrol hasthree modes: pressurereducing,pressureretaining,and pressureintensifying.
T---
Self-diagnosisFunction
1 . T h e A B S c o n t r ou ln i t i s e q u i p p e d w i t h a m a i n C P U a n d a s u b - C P U . E a c h C P U c h e c k s t h e o t h e r f o r p r o b l e m s .
2. The CPUScheckthe circuitof the system.
3 . T h e A B S c o n t r oul n i t t u r n so n t h e A B S i n di c a t o rw h e n t h e u n i t d e t e c t s ap r o b l e ma n d t h e u n i ts t o p st h e s y s t e m .
4. The self-diagnosiscan be classifiedinto thesetwo categories:
. l n i t i a ld i a g n o s i s
. R e g u l ad
r iagnosis
On-boardDiagnosisFunction
The ABS can be diagnosedwith the Honda PGM Tester.
The ALB Checkercannot be usedwith this system.For air bleedingand checkingwheel sensorsignals.usethe Honda
PGM Tester.Seethe Honda PGMTesteruser's manualfor specificoperatinginstructions.
(cont'd)
19-39
ABSComponents
SystemDescription(cont'd)
ABSModulator
The ABS modulatorconsistsof the inlet solenoidvalves,outlet solenoidvalves,reservoir,pump, pump motor, and the
damping chamber.The modulator reducesthe caliperfluid pressuredirectly.lt is a circulating-typemodulator
b e c a u s e t h eb r a k e f l u i d c i r c u l a t e s t h r o u g h t h e c a l i p e r , r e s e r v o i r , a n d t h e m a s t e r c y l i n d e r . T h e h y d r a u l i ch caos n t r o l
three modes:pressureintensifying,pressureretaining,and pressurereducing.The hydrauliccircuitis an independent
four-channeltype
o ,n e c h a n n efl o r e a c hw h e e l .
Pressurereducingmode:
lvlotoroperationmode:
19-40
t
WheelSensors
The wheel sensorsare the magneticcontactlesstype. As the gear pulserteeth rotate pastthe wheel sensor'smagnetic
coil, AC current is generated.The AC frequencychangesin accordancewith the wheel speed.The ABS control unit
detectsthe wheel sensorsignalfrequencyand therebydetectsthe wheel speed.
GEARPULSER
.r HIGXSPEED
WHEELSNSOR
!t LOW SPEED
PRESSURE
OUTLET
VALVE 9p
OFF
INLET
VALVE oN
OFF
MoroR
-,.
I
l
t
OFF
When the wheel speeddrops sharplybelow the vehiclespeed,the inlet valve closesand il necessary,the outlet valve
opens momentarilyto reducethe caliperfluid pressure.The pump motor startsat this time. As the wheel speed is
restored,and the outlet valve closes,the inlet valve opens momentarilyto increasethe caliperfluid pressure.
19-41
ABSGomponents
CircuitDiagram
"'----G50l
L "*'*" lJ5 Il
rI * *r +' tl ? l
I
Gu
csl
19-42
lo+-sN
LqF**,
*- :ffrre, *riq.r.srbm
r.l
q_
L
md/Y4
7--:::
19-43
ABSComponents
CircuitDiagram(cont'd)
UNDER-HOOD
FUSE/RELAY
BOXCONNECTORS
CONNECTOR
CONNECTOR
A {12P)
{12P)
CONNECTOR
B {2P}
BRAKEPEDALPOSITION
SWITCH4PCONNECTOR
UNDER.DASH
FUSE/RELAY
BOXCONNECTORS
CONNECTOR
I {5P)
CONNECTOR
K I17P)
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
5 67
1011121 31 415 1 1
1l2l3l,/15 1 2 3 4
8
GAUGEASSEMBLY
CONNECTORS
CONNECTOR
A I22P)
1 2 3
CONNECTOR
B I22PI
q,
ABSCONTROL
UNIT3IP CONNECTOR
1 2
4 5 6 7 8 I
16 1 1 1 8 1 9
1112 1 415
20 21/1,/1,/vl,/l
/t,/t/t,/t/
WHEELSENSOR2PCONNECTORS
FRONT
J --T:-l
L
q t t / ) l
'lt L_.:-:J
r
\-r-----Tr'
e:l
Terminalside of femaleterminals
RIGHT.REAR
LEFT-REAR
tslTt?t
I
tL |
/J 1T-1\
\t rlziJ
T e r m i n asl i d eo f m a l el e r m i n a l s
19-44
,/ ,/
6 7 8 9 10 11n213
DTCTroubleshooting
DTC11,13,15,17:WheelSensor
(Open/Short
to Power)
to BodyGround/Short
DTC
2. Start the engine.
3. Measurethe voltagebetweenthe appropriate
w h e e ls e n s o r( * ) c i r c u i t t e r m i n a lo f t h e A B S
control unit 31Pconnectorand body ground (see
table).
DTC
11(Rioht-front)
13(Left-front)
Appropriate Terminal
11 (Riqht-front)
N o .5 : F R S( + )
13(Left-front)
1 5( R i o h t - r e a r )
17(Left-rear)
N o . 7 : F L S( * )
No.2R
: R S( * )
N o . 9R L S( + l
ABS CONTROLUNIT31PCONNECTOR
ADpropriate Terminal
N o . 5 :F R S( t )
N o , 7 : F L S( * )
15 {Riqht-rear}
17 (Left-rear)
N o .2 : R R S( * )
N o . 9R t S( f )
F R S{ + I I G N R / B L K } F L SI + I ( B L U
R R S{ + )
(GNR/YEL)
Wire
W i r esside
i d eof femaleterminals
ls therecontinuity?
(cont'd)
19-45
ABS Components
DTCTroubleshooting(cont'dl
7. Checkthe resistancebetweenthe appropriate
w h e e ls e n s o r( + ) a n d ( ) c i r c u i t e r m i n a l s{ s e e
ta ble).
DTC
11 {Riqht-front)
'13
{Left-front)
1 5( R i o h t - r e a r )
17 (Left-rear)
Appropriate Terminal
*lSide
l+) Side
N o . 5 :F R S( * ) N o . 4 : F R1S- )
N o .7 : F L S{ + i N o . 6F: L S( (-)
No.2:RBS
{+) N o .1 : R B S
N o . 9 :R L S1 - N o . 8B
: L S( -
ABS CONTROLUNIT31PCONNECTOR
DTC12,14,
16,18:WheelSensorPutse
Signal
NOTE:lf the ABS indicatorcomes on for the reasons
describedbelow,the indicatorgoes off when you testd r i v et h e v e h i c l ea t 3 1 m p h ( 5 0k m / n l .
. Only the drive wheel rotated
. T h e v e h i c l es p u n
. Electricalnoise
1 . V i s u a l l yc h e c kf o r a p p r o p r i a t w
e h e e ls e n s o r a n d
pulserinstallationand condition(seetable).
DTC
12
14
18
2,000 A ?
NO Go to step 8.
DTC
Disconnectthe harness2P connectorfrom the
appropriatewheel sensor,and checkthe resistance
b e t w e e nt h e ( + ) a n d { ) t e r m i n a l s o ft h e w h e e l
sensor.
12 {Rioht-front)
14 (Left-front)
1 6( R i q h t . r e a r )
18 (Left-read
Appropriate Terminal
l*) Side
) Side
N o . 5 : F (B*S
No.4:FBS
N o . 7 ; F Ll *S
No,6:FLS
N o . 2R: R(S*
N o1
. :BRS
N o . 9B: L S
1No.8:RLS
Y E S - R e p a i ro p e ni n t h e ( + ) o r ( - ) c i r c u i tw i r e ,o r
short betweenthe (+) circuitwire and the { )
circuitwire betweenthe ABS modulator-control
u n i ta n d t h e w h e e ls e n s o r . l
NO Replace
t h e w h e e ls e n s o r . l
ls therc less than 450 Q ?
YES Go to step 1.
N O - G o t o s t e p4 .
19-46
\\|D
DTC Appropiate
Terminal
12
No.5:
F R W( * i
'14
No.7:
FLWIT.)
to
No.2;
RRW(T-)
No.9:
18
R L W( * )
Other Terminal
(Chipped
Operation
DTC21:Continuous
pulser)
1. Clearthe DTC,then disconnectthe HondaPGM
tesler.
No.7
No.2
No.9
No.5
No.2
No.9
No.5
No.7
No.9
No.5
N o .7
No.2
YES Go to step 3.
ls there continuity?
YES Repairshort in the wires betweenthe
appropriatewheel sensorand the other wheel
s e n s o rh a r n e s s e s . l
NO Clearthe DTC,disconnectthe Honda PGM
Tester,and test-drivethe vehicle.lf the ABS
indicatorcomes on and the same DTCis indicated,
replacethe ABS modulator-controlunit.l
1g-47
ABSComponents
DTCTroubleshooting(cont'd)
DTC31,32.33,34,35,36,37,38:Solenoid
1. Clearthe DTC,thendisconnect
the HondaPGN4
Tester.
2. Test-drive
thevehicle.
Doesthe ABSindicator comeon and are DTCs 31,
32, 33, 34, 35, 36, 37, 38 indicated?
YES Replace
theABSmodulator-control
unit.t
NO Thesystemis OKat thistime.t
DTC51:Motor Locked
'1.
C h e c kt h e N o . 1 0 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d f u s e /
retayDox.
ls the tuse OK?
I
Wiresideof femaleterminals
19-48
DTG52:MotorStuckOFF
1 . C h e c tkh eN o .1 0 ( 4 0 Af )u s ei n t h eu n d e r - h o o d
box.
fuse/relay
ls thef useOK?
YES-Reinstall the fuse, and go to step 2.
NO-Replace the fuse, and recheck.l|
ls there continuity?
3 1 Pc o n n e c t otre r m i n a lN o . 1 7 a n d b o d y g r o u n d
UNIT31PCONNECTOR
ABSCONTROL
YES-Go to step 5.
NO Repairopen in the wire betweenthe ABS
control unit and body ground (G202).1
Reconnectthe ABS control unit 31Pconnector.
6. Clearthe DTC,then disconnectthe HondaPGM
tester.
YES-Go to step 4.
(cont'di
19-49
ABS Components
DTCTroubleshooting(cont'dl
4. Checkfor continuitvbetweenthe ABS control unit
3 1 Pc o n n e c t otre r m i n a lN o . 1 6 a n db o d y g r o u n d .
ABSCONTROL
UNIT31PCONNECTOR
DTC53:MotorStuckON
1 . C l e a rt h e D T C t, h e n d i s c o n n e ct th e H o n d ap GM
Tester.
2. Test-drivethe vehicle.
Does the ABS indicatot come on and is DTC 53
indicated?
YES -Go to step 3.
NO- lntermittentfailure,the system is OK at this
trme.l
Wiresideol femaleterminals
Wiresideof femaleterminals
ls therc continuity?
YES-Replacethe ABS modulator-controlunit.t
NO-Repair open in the wire betweenthe ABS
c o n t r o lu n i ta n d b o d y g r o u n d( G 2 0 2 ) . I
19-50
DTC54:MainRelayStuckOFF
1 . C h e c k t h eN o . 8 ( 2 0 A )f u s e i n t h e u n d e r - h o o fdu s e /
f u s ei f i t i s O K .
r e l a yb o x ,a n d r e i n s t a l l t h e
ls the f use OK?
DTC61:lG2Voltage
N O T EC
: h e c kt h e N o . 1 1 ( 7 . 5 A f)u s ei n t h e u n d e r - d a s h
fuse/relaybox beforetroubleshooting.
1 . C l e a rt h e D T C ,t h e n d i s c o n n e ct th e H o n d aP G M
tesler.
YES-Go to step 2.
2. Test drive the vehicle.
NO Replacethe fuse, and recheck.l
2. Disconnectthe ABS control unit 31Pconnector.
the voltagebetweenthe ABS control unit
3. l\4easure
c o n n e c t otre r m i n a lN o . 1 8 a n d b o d y g r o u n d .
ABSCONTROL
UNIT31PCONNECIOR
t e A B S c o n t r o lu n i t 3 l P c o n n e c t o r .
3 . D i s c o n n e ct h
4 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
5. Measurethe voltage betweenthe ABS control unit
3 1 Pc o n n e c t o r t e r m i n aNl o . 1 5 a n d b o d y g r o u n d .
ABSCONTROL
UNIT31PCONNECTOR
Wiresideof femaleterminals
19-51
ABSComponents
DTCTroubleshooting(cont'd)
DTC81:CPU(Central
Processing
Unit)
1. Clearthe DTC,then disconnectthe HondaPGM
Tester.
2. Test-drivethe vehicle.
Does the ABS indicator come on and is DTC 81
indicated?
ABS IndicatorGircuit
Troubleshooting
ABS indicator does not come on
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a t c ht h e A B S
indicator.
Does the ABS indicator come on?
YES The system is OK at this time.I
5. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the ABS indicator come on?
YES-Check for looseterminalsin the ABS control
unit 31Pconnector.lf necessary,substitutea
known-goodABS modulator-controlunit, and
recheck.l
NO Go to step 6.
6 . Turn the ignition switch OFF.
7 . Removethe gauge assembly(seepage 22-64).
19-52
YES Go to step 3.
NO Go to step 10.
Wiresideol Iemaleterminals
ls there battery voltage?
ls there continuity?
YES-Go to step 5.
YES Checkfor looseterminalsin the gauge
assemblyconnectors.lf the connectorsare OK,
replacethe gaugeassembly.l
19-53
ABSComponents
ABS IndicatorCircuitTroubleshooting(cont'dl
5. Turn the ignitionswitch ON (ll).
6 . Measurethe voltage betweenthe ABS control unit
ABSCONTROL
UNIT3IP CONNECTOR
Wiresideof femaleterminals
YES-Go to step 7.
NO-Repair open in the wire betweenthe No. 11
(7.5A)fuse and the ABS control unit.I
1 . Turn the ignition switch OFF.
8 . Checkfor continuitybetweenthe ABS control unit
31Pconnectorterminal No. 19 and body ground.
ABSCONTROL
UNIT31PCONNECTOB
NO Go to step 11.
'l '1.
Wiresideof femaleterminals
ls there continuity?
YES Go to step 9.
19-54
BrakeSystemIndicatorGircuitTroubleshooting
Brakesystem indicator does not come on
'1.
ls there continuity?
Does the ABS indicator stay on?
YES Repairshort to body ground in the wire
betweenthe multiplexcontrol unit and the ABS
c o n t r o lu n i t . l
NO Go to multiplexcontrol system
trou bleshootinglsee page 22''172).a
ABS CONTROLUNIT31PCONNECTOR
W i r es r d eo f l e m a l el e r m i n a l s
(cont'd)
19-55
ABSComponents
BrakeSystemIndicatorGircuitTroubleshooting(cont'd)
8 . Turn the ignititonswitch ON (ll).
9 . Checkthe brakesystem indicator.
Does the brake system indicatot go off?
YES-Replace the ABS modulator-controlunit.l
NO-Go to step 10.
'l
t e r m i n a lN o . a n d b o d y g r o u n dw i t h a j u m p e rw i r e .
MULTIPLEX
CONTROL
UNIT13PCONNECTOR
JUMPER
WIRE
\
Wiresideof femaleterminals
19-56
Removal
'1.
2 . P u l lu p t h e l o c k ( A )o f t h e A B S c o n t r o u
l nit3lPconnector(B),thendisconnecttheconnector.
FLARENUT
l5 N.m (1.5kgt.m,11lbt.ftl
6)o
CI
--/Q
\.
I mm NUT
8.8N.m {0.9kgl m.6.5lbfft)
\,
\---'
6 mm BOLT
9.8N.m
11.0ksf.m,7.2lbf.ft)
(cont'd)
19-57
ABS Gomponents
ABS Modulator-ControlUnit Removaland Installation{cont'dl
3. Disconnectthesix brakelines.
4. Removethe two I mm nuts.
5. Removethe ABS modulator-controlunit (C).
Installation
'1.
I n s t a l l t h e A B Sm o d u l a t o r c o n t r oul n i t ,t h e nt i g h t e nt h e t w o 8 m m n u t s .
19-58
WheelSensorInspection
WheelSensorReplacement
Front:
6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl
Standard:
Front;
0.4- 1.0mm (0.02-0.04 in.)
Rear:
0.2 1.0mm (0.01 0.04 in.l
Front:
0.4 '1.0mm
10.02 0.0'l in.l
6 mm BOLT
9.8 N.m
{1.0kgf.m,7.2lbf.ftl
WHEELSENSOR
Rear:
6 mmBOLT
9.8 N.m
11.0kgf.m,7.2lbf.ft)
6 mm BOLT
9.8 N.m
(1.0kgf'm,
7.2rbr.ft)
Bear:
0.2 1.0mm
{0.01 0.04in.}
19-59
Body
Doors
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . .
20-2
D o o rP a n eR
l e m o v a l / l n s t a l l a t i o. .n. . . , . . . . . .20,4
....
DoorOuterHandleReplacement
20-6
DoorLatchReplacement
20-7
DoorGlassand Regulator
Replacement
20-9
D o o rS a s hT r i mR e p l a c e m e n. .t. . . . . . . . . . . . . . 2. .0. .t.0. .
DoorGlassOuterWeatherstrip
Replacement
20- 10
Beplacement
DoorWeatherstrip
20-11
D o o rG l a s sA d j u s t m e n t. . . . . . . . . . . . . . . . . . . . . . .20-11
..........
D o o rP o s i t i oA
n d j u s t m e n .t . . . . . . . . . . . . . . . . . . .20-12
.........
D o o rS t r i k eA
r d i u s t m e n.t. . . . . . . . . . . . . . . . . . . . .2. .0. .1. 3. . . . .
Mirrors
........
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . . . .20-14
P o w e rM i r r o rR e p l a c e m e n. .t . . . . . . . . . . . . . . . . .2. 0
. .-. 1. .5. .
M i r r o rH o l d e R
r e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-15
........
Rearview
M i r r o rR e p 1 a c e m e.n. t. . . . . . . . . . . . . .2. 0. .-.1. .6
Glass
Moonroof
lnterioiTrim
........
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . . . .20-49
Trim Removal/lnstallation
DoorArea ..........
20 50
Trim Removal/lnstallation
-RearSideArea
20-51
Trim Removal/lnstallation
-CargoFloorArea
20-52
Trim Removal/lnstallation-Hatch
Area .........20-53
HeadlinerRemoval/lnstallation
20-54
* C a r p eR
............
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . . . .20-55
Consoles
Frontand Rear
Consoles,
Removal/lnstallation
20-57
FrontConsoleDisassembly/Reassembly
.....20-58
Dashboard
InstrumentPanelRemoval/lnstallation
........20-59
Driver'sDashboardLowerCover
RemovatInstallation
20-59
Driver'sDashboardUnderCover
Removat Installation
20-60
Oriver'sPocketRemoval/lnstallation
............
20,60
ShiftLeverTrim Removal/lnstallation
..........2 0 6 1
C e n t eP
r a n eR
l e m o v a l / l n s t a l l a t i. o. .n. . . . . . . .20-62
....
Passenger's
DashboardLowerCover
Removal/lnstallation
20-63
x GloveBox Removal/lnstallation
20-63
Dashboard
SideVent
R e m o v a l / l n s t a l l a t i. o. .n. . . . . . . . . . . . . . . . . . . . 2
. .0. .-.6. .4. . . .
BeverageHolderRemoval/lnstallation
........20-64
Driver'sTrayRemoval/lnstallation
...............
20-65
Passenger's
Tray Removal/lnstallation
........20 65
* DashboardRemoval/lnstallation
..................
20-66
S t e e r i"n H
q a n q eB
r e a mR e o l a c e m e n. .t. . . . . . .2. 0. - 6 8
Seats
ComponentLocationIndex ...........................
20-10
* FrontSeatRemoval/lnstallation
...................
20-11
* FrontSeatDisassembly/
R e a s s e m b l y - D r i v e. .r .' s. . . . . . . . . . . . . . . . . . . . 2. .0. .-.7. .3. . . .
* FrontSeatDisassembly/
R e a s s e m b l y - P a s s e n g. .e.r. '.s. . . . . . . . . . . . . .2. 0
. .-. 7. .4. .
* F r o n tS e a tC o v e rR e p l a c e m e n. .t . . . . . . . . . . . . .2. .O. .-.7. 5
R e a rS e a tR e m o v a l / 1 n s t a 1 1.a. t. i. o. .n. . . . . . . . .2. .0. -. .8.0
RearSeat-back
LatchReplacement..............
20-81
RearSeat-backStriker
Replacement............
20-81
RearSeat-back
CoverReplacement.............
20-82
R e a rS e a tC u s h i o n
C o v e rR e p l a c e m e n. .t . . . .2. 0 . 8 4
Bumpers
F r o n tB u m p e R
r e m o v a l / l n s t a l l a t .i o
. .n. . . . . . .20,85
...
R e a rB u m o e R
r e m o v a l / l n s t a l l a t.i.o. .n. . . . . . .20-86
....
Hood
Adjustment
20-47
H o o dS e a lR e p l a c e m e n t
20,88
H o o dI n s u l a t oRr e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20,89
.......
Hatch
Adjustment
. . . . . . . . . . . . . .2. 0
. .-. 9. 0
H a t c hS u p p o nS t r u tR e p l a c e m e n. .t. . . . . . . . . .2. .0.-. 9 1
HatchWeatherstriD
Reo1acement
.................
20-92
FuelFill Door
Adiustment
ExteriorTrim
. . . . . . . . . . . . . .2. 0
. .-. 9. 3
F r o n tG r i l l eR e p l a c e m e n. .t. . . . . . . . . . . .
20-94
CowlCoversReplac"rn""t .. . .....................
20-95
A p i l l a rC o r n eTr r i mR e p l a c e m e n. .t. . . . . . . . . .20-96
....
R o o fl M o l d i nR
g e p l a c e m e n. .t. . . . . . . . . . . . . . . . .20-97
........
RearLicenseTrim Replacement
20,98
H a t c hS p o i l e8r e p 1 a c e m e .n.t. . . . . . . . . . . . . . . . .20-99
........
E m b l e mR e p 1 a c e m e.n. .t. . . . . . . . . . . . . . . . . . . . . .2 0 - 1 0 0
Fenderwell
FrontInnerFenderReplacement
20-102
F r o n tF e n d eFr a i r i n gR e p l a c e m e n. .t . . . . . . . . .2. .0. .- 1 0 3
FuelPipeProtectorReplacement
20-104
R e a rA i r O u t l e R
t e p 1 a c e m e.n. .t. . . . . . . . . . . . . . .20-'to4
.......
Openers
Frame
SubframeReplacement.................................
20-112
FrameStiffener,Brace,and Gusset
Replacement
.............
20-113
r Fremp RFnrir Chrrr
. . . . . . . . . . . . . .2. 0
. -114
Doors
ComponentLocationIndex
DOOROUTERTRIM
DOORSASHTRIM
page20-10
Replacement,
DOORGLASSOUTER
WEATHERSTRIP
page20-10
Replacement,
DOOR
Adiustment,
Position
page20-12
K-p
IJ
A'A
dq
W2"'
Ya
\J
aita.
t
DOORWEATHERSTRIP
page20-'l'l
Replacement,
POWERWINDOW
swtTcH
\
POWERDOORLOCKSWITCH
(Driver's)
20-2
GLASS
page20-9
Replacement,
Adjustment,page20-11
IMMOBILIZER
LABEL
@
REGULATOR
page20-9
Replacement,
RETAINERCLIP
LOCK
CYLINDER
\
\
LOCKKNOB O
OUTERHANDLE
PROTECTOR
CYLINDERROO
PROTECTOR
,-\
tt
v4,,(,
E ) i l
- /6X@
W (
STRIKER
Adjustment,page20-13
LATCH
page20-7
Replacement,
POWERDOOR
LOCKACTUATOR
20-3
Doors
Door PanelRemoval/lnstallation
SpecialToolsRequired
Trim pad remover,Snap-onA 177Aor equivalent,
c o m m e r c i a l la
yvailable.
NOTE:When prying with a flat-tipscrewdriver,wrap it
with protectivetape, and apply protectivetape around
the relatedparts.to preventdamage.
20-4
> : Clip,9
ffi
EtA
95 mm (3.74in.l
12 mm r q---------i.0.17in.l r <_--'rlmm
{0.04in.l
45 mm {1.77in.l
20-5
Doors
Door Outer HandleReplacement
NOTE:Puton glovesto protectyour hands.
1, Removetheseitems:
. Door panel (seepage 20-4)
. Plasticcover,as necessary(seepage 20-2)
2 . R a i s et h e g l a s sf u l l y .
5.
6x1.0mm
9.8 N.m
{1.0kgf.m,
7.2 tbt.ft')
20-6
Door LatchReplacement
7. Pull out the outer handle(A),then remove it.
FastenorLocation
> : Bolt,1
IIilE
6x1.0mm
8 N.m
{0.8 kgf.m, 6 lbf.ftl
(cont'd)
20-7
Doors
Door LatchReplacement(cont'dl
5 . Disconnectthe cylinder rod (seestep 4 on page 206).
6 . Disconnectthe outer handle rod (seestep 5 on
page 20-6).
7 . Disconnectthe actuatorconnectors(A),and release
t h e i n n e rh a n d l ec a b l e( B ) f r o mt h e d o o r b y
d e t a c h i n gt h e c a b l ec l i p ( C i .
6x1.0mm
5Nm
{0.5kgf.m,
4 tbf.ft)
20-8
6x1.0mm
8 N.m
(0.8kgf.m,
6 rbf.ftl
@
Removethe bolts(C),andloosenthe bolts(D),then
removethe regulator(E)throughthe holein the
door,
greaseto allthe sliding
Applymultipurpose
surfaces
of the regulator(A)whereshown.
6x1.0mm
9.8 N m {1.0kgl.m, 7.2 lbf.ftl
20-9
Doors
Door SashTrim Replacement
Door GlassOuterWeatherstrip
Replacement
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe door
1 . R e m o v et h e p o w e rm i r r o r( s e ep a g e2 0 - 1 5 ) .
2. Startingat the front, pry the door glassouter
weatherstrip(A) up to detachthe clips (B),and
releasethe weatherstripfrom the door sashtrim
(C),then removethe weatherstrip.
Fastener Locations
B>:Clip,s
20-10
Door WeatherstripReplacement
Door GlassAdjustment
NOTE:
. Takecare not to scratchthe door.
. Use a clip removerto removethe clips.
NOTE:
. Checkthe weatherstripsand glassrun channelfor
damageor deterioration,and replacethem if
necessary.
. Wipe the run channelcleanwith a shop towel.
. Lubricatethe run channelwith Shin-Etsugrease
P/N 08798-9013.
B>:Clip,1
C > : C l i p ,1 8
'
14.----'
'r,
.,'o-,,tL' .
.rrt
B
6x1.0mm
9.8N.m(1.0kgf.m,7.2lbf.ft)
Pushthe glassagainstthe channel(C),then tighten
the glass mounting bolts.
Detachthe clips (8, C),then removethe door
weatherstrip(D).
(cont'd)
20-11
Doors
DoorGlassAdiustment{cont'd)
6. Raisethe glassfully, and checkfor gaps.Checkthat
the glass(A) contactsthe glass run channel(B)
evenrv.
Door PositionAdiustment
U s ea 1 2 m m ( 1 / 2i n . )d i a m e t e rh o s e( A ) .
Adjust the rate of water flow as shown {B).
Do not use a nozzle.
H o l dt h e h o s ea b o u t3 0 0 m m ( 1 2i n . )a w a y f r o m
the door (C).
\
t,
12mm1112in,l
\e
300mm {12in.l
20-12
8x1.25mm
29 N.m (3.0kgf.m,
22 tbt.trl
Door StrikerAdjustment
3. Checkthat the door and body edges are parallel.lf
necessary,adjustthe door cushions(A)to make the
rear of the door flush with the bodv.
M a k es u r et h e d o o r l a t c h e s e c u r e l yw i t h o u ts l a m m i n g
it. lf necessary,adjustthe striker(A):The strikernuts
a r ef i x e d ,b u t t h e s t r i k e rc a n b e a d j u s t e ds l i g h t l yu p o r
d o w n ,a n d i n o r o u t .
1. Loosenthe screws(B),rhen inserta shop towel (C)
betweenthe body and striker.
8 x 1 . 2 5m m
18 N.m 11.8kgf m, 13 lbf.ft)
20-13
Mirrors
ComponentLocationIndex
POWERMIRRORACTUATOR
page22-1'18
Replacement,
.a\
b\.\
|
\ \-r<,,/
\.J
\.4
\\
TWEETER
\
TWEETER
MIRRORMOUNTCOVER
POWERMIRROR
page20-15
Replacement,
MIRRORHOLDER
Replacement,page20 '15
__.Q
-'-'
MOUNT
/
REARVIEW
MIRROR
page20 16
Replacement,
20-14
PowerMirror Replacement
1 . Lower the door glassfully.
Mirror HolderReplacement
1 . C a r e f u l l yp u l l o u t t h eb o t t o me d g eo f t h e m i r r o r
holder (A) by hand.Takecare not to scratchthe
mrrror.
3 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) .
4. Disconnecttheconnector(A),and detachthe
h a r n e s sc l i p ( B ) .W h i l eh o l d i n gt h e m i r r o r{ C ) ,
removethe nuts,then removethe mirror. Takecare
not to scratchthe door.
FastenerLocrtions
O: Nut.3
20-15
Mirrors
RearviewMirror Replacement
1. Turnthe mirrorbase(A)90.in eitherdirection.
20-16
Glass
ComponentLocationIndex
PASSENGER'SAIRSAG
CAUTION LABEL
FASTENER,2
glassside)
{Self-adhesive-type,
SIDERUBBERDAM
WINDSHIELDSIDETRIM
',
m-_-==}lny'
S{|---..------'RErA'NER,6
f..N\
;\tJ
e
N8*?'
CLIP,4
Blue
WINDSHIELD
page20-19
Beplacement,
CLIP
DAM
LOWERRUBBER
DAM,4
UPPER
RUBBER
SPOILER
FASTENER,2
(Selt-adhesive-type)
'9>
LOWERRUBBERDAM
(cont'd)
20-17
Glass
ComponentLocationIndex(cont'd)
OUARTER
GLASS
FRONTSEAL
- UPPER
CLIP
tsetl adhesive-typel
..,////
\n iT-
l/ / Pll
/nJ l"
vI
/
LowERcLrp
.--"..---.-_
(Self-adhesive-type)
-.,-''
LEVEMBLEM
('03model)
page20-100
Replacement.
20-18
OUARTER
GLASS
page20-29
Beplacement,
R AR CLIP
(Self-adhesive-type)
WindshieldReplacement
NOTE:
. Puton glovesto protectyour hands,
. Weareyeprotection
whilecuttingthe glassadhesive
with pianowire.
. Useseatcoversto avoiddamaging
the seats.
1. Removetheseitems:
. Rearview
mirror(seepage20-16)
. Windshield
wiperarms(seepage22-145)
2. Pullup the sidetrim (A)to release
the clips(B)from
(C),andpullthetrim rearwardto
the retainers
releaseit fromthecliD(D)thenremovethetrim
from eachsideof thewindshield.
(cont'd)
20-19
Glass
WindshieldReplacement(cont'd)
W i t h a h e l p e ro n t h e o u t s i d e p, u l l t h e p i a n ow i r e { A )
backand forth in a sawing motion. Hold the piano
wire as closeto the windshield(B)as possibleto
preventdamageto the body and dashboard.
Carefullycut through the rubber dam and adhesive
( C )a r o u n dt h e e n t i r ew i n d s h i e l d .
\,
,.-
-A
,,t""""""""',-\
i-..
-1:-,
-= -.--
20-20
t5.
1 4 . G l u et h e m o l d i n g( A ) w i t ha d h e s i v et a p e{ B )
( 3 M 4 2 1 2 ,o r e q u i v a l e n t ) t toh e u p p e re d g eo f t h e
w i n d s h i e l d( C ) ;
. B e s u r et h e a l i g n m e n m
t a r k( D )o f t h e m o l d i n g
l i n e su p w i t h t h e a l i g n m e n m
t a r k( E )o f t h e
windshield.
. Be carefulnot to touch the windshieldwhere
a d h e s i v ew i l l b e a p p l i e d .
t3.
q\
C > : R e t a i n e r , 6O> : C l i p , 2
(cont'd)
20-21
Glass
WindshieldReplacement(cont'dl
t o . Set the windshieldin the opening,and centerit.
up.
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
w i n d s h i e l dp r o p e r l yc. a u s i n ga l e a ka f t e r t h e
w i n d s h i e l di s i n s t a l l e d .
. Keepwater. dust, and abrasivematerialsaway
from the primed surface.
'l',,1rr Applyglassprimerhere.
) - '
G1)'r'
1 7 . R e m o v et h e w i n d s h i e l d .
l l
ol
,,/ ll\
tl
lnside
20-22
-A
l'1fifr.,1:
?mm
n
,..-
in.l
10.28
A..
20 mm
(0.79in.l
)t
$?I.",x1"u.80.".,
trl
.,r []\"
Inside
- '
"V"
n o z z l e( A )a s s h o w n .
c.. N
\F1
2 m m I 'Zn l
in.}I
{0.08
l
A
12 mm (0.47in.)
./"
U s es u c t i o nc u p st o h o l dt h e w i n d s h i e l do v e rt h e
t a r k sm a d ei n
o p e n i n ga
, l i g ni t w i t h t h e a l i g n m e n m
step 16,and set it down on the adhesive.Lightly
p u s ho n t h e w i n d s h i e l du n t i li t s e d g e sa r ef u l l y
s e a t e do n t h e a d h e s i v ea l l t h e w a y a r o u n d .D o n o t
open or closethe doors until the adhesiveis dry.
7 mm {0.27in.)
(cont'd)
20-23
Glass
WindshieldReplacement(cont'd)
23. Scrapeor wipe the excessadhesiveoff with a putty
knife or towel. To remove adhesivefrom a painted
surfaceor the windshield,wipe with a soft shop
towel dampensdwith alcohol.
28. R e i n s t a al l l l r e m a i n i n gr e m o v e dp a r t s .I n s t a l l t h e
rearviewmirror afterthe adhesivehas dried
thoroughly.
NOTE:Advise the customernot to do the following
things for 2 to 3 days:
. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough, unevenroads).
20-24
RearWindow Replacement
NOTE:
. Put on glovesto protectyour hands.
. Wear eye protectionwhile cuttingthe glassadhesive
w i t h p i a n ow i r e .
. Use seat coversto avoid damagingany surfaces.
. Do not damagethe rearwindow defoggergrid lines
a n dt e r m i n a l s .
1 . Removethese items:
. Hatchlower trim panel (seepage 20-53)
. Hatchspoiler(seepage 20-99)
Removethese items:
. High mount brakelight {seepage 22-821
. Rearwindow wiper motor {see page22-1461
Disconnectthe rearwindow defoggerconnectors
(A).
Cutting positions:
(cont'd)
20-25
Glass
RearWindow Replacement(cont'd)
With a putty kniie. scrapethe old adhesivesmooth
to a thicknessof about 2 mm (0.08in.) on the
bonding surfacearoundthe entire rear window
openingflange:
. Do not scraDedown to the Daintedsurfaceof the
body; damagedpaint will interferewith proper
bonding
. Removethe fastenersfrom the tailqate.
Cleanthe hatch bonding surfacewith a sponge
dampenedin alcohol.After cleaning,keepoil,
greaseand water from getting on the surface,
1 1 . G l u et h e s i d eu p p e rf a s t e n e r s( A )a n d s i d e l o w e r
fasteners{B)with adhesivetape {3M 5312,or
e q u i v a l e n tG
) . l u et h e u p p e rr u b b e rd a m s ( C ) w i t h
adhesivetape (NITTO501fM,or equivalent)and
glue the lower rubberdam (D)with adhesivetape
(3M 4216,or equivalent)to the insideface of the
rearwindow (E)as shown. Beforeinstallingthe
lower rubberdam, apply primer (3M N-200,or
equivalent)to the areasbetweenthe alignment
marks {F),then glue the rubberdam on. lf
necessary,glue the spoilerfasteners(G)with
adhesivetape (3M 5671,or equivalent)to the
outsideface of the rearwindow:
. Be sure the side upper fasteners,and upper
r u b b e rd a m s l i n e u p w i t h a l i g n m e n m
t a r k s{ H ,l ) .
. Be sure both ends of the lower rubberdam line
up with the edge of the glass,
. Be sure the spoilerfastenersline up with
a l i g n m e nm
t a r k s{ J ) .
. Be carefulnot to touch the rearwindow where
a d h e s i v ew i l l b e a D o l i e d .
1,1,.,1,'
: Applyprimerhere.
G
E
"6'J1r-,
20-26
T-8.
2
B >: Fastener,
cl
ar\\
itf,
1 5 . W i t h a s p o n g ea
, p p l ya l i g h tc o a to f g l a s sp r i m e r
along the edge of the rear window (A),upper
rubber dams (B),and lower rubberdam (C)as
shown, then lightly wipe it off with gauzeor
cheesecloth:
. With the printeddots (D) on the rearwindow as a
guide, apply the glassprimer to both side
portionsof the rearwindow.
. Do not apply body primer to the rearwindow,
and do not get hatchand glass primer sponges
m i x e du p .
. Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the rear
window properly.causinga leak afterthe rear
w i n d o wi s i n s t a l l e d .
. Keepwater, dust, and abrasivematerialsaway
from the primed surface.
..
t5.
: Applyglasspiimer here.
1 4 . R e m o v et h e r e a rw i n d o w .
(cont'd)
20-27
Glass
RearWindow Replacement(cont'd)
1 6 .With a sponge,apply a light coat of body primer to
t h e o r i g i n aa
l d h e s i v er e m a i n i n ga r o u n dt h e r e a r
window openingflange. Letthe body primer dry for
at least 10 minutes;
. Do not apply glassprimer to the body, and be
carefulnot to mix up glassand body primer
sponges.
. Nevertouch the primed surfaceswith your hands.
',,,,,': Applybodyprimerhe.e.
ii'(0.28
in.l
20 mm
in.l
10.79
2mm
{0.08in.)
1 7 . Beforefilling a cartridge,cut a
nozzle{A} as shown.
7 mm (0.27in.)
20-28
aru'.1{-----"
OuarterGlassReplacement
19. Use suctioncups to hold the rearwindow over the
opening.align it with the alignmentmarks you
'13,
made in step
and set it down on the adhesive.
Lightlypush on the rearwindow until its edgesare
fully seatedon the adhesiveall the way around.Do
not open or closethe doors until the adhesiveis dry.
20. Scrapeor wipe the excessadhesiveoff with a putty
knife or towel. To removeadhesivefrom a painted
surfaceor the rearwindow, use a soft shop towel
dampenedwith alcohol.
21. Letthe adhesivedry for at least 'l hour,thenspray
water over the rear window and checkfor leaks.
Mark the leakingareas,let the rear window dry,
then sealwith sealant.Let the vehiclestandfor at
least4 hours after rearwindow installation,lf the
vehiclehas to be used within the first 4 hours,it
must be driven slowly.
NOTE:
. Put on glovesto protectyour hands.
. Wear eye protectionwhile cuftingthe glassadhesive
with piano wire,
. Use seatcoversto avoid damagingany surfaces.
1 . R e m o v et h e C - p i l l atrr i m ( s e ep a g e2 0 - 5 1 ) .
lf necessary,removethe rear side trim panel (see
page 20-51) and B-pillarupper trim (seepage 2050).
2. Removethe front seal {A) from the front edge of the
glass (B).lf necessary,cut the seal with a utility
knife.
2 2 . R e i n s t a l l a lrle m a i n i n gr e m o v e dp a r t s .
NOTE:Advise the customernot to do the following
things for 2 to 3 days:
. S l a mt h e d o o r sw i t h a l l t h e w i n d o w sr o l l e du p .
. Twist the body excessively(suchas when going
i n a n d o u t o f d r i v e w a y sa t a n a n g l eo r d r i v i n g
over rough, unevenroads).
(cont'd)
20-29
Glass
OuarterGlassReplacement(cont'dl
3 . Apply protectivetape to along the insideand
outsideedgesof the body. Using an awl, make a
hole through the adhesivefrom insidethe vehicle.
Pusha pieceof piano wire through the hole, and
wrap each end around a pieceof wood.
With a helperon the outside,pull the piano wire (A)
backand forth in a sawing motion. Holdthe piano
wire as closeto the quarterglass(B) as possibleto
preventdamageto the body, and carefullycut
through the adhesive(C)aroundthe entirequarter
grass.
Cuttingpositions:
5. Carefullyremovethe quarterglass.
20-30
11 . A l i g nt h e u p p e rc l i p { A )a n d l o w e rc l i p ( B )w i t h t h e
edge of the quarter glass(C),then anachthem with
adhesivetape (NITTO571,or equivalent)to the
insideface of the quarter glass,and align the center
of the rearclip (D)with the alignmentmark (E)you
made in step 9, and attach it with adhesivetape (3
M 4215,or equivalent)to the insideface of the
quarterglassas shown. Be carefulnot to touch the
glasswhere the adhesivetape will be applied.
25.5mm
{ 1 . 0i n . )
(cont'd)
20-31
Glass
OuarterGlassReplacement(cont'dl
Firstglue the front seal (A)with adhesivetape {31\4
4 2 1 3 ,o r e q u i v a l e n t a
) .n d g l u et h e r u b b e rd a m ( B )
with adhesivetape (NITTO501M,or equivalent)to
the insldeface of the quarterglass(C)as shown.
Beforeinstallingthe front seal and rubber dam,
a p p l yp r i m e r( 3 M N - 2 0 0 o, r e q u i v a l e n t ) t toh e i n s i d e
tace of the glass.then glue the seal on:
. Be sure the front seal lines upwiththe bottom
and front edgesof the glass.
. Be careful not to touch the glasswhere adhesive
will beaoolied.
.,1.,,/:/| Apply prlJnerhete.
30 mm
1 1 . 1i8n . l
-"-c
'13.
With a sponge,apply a light coat of glassprimer
along the edge of the rubber dam (A) and front seal
(B)as shown, then lightly wipe it off with gauzeor
cheesecloth:
With the printeddots (C)on the quarterglass(D)
as a guide, apply the glass primer to the upper
and lower corner ponions of the quarterglass.
Do not apply body primer to the quaner glass,
and do not get body and glassprimer sponges
m r x e du p .
Nevertouch the primed surfaceswith your hands.
lf you do, the adhesivemay not bond to the
quarterglassproperly,causinga leak afterthe
quarterglassis inslalled.
Keepwater, dust, and abrasivematerialsaway
from the primed surface.
50 mm
I
{1.97in.1
/
\ t
nL
v - -
i--l
'100mm
{3.9i1in.)
45 mm
{ 1 . 7 7i n . }
6 mm (0.24in.) 3.5 mm
{0.r4 in.l
1 1m m
lo.i(} in.)
20-32
mm
(0.08in.l
l.:J611,
;\
2mm
{0.08in.)
7mm
{0.28in.)
3mm
{ 0 . ' 1 2i n . }
20 mm
{0.79in.)
t5.
'10mm (0.39in.)
7 mm 10.27in.)
( c o n l ' d)
20-33
Glass
OuarterGlassReplacement(cont'd)
17. Use suctioncups (A)to hold the quarterglassover
the opening.align it with the clips (B)and set it
down on the adhesive.Lightly push on the quarter
glass until its edges are fully seatedon the
adhesiveall the way around.Do not open or close
the doors untilthe adhesiveis drv.
20-34
Moonroof
ComponentLocationIndex
GLASS
HeightAdjustment,page 20 37
paqe 20-37
Replacement,
C l o s i n oF o r c ea n d O o e n i n" oD r a o
Check;page20-48
DRAINCHANNEL
page20-39
Replacement,
COVER
/,BR^CKEI
,5
_-""-\\q @?a<&,
..t'- ?
.@
-@c
I
LIMITSWITCH
(AUTO.STOP
SWITCH)
page20-46
Adjustment,
E R
_a
WIND DEFLECTOR
page20-38
Replacement,
CABLETUBE
REARBRACKET
E
@
E STOP
.a'
CABLEASSEMBLY
Beplacement,page20-44
page20'41
Replacement,
gJ
-.- REARDRA'N TUBE
*\
MOONROOF
CONTROLUNIT
)
REARDRAIN VAI-VE
FRAME
page 20-42
Replacement,
20-35
Moonroof
Symptom TroubleshootingIndex
Diagnosticprocedure
Symptom
'1.
Water leaks
W i n dn o l s e
Deflectornoise
Motor noise
20-36
1.
2.
3.
4.
5.
6.
Checkclosingforce
GlassHeightAdjustment
The roof panel (A) should be even with the glass
weatherstrip(B).to within 2*0.5/ 1 mm (0.08+0.02l
0.04 in.) all the way around.lf not, make the following
adjustment:
GlassReplacement
'L
C l o s et h e g l a s sf u l l y .
S l i d et h e s u n s h a d ea l l t h e w a y b a c k .
Removethe screws (A),then remove both bracket
covers (B).Removethe nuts (C)and shims {D)from
both glassbrackets(E).
B
2 + 0.5/ 1mm
{0.08+ 0.02/-0.0i1in.}
FastengrLocations
A } : Screw, 2
c O ,Nut.
il
@
E
\o
1 , Removethe bracketcover from each side.
2. L o o s e nt h e n u t s{ A ) ,a n d i n s t a l l t h es h i m s( B )
betweenthe glassframe (C)and glass bracket(D)
on each side.
Shim ihickness: Front and rear max. 2 mm 10.08in.l
6x1.0mm
9 N.m {0.9kgf.m,7 lbf.ft}
4. Removethe glass{A) by lifting it up. Do not
damagethe roof panel.
B
\
Forward
A
6x1.0mm
I N.m(0.9kgf.m,7lbt.ft)
3. lf necessary,repeaton the oppositeside.
5. Installthe glassin the reverseorder of the removal,
a n d a d j u s t h e g l a s sh e i g h ta l i g n m e n t .
6. Checkfor water leaks.Use free-flowingwater from
a hose without a nozzle.Do not use high-pressure
water.
20-37
Moonroof
Wind DeflectorReplacement
1 . O p e nt h e g l a s sf u l l y .
A>:Screw,2B>:
Screw, 2
' a -- ' -
20-38
DrainChannelReplacement
1 . Removethe moonroof glass(seepage 20-37).
4 . R e m o v et h e d r a i nc h a n n e (l A ) .
I n s t a l l t h ec h a n n e il n t h e r e v e r s eo r d e ro f r e m o v a l ,
and notethese items:
P u s ht h e d r a i nc h a n n e o
l n t ot h e h o o k su n t i la
faint click is heard.
Checkthe glass height adjustment(seepage 2031).
Checkfor water leaks.Letthe water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-39
Moonroof
SunshadeReplacement
1 . R e m o v et h e d r a i nc h a n n e l .
Slidethe sunshade(A) until you can see both
s u n s h a d es l i d e rs p a c e r s( B ) .
FastenerLocations
FastenerLocations
> : Screw,4
) : Screw,4
tF
(F
20-40
Motor Replacement
6. Removethe sunshade(A),
::lll'
=r'"'------.-..
--.,
FastenerLocations
>:Bolt,2
'l'i
\
?
@@
,
..
7 . Removeboth front sunshadebasesliders (A) and
b o t h r e a rs u n s h a d eb a s es l i d e r s( B )
{0.9kgf.m.
7 rbf.ftl
t'-^'
' a {
8 . I n s t a l l t h es u n s h a d ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
and checkthe glassheight adjustment(seepage
20-37).
9 . Checkfor water leaks.Let the water run freely from
a hose without a nozzle.Do not use a high-pressure
spray.
20-41
Moonroof
Frameand DrainTubeReplacement
1 . Removethese items:
. Headliner(seepage 20-54)
. Moonroof glass(seepage20-37)
moonroofrelays(F).
FastenorLocations
> : Bolt,10
{um
irl
/^
6x1.0mm
9.8N.m
(1.0kgf.m,7.2lbfft)
Removethe interiorharness(G) by detachingthe harnessclips (H).
4 . With an assistantholdingthe frame (l). removethe bolts,startingat the rear,and releasethe rear hooks (J) by
20-42
8 . I n s t a l l t h ef r a m ea n d d r a i nt u b e i n t h e r e v e r s eo r d e r
of removal,and note these items:
. B e f o r ei n s t a l l i n g
t h e f r a m e ,c l e a rt h e d r a i nt u b e s
and drain valves using compressedair.
. Checkthe frame seal.
. C l e a nt h e s u r f a c eo f t h e f r a m e .
. When installingthe frame, first attachthe rear
hooks into the body holes.
. Make sure the connectorsare plugged in
properly.
. When connectingthe drain tube, slide it overthe
f r a m en o z z l ea t l e a s t1 0 m m ( 0 . 3 9i n . ) .
.Installthetubeclip(A
o )n t h e d r a i nt u b e( B )a s
shown.
Upward
tI I
20-43
Moonroof
DrainChannelSliderand CableAssemblyReplacement
1. Removethe frame (seepage 20-42).
2. Removethese partsfrom the frame:
5 . P i v o t t h eg l a s sb r a c k e (t A )d o w n b y s l i d i n gt h e l i n k
lifter (B) back,then slide both glassbracketsback
with the link lifter.
. Sunshade(seepage 20-40)
. Moonroof motor (seepage 20-41)
3. Put on glovesto protectyour hands,Removethe
screws(A, B),then removethe slide stops (C)and
cabletube rear brackets(D).Removethe bolts (E)
from the cabletube side bracket(F)and the cable
tube mounting screws(G)from both sidesof the
f r a m e( H ) .
FastenerLocations
A> rScrew.2 B): Screw,2 E > : B o l t , 2
@
r):
@
S l i d et h e c a b l ea s s e m b l y( A )a n d b o t hg l a s s
brackets(B) back,then removethem from the
f r a m e( C ) .
Screw
6\-'1
No switch sidel
o
B
6x1.0mm
9.8 N.m
11.0kgf.m,7.2 lbf.ft)
20-44
7 . R e m o v et h e d r a i nc h a n n e sl l i d e r ( A )f r o m t h e g l a s s
bracket(B).
8 . I n s t a l l t h es l i d e ra n d c a b l ea s s e m b l yi n t h e r e v e r s e
o r d e ro f r e m o v a l a, n d n o t et h e s ei t e m s ;
. D a m a g e dp a r t ss h o u l db e r e p l a c e d .
' Apply multipurposegreaseto the glassbracket
( A )a n d g u i d er a i lp o r t i o no f t h e f r a m e ( B )
indicatedby the arrows.
. Beforereinstallingthe motor, make sure both
l i n kl i f t e r sa r e p a r a l l e la, n d i n t h e f u l l y c l o s e d
position.
. Beforereinstallingthe motor, installtheframe
a n d g l a s s t, h e nc h e c kt h e o p e n i n gd r a g ( s e ep a g e
20-481.
B
\
\
----lll
---':rdrt'Irrt
fl
u,t La/J'
I ll
l$=-r:-
20-45
Moonroof
Limit Switch Adjustment
1. Removethe headliner(seepage 20-54).
Fullyclosedpositionadiustment
2. With the moonroof wrench,closethe glass(A) fully:
. Make sure both link lifters(B)are parallel,and in the positionshown.
. Checkthe g lassfit to the roof panel and the glass height (seepage 20-37).
5x0.8mm
5 N.m {0.5kgf.m,4lbf.ft)
3 . W i t h a n o p e n - e n dw r e n c h ,l o o s e nt h e l i m i ts w i t c hm o u n t i n gb o l t s( C ) .
4. Adjust the limit switch (D):
' Move the switch plate (E)a little at a time, then secureit atthe positionwhere you hear a faint clickwhen
the
switch cam (F) pushesthe positionswitch (open/close).
. Checkthat the switch plate contactsthe switch bracket(G).
20-46
/--:.!Jtr+rtl
.
,
G
\_-_:_t+#1 <F
/
\
/
\
i!
..
20-41
Moonroof
ClosingForceand OpeningDragCheck
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
2. Closingforce check:
. With a shop towel {A) on the leadingedge of the
g l a s s( B ) ,a f t a c ha s p r i n gs c a l e( C )a s s h o w n .
. Havean assistanthold the switchto closethe
glasswhile you measurethe force requiredto
stop it.
. Readthe force as soon as the glassstops moving,
then immediatelyreleasethe switch and spring
scale.
Closing Force; 200 290 N (20 30 kgf,44
66 tbl)
20-48
InteriorTrim
ComponentLocationIndex
HATCHLOWERTRIM PANEL
oaoe20-53
HATCHSIDETRIM
page20 53
B.PILLARUPPEBTRIM
page20-50
TRIM
C-PILLAR
page20'51
DOOROPENINGTRIM
page20-50
A.PILLARTRIM
page20-50
R e m o v a l / l n s t a l l a t ipoang, e2 0 5 4
KICKPANEL
page20 50
Replacement,
page20-55
DOORSILLTRIM
page20-50
CARGOAREA FLOOR
page20-52
REARSIDESHELF
page20 5l
REARCENTERSHELF
page20-51
REARSIDETRIM PANEL
page20-51
CARGOFLOORMAT
page20-52
REARTRIM PANEL
page 20-52
20-49
InteriorTrim
Trim Removal/lnstallation- Door Area
NOTE:
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Takecare not to bend or scratchthe trim and panels.
1 . R e m o v et h e t r i m a s s h o w n .T o r e m o v et h e d o o r s i l l t r i m a n d B - p i l l a ur p p e rt r i m , r e m o v et h e r e a rs i d et r i m p a n e l
as necessary(seepage 20-51).
2. Installthetrim in the reverseorder of removal,and note these items:
. Replace
a n y d a m a g e dc l i p s .
. Apply liquid thread lockto the anchor bolts before reinstallatior,.
. Beforeinstallingthe anchorbolts, make sure there are no twists or kinks in the belts.
FastenerLocations
2ffi
Tl|t
{White)
FRONTSEATBELT
UPPER
ANCHORBOLT
7/16-20
UNF
32 N m (3.3kgf m,24 lbf.ft)
,"lF
\r{
A-PILLARTRIM
il-::7
KICKPANEL
ao-----
LowERANcHoRcAP
FRONTSEAT BELTLOWER
ANCHORBOLT
7/16-20UNF
32 N.m (3.3kgt.m,24lbl.ftl
REARSIDETRIM PANEL
20-50
B> rClip,2
c>rClap,l
-..:.:'
TRIM
S I D ES H E L F
REARSEATSELT
SIDETRIM PANEL
SEAT
STRIKERCAP
S I L LT R I M
SELF-TAI
scREws
5x0.8mm
{ 0 . 4k g f m , 3 l b f . f t )
.. F . -\ *: : :- . n: \
,/\
,/
\*J
R E A RB U L K H E A O
COVER
REARSPEAKERCOVER
FRONTSEAT AELT
LOWERANCHORBOLT
REARSEAT BELTLOWER
\
7/16-20UNF
ANCHOF BOLT
\
32 N.m
7/16-20UNF
\
{ 3 . 3k g f m , 2 4 l b t . t t )
32 N m (3.3 kgf m, 24 lbf ft,
\
L O W E RANCHORCAP
20-51
lnteriorTrim
- CargoFloorArea
Trim Removal/lnstallation
NOTE:
. Put on glovesto protectyour hands.
. When jrying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage'
. Takecare notto bend or scratchthe trim and panels.
( s e ep a g e2 3 - 1 1 ) '
1 . T o r e m o v et h e r e a rt r i m p a n e l ,r e m o v et h e c h i l ds e a tt e t h e ra n c h o r
2. Removethe trim as shown.
, n d r e p l a c ea n y d a m a g e dc l i p s '
3 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
Fastener Locations
A > :C l i p , 3 B > : C l i p . 4
j-=
E T r
\t
FLOORMAT
COVER
REARSEAT-BACK
-t
CARGOAREA FLO
7
To rearsade
trim panel.
To rearsidetrim
panel.
20-52
REARTBIM PANEL
Hatchuppertrim panel
Left hatchside trim
Righthatchside trim
Hatchlower trim panel
2 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
, n d r e p l a c ea n y d a m a g e dc l i p s .
Fastener Locations
o>
A>;crip,a B>:crip,2 .>,l,l,Jil,l3
"-{q .1
\.
Y,]
3il;1,
n l f nl t
gg
E>:crip.2
itr^
O HATCHLowER TRrM
PANEL
HATCHLOWERTRIMPANEL
a- ,,) I
t7,
f.
=- -1
->
.D HATCHUPPERTRIM PANEL
HATCHSIDETRIM
20-53
InteriorTrim
HeadlinerRemovaUlnstallation
NOTE:
. When prying with a flat-tip screwdriver,wrap itwith
protectivetape to preventdamage.
. Takecare not to bend and scratchthe headliner.
. Be carefulnot to damagethe dashboardand other
interiortrim.
1. Removethese items:
FastenerLocations
> : Screw,4
r(\'-r
\)*
5x0.8mm
5 N.m
{0.5kst m.4lbf ft}
20-54
)e
5x0.8mm
4 N.m
{0.4 kgf.m, 3 lbf.ft}
CarpetReplacement
4. Removethe headliner.
-1 Removethe socketplug (A).
- 2 R e m o v et h e r e m a i n i n gd o o r o p e n i n gt r i m { B }
from each roof portion.
-3 Detachthe clips (C),and releasethe fasteners
( D )b y p u l l i n gt h e f r o n t p o r t i o no f t h e h e a d l i n e r
(E)down.
-4 With the help of an assislant,releasethe clips
(F)of the headlinerfrom the moonroof frame
( G ) ,a n d r e l e a s et h e h e a d l i n efrr o m t h e c l i p s( H )
by slidingthe headlinerforward, and lowering
the headliner.
-5 Removethe headlinerthrough the passenger's
opening.
FastenerLocations
C>:Clip,3
F>:Clip,2
H>:Clip,2
B):Clip,'l
--'1
;tt4f
tj=\-/I
5 . Installthe headlinerin the reverseorder of removal,
and note these items:
-JrL
--\
l[il
A
6x1.0mm
9.8Nm
11.0kgf m,7.2 lbf.ft)
-o
. W h e n r e i n s t a l l i ntgh e h e a d l i n etrh r o u g ht h e
passenger'sdoor opening,be carefulnot to fold
or bend it, Also, be carefulnot to scratchthe
DOOy.
. C h e c kt h a t b o t hs i d e so f t h e h e a d l i n ear r e
securelyattachedto the trim.
. R e p l a c ea n y c l i p st h a t r e m a i ni n t h e r o o f d u r i n g
r e m o v a lR
. e i n s t a l l t h cel i p sb a c ki n t h e h e a d l i n e r
before installation.
(cont'd)
20-55
InteriorTrim
CarpetReplacement(cont'dl
Using a utility knife,cut the carpet(A) underthe
heaterareas(B),and cut out the parkingbrakelever
area (C)as shown, then pull backthe carpet.
A
tr
20-56
Consoles
Console,Frontand RearRemoval/lnstallation
NOTE:Takecare not to scratchthe front seal,
dashboard,and relatedparts.
1 . R e m o v et h e r e a rc o n s o l e( A ) .
-1 Slidethe front seatforward fully on each side.
-2 Removethe screws{B)from the rear portionof
the rearconsole,
-3 Slidethe front seat rearwardfully on each side.
- 4 P u l l t h ef r o n t p o r t i o no f t h e r e a rc o n s o l eu p t o
detachthe clips (C)and hooks (D),then release
the rearconsolefrom the front console(E).
- 5 S t a r t i n ga t t h e r e a r ,p u l l t h e r e a rc o n s o l eu p ,
then remove it.
FastenerLocations
C >: Clip,2
B >:Screw,2
6x1.0mm
98Nm
(1.0kgt.m,7.2lbf.ft)
Installthe consolein the reverseorder of removal,
and note these ltems:
. R e p l a c ea n y d a m a g e dc l i p s .
. Make sure the accessorypower socketconnector
i s p l u g g e di n p r o p e r l y .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
20-57
Consoles
Front ConsoleDisassembly/Reassembly
NOTE;Takecare not to scratchthe consoleand relatedparts.
Fastener Locations
):Screw,8
C*
FRONTCONSOLE
\
BEVERAGE
HOLDER
ASSEMBLY
',/
BOX
CONSOLE
20-58
,/
Dashboard
InstrumentPanelRemoval/
Installation
Driver'sDashboardLower Cover
Removal/lnstallation
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape aroundthe
relatedparts,to preventdamage.
. Takecare not to scratchthe dashboardand related
parts.
B> : c l i p . 2
D D:,C l i p , 2
^*,
Installthecover in the reverseorder of removal,
and push the hook portions into placesecurely.
20-59
Dashboard
Driver'sDashboardUnderCover
Removal/lnstallation
Driver'sPocketRemoval/
lnstallation
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe dashboardand related
p an s .
;;t='
20-60
,,.;w,
D>: Hook,3
, ,
U s i n ga r a t c h ew
t r e n c ha n d a n 1 1 i n c he x t e n s i o n
(A)wrapped with a shop towel (B),carefullyinsert
the extensionthrough the glove box opening,and
push the shift levertrim (C)from underthe trim to
releasethe clips (D)and hooks (E)of the left side.
Fastener Locations
D>clip,2
i:F
\V
E> H o o k , 2
.-a7
\rt1
20-61
Dashboard
DashboardCenterPanelRemoval/lnstallation
NOTE:
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape around the
relatedparts,to preventdamage.
. Takecare not to scratchthe dashboardand related
parts.
1. Make sure you have the anti-theftcode for the radio,
the write down the frequenciesfor the preset
buttons.
*4
, F
2 . Removethese items:
. Driver'sdashboardlower cover (seepage20-59)
. Passenger'sdashboardlower cover (seepage
20-63).
. Glove box (seepage20-63).
. Shift levertrim {seepage20-61).
From the glove box and driver'sdashboardIower
cover openings,loosenthe bolts (A) securingthe
centerpanel (B).
Fastener Locations
A): Bolt,2
;.'
20-62
x 0.8 mm
5Nm
Passenger's
DashboardLower
CoverRemoval/lnstallation
NOTE:Takecare not to scratchthe dashboardand
relatedparts.
1. Removethe passenger'sdashboardlower cover
(A).
-1 Gently pull down the rear edge to releasethe
c t i p s( B ) .
-2 Pullthe cover away to releasethe pins (C)from
t h e h o l d e r s( D ) .
FastenerLocations
B>: Clip,3
I jl
GloveBox Removal/lnstallation
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) n dt h e
p r e c a u t i o nasn d p r o c e d u r e (ss e ep a g e2 3 1 4 )i n t h e S R S
sectionbeforeperformingrepairsor service.
NOTE:Takecare not to scratchthe dashboardand
relatedparts.
1. Removethe passenger'sdashboardlower cover.
2. While holding the glove box (A),removethe glove
box stop (B)on each side.
FastenerLocalions
>Boh.2
.-6\
{Ill
.-<,/fir-"b
B
tJ
r-3t.oi,t-'
10.5kgf m,
4 tbf.ft)
20-63
Dashboard
DashboardSide Vent RemovaU
Installation
BeverageHolderRemoval/
lnstallation
NOTE:
. Takecare not to scratchthe dashboard.
. Put on glovesto protectyour hands.
NOTE:
. Takecare not to scratchthe dashboard,
. Put on glovesto protectyour hands.
1. Removethe dashboard(seepage20-66).
FastenerLocations
):Screw.2
FastenerLocations
):Screw, 7
6hD
t
5 . l n s t a l l t h es i d ev e n t i n t h e r e v e r s eo r d e ro f r e m o v a l .
20-64
Driver'sTray Removal/lnstallation
NOTE:
. Takecare not to scratchthe dashboard.
. Put on glovesto protectyour hands.
1. Removethe dashboard(seepage 20-66).
Passenger's
Tray Removal/
Installation
NOTE:
. Takecarenotto scratchthe dashboard.
. Puton glovesto protectyourhands.
FastenerLocations
):Screw.3
tray(A).
FastenerLocations
):Screw, 8
20-65
Dashboard
DashboardRemoval/lnstallation
SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage23-13)and the
precautionsand procedures(seepage23-14)in the SRS
sectionbeforeperformingrepairsor service.
NOTE:
. When prying with a flat-tipscrewdriver,wrap it with
protectivetape, and apply protectivetape aroundthe
relatedpartsto preventdamage.
. Havean assistanthelp you when removing and
rd.
installing
thedashboa
. Takecare not to scratchthe dashboard,body, and
other relatedparts.
. Put on glovesto protectyour hands.
1. Make sure you have the anti-theftcode for the radio,
then write down the frequenciesfor the preset
buttons.
Disconnectthe negativecablefrom the battery,and
wait at leastthree minutesbefore beginningwork.
Removethese items:
. Driver'sdashboardlower cover (seepage 20-59)
. Driver'sdashboardunder cover (seepage 20-60)
. Passenger'sdashboardlower cover (seepage
20-63)
. Glove box (seepage 20-63)
. Consoles,front and rear (seepage 20-57)
. Shift levertrim {seepage 20-61)
. Centerpanel (seepage 20-62)
. Kick panels,both sides(seepage 20-50)
. A-pillartrim. both sides(seepage 20-50)
. Steeringcolumn (seepage 17-9)
20-66
Driver's side:
7. From underthe dash,disconnectthe interiorwire
harnessconnector(A),driver'sdoor wire harness
connectors(B),side turn signallight connector(C).
roof antennaconnector(D),antennalead (E).clutch
switch connectors(F),and brakeswitch connector
(G),and disconnectthe floor wire harness
connectors(H)and engine compartmentwire
harnessconnectors(l)from the under-dashfuse/
r e l a vb o x ( J ) .
Middle portion:
8. Disconnectthe floor wire harnessconnectors(A)
a n dc o m b i n a t i o n
s u b h a r n e scso n n e c t o(rB ) .
Passenger'sside:
9. From under the dash,disconnectthe dashboard
wire harnessconnectors(A),EPSsubharness
connectors(B),enginecompartmentwire harness
connectors(C),A,/Csubharnessconnectors(D),
passenger'sdoor wire harnessconnectors{E),and
s i d et u r n s i g n a l i g h tc o n n e c t o(rF ) .
1 0 . D e t a c ha l l o f t h e h a r n e s sa n d c o n n e c t ocr l i p s .
(cont'd)
20-67
Dashboard
DashboardRemoval/lnstallation
(cont'd)
SteeringHangerBeam
Replacement
FastenerLocations
B>rBolt.3 C>: Bolt,2 D>: Bolt,2
m6[-,,,,",",,-,F6't---''
ffi'!-v{/-
Kr*
w-
$7:
^/761:
/
{2.2kgf m, 16lbf.ftl
,. r:; 8 x 1.25mm
22Nm
(2.2kgf.m,16lbf.ft)
20-68
5 . I n s t a l l t h eb e a mi n t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
. N 4 a kseu r et h e d a s h b o a r dw i r e h a r n e s s( G ) i s n o t
pinched.
. Make sure the connectorsare plugged in
properly.
A>rBolt,4 B>:Screw,9
20-69
Seats
ComponentLocationIndex
REARSEAT
page20-80
Removal/lnstallation,
Seat-backLatchReplacement,
page20-81
Seat-backStrikerReplacement,
page20-81
Seat'backCoverReplacement,
page 20-82
SeatCushionCoverReplacement,
page20-84
FRONTSEAT
page20-i 1
Removal/lnstallation,
page20 73
Disassembly/Reassembly-Driver's,
page20-74
Disassembly/Reassembly-Passenger's,
SeatCoverReplacement,page20-75
20-70
> : Bolt,
1 0 x 1 . 2 5m m
lnner:
(cont'd)
20-71
Seats
(cont'dl
FrontSeatRemoval/lnstallation
Lift up the front seat,then detachthe harnessclip
(A).and disconnectthe seat belt switch connector
( B )a n d s e a tb e l tb u c k l et e n s i o n ecr o n n e c t o(rC ) .l f
, i s c o n n e ct th e s i d e
e q u i p p e dw i t h a s i d ea i r b a g d
a i r b a gc o n n e c t o (r D ) ,a n d o n t h e p a s s e n g e r 'sse a t ,
d i s c o n n e ct th e O P D Su n i tc o n n e c t o(rE ) .T h e
p a s s e n g e r 'sse a ti s s h o w n ,t h e d r i v e r ' ss e a ti s
s i m i l a re x c e p ti t h a sn o O P D Su n i tc o n n e c t o r .
20-72
- Driver's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage 23-13)
and the precautionsand procedures(seepage 23-14)in the SRSsectionbefore performingrepairsor service.
NOTE:
. Takecare not to tear the seamsor damagethe seatcovers,
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver.wrap it with protectivetape to preventdamage.
' Apply multipurposegreasetothe moving portion of the seattrack.
. To preventwrinklesin the seat cushioncover,stretchthe materialevenlyoverthe pad.
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
SEAT-BACK
10 x 'l.25mm
47 N.m {4.8kgf.m,
35 rbt.ft)
WIRETIE
RECLINECOVER
RECLINEKNOB
20-73
Seats
- Passenger's
FrontSeat Disassembly/Reassembly
For some models:SRScomponentsare locatedin this area.Reviewthe SRScomponentlocations(seepage23-'13)
and the precautionsand procedures(seepage 23-14)beforedoing repairsor service.
NOTE;
. Takecare not to tear the seamsor damagethe seatcovers
. Put on glovesto protectyour hands.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage
. Apply multipurposegreaseto the moving portion of the seattrack
. To Dreventwrinklesin the seat cushioncover,stretchthe materialevenlyover the pad.
. lvlakesure the rear seat accesscable is connectedproperlyon each side
. Replaceany damagedclips,and replacethe wire ties with new ones
SIDEAIRBAG
HARNESS
SEAT"BACK
Releasethe seatcushion
coverfrom the cushion
f r a m es p r i n g .
10 x 1.25mm
47 N.m (4.8kgf.m,
3s rbf.ft)
OPDSHARNESS
HANGERSPRING
CENTEBCOVER
WIRETIE
SEATCUSHION
FRAME/SEAT
TRACKS
/
REARSEAT
ACCSSCABLE
,/CLIP
*r(".o,
ACCESSKNOB
v/
,/
/-
I
SLIDELEVER
/ H o o K
RECLINEKNOB
RECLINE
COVER
20-74
Front SeatCoverReplacement
For some models:SRScomponentsare locatedin this
area.Reviewthe SRScomponentlocations(seepage
23 13)and the precautionsand procedures(seepage
23-'14)in the SRSsectionbeforeperforming repairsor
service,
3 . Foldthe seat-backforward.
4. Release
t h e h o o k s( A ) ,a n d u n z i pt h e s e a t - b a c k
c o v e r( B ) .
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers,
. On the passenger'sseatwith side airbag,do not
touch the OPDSsensorin the seat-backpad, and keep
it away from oil. Oil can corrodethe sensorcausingit
to fail.
. Puton glovesto protectyour hands.
Seat-backCover
'L
2. W i t h s i d ea i r b a g :F r o mu n d e rt h e s e a tc u s h i o n ,
detachthe side airbagconnectorclip (A),and on
the passenger'sseat,detachthe OPDSunit
c o n n e c t ocr l i p ( B ) .R e l e a s teh e h o o ks p r i n g s( C )
f r o m t h e s e a tc u s h i o nf r a m es p r i n g{ D ) ,t h e n p u l l
the guide cover (E)back,and removethe wire ties
(F).The passenger'sseat is shown, the driver'sseat
is svmmetricalexceptit has no OPDSunit
connector.
(cont'd)
20-75
8 . Using a flat-tipscrewdriverwrappedwith
protectivetape, insert it into the hook portions
( s e v e np l a c e so) f t h e h e a d r e srte a rt r i m i A ) f r o m t h e
headrestfront trim side. Prv up the hooks (B)to
releasethe labs (C)of the headrestfront trim (Di
w h i l e p u l l i n gt h e h e a d r e sftr o n tt r i m f o r w a r d ,a n d
removethe tflm.
D
/
(cont'd)
20-77
Seats
Front Seat CoverReplacement{cont'd)
SeatCushionCover
Outside:
20-78
6 . R e m o v et h e s e a tc u s h i o nc o v e r( A )w i t h t h e s e a t
cushion pad from the seat cushionframe.
{,
r
:
r *
]
r
?
20-79
Seats
RearSeat Removal/lnstallation
NOTE:Takecare not to scratchthe body or tear the seatcovers.
'1.
Removethe rear seat as shown.To removethe seat-back,removethe front portion of the cargofloor mar lsee
page 20-52).
D > : C l i p ,2
/-<.{\.--
K\| J ] . P F.i\-t-HAP
lltl
agr
f ( 1
Vt-
r_r+*.
8 x 1.25mm
22 N.m 12.2kgt m, 16lbf.ft)
CENTERPIVOTBOLT
8 x 1.25mm
22 N.m
{2.2kgf.m, 16lbf.ftl
RIGHTSEAT-BACK
\'7
SEAT.BACK
CENTERHINGE
BUSHING
LEFTSEAT.BACK
CENTERBELT
PIVOTBUSHING
PIVOT
BUSHING
CENTERANCHORBOLT
7/16-20UNF
32Nm
(3.3kgf m.24 lbt ftl
SEATBELTBUCKLE
6x1.0mm
9.8Nm
{1.0kgf.m,7.2lbf.ft)
HOOK
SEATCUSHION
20-80
RearSeat-backLatchReplacement
1 . Removethe seat-back(seepage 20-80).
RearSeat-backStriker Replacement
NOTE:Takecare not to scratchthe interiortrim.
1 . R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 ' l ) .
,-;1
8 x 1.25mm
22 N m 12.2kgl rn,
16 tbf.ft)
3 . l n s t a l l t h es t r i k e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
and move the striker(A) up or down until it is
centeredin the seat-backlatch {B).
FastenerLocations
20-81
Seats
RearSeat-backCoverReplacement
NOTE:
. Takecare not to tear the seamsor damagethe seat
covers.
. Put on glovesto protectyour hands.
'1.
6x1.0mm
9.8Nm
(1.0kgf.m,7.2lbf.ft)
1W
Releasethe hook (A),and unzipthe seat-backcover
(B).The right seat-backis shown. the left seat-back
i ss i m i l a r .
rJ
20-82
20-83
Seats
RearSeat CushionCoverReplacement
'1.
Removethe rear seat cushion (seepage 2O-80).
Releaseall the clips (A)from under the seat
c u s h i o n a, n d f o l d b a c kt h e s e a tc u s h i o nc o v e r( B ) .
B
Pull backthe edge of the seat cushioncover all the
way around,and releasethe clips (A),then remove
the seatcushioncover.
\
iw F
1.,
1L
ts+'
+.
l-,+
20-84
,+
r
l
Bumpers
Front BumperRemovaUlnstallation
NOTE:
. H a v ea n a s s i s t a nht e l py o u w h e n r e m o v i n ga n d i n s t a l l i n g
t h ef r o n tb u m p e r .
. Takecare not to scratchthe front bumper and body.
. Puton glovesto protectyour hands.
'L
, n d n o t et h e s ei t e m s :
2 . I n s t a l l t h eb u m p e ri n t h e r e v e r s eo r d e ro f r e m o v a l a
. Make sure both front side markerlight connectorsare plugged in properly.
. Make sure the front bumper engagesthe hooksof the side spacersand upper beamson both sidessecurely.
. Replace
a n y d a m a g e dc l i p s .
FastenerLocations
A ) , Screw, 2
B >: Screw,2
C>:Bolt.4
k/- '
{D[]
E>:Clip,2
D>:Clip,7
*S-
=$
t
ABSORBER
SIDESPACER
UPPERBEAM
LEFTFRONTSIDEMARKER
LIGHTCONNECTOR
' * D
e 3
INNER
FRONT
FENDER
BUMPER
ti-\
FEONTBUMPER
C l
A
E
FRONTAIR SPOILER
SPOILER
PLATE
AIR SPOILER
PLATE
6 x 1 . 0m m
9.8 N.m (1.0kgt.m,7.2lbf.ft)
20-85
Bumpers
RearBumperRemovaUlnstallation
NOTE:
' Havean assistanthelp you when removingand installingthe rear bumper.
. Takecare not to scratchthe rear bumper and body.
. When prying with a flat-tipscrewdriver,wrap it with protectivetape to preventdamage.
. Put on glovesto protectyour hands.
L R e m o v et h e r e a rb u m D e ra s s h o w n .
2. Installthe bumper in the reverseorder of removal,and note these items:
. Make sure both rear side marker light connectorsare pluggedin properly.
'Makesuretherearbumperengagesthehooksofthesidespacers,sidebrackets,andupperbracketsonboth
sidessecurely.
. Make sure the upper spacersof the rear bumper engagethe clips on the body securely.
. R e p l a c ea n y d a m a g e dc l i p s .
Fastener Locations
A>:Bolt,2
/h-
\-P-
B)
: Screw, 2
ffiI"ut ^*
c >: Screw, 2
) : Clip,
?
ri)
XJ
\s
I
SIDEBRACKET
UPPERBRACKET
, 6 x 1 . 0m m
/ 9.eN.n
,/ 11.0kgl m,
1.2tbt.ttl
./
SIDESPACER
a
\
'-
:r
A
CAP
LEFTREARSIDEMARKER
LIGHTCONNECTOR
A
UPPERSPACER
REARBUMPER
20-86
Hood
Adjustment
'1.
Slightly looseneach hood hinge bolt,
2 . Adjustthe hood (A) alignmentin this sequence.
. A d j u s t t h e h o o d r i g h t a n d l e f t , a s w e al l s f o r w a r da n d r e a r w a r db, y u s i n gt h e e l o n g a t e dh o l e so n t h e h o o dh i n g e
(B).
. Turn the hood edge cushions(C),as necessary,to makethe hood iit flush with the body at the front and side
edges.
6x1.0mm
9.8 N.m
{1.0kgl.m,7.2 lbf.ftl
6x1.0mm
9.8 N.m
{1.0kgf.m,7.2lbf.ft}
3 . Adjustthe hood latch (D)to obtainthe proper height at the forward edge,and move the hood latch right or left
until the striker(E)is centeredin the hood latch.
Tighteneach bolt securely.
(contd)
20-87
Hood
Adjustment(cont'd)
5. Checkthat the hood opens properlyand locks
securely.
6. Apply body paint to the hinge mounting bolts and
a r o u n dt h e h i n g e s .
HoodSealReplacement
1 . Using a clip remover,detachthe clips,then remove
the hood seal (A).Takecare not to scratchthe hood.
Fastener
Locations
I n s t a l l t h es e a li n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. P u s ht h e c l i p si n t o p l a c es e c u r e l y .
. : I
20-88
HoodInsulatorReplacement
1 . D i s c o n n e ct h
t e w i n d s h i e l dw a s h e rt u b e s( A ) .
FastenerLocations
'10
) : Clip,
t*'-&
,2V..=-'
(
20-89
Hatch
Adjustment
1. Removethe support strut from each side (seepage 20-91).
2 . R e m o v e t h e C - p i l l a r t r i m f r o m e a c h s i d e ( s e e p a g e 2 0 - 5 ' l ) ,daonw
dn
p tuhl le r e a r p o n i o n o f t h e h e a d l i n e r ( s e e
page20-54).Takecare not to bend the headlinerexcessively.
3. Removethe reartrim panel (seepage 20-52).
4, Slightly looseneach bolt and nut.
5 . A d j u s t t h eh a t c h( A )a l i g n m e n it n t h e f o l l o w i n gs e q u e n c e .
. Adjustthe hatch hinges(B) right and left, as well as forward and rearward,using th e elongatedholes.
'Turnthehatchedgecushions(C),inoroutasnecessary,tomakethehatch(D).fitflushwiththebodyattheside
edges.
. Adjustthe fit betweenthe hatch and hatchopening by moving the striker(D).
8 x 1.25mm
22 N.m
{2.2kgf.m,16lbf.ft}
8 x 1.25mm
18 N.m 11.8kgf.m, 13 lbf.ft)
20-90
HatchSupportStrut Replacement
Tighteneach bolt and nut securely.
7 . Checkthat the hatchopens properlyand locks
securery.
Reinstallthe supportstruts securely.
9 . R e i n s t a lal l l r e m a i n i n gr e m o v e dp a r t s .
1 0 .Apply multipurposegreaseto the pivot portion of
the hatch hinges{A) as indicatedby the arrows.
D
8 x 1.25mm
22 N.m(2.2kgf.m,16lbf ft)
2 . Set the clips (A) to the original position,then
reattachthe supportstrut (B)on the pivot bolts (C)
by pushingon the supportstrut.
20-91
Hatch
HatchWeatherstripReplacement
1 . R e m o v et h e h a t c hw e a t h e r s t r i{pA ) b y p u l l i n g o u t
on it.
t a r k{ B )o n t h e h a t c h
2 . L o c a t et h e p a i n t e da l i g n m e n m
weatherstrip.Allgn the paintedmark with the
alignmenttab in the the centerof the hatchopening,
p l l t h ew a y
a n d i n s t a l tl h e h a t c hw e a t h e r s t r i a
around in the directionshown. Make surethere are
no wrinklesin the weatherstrip.
3. Checkfor water leaks.
20-92
FuelFill Door
Adjustment
1. Removethe nut (A),and removethe fuel fill door
o p e ns p r i n g{ B ) .
5x0.8mm
1.8Nm
(0.18kgf.m,
1.3rbf.ft)
>t=-
r'
2 . S l i g h t l yl o o s e nt h e h i n g em o u n t i n gb o l t s( A ) .
3 . A d j u s tt h e f u e lf i l l d o o r ( B )i n o r o u t u n t i li t ' sf l u s h
with the body, and up or down as necessaryto
a^rr.li7a
tha
n.nc
T i g h t e nt h e h i n g em o u n t i n gb o l t s .
5 . R e i n s t a l l t h feu e lf i l l d o o r s p r i n g .
6 . Checkthat the fuel f ill door opens properlyand
lockssecurely,and checkthat the rear of the door is
flush with the body.
20-93
ExteriorTrim
FrontGrille Replacement
1 . Removethe front bumper (seepage 20-85).
FastqnErLocations
C >:Screw.4
D ) : Clip, 4
ll
-S---:
i")
3 . I n s t a l l t h eg r i l l ei n t h e r e v e r s eo r d e ro f r e m o v a l ,
a n d r e p l a c ea n y d a m a g e dc l i p s .
Reinstallthe front bumper.
20-94
Cowl CoversReplacement
1 . R e m o v et h e w i n d s h i e l dw i p e r a r m s ( s e ep a g e2 2 - 1 4 5 ) .
2. Removethe windshieldsidetrim from both sides(seestep 2 on page 20-19).
3. Pullthe hood rear seal (A) away from the cowl covers,then remove it, and using a clip remover,detachthe clips
(B)from the cowl covers.Takecare not to scratchthe cowl covers.
FastenerLocations
B> rClip,3 C>:Clip,8
:- ::::
= - --::;-:
4 . Detachthe clips (C)by carefullypulling the passenger'scowl cover {D) upward,to releasethe hooks{E),and pull
out the cover forward to releasethe hooks(F),then removethe cover.Takecare not to scratchthe body,
Detachthe clips (C)by carefullypulling the driver'scowl cover (G) upward.and pull out the cover forward to
releasethe hooks(H),then removethe cover.Takecare not to scratchthe body.
Installthecovers in the reverseorder of removal,and note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. Pushthe clip portionsinto placesecurely.
. Reinstallboth windshieldside trim properly(seestep 26 on page 20-24).
20-95
ExteriorTrim
A-PillarCornerTrim Replacement
1 . Open the door.
Wrap a flat-tipscrewdriverwith protectivetape,
and apply protectivetape aroundlhe body to
preventdamage.Carefullyinserta flat-tip
screwdrivernext to the upper clip, and detachthe
c l i p b y p r y i n go n t h e A - p i l l a rc o r n e rt r i m ( A ) .T a k e
care not to scratchthe body and relatedparts.
5 . R e p l a c ea n y d a m a g e dc l i p s .
H o l dt h e t r i m u p , a n df i t t h e u p p e rc l i p a n d l o w e r
c l i p si n t ot h e h o l e si n t h e b o d y ,t h e n p u s ho n t h e
t r i m u n t i lt h e c l i p ss n a pi n t op i a c e .
FastenerLocation
20-96
RoofMolding Replacement
1 . Apply protectivetape to the body (A).Using a
flat-tipscrewdriverwrapped with protectivetape
(B),pry up on the roof molding (C).Takecare not to
scratchthe bodv.
..:.::.l.
g
20-97
ExteriorTrim
RearLicenseTrim Replacement
NOTE:Put on glovesto protectyour hands.
1. Removethe hatch lower trim panel (seepage 20-
3 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s( A , B ) w h i l e
h o l d i n gt h e r e a rl i c e n s et r i m ( C ) ,t h e n r e m o v el h e
trim, Takecare not to scratchthe hatch.
FastenerLocations
A>:Clip,2 B>:Clip.2
cHl
\ ! -
:t+
> : Bolt,2
-)
4 . I n s t a l l t h et r i m i n t h e r e v e r s eo r d e ro f r e m o v a l a
, nd
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ftl
20-98
. Replaceany damagedclips.
. Pushthe clip portionsinto placesecurely.
HatchSpoilerReplacement
NOTE:Put on glovesto protectyour hands.
'l.
4 . F r o mi n s i d et h e h a t c h ,r e l e a s et h e c l i p s ,w h i l e
p u l l i n gt h e h a t c hs p o i l e r( A )a w a y ,a n d r e l e a s et h e
fasteners(B),then removethe spoiler.Takecare
not to scratchthe body.
FastenerLocations
> : C l i p2.
Fastener Locaiions
fi'f$t-uLt*
/,fl
v_/
$. A
5 . I n s t a l l t h es p o i l e ri n t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
5x1.0mm
9.8Nm
(1.0kgf.m.7.2lbf.ft)
R e p l a c ea n y d a m a g e dc l i p s .
Replaceany damagedfasteners.Before
installingthe fastenerto the spoiler,cleanthe
spoilerbonding surfacewith a sponge
d a m p e n e di n a l c o h o l G
r ith
. l u et h e f a s t e n e w
a d h e s i v et a p e( 3 M 5 6 7 1 ,o r e q u i v a l e n t ) t toh e
spoiler.
Pushthe clip and fastenerportions into place
securely.
20-99
ExteriorTrim
EmblemReplacement
NOTE:When removingthe emblem,take care not to scratchthe body.
1. To removethe front
"H" emblem and front type emblem, removethe front bumper (seepage 20-85)
FRONTTYPEEMBLEM
FBONT"H" EMBLEM
FRONT"H" EMBLEMBASE
FBONTGRILLE
SCREWS
FRONTSi EMBLEMPLATE
PUSHNUTS
PINS
FRONTGRILLE
20-100
FRONTGRILLE
REARCIVICEMBLEM
LEVEMBLEM
(Leftsideonly)
('03model)
REARVERSIONEMBLEM
SIDE|-VTECEMBLEM
REAR"H" EMBLEM
Unit: mm {in.l
Adhesivetape:
3M 4213E,o. equivalent
Thickness:0.8mm (0.03in.)
REAR"H'' EMBLEM
APPLICATION
TAPE
LEVEMBLEM
Ontoinsideface
Align.
of the guarterglass.
HATCHLINE
REARLICENSE
TRIM
REARsi EMBLEM
REARSiR EMBLEM
(Canada)
34
11.3)
, ilg
(1.93)
=-t
.,!!ll,'nt
(1.s31
50
{'!,9?)
CIVICEMBLEM
E d g eo f t h e
hatch.
ADHESIVETAPE
SIDEi-VTECEMBLEM
Left Side:
.
SIDEi.WEC
EMBLEM
Edge of the
hatch.
Right Side:
63 (2.5)
114(4.49)
F.l^6
^l
rh-
wheelarch.
.=4,
y'
Li.Est
Edgeof the
wheel arch.
APPLICATION
TAPE
BODY
LINE
BODY
LINE
112
o"f,r,ao.o"
(5'5s)
TAPE
4. After installingthe front "H" enblem and front type emblem, reinstallthe front bumper.
20-101
Fenderwell
FrontInnerFenderReplacement
NOTE:Takecare not to scratchthe body.
1, Removethe front inner fender (A).
-1 On the backofthe wheel arch,removethe screws(B).
- 2 F r o mu n d e r t h e f r o n tb u m p e r ( C )r, e m o v e t h e s c r e w( B )s e c ur i n gt h e f r o n t b u m p e r .s p l a s hs h i e l d( D ) ,a n d f r o n t
inner fender,and removethe clip (E)securingthe front air spoiler,front bumper,and front inner fender.
- 3 F r o m t h e w h e e la r c h ,r e m o v et h e c l i p s{ F ,G ) s e c u r i n gt h e f r o n t i n n e rf e n d e r( a n ds p l a s hs h i e l d )o n t h e b o d y .
- 4 R e l e a s teh e h o o k( H )o f t h e s p l a s hs h i e l d , t h e nr e m o v e t h e f r o n it n n e r f e n d e r .
FastenerLocations
B):Screw,4
E>:Clip,1
0*
,ws
F > : C l i p ,1
G):Clip,8
20-102
Front FenderFairingReplacement
1 . Removethe front inner fender as necessary(see
p a g e2 0 - 1 O 2 1 .
Open the front door. From outsidethe door,
r e m o v et h e u p p e rc l i p ( A ) ,a n d f r o m i n s i d et h e d o o r ,
removethe lower clip (A) securingthe front fender
f a i r i n g( B )a n d f r o n tf e n d e r( C ) .
FastenerLocations
B > : C l i p1,
J*.' -@
A>:Clip,2
J<a-'
o --____--
20-103
Fenderwell
FuelPipeProtectorReplacement
1 . R e m o v et h e c l i p s ,t h e n r e m o v et h e f u e l p i p e
r n e r e a ra t r
the body.
> : Clip,4
I n s t a l l t h ep r o t e c t o irn t h e r e v e r s eo r d e ro f r e m o v a l ,
and note these items:
. R e p l a c ea n y d a m a g e dc l i p s .
. P u s ht h e c l i p si n t o p l a c es e c u r e l v .
20-104
I n s t a l l t h ea i r o u t l e t sb y p u s h i n go n t h e h o o k
p o r t i o n su n t i l t h eh o o k ss n a pi n t o p l a c e .
Openers
ComponentLocationIndex
HATCHLOCK
CYLINDER
page20-1'l1
Replacement,
HATCHHANDLE
Replacement,
p a g e2 0 - 1 1 0
HATCHLATCH
Replacement,page20'110
FUELFILLDOORLATCH
page20-107
FUELFILLDOOROPENEBCABLE
page 20-107
Replacement,
FUELFILLDOOROPENER
Replacement,page20-109
I{OOD RELEASEHANDLE
page20-'106
HOODOPENERCABLE
Replacement,page20-106
z)-105
Openers
Hood OpenerCableReplacement
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe body and relatedparts.
l. Removethese items:
. Front bumper (seepage 20-85)
. F r o n ti n n e rf e n d e r ,l e f t s i d e ( s e e p a g e 2 0 - 1 0 2 )
. Kick panel,left side (seepage 20-50)
2. Disconnectthe hood openercable(A) from the hood latch {B) (seepage20-108),and removethe bolts (C),then
removethe hood releasehandle(D)from the body.
FastenerLocations
C>:Bolt,2
@m
6x1.0mm
9,8 N.m
11.0kgl.m, 7.2 lbl.ft)
E >:Clip,3
l,.t'.
W:"
Using a clip remover,detachthe clips (E),and removethe grommet (F)from the body, then removethe hood
openercablefrom the vehicle.Takecare not to bend the cable.
4 . I n s t a l l t h ec a b l ei n t h e r e v e r s eo r d e ro f r e m o v a l a
, n d r e p l a c ea n y d a m a g e dc l i p s .
20-106
Disconnectthe fuel fill door openercable (A)from the opener(B) (seestep 3 on page 20-109).
FastenerLocations
C > : C u s h i o n t a p e1,
D > : C l i p 1,
E > : Clip,2
4 . K C m o d e l :R e m o v e t h el e f tm i d d l ef l o o rc r o s s - m e m b egru s s e t( s e ep a g e2 0 - 1 1 3 ) .
5 . R e m o v et h e c u s h i o nt a p e{ C ) ,a n d r e l e a s et h e c a b l ef r o m t h e c l i p s( D ,E ) .
6 . R e m o v e t h e f u efli l l d o o r l a t c h( F ) f r o m t h eb o d y b y t u r n i n gi t 9 0 ' .
7. Removethe fuel fill door openercablefrom the vehicle.Takecare not to bend the cable
8 . I n s t a lt lh e o p e n e r c a b l e i n t h e r e v e r s e o r d e r o f r e m o v a l , r e p l a c e t h e c u s h i o n t a p e , a n d r e p l a c e t h e c l i p i f i t i s
oamageo.
20-107
Openers
Hood LatchReplacement
NOTE:
. Put on glovesto protectyour hands.
. Takecare not to scratchthe body.
1. Removethe bolts,then removethe hood latch (A)
from the body.
FastenerLocations
> i Bolt,3
--------------'
6x1.0mm
9.8 N.m (1.0kgf.m,7.2lbf.ft)
20-108
FuelFillDoorOpenerReplacement
1 . Using a flat-tipscrewdriverwrapped with
protectivetape, detachthe hooks(A) by prying the
front side cap (B),then remove it from the left door
s i l l t r i m ( C ) ,a n d l o o s e nt h e b o l t ( D )s e c u r i n gt h e
f u e lf i l l d o o r o p e n e r .
6x1.0mm
9.8 N.m
11.0kgf m,7.2 lbf.ft)
20-109
Openers
HatchHandleReplacement
HatchLatchReplacement
1. Removethese items:
. Hatchlower trim panel (seepage 20-53)
. Rear licensetrim panel (seepage 20-98)
2. Removethe rearwindow wiper motor (seepage
22-1461.
3. Disconnectthe hatch o p e n e rc a b l e1 A ) f r o mt h e
h a t c hh a n d l e( B ) ,a n d removethe nuts.
Fastener Locations
a : Nut,
6x1.0mm
9.8N.m
ttb
()rI
a
,t.
i-'-3;li9#k g tm , 7 . 2 l bfft l
11,0
R e m o v et h e b o l t s ,t h e n p u l l t h eh a t c hl a t c h( E )o u t ,
then remove it.
I n s t a l l t h el a t c hi n t h e r e v e r s eo r d e ro f r e m o v a l a, n d
notethese items:
. Make sure each connectoris plugged in properly,
and the rod and cableare connectedproperly.
. l\4akesure the cable actuatesthe latch beforeyou
c l o s et h e h a t c h .
. Make sure the hatch opens properlyand locks
securely.
I n s t a l l t h eh a n d l ei n t h e r e v e r s eo r d e ro f r e m o v a l .
and note these items:
lMake
surethe hatchopenercableis connected
securely.
M a k es u r et h eh a t c ho p e n sp r o p e r l y .
20-110
HatchLockCylinderReplacement
NOTE;Put on glovesto protectyour hands.
'1.
Removethese items:
. Hatchlower trim panel (seepage 20-53).
. Rearlicensetrim (seepage 20-98).
- . .
> : Bolt,1
rS'l-.
u-ar
*/t
20-111
Frame
SubframeReplacement
SubframeTorque
NOTE:After looseningthe subframemounting bolts,be sureto replacethem with new ones.
Referenceholesalignment:
SUBFRAME
REFERENCE
HOLE
( B o d yS i d e )
INSTALLATION
REFERENCE
HOLE
(Subframe
side)
INSTALLATION
REFERENCE
HOLE
SCREWDRIVER
or TAPEREDPUNCH
FRONTSUSPENSION
To body.
INSTALLATION
REFERENCE
HOLE
To body.
I
n
E
SPECIAL
' 1 4x 1 . 5mBOLTS
m
103 N.m
(10.5kgf.m,75lbf.ft)
Replace.
20-112
FrameStiffener,Brace,and GussetReplacement
FrameStiffener,Brace,and GussetTorque
NOTE:When installingthe middle floor cross member braceor gussets,torque the mounting hardwarein the
following sequenceto avoid damageto the quarterpanel.
MIDDLE
FLOOR
CROSS-MEMgER
BRACE/GUSSET
SIDEFRAMESTIFFENER
8 x 1 . 2 5m m
29 N.m
(3.0kgf m,22 lbf ft)
To body.
model:
Canada
U.S.model:
1 0x 1 . 2 5m m
38 N.m
(3.9kgf.m.28lbf.ftl
MIODLE
FLOOR
CROSS-MEMBER
BRACE
..
__!:::-| -
1 0 x 1 . 2 5m m
38 N m (3.9 kgt.m, 28 lbf.ftl
MIDDLE
FLOOR
CROSS.MEMBER
GUSSET
1 0 x 1 . 2 5m m
38Nm
(3.9kgf.m,28 lbl.ftl
20-113
Frame
FrameRepairChart
Top view
Unit:mm {in.}
o: Inner diametel
a
b1
b2
b3
cl
c2
c3
Forsublrameo1510.59)
Forenginemount e13 (0.511
Forenginemount o13 (0.51)
Forenginemount rl3 (0.51)
Formanualtransmission
mouoto13{0.5'
Formanualtransmission
mounto13 10.5'
Formanualt.ansmission
mo!nt d13{0.51)
o
I
g
h
Fordampermounts11.5{0.45}
For damper centero78 (3.07)
Fordampermounts11.5(0.451
Fordampeimountd11.510.45)
Forsubframeo15 {0.591
Localinghole s25 {0.98}
Locatingholee50 (1.97)
VEFTICAL
UNE
20-114
m
n
p
q
t1, t2
x1
x2
(cont'd)
20-115
Frame
FrameRepairChart(cont'dl
Sideview
Unitrmm {in.)
o: InnerdiameteJ
a
b1
b2
b3
cl
c2
c3
o
e
I
s
h
i
Fordampermounto11.5{0.45)
For damper centerr78 {3.07}
Fordampermounto11.5(0.45)
Fordampermountr11.5{0./t5l
Forsubtrameel5 10.591
Locatinghole o25 (0.98)
Locatinghole s 11.97)
SECTIOiIAA
BASE
UNE
trr2xt.6
VERTICAI
LINE
20-116
Frame
FrameRepairChart(cont'dl
Sideview
Unitrmm {in.)
o: InnerdiameteJ
a
b1
b2
b3
cl
c2
c3
o
e
I
s
h
i
Fordampermounto11.5{0.45)
For damper centerr78 {3.07}
Fordampermounto11.5(0.45)
Fordampermountr11.5{0./t5l
Forsubtrameel5 10.591
Locatinghole o25 (0.98)
Locatinghole s 11.97)
SECTIOiIAA
BASE
UNE
trr2xt.6
VERTICAI
LINE
20-116
m
p
q
11,t2
xl
x2
20-117
HVAC(Heating,
Ventilation,
andAir Gonditioningl
HeatingandAir Conditioning
21-2
SpecialTools
Comoonent
Location
lndex ........z t-'5
A/CService
Tiosand
z t-o
Precautions
A,/CRefrigerant
Oil
z t-o
ReDlacement
Troubleshooting
General
21-8
lnformation
Index .......21-9
DTCTroubleshooting
SymptomTroubleshooting
21-10
1ndex..............
21-11
SystemDescription.....................
21-14
CircuitDiagram
D T CT r o u b l e s h o o t i n. .g. . . . . . . . . . .z. .t .- .t .o
Recirculation
ControlMotor
..........
CircuitTroubleshooting
21-25
HeaterControlPowerandGround
Troubleshooting
........21-27
Circuits
Condenser
FanCircuit
Troubleshooting
......................
21-28
Fans
Radiator
andCondenser
CommonCircuit
......................
21-29
Troubfeshooting
Compressor
ClutchCircuit
T r o u b l e s h o o t i n. .g. . . . . . . . . . . . . 2
. .1. .-.3. .0
A,/CPressureSwitchCircuit
......................
21-32
Troubleshooting
Air Mix ControlMotor
.............
21-34
TestandReolacement
ModeControlMotor
.............
21-35
TestandReplacement
Recirculation
ControlMotor
.............
21-36
TestandReolacement
Evaporator
Temperature
Sensor
andTest .............
21-31
Reolacement
Test .................
21-38
PowerTransistor
HeaterControlPaneland
PushSwitchAssemblv
RemovalandInstallation........21-38
DustandPollenFilter
Reolacement
..21-39
BlowerUnitRemovaland
......21-39
lnstallation
BlowerUnitComoonents
R e D l a c e m e .n. t. . . . . . . . . . . . . . . . .2. .1. .- .4. 1. . .
Evaporator
Core
..21-42
Reolacement
*HeaterUnit/Core
..21-43
ReDlacement
HeaterValveCable
.....21-46
Adjustment
..........
21-47
CompressorReplacement
21-48
Comoressor
ClutchCheck ..........
Comoressor
ClutchOverhaul.....21-49
ThermalProtector
Compressor
R e o 1 a c e m e.n. .t . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
ReliefValve
Comoressor
R e o l a c e m e n. .t. . . . . . . . . . . . . . . . .2. .1. .- .5. 1. . .
21-52
Reolacement............
Condenser
Recovery
..................
21-53
Refrigerant
......................
21-54
SystemEvacuation
21-55
SystemCharginS.........................
21-56
LeakTest..................
Refrigerant
21-57
A,/CSvstemTests ........................
Tool Number
DescriDtion
07sAz-001000A
BackprobeSet
---2
att-,,/'Tt
e^t"'
T
21-2
KCe
"-t--'
Otv
2
VALVE
SERVICE
{LOW.PRESSUBE
SIDEI
EVAPORATOR
CORE
(Built-in
theheaterunit)
B e p l a c e m epnat ,g e2 1 4 2
SERVICE
VALVE
{HIGH-PRESSURE
SIDEI
RECEIVER/DRYER
COMPRESSOR
Beplacement,page21 47
CONOENSEB
ClutchCheck,page21-48
page 21-52
Replacement,
C l u t c hO v e r h a u lp, a g e2 1 - 4 9
ThermalProtectorCheck,page21-48
page21 51
ThermalProtectorReplacement,
R e l i eV
f a l v eR e p l a c e m e npta, g e2 1 5 1
RADIATORFAN RELAY
Test,page22-51
CLUTCHRELAY
MOTORRELAY
'-t
/l
l-
-::--
t_]]l
BOX
UNDER.HOOD
FUSE/RELAY
-l
CONDENSERFAN
Test, page 22-51
.\\
RADIATORFAN
CONOENSERFAN
21-4
HEATER
UNIT/CORE
page21-43
Beplacement,
BLOWEN
UNIT
page21-39
Removal
andInstallation,
BLOWERUNITCOMPONENTS
page21-41
Replacement,
HEATERVALVECABLE
page21-46
Adjustment,
DUSTAND
POLLEN
FILTER
page21'39
Replacement,
RECIRCULATION
CONTROLMOTOR
Test,page21-36
page21-36
Replacement,
MODE CONTROLMOTOR
Test,page21-35
page21-35
Replacement,
POWERTRANSISTOR
Test,page 21-38
PUSH SWITCHASSEMBLY
Removaland Installation,page21'38
HEATERCONTROLPANEL
RemovalandInstallation,page21 38
21-5
HeatingandAir Conditioning
A/C ServiceTips and Precautions
A/C Refrigerant
Oll Replacement
R e c o m m e n d eP
d A Go i l : K E I H I NS P 1 0 :
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor.
T h e a i r c o n d i t i o n i n sg y s t e mu s e sH F C - 1 3 4(aR - 1 3 4 a )
r e fr i g e r a n at n d p o l y a l k y l e n e g l y c(oPl A G )r e fr i g e r a n ot i l ,
w i t h C F C ' 1 2( R - 1 2r)e f r i g e r a n t
w h i c ha r e n o t c o m p a t i b l e
r e f r i g e r a not r m i n e r a l
l i l .D o n o t u s eR - ' 1 2
andminerao
oil in this system,and do not aftemptto use R 12
s e r v i c i n ge q u i p m e n td; a m a g et o t h e a i r c o n d i t i o n i n g
t ill result.
s y s t e mo r y o u r s e r v i c i n ge q u i p m e nw
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . - l i s t eadn d i s
certifiedto meet the requirementsof SAE J2210to
r e m o v eR - 1 3 4 af r o m t h e a i r c o n d i t i o n i n sg y s t e m .
lf accidentalsystem dischargeoccurs,ventilatethe
w o r k a r e ab e f o r er e s u m i n gs e r v i c e .
. P/N38897-Pl3-A01AH:'120m0 i4 fl oz)
. P/N38899-P13'A01:
40 m0 i1 1/3fl oz)
Add the recommendedrefrigerantoil in the amount
listedif you replaceany of the following parts.
. T o a v o i dc o n t a m i n a t i o nd.o n o t r e t u r nt h e o i l t o t h e
c o n t a i n eor n c ed i s p e n s e da, n d n e v e rm i x i t w i t h o t h e r
refrigerantoils.
. l m m e d i a t e la
y f'teu
r s i n gt h e o i l , r e i n s t a l l t h e
c a po n
the container,and seal it to avoid moisture
aosorpron.
. D o n o t s p i l lt h e r e f r i g e r a not i l o n t h e v e h i c l e i;t m a y
damagethe paint. lf it gets on the paint,wash it off
immediately.
, . 9l m p . o z )
C o n d e n s e r. . . . . . . . . . . 2m5A\ 5 1 6t l . o z 0
'1.4
E v a p o r a t o r. . . . . . . . .4. 5
. m0 (1113Il.oz, lmp.oz)
'10
L i n eo r h o s e . . . . . . . . . m 0 { 1 / 3f l . o z , 0 . 4l m p . o z )
'10
R e c e i v e r / D r y e.r. . . m 0 ( ' 1 1f3l . o z , 0 . 4l m p . o z )
Leakagerepair ....25 m0,1516
Il oz,0.9 lmp.oz)
. .o rc o m p r e s s orre p l a c e m e n l ,
C o m p r e s s o r. . . . . . . F
s u b t r a ctth e v o l u m eo f o i l d r a i n e d
from the removedcompressorfrom
1 3 0m 0 ( 4 1 / 3 f l . o z4, . 6 l m p . o z )a, n d
d r a i nt h e c a l c u l a t e vdo l u m eo f o i l
'130
f rom the new compressor:
m0
i . 4 1 1 f3l . o z , 4 . 6l m p . o z ) V o l u m eo f
removedcompressor= Volume to
d r a i nf r o m n e w c o m p r e s s o r .
R - 1 3 4 as e r v i c ee q u i p m e not r v e h i c l ea i r c o n d i t i o n i n g
systemsshould not be pressuretested or leaktested
withcompressed
air.
A d d i t i o n ahl e a l t ha n d s a f e t yi n f o r m a t i o nm a y b e
obtainedfrom the refrigerantand lubricant
manufacturers.
. Always disconnectthe negativecablefrom the
parts.
b a t t e r yw h e n e v e r e p l a c i n ga i r c o n d i t i o n i n g
. Keepmoistureand dirt out of the system.When
d i s c o n n e c t i nagn y l i n e s ,p l u g o r c a pt h e f i t t i n g s
immediately;don't removethe caps or plugs until
iust be{oreyou reconnecteach line.
' B e f o r ec o n n e c t i n g
a n y h o s eo r l i n e ,a p p l ya f e w d r o p s
of relrigerantoil to the O-ring.
. W h e nt i g h t e n i n go r l o o s e n i n ga f i t t i n g ,u s ea s e c o n d
wrench to supportthe matchingfitting.
. W h e n d i s c h a r g i ntgh e s y s t e m u
, s ea R - ' 1 3 4 a
station;don't
refrigerantrecovery/recycling/charging
releaserefrigerantinto the atmosphere.
21-6
r\
REMOVED
COMPBESSOR
l i
\..
rJ
\tb
NEW
COMPRESSOR
/- a\
r /
\:)-) -/
'r:l_
_ 0L
I "o*tttu" _*lH
,lEL.-
I I I DRAINING
I voLUME
],^
RECEIVER
LINEA
RECEIVER/DRYER
CONDENSER
LINE
21-7
atc INOICATOR
BECIRCULATION
INDICATOB
/A\
-:@
RECIRCULATION
CONTROLSWITCH
REARWINDOW
INDICATOR
OEFOGGER
@r
REARWINDOW
DEFOGGER
SWITCH
DTC 7
Recirculation +
indicatot
Recirculation+
indicalor
go6s oft
----->
21-8
DTCTroubleshootingIndex
DTC{Recirculation
IndicationBlinks)
7
8
9
10
11
12
13
14
Detection ltem
A n o p e n i n t h e a i r m i x c o n t r o lm o t o rc i r c u i t
A short ln the air mix control motor circuit
A p r o b l e mi n t h e a i r m i x c o n t r o l i n k a q ed, o o r ,o r m o t o r
An open or shon in the mode control motor circuit
A p r o b l e mi n t h e m o d ec o n t r o l i n k a g ed, o o r s ,o r m o t o r
A p r o b l e mi n t h e b l o w e rm o t o rc i r c u i t
A problem in the EEPROMin the heatercontrol panel;
the control oanel must be reolaced
An ooen in the evaDoratortemDeraturesensorcircuit
A short in the evaDoralortemoeraturesensorcircuit
Page
( s e ep a q e2 1 - 1 6 )
( s e eD a o e2 1 - ' 1 6 )
( s e ep a q e2 1 -1 7 )
( s e eo a q e2 1 - 1 8 )
( s e ep a q e2 1 1 9 1
( s e ep a q e2 1 - 2 0 )
( s e ep a g e2 1 - 3 8 )
(seepaqe 21-23)
( s e eo a q e2 1 - 2 4 1
In case of multiple problems,the recirculationindicatorwill indicateonly the DTCwith the least number of blinks.
ln caseof an intermittentfailure,the heatercontrol panelwill storethe DTCuntil the ignition is turned off.
21-9
Index
SymptomTroubleshooting
(see
CircuitsTroubleshooting
page21-27)
Condenserfan does not run at all (but
radiatorfan runs with the Ay'Con)
Both fans do not run with the A,/Con
fuse/relay
box
under-dash
Poorgroundat G501
C l e a n l i n easns dt i g h t n e sosf a l l
conneclors
. P o o rg r o u n da t G 3 0 1
. C l e a n l i n e sasn d t i g h t n e s so f a l l
connectors
R a d i a t oarn dC o n d e n s e
Fra n s
B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
CommonCircuitTroubleshooting (20A)in the under-hoodfuse/relay
( s e ep a g e2 1 - 2 9 )
box
P o o rg r o u n da t G 3 0 l
C l e a n l i n e sasn dt i g h t n e s so f a l l
connectors
CompressorClutchCircuit
C l e a n l i n e sasn dt i g h t n e s so f a l l
T r o u b l e s h o o t i n(qs e eD a q e2 1 - 3 0 ) connectors
Ay'CPressureSwitch Circuit
B l o w nf u s eN o . 1 ( 2 0 A )a n d N o . 4
(20A)in the under-hoodfuse/relay
T r o u b l e s h o o t i n(gs e ep a g e2 1 - 3 2 )
box
Poor ground at G301
C l e a n l i n e sasn dt i g h t n e s so f a l l
connectors
C o n d e n s eFr a nC i r c u i t
Troubleshooting{seepage 21-28)
!
21-10
SystemDescription
HeaterControlPanelInputsandOutputs
HEATERCONTFOLPANELCONNECIORS
CONNECTOR
A {r/rP)
CONNECTORB (22P)
CONNECTOR
Cavity
_|
Wire color
\ln Y
2
3
LT GRN
PNK/BLU
BLU
GRNA/EL
GRNA/VHT
BLUI/EL
BLU/RED
5
6
7
8
I
GRN
10
11
YEL/RED
YEVBTU
YEL/BLK
BLK
BLK/YEL
14
CONNECTOR
B
Cavity
Sional
AIRMIXPOTENTIAL
+5V
S E N S OC
RO M M O N
GROUND
OUTPUT
OUTPUT
INPUT
INPUT
INPUT
OUTPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
INPUT
OUTPUT
INPUT
INPUT
A,/CPRESSURE
SWITCH
RECIRCULATE
FRESH
POWER
TRANSISTOR
BLOWERFEEDBACK
AIR MIX COOL
MODEDEF
MODEVENT
REARWINDOWDEFOGGER
RELAY
GROUND
l G 2( P o w e r )
on
Wire color
Siqnal
2
3
4
5
6
7
8
9
BLIVRED
--T
PNVBLK
R E A RW I N D O WD E F O G G ES
RW I T C HL E D
A./CSWITCHLED
RECIRCULATIO
CN
ONTROL
S W I T C HL E D
AIR MIX POTENTIAL
BRN
EVAPORATOR
TEIMPERATURE
SENSOR
INPUT
INPUT
INPUT
OUTPUT
OUTPUT
GAUGE
ASSEMBLY
al' 'TDr ri
LT GRN
L TG R N / B L K
10
11
14
ic
16
17
18
19
20
RED
RED/BLK
BLU
LT GRN/RED
YEVRED
YEUGRN
WHT/BLU
RED/BLU
RED/YEL
BRN^,^/HT
22
REDA/r'HT
TAILLIGHTSRELAY
INPUT
REARWINDOWDEFOGGER
SWITCH
INPUT
A/C SWITCH
RECIRCULATIO
CN
ONTROL
SWITCH
INPUT
INPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
OUTPUT
MODE4
MODE3
M O D E2
M O D E1
I G N( P o w e d
(Not used)
(cont'd)
21-11
BLOWER
FAN
\
\ r\,u
EXPANSIONVALVE
(Metersthe required
amount of refrigerant
into the evaporator)
APOBATORTEMPERATURE
SENSOR
THERMALPROTECTOR
(Opensthe compressorclutchcircuit
when the compressottemperature
becomestoo high)
A/C PRESSURESWITCH
When the refriqerantis below
196kPa(2.0kgi/cm',28psi)
or above3,140kPa(32 kgf/cm'
455 psi),the Py'cpressure
switchopensthe circuitto
the Py'Cswitch and stopsthe
air conditioningto protectthe
compressor-
RELIEF
VALVE
(Relieves
pressure
at thecompressor
w h e nt h ep r e s s u ri e
st o oh i g h )
A/C COMPRESSOR
(Suctionand comoression)
RECEIVER/DRYER
(Trapsdebris,and
\-^
removesmorsturel
/CONDENSER
(Radiationof heat)
vAPoR
HrcHPRESSURE
-:--l
[ '....
Low PREsSUBE
LrourD
tffi
Low PREssURE
vAPoR
21-12
HeatingandAir Conditioning
GircuitDiagram
UNDEN
rcODFUSVRELIYSOX
UNOER
DASN
fUSE/8EIlYBOX
|GNUION
SWTCfi
lG2HoI ii 0l\lllll
+.
\
C}F
rG2/
BLK/RED
.I
\ IHEFMAI
PBorEcro8 I
*n*,*,
lTl
| <l I CLUTCH
tf
_l
G301
MUITIPLD(
CONTFOI
UNITI
-!10.
RADIATOS\ NADIATOS
) tAl'/
/ swtlcll
oT0n
B LX
G301
21-14
19S"F
193"C) l
I
I
n
A/CPnESSUEt
swTOt
irgF 8Ll
t...iCF
BLU
CONDEN$N
MOTOB
I
I
8u(
I ilnthoundor dasiluse/lelay
box
BU/YEL
-8lU/wH'I
EVAPORATOB
TEMPERATUNESENSOR
sn 4-Lrenil
m
::-:::: ., . a/c
YEUBLU
YEL/NED
M DEF
MODEl
BED/YEI
Mq)EI
RED/8LU
M002
M00t3
WHT/8LU
MOOE3
YEL/GRN
MOOEI
M00l
co TnoL
MOTOS
LTGRI'l
ffftH,,
F*u,*
GNNMHT
8U
GRN/YEL
8LK--..-...-l
(
f
coNNEcroFrir.Pt
mxr{EcroB
! {2P)
G5'1
G602
21-15
A {I4PI
HEATERCONTROL
PANELCONNECTOR
22P:
No.6
5P:
No.3
W i r e s i d eo f f e m a l et e r m i n a l s
ls there continuity?
YES-Check for loosewires or poor connectionsat
heatercontrol oanel connectorsA (14P)and B (22P)
and at the air mix control motor 5P connector.lf the
connectionsare good. substitutea known-goodair
mix control motor, and recheck,lf the symptom/
indicationgoes away, replacethe originalair mix
control motor. lf the symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and
recheck.lf the symptom/indicationgoes away,
replacethe original heatercontrol panel.l
N O R e p a i ra n y o p e n i n t h e w i r e ( s )k e t w e e n t h e
heatercontrol panel and the air mix control
motor.l
21-16
W i r e s i d eo i l e m a e l e r m i n a l s
ls therc continuity?
Y E S - R e p a i ra n y s h o r t t o b o d y g r o u n dl n t h e
wire(s)betweenthe heatercontrol panel and the air
mix control motor.l
N O - G o t o s t e p5 .
HEATERCONTROLPANELCONNECTOR
B I22PI
Wiresideof femaleterminals
21-17
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h e s a m e
t e r m i n a l sf o r v o l t a g e .
HEATEB
CONTROL
PANEL
CONNECTOR
A {14P)
HEATERCONTROLPANELCONNECTOR
B {22PI
3
tl
12
15 T6
1 1 1 8 t 9 2A 21 22
RED/YEL
WHT
Wiresideof femaleterminals
HEATERCONTROLPANELCONNECTOR
B {22P)
W i r e s i d e o f f e m a L el e r m i n a l s
ls there continuity?
Y E S R e p a i ra n y s h o r t t o b o d y g r o u n di n t h e
wire(s)betweenthe heatercontrol panel and the
mode control motor.l
NO
21-18
Go to step 5.
10P:
No.8
No.6,9
No.5
N o .4 , 7
HEATER
PANELCONNECTOR
A (14PI
CONTROL
Wiresideof lemaleterminals
MODECONTROLMOTORlOPCONNECTOR
Wiresideof femaleterminals
HEATERCONTROLPANELCONNECTORB {22PI
Wire side of femaleterminals
ls there continuity?
YES-Check for loosewires or poor connectionsat
heatercontrol panelconnectorsA (14P)and B (22P),
and at the mode control motor 10Pconnector.lf the
connectionsare good, substitutea known-good
mode control motor, and recheck.lf the symptom/
indicationgoes away. replacethe original mode
control motor.lfthe symptom/indicationcontinues,
substitutea known-goodheatercontrol panel,and
recheck.lf the symptom/indicationgoes away,
replacethe originalheatercontrol panel.l
NO Repairany open in the wire(s)betweenthe
heatercontrol Daneland the mode control motor.l
21-19
HeatingandAir Gonditioning
DTCTroubleshooting{cont'd)
DTC12:A Problemin the BlowerMotor
Circuit
'1.
C h e c kt h e N o . 1 2 ( 4 0 A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox, and the No. 14 (10A)fuse in the
under-dashf use/relaybox.
2
Are the tuses OK?
BLK
YES-Go to step 2.
ls there continuity?
YES-Go to step 8.
JUMPER] BLU/BLK
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
Does the blower motor tun at high speed?
Y E S - G o t o s t e p1 0 .
NO-Repair open in the wire betweenthe power
transistorand the blower motor.l
1 0 . Turn the ignition switch OFF.
1 1 . Disconnectlhe jumper wire.
21-20
1a
ls there continuity?
YES Repairany shortto body ground in the
wire(s)betweenthe heatercontrol panel and the
power transistor.I
BLOWERMOTOR2PCONNECTOR
BLU/WHT
NO Go to step 14,
1 4 . Checkfor continuitybetweenthe following
terminalsof heatercontrol panelconnectorA ( 14P)
and power transistor4P connector.
'l4Pt
4P:
No.4
No.7
No.8
No.2
HEATER
CONTROL
PANEL
CONNECTOR
A (14P)
Wiresideof femaleterminals
z 3
T 8
4 1 5 1 6
r ol x l I
1 2 l1 3l 1 4
BLU/YEL
)
8LU/RED
NO Go to step 20.
2 1 .Removethe blower motor relayfrom the underhood fuse/relaybox, and test it (seepage 22-511.
ls the relay OK?
ls thete continuity?
21-21
BLOWERMOTORRELAY4PSOCKET
2
4
BLOWERMOTORRELAY4PSOCKET
ls there continuity?
NO Replacethe under-hoodfuse/relaybox.t
BLOWERMOTORRELAY4PSOCKET
ls therebattery voltage?
YES-Go to step25.
NO Repairopenin thewire betweenthe No.14
fusein the under-dash
fuse/relay
boxandthe
blowermotorrelay.I
21-22
EVAPORA
TORTEMPERATURE
SENSOR
ll#l
t-l
SENSOR
2PCONNECTOR
EVAPORATOR
TEMPERATURE
Wiresideof femaleterminals
lI UT-TU
l , l , l l
---r---T--I
t
11c))-l
ls there continuity?
\9/
T e r m i n asl i d eo f m a l et e r m i n a l s
YES Go to step 5.
NO Repairopen in the wire betweenthe heater
control panel and the evaporatortemperature
sensor.I
5. Disconnectheatercontrol panelconnectorA (14P).
RESISTANCE
k0
50
10
68
20
86'F
30'c
TEMPERATURE
ls the tesistancewithin the specificationsshown
on the graph?
Y E S - G o t o s t e p3 .
NO Replacethe evaporatortemperature
sensor.I
3. Disconnectheatercontrol panelconnectorB {22P).
(cont'd)
21-23
EVAFORATOR
TEMPERATURE
SENSOR
2PCONNECTOR
Wiresideof femaleterminals
ls there continuity?
YES-Check for loosewires or Doorconnectionsat
heatercontrol panel connectorA ('l4P)and B l22Pl
and at the evaporatortemperaturesensor2P
connector.lf the connectionsare good, substitutea
known-goodheatercontrol panel,and recheck.lf
the symptom/indicationgoes away, replacethe
original heatercontrol panel.l
ls there continuity?
YES Repairshort to body ground in the wire
betvveenthe heatercontrol paneland the
evaporatortemperaturesensor.I
NO-Substitute a known-goodheatercontrol panel,
and recheck.lf the symptom/indicationgoes away,
replacethe original heatercontrol panel.I
21-24
RecirculationControlMotor CircuitTroubleshooting
1 . C h e c kt h e N o . 1 4 ( ' 1 0 A ) f u sien t h e u n d e r - d a s h f u s e /
relay box.
A I14P)
HEATER
CONTROL
PANELCONNECTOR
ls there continuity?
YES Repairany shortto body ground in the
wire(s)betweenthe heatercontrol panel and the
recirculationcontrol motor.l
NO-Go to step 9.
9. Turn the ignition switch ON (ll),and checkthe same
wires for voltage.
Wiresideof femaleterminals
A Il4PI
PANELCONNECTOR
HEATER
CONTROL
Wiresideof lemaleterminals
{cont d r
21-25
RECIRCULATION
CONTROL
MOTOR5PCONNECTOR
Wiresideol lemaleterminals
ls there continuity?
YES Checkfor loosewires or poor connectionsat
heatercontrol panel connectorA ( 14P)and at the
recirculationcontrol motor 5P conneclor.lf the
connectionsare good, substitutea known-good
heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel,I
NO Repairany open in the wire{s)betweenthe
heatercontrol panel and the recirculationcontrol
motor.l
21-26
HeaterControlPowerand GroundCircuitsTroubleshooting
1 . C h e c kt h e N o . 1 4( 1 0 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
YES-Go to step 2.
N O - R e p l a c et h e f u s e ,a n d r e c h e c k . l
2. Disconnectheatercontrol panelconnectorA{'14P).
1 2 3
I
8 9
4 5 6
r0t, 1 l 12
.o
2 3
7 8 I 1 0l ,
11 12
14
BLK
5 6
14
BLK/YEL
ls therc continuity?
YES Checkfor loosewires or poor connectionsat
healercontrol panel connectorA (14P).lfthe
connectionsare good, substitutea known-good
heatercontrol panel,and recheck.lf the symptom/
indicationgoes away, replacethe original heater
control panel.l
NO Checkfor an open in the wire betweenthe
heatercontrol paneland body ground. lf the wire is
O K ,c h e c kf o r p o o r g r o u n da t G 5 0 1I.
21-27
4 . C o n n e ctth e N o . l a n d N o . 2 t e r m i n a l s o f t h e
condenserfan relay 4P socketwith a jumper wire.
CONDENSERFAN RELAYitP SOCKET
JUMPERWIRE
YES-Go to step 2.
NO Replacethe fuse(s),and recheck.t
2. Removethe condenserfan relayfrom the
under-hoodfuse/relaybox, and test it
( s e ep a g e2 2 - 5 1 ) .
Does the condenser lan tun?
ls the relay OK?
YES-Go to step 5.
YES Go to step 3.
NO Go to step8.
NO- Replacethe condenserfan relay.l
5. Disconnectthe jumper wire.
3. Measurethe voltage betweenthe No, 2 terminal of
the condenserfan relay 4P socketand body ground.
CONDENSERFAN RELAYilP SOCKET
r-,_-l
1
2 |
Flr
\----1--rl
IELK/YEL
d,
ls thete battery voltage?
YES-Go to step 4.
ls there battery voltage?
NO-Replace the under-hoodfuse/relaybox.l
YES Replacethe under-hoodfuse/relaybox.t
N O - R e p a i r o p e ni n t h e w i r e b e t w e e nt h e N o . 1 4
fuse in the under-dashfuse/relaybox and the
c o n d e n s efra n r e l a y . l
Disconnectthe jumper wire.
21-28
Radiatorand CondenserFans
CommonCircuitTroubleshooting
9 . Disconnectthe condenserfan 2P connector,
1 0 .Checkfor continuitybetweenthe No. 1 terminal of
the condenserfan relay 4P socketand the No. 2
terminal of the condenserfan 2P connector.
CONDENSER
FANRELAY4PSOCKET
CONDENSERFAN 2P CONNECTOR
Wire side of femaleterminals
Is there continuity?
4. Measurethe voltage betweenthe No. 3 terminal of
the condenserfan relay 4P socketand body ground.
-l
r-,
FANRELAY4PSOCKET
CONDENSER
1
2 l
f---r---
l,l,l
lar-vverl
oI
BLK
ls there continuity?
l e c o n d e n s efra n r e l a y .
6 . R e i n s t a tl h
7 . M a k es u r et h e I V Cs w i t c hi s O F F .
8 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
(cont'd)
21-29
HeatingandAir Conditioning
Radiatorand CondenserFans
CommonCircuitTroubleshooting
(cont'dl
CompressorClutchCircuit
Troubleshooting
1. Checkthe No. 1 (20A)fuse in the under-hood
f u s e / r e l a yb o x ,a n dt h e N o . 1 4 { 1 0 A ) f u s ei n t h e
under-dashfuse/relaybox.
Are the tuses OK?
YES Go to step 2.
NO Replacethe fuse(s),and recheck.I
2. Checkthe enginecoolanttemperature,the throttle
positionsensor,and the idle speed (usethe Honda
PGMTesterPGM-Fldata list if possible).
ls the coolant temperaturc above nomal, the
throttle position sensor rcading too high, or the
idle speed too low?
21-30
JUMPERWIRE
3 t 4 5
1 4 1 5 16
22 23 24
26
27
21
29
31
RED
YES Go to step 6.
N O - G o t o s t e p1 4 .
6. Disconnectthe jumper wire.
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
ls there battery voltage?
8. Measurethe voltagebetweenthe No. 3 terminal of
the compressorclutch relay 4P socketand body
ground.
COMPRESSOR
CLUTCHRELAY4PSOCKET
{cont'd)
21-31
COMPRESSORCLUTCH1P CONNECTOR
Terminalside of male terminals
ls therc continuity?
YES-Check the compressorclutchclearance,the
thermal protector,and the compressorclutchfield
c o i l ( s e ep a g e2 1 - 4 8 ) . I
5 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
6. Measurethe voltage betweenthe No, 4 terminal of
heatercontrol panelconnectorA {14P)and body
ground.
HEATER
CONTROL
PANELCONNECTOR
A (I4P}
21-32
HEATER
CONTROLPANELCONNECTOR
A I14P}
A/C PRESSURE
SWITCH2PCONNECTOR
W i r e s i d eo f f e m a l et e r m i n a l s
BLU
2 3
7 8 I
r 0 l x 11
5 6
12 l 3 t 4
JUMPER
WIBE
Wiresideoffemale
terminals
ls there continuity?
BOXCONNECTOR
F{12P}
UNOER.DASH
FUSE/RELAY
2
6 1
B g l r ot l
5
l2
BLU/WHT
JUMPER
WIRE
ls there continuity?
Does the NC system come on?
YES Go to step 10.
NO- Referto the multiplexcontrol system (see
p a g e2 2 - 1 6 8 ) . 1
'1.
N O T EC
: h e c kf o r m u l t i p l e xc o d e si n m o d e F o l l o w
the troubleshooting{or any codesfound. lf no
codesare found, subsititutea known-9ood
m u l t i p l e xc o n t r o lu n i ta n d a E C Mo n e a t a t i m e .
1 0 . Disconnectthe Ay'Cpressureswitch 2P connector
and under-dashfuse/relaybox connectorF { 12P).
Repairthe AilCpressureproblem.I
21-33
HeatingandAir Conditioning
Air Mix ControlMotorTest
1. Disconnectthe 5P connectorfrom the air mix
control motor.
2. Connectbatterypowertothe No. l terminal ofthe
air mix control motor, and ground the No. 2
t e r m i n a l t; h e a i r m i x c o n t r o lm o t o rs h o u l dr u n ,a n d
stop at Max Cool.lf it doesn't,reversethe
connections;theair mix control motor should run,
and stop at Max Hot. lf the air mix control motor
does not run, remove it. then checkthe air mix
control linkageand door for smooth movement.
,.,:l'
t h e nt u r n t h e i g n i t i o ns w i t c hO N { l l ) .
Using the BackprobeSet, measurethe voltage
betweenthe No. 3 and No. 4 terminals.
Max Cool about 1V
Max Hot
about 4 V
lf eitherthe resistanceor voltage readingsare not
as specified,replacethe air mix cotrol motor.
21-34
\'
MODECONTROLMOTOR
21-35
HeatingandAir Conditioning
RecirculationControlMotor Test
RecirculationControlMotor
Replacement
RECIRCULATION
CONTROL
MOTOR
21-36
EvaporatorTemperatureSensor
Replacement
1 . Removethe driver'sdashboardlower cover (see
page 20-59)and the under cover (seepage 20-60).
Removethe under-dashfuse/relaybox (seepage
22-491.
EvaporatorTemperatureSensor
Test
l. Dip the sensorin ice water, and measurethe
resistancebetweenits terminals
EVAPORATOR
TEMPERATURE
SENSOR
t0
32
0
50
10
68
20
86 'F
30'c
TEMPERATURE
21-37
HeatingandAir Gonditioning
PowerTransistorTest
1. Disconnectthe 4P connectorfrom the power
Iranslslor.
2, Measurethe resistancebetweenthe No. 1 and
No. 2 terminalsof the power transistor.lt should be
'1.4
1 . 5k Q .
about
. lf the resistanceiswithln the specifications,
go to
step 3.
. lf the resistanceis notwithin the specifications,
replacethe power transistor.
HeaterControlPaneland Push
Switch AssemblyRemovaland
Installation
1 . Removethe centerpanel (seepage 20-62).
Removethe dials (A),then removethe self-tapping
screwsand the heatercontrol panel (B)from the
centerpanel (Cl. Removethe self-tappingscrews
and the push switch assembly(D)from the center
panel.
POWERTRANSISTOB
C a r e f u l l yr e l e a s et h e l o c kt a b o n t h e N o . 4 t e r m i n a l
(BLUI/EL)(A) in the 4P connector,then removethe
terminaa
l n d i n s u l a t ei t f r o m b o d y g r o u n d .
\
3 . lnstallthe control panel and push switch assembly
in the reverseorder of removal.After installation,
operatethe control panel controlsto see whether it
worKspropeny.
functionto confirm that
4 . Runthe self-diagnosis
there are no problemsin the system (seepage218).
(To112
power
o w e rssource
2V p
o u r c eo
n vvehicle)
ehicle)
on
Reconnectthe 4P connectorto the power transistor.
S u p p l y1 2v o l t st o t h e N o . 4 c a v i t yw i t h a j u m p e r
wire.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
b l o w e rm o t o r r u n s .
. lf the blower motor does not run, replacethe
power rranstsror.
. l f t h e b l o w e rm o t o r r u n s , t h ep o w e r t r a n s i s t o r i s
oK.
21-38
Dustand PollenFilterReplacement
The dust and pollenfilters should be replacedevery
3 0 , 0 0 0m i l e s( 4 8 . 0 0 0
k m ) o r 2 4 m o n t h sw h i c h e v e r
comes first. Replacethe filters more often if the air flow
i s l e s st h a n u s u a l .
1. Openthe glove box. Removeboth glove box stops,
then let the glove box hang down (seepage 20 63).
2 . R e m o v et h e f i l t e rl i d ( A ) f r o mt h e b l o w e ru n i t ,t h e n
p u l l o u t t h e f i r s td u s ta n d p o l l e nf i l t e r( B ) .S l i d et h e
secondfilter to the left,and pull it out.
BlowerUnit Removaland
lnstallation
For some models:SRScomponentsare locatedin this
area.Reviewthe SRScomponentlocations(seepage
23-13)and precautionsand procedures(seepage 23-14)
in the SRSsectionbeforeperforming repairsor service.
1. Make sure you havethe anti-theftcode for the radio,
then write down the frequenciesfor the preset
buttons.
2. Disconnectthe batterynegativecable,and wait 3
minutesbefore beginningworK.
3. Removethe right kick panel (see page 20-50),
passenger'sdashboardlower cover,and the glove
box {seepage 20-63).
4. Cut the plasticcross bracein the glove box opening
with diagonalcuttersin the area shown. Remove
and discardthe plasticcross brace,
Cut heare.
{cont'd)
21-39
6 x 1 . 0m m
I
9.8N.m(1.0kgt.m,
7.2tbt.ftl
6x1.0mm
9.8 N.m (1.0kgf.m,
?.2 tbf.ft)
1 1 .I n s t a l l l h eu n i t i n t h e r e v e r s eo r d e ro f r e m o v a l .
M a k es u r et h a tt h e r ei s n o a i r l e a k a g e .
Reconnectthe negativebatteryterminal.
'13.
D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
procedure
{ s e ep a g e1 1 - 1 3 9 ) .
21-40
21-41
EvaporatorCoreReplacement
1 . Recoverthe refrigerantwith a recovery/recycling/
chargingstation(seepage 21-53).
6x10mm
9.8N.m(1.0kgt.m,7.2lbf.ft)
Removethe blower unit (seepage 21-39).
Removethe self-tappingscrewsand the expansion
valve cover.
21-42
HeaterUnit/CoreReplacement
SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage23'13),and
precautionsand procedures(seepage 23-14)in the SRS
sectionbefore performingrepairsor service.
1. Make sure you have the anti-theftcode forthe radio,
then write down the freouenciesfor the radio's
Dresetbuttons.
W h e nt h e e n g i n ei s c o o l ,d r a i nt h e e n g i n ec o o l a n t
from the radiator(seepage 10-6).
8 x 1.25mm
12 N.m (1.2kgf.m,8.7lbf.ft)
(cont'd)
21-43
1 1 . R e m o v et h e m o u n t i n gb o l t s ,t h e m o u n t i n gn u t s ,
and the heaterunit.
7 t ,
5 x 1 . 0m m
9.8 N.m
11.0kgl m,
7.2 tbf.ftl
21-44
21-45
.'.-:',,
- " l l
......
t
\
t.- l
\'r2t'
'
''' '
::"'
21-46
CompressorReplacement
1 . l f t h e c o m p r e s s oirs m a r g i n a l l yo p e r a b l er,u n t h e
engineat idle speed,and let the air conditioning
work for a few minutes,then shut the engine off.
u1/
(
8 x 1 . 2 5m m
22 N.m12.2kgf.m.
9 . I n s t a l l t h ec o m p r e s s oirn t h e r e v e r s eo r d e ro f
removal,and note these items:
. Beforeinstallingthe new compressor,checkfor
m e t a lo r o t h e rc o n t a m i n a t i o inn t h e l i n e .R e p l a c e
any contaminatedparts.
. lf you're installinga newcompressor,you must
calculatethe amount of refrigerantoil to be
removedfrom it (seepage 21-6).
. Replacethe O-ringswith new ones at each fitting,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to use the correctO-rings
f o r H F C - 1 3 4{aR - 1 3 4 at o
) a v o i dl e a k a g e ,
. U s er e f r i g e r a not i l ( K E l H l NS P - ' 1 0f o
) r HFC-134a
K E I H I Ns p i r a lt y p e c o m p r e s s oor n l y .
. To avoid contaminatlon,do not returnthe oilto
the containeronce dispensed,and never mix it
with other refrigerantoils.
. l m m e d i a t e l ya f t e ru s i n gt h e o i l , r e i n s t a l l t h ec a p
on the container,and seal it to avoid moisture
absorption.
. Do not spill the refrigerantoil on the vehicle;it
may damagethe paint. lf the refrlgerantoil
contactsthe paint,wash it off immediately.
. Chargethe system (seepage 21-55).
. D o t h e e n g i n ec o n t r o lm o d u l e( E C M )i d l e l e a r n
p r o c e d u r e( s e ep a g e1 1 - ' 1 3 9 ) .
. Enterthe antitheft code for the radio,then enter
the customer'sradio station presets.
21-47
HeatingandAir Gonditioning
CompressorClutchCheck
1 . Checkthe armatureplatefor discoloration,peeling,
or other damage.lf there is damage,replacethe
clutch set (seepage 21-49),
Checkthe rotor pulley bearingplay and drag by
rotatingthe rotor pulley by hand.Beplacethe
clutchset with a new one if it is noisy or has
excessiveplay/drag(seepage 21-49).
,\.
Measurethe clearancebetweenthe rotor pulley (A)
and the armatureplate (B)all the way around.lf the
clearanceis not within specifiedlimits, removethe
armatureplate (seepage 21-49)and add or remove
shims as neededto increaseor decreaseclearance.
21-48
t20"c)
Compressor
ClutchOverhaul
Special Tool Required
A,/Cclutch holder,Robinair10204.Kent-MooreJ37872,
or HondaTool and EquipmentKMT-J33939,
c o m m e r c i a l la
yvailable
1 . R e m o v et h e c e n t e rn u t ( A )w h i l e h o l d i n gt h e
armatureplatewith a commerciallyavailableA,/C
c l u t c hh o l d e r( B ) .
1 7 . 6N . m
{1.8kgf.m,
13 tbt.ft)
\ot
-@
/@h"
.ffi
Removethe armatureplate (A) and shim(s)(B),
taking care not to losethe shim(s).lf the clutch
needsadjustment,increaseor decreasethe
number and thicknessof shims as necessary,then
reinstallthearmatureDlate,and recheckits
clearance(see page21-481.
N O T ET
: h e s h i m sa r e a v a i l a b l ei n f o u r t h i c k n e s s e s :
0 . 1 m m , 0 . 2 m m , 0 . 4 m m , a n d 0 . 5m m .
9-=-g
7.4 N.m
(0.75kgf m,
5 tbf.ft)
----------------
"\)
(cont'd)
21-49
HeatingandAir Gonditioning
CompressorClutchOverhaul(cont'd)
5. Reassemblethe clutch in the reverseorder of
disassembly,and note these items:
. I n s t a l l t h ef i e l dc o i lw i t h t h e w i r e s i d ef a c i n g
down, and align the boss on the field coil with the
h o l ei n t h e c o m p r e s s o r .
. Cleanthe rotor pulley and compressorsliding
surfaceswith contactcleaneror other
non-petroleumsolvent.
. I n s t a l l n e w s n a pr i n g s ,n o t et h e i n s t a l l a t i o n
direction,and make surethey are fully seatedin
the groove.
. Make sure that the rotor pulleyturns smoothly
after it's reassembled,
. R o u t ea n d c l a m pt h e w i r e sp r o p e r l yo r t h e y c a n
be damagedby the rotor pulley.
21-50
CompressorThermalProtector
Replacement
1. Removethe bolt, the ground terminal (A),and the
holder (B).Disconnectthe field coil connector(C).
then removethe thermal protector(D).
CompressorReliefValve
Replacement
1 . Recoverthe refrigerantwith a recovery/recycling/
chargingstation(seepage 21-53).
7.4 N.m
(0.75kgf.m,
5 rbf.ftl
9,8 N.m
(1.0kgf m,7.2lbf.ft)
A
3. lnstall in the reverse order of removal.
21-51
6 x '1.0mm
9.8 N.m ('1.0kgf.m,
7.2 tbl.ftl
t-
-"'.
f,
-li
:.--\ ----
.:)-
- -'
5 . l n s t a l l t h ec o n d e n s eirn t h e r e v e r s eo r d e ro f
removal,and note these items.
6x1.0mm
9.8 N.m ('1.0kgf.m,7.2lbf.ft)
,t\
6x1.0mm
9.8 N.m (1.0kgt.m.7.2lbf.ft)
21-52
. l f y o u ' r ei n s t a l l i n ga n e w c o n d e n s e ra,d d
r e f r i g e r a not i l ( K E l H l NS P -1 0 )l s e ep a g e2 1 ' 6 ) .
. Replacethe O-ringswith new ones at eachfitting,
and apply a thin coat of refrigerantoil before
installingthem. Be sure to usethe correctO-rings
t ov o i dl e a k a g e .
f o r H F C - 1 3 4(aR - ' 1 3 4 a ) a
. lmmediatelyafter using the oil, reinstallthecap
on the container,and seal it to avoid moisture
absorption.
. D o n o t s p i l l t h er e f r i g e r a not i l o n t h e v e h i c l e ; i t
may damagethe paint.lf the refrigerantoil
contactsthe paint,wash it off immediately.
. Be carefulnot to damagethe radiatoror the
condenserfins when installingthe condenser.
. Chargethe system (seepage 21-55).
RefrigerantRecovery
1. Connecta R-134arefrigerantrecovery/recycling/
chargingstation{A) to the high-pressureservice
port (B)and the low-pressureserviceport (C),as
shown, following the equipmentmanufacturer's
instructions.
1!l
-'',
r:
'=i
-:
t:
(
-
Additionalhealthand safetyinformationmay be
obtainedfrom the refrigerantand lubricant
manufacturers.
21-53
2. Connecta R-134arefrigerantrecovery/recycling/
chargingstation(A)to the high-pressureservice
pon (B)and the low-pressureserviceport (C),as
shown,following the equipmentmanufacturer's
instructions.Evacuatethe system.
-i -
r4.t
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice.
Additionalhealthand safety informationmay be
obtainedfrom the refrigerantand lubricant
manufacturers.
1. When an Ay'Csystem has been openedto the
atmosphere,such as during installationor repair,it
must be evacuatedusing a R-134arefrigerant
recovery/recycling/charging
station(lf the system
has been open for severaldays,the receiver/dryer
should be replaced,and the system should be
evacuatedfor severalhours.)
21-54
SystemCharging
2 . Evacuatethe system(seepage 21'54).
Air conditioningrefrigerantor lubricantvapor
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor,
dn di s
U s eo n l y s e r v i c ee q u i p m e ntth a t i s U . L . ' l i s t e a
certifiedto meet the requirementsof SAEJ2210to
r e m o v eH F C - 1 3 4{aR - 1 3 4 af r) o m t h e a i r c o n d i t i o n i n g
system.
lf accidentalsystem dischargeoccurs,ventilatethe
work area before resumingservice
Additionalhealthand safetyinformationmay be
obtainedfrom the refrigerantand lubricant
manufacturers.
1. Connecta R-134arefrigerantrecovery/recycling/
c h a r g i n gs t a t i o n( A )t o t h e h i g h - p r e s s u rsee r v i c e
pon (B)and the low-pressureserviceport {C),as
shown, following the equipmentmanufacturer's
instructions.
21-55
HeatingandAir Conditioning
RefrigerantLeakTest
Special Tool Required
Leakdetector,HondaTool and EquipmentYGK-H-10PM
c o m m e r c i a l la
vvailable
1. Connecta R-134arefrigerantrecovery/recycling/
chargingstation(A)to the high-pressureservice
port (B)and the low-pressureserviceport (C),as
shown, following the equipmentmanufacturer's
anstructions.
injury.
Neverusecompressed
airto pressure
test
R - 1 3 4 as e r v i c ee q u i p m e n ot r v e h i c l ea i r
conditioningsystem.
A i r c o n d i t i o n i n gr e f r i g e r a not r l u b r i c a nvt a p o r
can irritateyour eyes,nose,or throat.
Be carefulwhen connectingserviceequipment.
Do not breatherefrigerantor vapor
21-56
A/C SystemTests
Pressure
Test
Test results
(high)
Discharge
pressure
abnormallyhigh
svmotom3
pressure
Afterstoppingcompressor,
to
dropsquickly,andthencontinues
Beduced
or no airflow through
condenser
hot.
Lineto condenser
is excessively
DGaUSe
Air in system
Cloggedcondenser
or radiator
fins
or radiatorfan not
Condenser
Restrictedflow of refrigerantin
discharge
pressure Highand low pressures
arebalanced . Faultycompressor
Discharge
valve
Low
soonafterstoppingcompressor,
. Faultvcomoressor
seal
sideis hioherthannormal.
valve
Faultyexpansion
Outletof expansionvalve is not
gaugeindicates
Moisturein system
frosted,low pressure
(low)
Suction
pressure
low
abnormally
Suctionpressure
high
abnormally
Expansion
valveis not frosted,and
lineis not cold.Low
low-pressure
pressure
gaugeindicates
vacuum,
is low,andthe Frozenevaporator
Discharge
temperature
air flow from vents is restricted.
Exoansion
valveis frosted.
Receivetdryer
outletis cool,and inlet Cloggedreceiver/dryer
is warm (shouldbe warm during
ooeralton),
Low pressure
hoseandcheckjointare E x p a n s i o nv a l v e o p e n t o o l o n g
around
coolerthanthetemperature
evaoorator,
in system
refrigerant
Excessive
is loweredwhen
Suctionpressure
..nrlenser
is cooled bv water.
areequalized
Highand low pressure
is stopped,
assoonasthecompressor
while
andbothgaugesfluctuate
Suctionand
dascharge
pressures
abnormallv
hioh
Suctionand
pressure
discharge
abnormally
low
leaks
Fefrigerant
' Frozenexpansion
valve
(Moisturein system)
. Faultyexpansion
valve
Faultygasket
valve
Faultyhigh pressure
Foreignpaniclestuckin high
or radiator
Reduced
airflow throughcondenser. . Cloggedcondenser
fins
' Condenser
or radiatorfan not
workinoorooerlv
Cloggedor kinkedlow-pressure
hoseand metalend
Low-pressure
hoseoarts
areasarecoolerthanevaoorator,
valve C l o g g e d h i g h - p r e s s u r el i n e
Temperature
aroundexpansion
is too low comparedwith thataround
:omoressor
clulchis dirtv.
lomoressorbolt(s)aredirtv.
; o m D r e s s o ro a s k e t i s w e t w i t h o i l .
:omoressor
shaftsealleakinq
no aroundbolt(s)
iet
no
Recover,evacuate(seepage21-54),
and rechargewith specifiedamount
{seeoaoe21 55).
Clean
Checkfan voltageand rpm.
Checkfan direction.
restricted
lines.
Replace
the compressor.
Beplace
. Replace
valve.
the expansion
. Recover,evacuatefor at least
30 minutes,and rechargewith
sDecified
amount.
Recover,evacuatefor at least
with
30 minutes,and recharge
amount.
specified
valve.
the expansion
Beplace
Runthe fan with compressoroff, then
checkevaooratottemoeraturesensor.
eanor reolace,
Replacereceaver/dryer.
Bepairor replace.
Recover,evacuate,and rechargewith
qnp.ifie.lamo'rnr
Replace
the compressor.
Clean
Checkvoltageand fan rpm.
Checkfan direction.
Repairor replace.
Repairor replace,
Reolace
the comDressor,
Tiohtenbolt{s)ot reolacecomDressor,
acethe comoressor.
(cont'd)
21-57
21-58
Test conditions:
.
.
.
.
7. To completethe charts:
.
.
.
.
.
.
.
.
M a r k t h ed e l i v e r y t e m p e r a t u a
r el o n gt h e v e r t i c a l i n e .
Mark the intaketemperature(ambientair temperature)along the bottom line.
Draw a line straightup from the air temperatureto the humidity.
M a r ka p o i n t 1 0% a b o v ea n d 1 0% b e l o w t h eh u m i d i t yl e v e l .
From each point. drawa horizontalline acrossthe deliverytemperature.
The delivervtemperatureshould fall betweenthetwo lines
Completethe low-sidepressuretest and high-sidepressuretest in the same way.
Anv measurementsoutsidethe line may indicatethe needfor further inspection.
kPa
(ksl{cm')
Lpsrl
2500[25) _
360l
{kgflcm')
Lpsil
600
{6t
80 yo
a0 0/"
tssl
2000
(201
1280
HUMIDITY
LEVEL
30 9o
fcl
1500{1s}
,21o)
30%
80%
1000(101
:1401
500 {5)
171l
DELIVERY
PRESSURE
100
{11
h4l
INTAKE
PRESSURE
OELIVERY
TEMPERATURE
68
t20l
I
I
86
77
t30)
t25l
INTAKETEMPEBATURE
95
(35)
104
{40)
.F
{'cl
21-59
BodyElectrical
Body Electrical
SpecialTools
GeneralTroubleshooting
tntorrnaiion.'......
22,3
RelayandControlUnit Locations.....22-7
Connectors
and Harnesses
22-13
Fuse/Relay
Boxes...............................
22-44
PowerDistribution.............................
22-46
GroundDistribution...........................
22-4A
Under-dash
Fuse/Relay
Box ..............
22-49
Battery ..............
Relays................
*lgnitionSwitch ..............
22-50
22-51
22-53
*Gauges
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-54
.......
S e l f - d i a g n o sPt irco c e d u r .e. . . . . . . . . . . . . . . . . 22-56
........
CircuitDiagram
22-54
G a u g eB u l bR e p l a c e m e n. .t . . . . . . . . . . . . . . . .22
. . . .63
....
GaugeAssemblyReplacement
22-64
CoolantTemperature
......
G a u g eT r o u b l e s h o o t i n.g. . . . . . . . . . . . . . . . 22-64
VehicleSpeedSignalCircuit
Troubleshooting
22-65
VSSReplacement
22 61
ExteriorLights
C o m p o n e nLto c a t i oInn d e x . . . . . . . . . . . . . . . . 22-68
.......
C i r c u iD
t iagram
22--71
DaytimeRunningLightsControi
U n i tI n p u tT e s t( C a n a d a .). . . . . . . . . . . . . . . .22-7
. . . . .6. .
H e a d l i g hAtd , u s t m e n .t . . . . . . . . . . . . . . . . . . 22-74
H e a d l i g hRr e p l a c e m e n. .t. . . . . . . . . . . . . . . . . . .22-79
.........
CombinationLightSwitch
Test/Replacement
22-AO
B u l bR e p l a c e m e n t
22-41
T a i l l i g hRt e p l a c e m e n. .t . . . . . . . . . . . . . . . . . . . .22-82
....
HighMountBrakeLightReplacement......22-42
LicensePlateLightReplacement..............
22-43
S i d eM a r k e L
r i g h tR e p l a c e m e n. .t. . . . . . . . . .22-43
....
BrakePedalPositionSwitchTest ..............
22-44
SideTurn SignalLightReplacement........22-84
Turn Signal/Hazard
Flasher System
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 22-85
.......
C i r c u iD
t iagram
22 A6
Turn Signal/Hazard
RelaylnputTest ........22-87
HazardWarningSwitchTest
22-88
InteriorLights
ComponentLocationIndex .......................
22-94
CircuitDiagram
.........22-95
CeilingLighVSpotlights
T e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. -. .9.6. . . . .
RearCeilingLightTesVReplacem
ent ........22-96
CargoAreaLightTest/Replacem
ent .........22-97
HatchLatchSwitchTest ..,..,.......................
22-97
*Audio System
ComponentLocationIndex .......................
22-98
CircuitDiagram
.........22,99
AudioUnit Removal/lnstallation
...............
22-1OO
Audio Unit ConnectorReplacement.........22-101
SpeakerReplacement................................
22-102
RoofAntennaRep1acement
....................-..
22-103
Rear Window Defogger
ComponentLocationIndex ...........
22-104
C i r c u iD
t i a s r a m. . . . . . . . . . . . . . . . . . . . . : : : : : . : :22-105
.::.
FunctionTest
D e f o g g eW
r i r eR e p a i r. . . . . . . . . . . . . . . . . . . . . . .22-106
..........
N o i s eC o n d e n s eCra p a c i t y T e s. t. . . . . . . . . . .22-107
....
Moonroof
C o m p o n e nLto c a t i o Inn d e x . . . . . . . . . . . . . . . . 2. .2. .-.1. .O B
CircuitDiagram
.........22-109
MoonroofControlUnitInputTest .............
22-'l10
S w i t c hT e s V R e p l a c e m e. n
. .t. . . . . , . . . . . , . . .2. .2. .- .11. .2.
MotorTest
.................
22-112
LimitSwilchTest
......22-'l'13
Auto-stopSwitchTest ................................
22-113
PowerMirrors
ComponentLocationIndex .......................
22-114
CircuitDiagram
.........22-115
FunctionTest
.............
22-116
P o w e rM i r r o rS w i t c hT e s t . . . . . . . . . . . . . . . . . . 2. .2. .-.l .l .7.
PowerMirrorActuatorTest .......................
22-117
PowerMirrorActuatorReplacement........22-11A
* Horns
ComponentLocationIndex .......................
22-120
CircuitDiagram
.........22-121
H o r nT e s V R e p l a c e m e. n
. .t. . . . . . . . . . . . . . . . .2. .2. -. .1. 2. -2.
HornSwitchTest
.,....22-122
PowerWindows
22 124
ComponentLocationIndex ..........
::::.:
c i r c u i tD i a g r a m. . . . . . . . . . . . . . . . . . . . . . : . : : : : .22-125
M a s t eS
r w i t c hI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-126
........
22-128
MasterSwitchTest
......
D r i v e r 'W
s i n d o wM o t o rT e s t . . . . . . . . . . . . . . .22-129
Passenger's
WindowSwitchlnputTest ... 22- t30
Passenger's
WindowSwitchTest .............
22-132
22 132
Passenger's
WindowMotorTest ..............
22-133
lMaster
SwitchReplacement......................
Passenger's
WindowSwitch
22-133
Replacement
Wipers/Washers
22-134
ComponentLocationIndex .......................
C i r c u iD
t iagram
RearWindowWiperIntermiftent
........
C o n t r oU
l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . .22-138
Wiper/Washer
Switch
22-140
TesVReplacement
..
C o n t r oU
l n i tI n p u tT e s t . . . . . . . . . . . . . . . . . . . . . .2.2. .-.1. .4. 1
22-143
WiperMotorTest
22-144
WasherMotorTest
WasherFluidLevelSwitchTesV
.......
R e p l a c e m e(nCt a n a d a.l . . . . . . . . . . . . . . . . . .22-144
WindshieldWiperMotor Replacement.... 22-145
RearWindowWiperMotor
Replacement
22-146
....
W a s h eR
r e s e r v oR
i r e p l a c e m e n. .t. . . . . . . . . .22-146
. . . 147
...
W a s h eTr u b e sB e p l a c e m e n. .t. . . . . . . . . . . . . .22
Accessory Power Socket
.........22-149
CircuitDiagram
AccessoryPowerSocket
. .t. . . . . . . . . . . . . . . . . . . . .2. .2. .- .14. .9. . . .
T e s V R e p l a c e m e. n
Keyless/Power Door Lock System
22-150
ComponentLocationIndex .......................
.........22-151
CircuitDiagram
22-153
KeylessReceiver
Unit InputTest ...............
22-155
ControlUnit InputTest ...............................
D o o rL o c k A c t u a t o r T e s. .t. . . . . . . , . . . . . . . , . .2, 2. ,-.1. .5. .8
. .5. .9
H a t c hL o c k A c t u a t o r T e s. .t. . . . . . . . . . . . . . . . .2. .2. -. 1
22-160
DoorLockKnobSwitchTest ......................
22-160
DoorLockSwitchTest ................................
.......22-161
TransmitterTest
T r a n s m i t t ePrr o g r a m m i n .g. . . . . . . . . . . . . . . . .2. 2. .-.1. .6. 1
lmmobilizerSystem
22-162
componentLocationIndex ...........
...
S y s t e mD e s c r i p t i o .n. . . . . . . . . . . . . . . :. . . : . . : . :22-163
22-164
CircuitDiagram
Troubleshooting
lmmobilizerControlUnit
- R e c e i v eRre p l a c e m e n. .t. . . . . . . . . . . . . . . . .22-167
........
Multiplex ControlSystem
22,164
ComponentLocationIndex ...........
:.:..:.::.:
c i r c u i tD i a g r a m. . . . .... . . . . . . . . . . . . . . . . . . . . . . :22-169
22-17'l
SvstemDescriDtion
22,112
Troubleshooting
M u l t i o l eC
x o n t r oUl n i tI n D uTt e s t . . . . . . . . . . .2.2. - 1 7 5
BodyElectrical
SpecialTools
Ref. No.
Q)
o)
o
Tool Number
07wAz-001010A
O7LAJ-PT3O2OA
07TAz-001020A
Description
MPCSServiceConnector
Test Harness
BackProbeAdaotet
1
1
1
22-2
Otv
GeneralTroubleshootingInformation
Tipsand Precautions
Before Troubleshooting
1. Checkapplicablefuses in the appropriatefuse/relay
oox.
(cont'd)
22-3
BodyElectrical
GeneralTroubleshootingInformation(cont'd)
Checkfor looseretainer(A)andrubberseals(B).
S l i p p l i e r s( A ) u n d e rt h e c l i p b a s ea n dt h r o u g ht h e
hole at an angle,then squeezethe expansiontabs to
r e l e a s et h e c l i p .
| . , ./ f
.ll
----E;
'l/ F.
I
22-4
t/
lwtl"//
\--------\
tflr'---'..-
It
Testingand Repairs
. Do not usewires or harnesseswith brokeninsulation.
Replacethem or repairthem by wrappingthe break
withelectricaltape.
. After installingparts,make surethat no wires are
o i n c h e du n d e rt h e m .
. When using electricaltestequipment,followthe
manufacturer'sinstructionsand those describedin
t h i sm a n u a l .
. l f p o s s i b l ei ,n s e r t t h ep r o b eo f t h e t e s t e r f r o m t h ew i r e
side (exceptwaterproofconnector).
UsebackDrobeadaotor07TM-0010204.
( c o n td )
22-5
BodyElectrical
GeneralTroubleshootingInformation(cont'dl
Five-stepTroubleshooting
'1.
2. AnalyzeThe Schematic
Look up the schematicfor the problem circuit.
Determinehow the circuit is supposedto work by
tracingthe currentpathsfrom the power feed
through the circuitcomponentsto ground. lf
severalcircuitsfail at the same time, the fuse or
g r o u n di s a I i k e l yc a u s e .
Basedon the symptoms and your understandingof
the circuitoperation,identifyone or more possible
causesof the problem.
3. lsolateThe ProblemBy TestingThe Circuit
Make circuitteststo checkthe diagnosisyou made
i n s t e p2 . K e e pi n m i n d t h a t a l o g i c a ls, i m p l e
procedureis the key to efficienttroubleshooting.
Testfor the most likelycauseof failure first, Try to
make tests at pointsthat are easilyaccessible.
4. Fix The Problem
Oncethe specificproblem is identified.make the
repair.Be sure to use propertools and safe
proceoures.
5. Make Sure The CircuitWorks
Turn on all componentsin the repairedcircuit in all
modes to make sure you've fixed the entire
problem.lf the problemwas a blown fuse, be sure
to test all of the circuitson the fuse. Make sure no
n e w p r o b l e m st u r n u p a n d t h e o r i g i n a p
l roblem
does not recur.
22-6
w H T . . . . . . . . . . . . . . . . . . . . , . , . White
............
Y E L . . . . . . . . . . . . . . . . . . . . . . , , .Y. .e.l.l .o. w
,......
B 1 K . . . . . . . . . . . . . . . . . . . . . . . . . . .B
. .l.a. .c. k. . . . .
B L U. . . . , . . . . . . . . . . . . . . . . . . . . . . .B. .l.u. .e. . . .
G R N . . . . . . . . . . . . . . . . . . . . . . . .G
. .r.e. .e.n. . . . . . .
R E D. . . . . . . . . . . . . . . . . . . . . . . . . . . .Red
........,
o R N . . . . . . . . . . . . . . . . . . . . . . . . Orange
.............
P N K . . . . . . . . . . . . . . . . . . . . . . . .P
. .i,n. k. . . . . . . . .
B R N . . . . . . . . . . . . . . . . . . . . . . . .Brown
.............
G R Y . . . . . . . . . . . . . . . . . . . . . . . .Gray
............,
P U R . . . . . . . . . . . . . . . . . . . . . . . .P
. .u. .r .p.l.e. . . . . .
1 T 8 1 U . . . . . . . . . . . . . . . . . . . . . Light
. . . . . ,Blue
.....
1TGRN....................L
. .i.g. h
. .G
t. ,r.e. .e n
The wire insulationhas one color or one color with
anothercolor stripe.The secondcolor is the stripe.
BLOWERMOTORRELAY
RADIATORFAN
RELAY
HORNRELAY
CONDENSERFAN
RELAY
ELDUNIT
UNDER-HOOD
FUSE/RELAY
BOX
\...
,-:1-'...
22-7
'
':
'-.:-
..? ;,
POWERWINOOW RELAY
TURN SIGNAL/HAZARDRELAY
TAILLIGHTRELAY
.[:_- -
-l:r
UNDER.DASH
FUSE/RELAY
BOX
--
MULTIPLEXCONTROLUNIT
22-8
(cont'd)
22-9
Dashboard(cont'd)
L
\
SRSUNIT
EPSCONTROLUNIT
AIR/FUEL
RATIOSENSOR
RELAY
[WirecolorsrWHT,WHT/RED, I
OBNandBLK/ORN
I
22-10
PGM.FIMAINRELAY1
lWirecolors:YEUBLK,
WHT/BLKand RED/YEL
LWHT/BLK,
PGM.FIMAN RELAY2
fwirecolors:YEUBLK,
I
YEUBLKand GRN/YELI
LYEUGRN,
Rearand Roof
OPENRELAY MOONROOF
Wirecolors:GRNI/EL,
GRN, I
BLKandYEL/GRNI
LRED/YEL,
MOONROOF
CLOSERELAY
GRN, l
fwire colors:GRN/BLK,
BLKand YEL/GRNI
IGRN,AtVHT,
REARWINDOWWIPERINTERMITTENT
CONTBOL
UNIT
22-11
l\:
].\
POWERWINDOWMASTERSWITCH
lHasbuilt-incontrolunit)
Passenger's
Seat:
22-12
Gonnectors
and Harnesses
GonnectorIndex
"G" for ground
ldentification
numbershavebeenassigned
to in-lineconnectors.
The numberis preceded
by the letter"C" for connectors,
terminalsor "T" for non groundterminals.
Hamess
Location
EngineCompartment
Dashboard
Others{Floor,Door,
Trunk.and Roo{l
Nots
Startersubharness
C 1 0 2a n dC 1 0 3
T1 andT2
T 1 0 1a n dT 1 0 2
(seepage22-15)
Batterygroundcable
T3
G'l and ( T4
{seepage22-l!)
Enginegroundcable
{seepage22-14)
Enginewire harness
C l 0 l t h r o u g hC 1 0 4
G1 0 1
Enginecompartment
wire harness G201andG202
{riohtbranchi
Enginecompartment
wire harness G301
(leftbrench)
Enginecompartment
wire harness
(dashboard)
(seepage22 16)
(seepage22 18)
(seepage22 18)
(seepage22-18)
c401
C451and C452
C501throughC503
c551
c851
G402
EPSsubharness
C 1 5 1a n d C 1 5 2
G'151
\seepage22 241
Dashboard
wire harness
A
lleftbranch)
C504throughC510
G501andG503
(seepage22-26)
L e f ts i d et u r n s i g n a l l i g h t
c506
(seepage22-26)
Dashboard
wire harness
A
(rightbranch)
C50lthroughC503
C 5 l l t h r o u g hC 5 1 5
C852andC853
G502
(seepage22-26)
lseepage22-26)
Dashboard
wire harnessB
ECMwire harness
(seepage22-30)
C40lthrough
C403
c510
G40l
c101
cl52
C451
through
C453
c511
{seepage22-32}
G451
Floorwireharness(frontside)
C402
andC403
c453
C508
andC509
c512
G551
Floorwire harness(rearside)
C553and C554
(seepage22-34)
Roo{wire harness
Hatchwire harness
Driver'sdoorwire harness
c507
C553andC554
C504andC505
5 1 4a n dC 5 1 5
)552
(seepaqe22-38)
( s 6 ep a q e 2 2 ' 3 9 )
(see paqe 22-40)
( s e eo a o e 2 2 - 4 1
( s e ep a q e 2 2 . 4 3 i
C 5 5 1a n . l C 5 5 ?
P a s s e n q e r ' sd o o r w i . e h a r n e s s
T eh a r n e s s
/C wire harness
(seeoaqe22-42i
22-13
and Harnesses
Connectors
Gonnectorto Harnesslndex
BatteryGroundCable
Connectoror Terminal
Cavities
T3
2
Location
Left side of enqinecompartment
Left side of enginecompartment
Batterv
Connectsto
Notes
Bodygroundviabattery
qroundcar)le
B a t t e r vn e o a t i v et e r m i n a l
EngineGround Cable
r4
Connectoror Terminal
Cavities
5
4
focation
Riohtsideof enoine
Rightsideof enginecompartment
Connec{sto
Bodygroundviaengine
ENGINEGROUNDCABLE
BATTERYGROUNDCABLE
\.....
22-14
Notes
StarterSubharness
Connectoror Terminal
Alternator
Knocksensor
Startersolenoid
c102
Ret
10
8
5
7
Cavities
4
1
1
6
c103
T1
T101
4
1
I
r2
r102
Location
Connoc,ts
to
R i g h t s i d e o f e n g ; n ec o m p a r t m e n t
Front of engine
Middle of enginecompartment
Front of enginecompartment
F r o n t o f e n g a n ec o m p a r t m e n t
Notes
Enginewire harness(see
page22 16)
Enginewire harness(see
o a a e2 2 - 1 6 )
Underhoodfuse/relay
box
Stanermotor
Battervpositiveterminal
STARTERSUB HARNESS
22-15
Connectorsand Harnesses
Connectorto HarnessIndex(cont'dl
EngineWireHarness
position(CMP)sensor
Camshaft
Lllr sensor
EC[,4connectorA
ECI/lconnectorB
(ECT)
Enginecoolanttemperature
sensor
Engineoil pressure
switch
EVAPcanisterpurgevalve
ldleair control(lAC)valve
lgnitioncoilNo. l
lgnitioncoil No.2
lgnitioncoilNo.3
lgnitioncoilNo.4
IniectorNo. 1
InlectorNo.2
IniectorNo.3
IniectorNo.4
Intakeairtemperature
{lAT)sensor
2
3
3
24
2
28
18
4
5
6
7
25
24
20
19
12
TDCsensor
Throttleposition(TP)sensor
Vehiclespeedsensor(VSSI
VTCoil controlsolenoidvalve
VTECoil pressureswitch
VTECsolenoidvalve
c 101
8
11
10
27
29
30
3
c102
22
1
2
3
3
3
3
3
2
2
2
2
2
3
3
3
2
2
2
20
Transmission
housing
Leftsideof engine
Rightsideofengine
Underglovebox
Underglovebox
Leftside of engine
BightsideoI engine
Leftside of intakemanifold
Left sideof intakemanifold
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompartment
Middleof enginecompanment
Leftsideof intakemanifold
Leftsideof engine
Left side of intakemanifold
housing
Transmission
Rightsideo{ engine
Rightsideof engine
Rightsideof engine
Underrightsideof dash
Frontof enginecompanment
Frontof enginecompartment
22-16
ECMwire harness{seepage
22-321
(seepage
Startersubharness
22-15)
(seepage
Startersubharness
22 151
....-
10
11
13
14
22-17
Connectorsand Harnesses
Connectorto HarnessIndex{cont'dl
EngineCompartmentWire Harness(Rightbranch)
Connsctoror Terminal
ABSmodulator-control
unit
Bearwasher
motor
RightfrontABSwheelsensor
Rightfrontairbagsnsor
Bightfrontparkinglight
Rightfrontsidemarkerlight
Rightfrontturn signallight
Rightheadlight
Righthorn
washrfluidlevelswitch
Windshield
washermotor
G201
G202
Cavitiss
8
12
1
10
11
2
7
6
2
2
2
2
2
2
I
2
2
Location
Bightsideo{ enginecompartment
Behindrightsideof {rontbumper
Rightsideot enginecompartment
Behindrightsideof frontbumper
Behindrightheadlight
Behindrightsideof Jrontbumper
Behindrightheadlight
Behindrightheadlight
Behindfrontbumper
Behindrightsideof trontbumper
Behindriohtsideof frontbumoer
Behindrightsideof trontbumper
Behindrightsideof Jrontbumper
Connectsto
Notes
Canada
Bodygroundviangine
compartment
wtreharness
Bodygroundviaengine
.omnerhent
wire harness
22-18
ENGINECOMPARTMENT
WIRE
HARNESS
(cont'd)
22-19
Connectors
and Harnesses
Connectorto HarnessIndex (cont'dl
EngineCompartmentWire Harness(Left branch)
AirJuel(A,,/F)
ratiosensor
Brakefluidlevelswitch
Condenser
fan motor
Cruisecontrolactuator
ELDunit
Foglightconnector
LeftfrontABSwheelsensor
Leftfrontairbagsensor
Leftfrontparkinglight
Leftfrontsidemarkerlight
Leftlrontturnsignallight
Leftheadlight
Lefthorn
Radiatorfan motor
Radiator
fan switch
Secondary
heatedoxygen(SHO2S)
Testtachometer
connector
Windshield
wipermotor
Under'hood
fuse/relay
box
connector
A {seepage22-44)
Under-hood
f use/relay
box
connectorB (seepage22-44)
Underhoodfuse/relay
box
connector
C (seepage22-44)
Underhoodfuse/relay
box
D (seepage22 44)
connector
fuse/relay
Under-hood
box
24
22
2
25
1
9
2
2
4
3
,l
Frontof enginecompanment
Leftsideof enginecompartment
Leftsideof enginecompartment
Leftsideo{ enginecompartment
Frontof enginecompartment
Underrightsideof cowlcover
Under'hood
f use/relay
box
Leftsideof enginecompartment
Leftsideof enginecompanment
Behindleftsideof frontbumper
Behindleftheadlight
Behindleftsideof frontbumper
Eehindleftheadlight
Behindleftheadlight
Behindfrontbumper
Leftsideof enginecompartment
Frontof enginecompartment
Leftsideof enginecompartment
11
7
2
5
2
Leftsideof enginecompanment
L.Jnder
leftsideof cowlcover
L.Jnder
hoodfuse/relay
box
L.Jnder
hoodfuse/relay
box
10
12
L.Jnder'hood
f use/relay
box
12
17
13
20
21
23
2
2
2
2
2
3
l
2
2
underhoodfuse/relay
box
fuse/relay
Under-hood
box
22-20
l'
\-
ENGINECOMPARTMENTWIRE
HARNESS
(conr'd)
22-21
and Harnesses
Connectors
Connectorto HarnessIndex (cont'd)
EngineCompartmentWire Harness(Dashboard)lcont'dl
Connectoror Terminal
Cavities
Location
Undermaddle
of dash
1
Underleftsideof dash
12
Foglightconnector
Under'dash
fuse/relay
box
connector
F (seepage22-45)
Underdash
fuse/relay
box
G (seepage22-45)
connector
Underdash
fuse/relay
box
connector
H (seepage22'45)
fuse/relay
Under-dash
box
connector
| (seepage22'45)
Under-dash
fuse/relay
box
connector
J (seepage22-45)
c151
c401
Underrightsideot dash
c451
Underrightsideot dash
c452
UnderrightsideoJdash
c501
10
'10
UnderrightsideoI dash
c502
Underrightsideol dash
c502
UnderrightsideoJdash
UnderrightsideoJdash
10
Undermiddleof dash
Underrightsideof dash
10
Underleftsideof dash
Underleftsideof dash
Underleftsideof dash
Underleftsideol dash
12
Underrightsideof dash
c503
c851
'14
G402
1' I
Connectsto
EPSsubharness
{seepage2224)
wire harnessB
Dashboard
(seepage22-30)
ECMwire harness(seepage
22-321
ECMwire harness(seopage
22 32)
Dashboard
wire harnessA
(seepage22-26)
Dashboard
wire harnessA
USA
lsee page 22-261
Dashboard
wire harnessA
Canada
(seepage22-26)
Dashboard
wire harnessA
(seepage22-26)
Floorwireharness(seepage
22-34l'
,VCwire harnesslsee page
22-43\
Eodygroundviaengine
..mdarlma.t
22-22
Notes
Oplion
w,rc harncss
BOX
FUSE/RELAY
UNDER-DASH
WIRE
ENGINECOMPARTMENT
D
'
' 1_-1.:,
-.,.i
ifa.: ,, ..j
,
. -,,
-g'-.t
';.-a
22-23
Connectorsand Harnesses
Connectorto Harnesslndex (cont'dl
EPSSubharness
Connectoror Terminal
EPScontrolunitconnectorA
EPScontrolunitconnectorB
EPScontrolunitconnector
C
EPSmotor
EPStorquesensor
c151
2
,l
3
1
6
c152
G151
22-24
Cavities
2
2
20
2
6
2
I
Location
Underrightsideofdash
Underrightsideof dash
Underrighrsideof dash
Middleof enginecompanment
Middleof enginecompartment
Underrightsideof dash
Underrightsideof dash
Connectsto
Enginecompartment
wire
harness(seepage22-18)
ECI\,4
wire harness(seepage
22-321
aodygroundvia EPS
Notes
EPSSUB HARNESS
22-25
Connectorsand Harnesses
Connectorto HarnessIndex (cont'd)
DashboardWire HarnessA {Leftbranchl
Connectoror Terminal
Accessorypower socket
Audioantenna
Brakepedalpositionswitch
Clutchinterlockswitch
Clutchpedalpoistionswitch
Cruisecontrolunit
Cruisemainswitch
Daytimer!nning lightscontrolunit
Daytimerunninglightsrelay
Gaugeassembly
connector
A
GaugeassemblyconnectorB
Hazardwarningswitch
Heatercontrol panelconnectorA
Heatercontrol panelconnectorB
HVACpush switch assembly
Keyless
receiverunit
Low beamcut relay
Optionalsecurityconnector
Powermirrorswitch
Under-dash
fuse/relay
box
connector
K (seepage22-45)
Under'dashfuse/relaybox
L {seepage22-45}
Underdashfuse/relay
box
connectorM lsee page22'45)
Under-dash
fuse/relay
box
connectorN (seepage22-45)
UndeFdash
fuse/relay
box
connector
O (seepage22-45)
UndeFdash
fuse/relay
box
connectorY(seepage22 45)
c504
22
2
26
30
29
6
28
I
8
20
11
18
19
10
5
3
27
,I4
2
2
4
2
2
14
5
14
4
22
22
10
22
'14
10
5
5
16
13
17
Undermiddleof dash
Underleftsideof dash
] Underleftsideof dash
] Underleftsrdeof dash
| Underleftsideof dash
I Underleftsideof dash
Underleftsideof dash
Underlettsideof dash
Underlettsideof dash
I Behindgaugeassembly
i Behindgaugeassembly
Behindhazardwarnningswitch
Behindheatercontrolpanel
Behindheatercontrolpanel
] BehindHVACswitchassembly
I Undermiddleof dash
lUnderleftsideofdash
Underlefrsideof dash
UnderleftsideoI dash
ln the under-dash
fuse/relay
box
l0
In the under-dash
fuse/relay
box
12
ffi
Canada
Canada
In the undeFdash
fuse/relay
box
In the underdashfuse/relay
box
12
11
Inthe under-dash
fuse/relay
box
In the under-dash
fuse/relay
box
Underleftsideof dash
c505
Underleftsideot dash
c506
34
Underleftsideof dash
c507
Underleftsideof dash
c508
Undermiddleof dash
c509
24
c510
25
G501
Undergaugeassembly
G503
21
Underleftsideof dash
Undermiddleof dash
12
Undermiddleol dash
Driver'sdoorwire harness
(seepage22'40)
Driver'sdoorwire harness
(seepage22-40)
Leftsideturo signallight
suonarness
Roofwire harness(seepage
22 3Al
Floorwire harness{seepage
22-341
Floorwire harness(seepage
22 34J
Dashboard
wire harnessB
(seeoaoe22-30)
Body ground via dashboard
Body ground via dashboard
22-26
35
34
Cavities
Location
2
B e h i n d l e f t s i d e t u r n s i g n a ll i g h t
2
Under left side of dash
Connectsto
Dashboard
wire harnessA
Noles
WIRE
DASHBOARD
A
HARNESS
,./
-19
20
34
LEFTSIDETURN SIGNAL LIGHT
SUB HARNESS
2s
). \'u
)t
30
(cont'd)
22-27
Connectorsand Harnesses
Connectorto HarnessIndex (cont'd)
DashboardWire HarnessA (Rightbranch)
Connecloror Terminal
Cavities
Location
20
Eehindaudiounit
10
Underrightsideof dash
Audiounitconnector
c501
c502
Underrightsideof dash
c502
Underrightsideof dash
c503
tJnderrightsideof dash
c5' 11
c512
c514
ca52
c853
Undermiddleof dash
12
Undermiddleof dash
Underrightsideof dash
Underrightsideof dash
10
Underrightsideof dash
21
Undermiddleofdash
'l
G502
Undermiddleof dash
Underrightsideof dash
Connectsto
Enginecompartment
wire
harness(seepage22,18)
Enginecompanmentwire
harness(seepage22-18)
Enginecompartment
wire
harness(seepage22-18)
Enginecompartment
wire
harness(seepage22-18)
ECN4
wire harness(seepage
22-321
Floorwire harness{seepage
22-341
Rightsideturn signallight
suonarness
Passenger's
doorwire
harness(seepage22 4l)
Passenger's
doorwire
harness(seepage22 4'l)
A,/Cwire harness(seepage
22-43)
ly'Cwire harness(seepage
22-431
Eodygroundvia dashboard
Notes
USA
Canada
22-28
1
8
Cavities
Location
2
Eehindrightsideturn signallight
2
Underriohtsideof dash
Connectsto
Dashboard
wire harnessA
Nots
WIBE
DASHBOARO
HARNESS
A
'---/...'
22-29
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
DashboardWire HarnessB
Collqctor or Terminal
C a b l e reel
2
1
17
16
't9
Cavities
Locatiol|
In steeringcolumncover
5
In steeringcolumncover
In steeringcolumncover
4
In steeringcolumncover
1
In steeringcolumncover
1
In steeringcolumncover
4
Undermiddleof dash
18
Undermiddleofdash
14
In steeringcolumncover
5
Underleft sideof dash
Combination
lightswitch
Driver'sairbaginflator
lgnitionkey switch
lgnitionswitch
lmmobilizer
controlunit receiver
Passenger's
airbaginflator
SRSunitconnector
A
Wiper/washerswitch
Underdashfuse/relay
box
connectorAlseepage22,45)
Under dashluse/relaybox
connectorB (seepage22-45)
Under'dash
fuse/relay
box
connectorC (seepage22-45)
Under-dash
fuse/relay
box
connector
S lseepage22-45)
Under'dash
fuse/relay
box
connectorX(seepage22 45)
c401
10
c402
12
10
Undermiddleof dash
c403
11
Undermiddleof dash
G510
14
12
Undermiddlesideof dash
G40l
22-30
18
I
3
5
6
Underleftsideofdash
14
Underleftsideof dash
Underlettsideof dash
Undergaugeassembly
Connectsto
Enginecompartment
wire
harness(seepage22-'18)
Floorwire harness(seepage
22-34J
Floorwire harness(seepage
22-341
Dashboard
wire harnessA
(seeoaoe22-26)
Bodygroundviadashboard
Notes
WIRE
OASHBOARD
HARNESS
B
22-31
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
ECMWire Harness
Connectoror TerminiF
Arrruert/vrl ralo sensorretay
Datalinkconnector
EC[/lconnectorE
PGM-Flmainrelay1
PGM-Flmainrelay2
Under-dash
fuse/relay
box
connector
D (seepage22 45)
Underdashfuse/relay
box
connectorE lsee page22-45)
under-dashfuse/relaybox
connectorR lsee page22-45)
c10'1
I Re- lcavities
8
7
6
1
4
4
Location
Eehindglovebox
Undermiddleof dash
Behindglovebox
Behindglovebox
Behindglovebox
In the under-dash
fuse/relay
box
Inthe under-dash
fuse/relay
box
In the under-dash
fuse/relay
box
20
Underrlghtsideof dash
c152
1' I
Underrightsideof dash
c451
c452
10
Underrightsideot dash
c453
14
UndermiddleoI dash
c511
12
G451
22-32
Connectsto
Underrightsideof dash
Undermiddleof dash
Undergaugeassembly
Enginewire harness(see
page22'16)
EPSsubharness(seepage
22-24)
Enginecompanment
wire
harness{seepage22-18)
Enginecompartment
wire
harness{seepage22-18)
Floorwire harness(seepage
22-34)
Dashboard
wire harness
A
{seeoaoe22-26)
Bodygroundvia ECMwire
harness
Notes
ECMWIREHARNESS
22-33
Connectorsand Harnesses
Connectorto Harnesslndex (cont'd)
FloorWire Harness(Frontsidel
Connec-tor
or Terminal
I
Driver'sseatbeltswitch
Driver'ssideairbaginflator
Driver'ssideimpactsensor
Leftside seatbelt buckletensioner
Memoryerasesignal(MES)connector
Parkingbrakeswitch
Passenger's
seatbelt switch
Passenger's
sideairbaginflator
Passenger's
sideimpactsensor
Rightsideseatbeltbuckletensioner
SRSunitconnector
B
SRSunitconnector
C
Under-dashfuse/relaybox
connector
P {seepage22-45)
Under-dash
fuse/relay
box
connectorO (seepage22,45)
c402
c403
Ref
uavftres
11
l0
13
12
19
9
5
3
7
4
20
21
11
3
2
2
4
2
1
3
2
2
4
18
8
18
'r8
22
23
c453
10
4
Location
I Underdriver'sseat
i Underdriver'sseat
I Leftside offloor
Underdriver'sseat
Underdashfuse/relay
box
1Middleoffloor
Underpassenger's
seat
Underpassenger's
seat
Rightsideoffloor
Underpassenger's
seat
I Undermiddleof dash
Undermiddleof dash
Underdashfuse/relay
box
Underdashfuse/relay
box
]
I
Undermiddleof dash
Undermiddleof dash
Undermiddleof dash
c508
Undermiddleof dash
c509
14
Undermiddleofdash
c512
8
10
6
G551
22-34
connects to
Undermiddleof dash
I
Undermiddleof dash
] Unaermiddleof aasn
L,nderpassenger's
seat
Dashboard
wire harnessB
{seepage22 30)
Dashboard
wire harnessB
(seepage22-30)
ECMwire harness(seepage
22-321
Dashboard
wire harnessA
(seepage22-26)
Dashboard
wire harnessA
\see page 22-26)
Dashboard
wire harnessA
{seepage22-26)
Enginecompartment
wire
harness(seepage22 18)
OPDSunitharness(seepage
22-421
Bodygroundviafloorwire
Nol6s
- 10
11
FLOORWIREHARNESS
( c o n t ' d)
22-35
Gonnectors
and Harnesses
6
2
24
2
1
2
2
LeftB pillar
Fueltank
Fueltank
I
3
25
1
26
4
2A
5
27
'13
5
3
2
2
2
2
2
2
3
2
Fueltank
Fueltank
Lefttaillight
Left rear offloor
Behindleftsideof rearbumper
Leftquarterpanel
Lefttaillight
LeftB-pillar
Lefttaillight
Rightquarterpanel
18
10
11
2
1
20
Rightquarterpanel
R i g hB
t pillar
Rightq uarterpanel
22
20
21
15
19
12
11
7
2
3
2
2
2
2
2
12
Righttai ight
Righttaillight
Righttaillight
Rightsideof cargoarea
Behindrightsideof rearbumper
Rightquanerpanel
RightB-pillar
Rightquanerpanel
12
Rightquanerpanel
rearseal bdcl
Rightsideof cargoarea
22-36
H a t c hw i r e h a r n e s s( s e ep a g e
22 39)
H a t c hw i r e h a r n e s s( s e e p a g e
Bodv ground vta
Bodygroundviafloorwire
FLOORWIREHARNESS
22-37
Connectors
and Harnesses
Connectorto HarnessIndex(cont'd)
RoofWire Harnsss
Connectoror Terminal
Moonroofclose
relay
Moonrool control unit
Moonroofmotor
Moonrootopenrelay
Moonroofpositionsensor1
N4oonroofpositionsensor2
Moonroofswitch
Rearceilinglight
SpotlighVceiling
light
c507
22-38
6
I
7
8
5
1
2
10
Cavities
5
5
2
5
2
4
5
3
4
8
tocation
Middleof roof
Middleof roof
Middleof roof
Middleof roof
MiddleoI roof
Middleof roof
Frontof roof
N4iddleof roof
Frontof roof
Underleftsideof dash
Connectsto
Dashboard
wire harnessA
(seeoaoe22-261
Notes
HatchWire Harness
Connectoror Torminal
Hatchlatchswitch
Hatchlockactuator
Highmountbrakelight
Licenseplatelight connectorA
Licenseplatelight connectorB
Rearwindowde{ogger
connector
A
I
3
Cavities
2
2
2
2
2
1
B
Bearwindowdetoggerconnector
10
LeftC-pillar
Bearwindowwipermoto.
c553
6
2
4
12
Middleof hatch
Rightquanerpanel
c554
Rightquanerpanel
( )
7
8
Location
Middleo{ hatch
Middleof hatch
Behindhighmountbrakelight
Middleof hatch
Middleof hatch
RightC-pillar
Connects to
Notes
Floorwire harness(seepage
22-341
Floorwire harness(seepage
)2-34\
22-39
Connectors
and Harnesses
Connectorto Harnesslndex (cont'd)
\,
Driver'sDoorWire Harness
Connectoror Terminal
Driver'sdoor lockactuator
Driver'sdoorlockknobswitch
Driver'sdoor lockswitch
Driver'sdoorspeaker
Driver'spowerwindow motor
Left power mirror actuator
Left tlveeter
Powerwindow masterswitch
c504
c505
ReI
9
10
1
7
2
3
Cavities
2
3
3
2
Location
8
5
20
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdooa
Driver'sdoor
Driver'sdoor
Driver'sdoor
Driver'sdoor
Underleftsideof dash
't3
Underleftsideof dash
6
2
DRIVER'SOOORWIREHABNESS
22-40
Connectsto
A
Dashboard
wire harness
\seepage22-261
A
Dashboard
wire harness
Notes
Rel
6
I
5
1
4
3
2
Cavities
2
2
2
5
6
2
13
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Passenger's
door
Underrightsideof dash
Underrightsideof dash
Location
Connectsto
Notes
Dashboard
wire harnessA
(seepage22'26)
Dashboard
wire harnessA
lsee oeoe 22-26\
PASSENGER'S
DOORWIREHABNESS
22-41
and Harnesses
Gonnectors
Connectorto Harnesslndex {cont'dl
OPDSUnit Harness
ConnoctororTorminal
OPDSunit
Cavitios
2
1
Location
In frontpassenger's
seat
Underfrontpassenger's
seat
FLOORWIBEHARNESS
22-42
Connectsto
Floorwareharness(seepage
22-34)
Notes
Rel
I
2
8
3
4
1
1
Cavities
5
2
2
10
5
1
Undermaddle
of dash
Underrightsideof dash
Undermiddleof dash
Underrightsideof dash
Underrightsideof dash
Underrightsideof dash
Undermiddleol dash
c852
21
Undermiddleofdash
c853
,]
Undermiddleo{ dash
Location
Connec'tsto
Notes
Enginecompartment
wire
harness(seepage22-18)
Dashboard
wire harnessA
{seepage22 26i
Dashboard
wire harnessA
lsee oaoe 22-261
22-43
Fuse/Relay
Boxes
Connectorto Fuse/RelayBox Index
Under-hoodFuse/RelayBox
Socket
Ref
14
2
Ay'Ccompressorclutch relay
B
Blower motor relay
15
9
C o n d e n s efra n r e l a y
D
E
E L Du n i t
H e a d l i g hrte l a y1
Headlightrelay 2
Horn relay
Radiatorfan relay
Rearwindow defoqqerrelay
T1 (Batterv)
T101 (Alternator)
L'
1'
11
to
5
6
10
'l
J
||
T---r .-:-
t L _ _| . 1 I
t
"
"
tr
T
T
tTt Tr
,/^-------lFr
-/1-l
szl:!)
lrt
22-44
Startersubharness(seeoaqe22-15)
Startersubharness{seeoaoe22-'15}
8
7
a-------) |
-
4
4
4
""""-l-
r^l
tt
Terminal
Connects to
Enginecompartmentwire harness(seepage 22-18)
2
4
Enginecompartmentwire harness(seepage22-18)
5
4
Enginecompartmentwire harness(seepage 22-18)
4
14
Enginecompartmentwire harness(seepage 22-18)
7
E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
3
Enginecompartmentwire harness{seepage 22-18)
4
Under-dashFuse/RelayBox
Socket
D
E
F
G
H
Ref
Terminal
2
3
1
5
6
14
5
19
9
I
20
13
12
10
3
J
K
24
22
27
26
7
M
N
o
P
Powerwindow relay
6
10
25
14
18
R
S
Startercut relay
T
Taillightrelay
Turn signal/hazardrelay
U
11
1:
.o^
;;
4
8
2
in
a
17
Optionalconnector
Optionalconnector
Floorwire harness(seepage22-34)
28
I
13
l5
to
W ( M e m o r ye r a s es i g n a l( M E S )
connector)
X
Y
:
11
'10
Connects to
Dashboardwire harnessB {seepage 22-30)
Dashboardwire harnessB {seepage 22-30)
Dashboardwire harnessB (seepage 22-30)
ECMwire harness(seepage 22-32)
ECI\4wire harness(seepage 22-32)
Enginecompartmentwire harness(seepage 22-'l8l
Enginecompartmentwire harness(see page 22-181
E n g i n ec o m p a r t m e nwt i r e h a r n e s s( s e ep a g e2 2 - 1 8 )
Enginecompartmentwire harness(see page 22-18)
Enginecompartmentwire harness(seepage 22-18)
Dashboardwire harnessA (seepage 22-26)
Dashboardwire harnessA (seepage 22-26)
Dashboardwire harnessA (seepage 22-26)
Dashboardwire harnessA (seepage 22-26)
Dashboardwire harnessA (seepage 22-26)
Floorwire harness(seepage 22-34)
l t
tn--rl
I U LI L.]L.J
h - - n UL]L]UL]
I] L] L] LI L]
!3
12
22-45
PowerDistribution
Fuseto Componentslndex
Under-hoodFuse/RelayBox
Fuse
Number
'I
Amps
204
15A
WireColor
15A
WHT/BLU C a r q oa r e al i q h t ,C e i l i n ql i q h t s l. q n i t i o nK e v l i q h t .S o o t l i o h t s
BLU/BLK Radiatorfan motor
WHT/BLK Turn siqnal/hazardrelav,Turn siqnal liqhts
WHT/BLK CKPsensor,ECM,IACvalve, lmmobilizercontrol unit-receiver,Injectors,
15A
20A
10A
B L U / R E D i1Orns
WHT/GRN ABS modulatorcontrol unit
, a u g ea s s e m b l yl,m m o b i l i z e r
WHT/RED A u d i o u n i t ,D a t al i n kc o n n e c t o(rD L C )G
7.5A
5
204
10A
P G M - Fm
I a i n r e l a v1 a n d 2 . T D Cs e n s o r
7
unit, ECM)
8
9
10
40A
11
30A
IJ
40A
40A
14
40A
t5
15A
16
17
204
WHT/RED ABSmodulator-control
unit
BLK/YEL Noisecondenser,Rearwindow defoqqer
BLU^^/HT Blower motor
WHT/BLK No. 7 fuse (in the under-dashfuse/relavbox), Powerwindow relav
WHT/RED No.2 and No.3 fuses (in the under-dashfuse/relavbox)
REDI/EL Daytimerunning lightscontrol unit (Canada),Daytimerunning lights relay
{ C a n a d a )H, i o hb e a mi n d i c a t o lri q h t .L e f th e a d l i q h t
18
19
20
15A
60A
WHT
Multiplexcontrol unit
RED
D a v t i m er u n n i n ql i q h t sc o n t r o lu n i t ( C a n a d a )R. i o h th e a d l i o h t
WHTiBLU EPScontrol unit
80A
40A'
50A'?
WHT
Batterv.Power distribution
lgnition switch (BAT)
* 1 :U S A
" 2. Canada
II
E'l
22-46
t4 " t |
lI
l - - -
l'lr]n
r L__J,a
,..r^{-------l^-,
n[:]$"Lrt
O: Sparefuse
" N2,
Eol E l f__--l
|
|
nf
- r^l
Under-dashFuse/RelayBox
Fuse
Number
Amps
15A
2
3
204
10A
10A
7.5A
204
7.5A
10A
10
7.54
11
7.5A
7.5A
12
13
't4
10A
10A
1E
Wire Color
BLKA/VHT l g n i t i o nc o i l s
WHT/RED Airlfuelratiosensor,ECM
RED/BLU D a y t i m er u n n i n gI i g h t sc o n t r o lu n i t{ C a n a d a )
BLI(ORN Air/fuel ratio sensorrelay,Alternator,CMP sensor,Cruisecontrol main
switch,Cruisecontrol unit. ELDunit, Evaporativeemission(EVAP)bypass
solenoidvalve, Evaporativeemission(EVAP)canisterpurge valve,
Evaporativeemission(EVAP)canistervent shut valve,SecondaryH02S,
Vehiclespeed sensor
Not used
Y E U G R N Moonroof control unit, Moonroof open and close relay,Powerwindow
relaV
GRN
Moonroof motor
YEURED A u d i o u n i t
GRN
OPDSunit, Rearwindow wiper motor, Rearwindow washer motor, Rear
window wiper intermittentcontrol unit
YEL
Back-uplights,Cruiseindicatorlight, EPScontrol unit, Gaugeassembly,
Keylessreceiverunit, Multiplexcontrol unit, Securitycontrol unit
connector(optional)
BLIVORN ABS modulator-controlunit
YEURED D a y t i m er u n n i n ol i o h t sc o n t r o lu n i t ( C a n a d a )
PNK
S R Su n i t
BLK/YEL A,,/C
compressorclutch relay,Blower motor relay,Condenserfan relay,
Heatercontrol panel,Power mirror actuator,Power mirror defogger
(Canada),Radiatorfan relay,Rearwindow defoggerrelay,Recirculation
control motor
Not used
17
15A
18
19
15A
7.5A
20
21
22
23
24
25
30A
Notused
YEL/BLK E C M ,F u e lp u m p
BLK/YEL >H> Unrr
Y E U G R N Accessorypower socket
Y E U B L K T u r ns i q n a l / h a z a rrde l a v T
, u r ns i q n a l i o h t s
G R N / B L K M u l t i p l e xc o n t r o lu n i t ,W i n d s h i e l dw a s h e rm o t o r .W i n d s h i e l dw i o e r m o t o r
204
20A.
G R N / B L K Passenqer'swindow motor
GRN,A/VHT Driver'swindow motor
lo
Not used
Not used
Notused
_ _ ^ :
Hr tl_l
f at-t
at\t I
r^,rl fl
!!;r -
!f 3 3 9: , i ; s ! ! s
Fnf
|rnITf
22-47
GroundDistribution
Groundto ComponentsIndex
Componentor circuit qrounded
Ground
Batterv,Transmissionhousinq
En g i n e
G1 0 1
G 15' ]
G201
G202
G301
ABSmodulator-control
unit
G401
G402
G4 5 1
G501
G502
G503
G551
G552
22-48
Under-dashFuse/RelayBox
Removaland Installation
SRScomponentsare locatedin this area.Reviewthe
SRScomponentlocations{seepage 23-13)and
precautionsand procedures(seepage23-14)in the SRS
sectionbeforeperformingrepairsor service.
Removal
1. Make sure you have the anti-theftcode for the radio,
then write down the frequenciesfor the radio's
presetbuttons.
5. Removethe mounting bolt, and slidethe underdash fuse/relaybox (A) down from the bracket{B).
6. Disconnectthe backside from connectorsfrom the
back of the under-dashfuse/relaybox, and remove
the fuse/relaybox.
N O T E : T h eS R Sc o n n e c t o irs a s p r i n g - l o a d eldo c k
type (seepage 23-11).
lnstallation
2. Disconnectthebatterynegativecable,then
disconnectthe positivecable,and wait at least
three minutes.
2 . I n s t a l l t h ed r i v e r ' sd a s h b o a r dl o w e rc o v e r .
22-49
Battery
Battery Test
22-50
Relays
PowerRelayTest
Usethischanto identifythetypeof relay,thendo the
testlistedfor it.
type 1:
NOTE:Turnsignal/hazard
relayinputtest(seepage2287).
Relay
A'lCcomoressor
clutchrelav
Airlfuel ratio sensorrelav
Condenserfan relay
H e a d l i o hrte l a v1
H e a d l i q hrte l a v2
H o r nr e l a v
Powerwindow relay
R a d i a t oIra n r e l a y
Reverserelav
Startercut relav
T a i l l i q h rt e l a V
D a y t i m er u n n i n gl i g h t sr e l a y
{ C a n a d)a
Test
Normally-open
type A
type 2:
P G M - FmI a i nr e l a v1
P G M - Fm
l a i n r e l a v2
Blower motor relav
Rearwindow defoqoerrelav
Moonroofclose relay
Moonroof oDenrelav
Low beam cut relav {Canada)
Normally-open
tvpe B
F i v et e r m i n a l
type
Normally-open
type A:
PGM-FImain relay 1
PGM-FImain relay 2
type 1:
type 2:
(cont'd)
22-51
Relays
PowerRelayTest (confdl
Normally-open
type B:
Five-terminal
type
C h e c kf o r c o n t i n u i t yb e t w e e nt h e t e r m i n a l s .
. T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d
N o . 2 t e r m i n a l sw h e n p o w e ra n d g r o u n da r e
c o n n e c t e tdo t h e N o . 3 a n d N o . 5 t e r m i n a l s .
. T h e r es h o u l db e c o n t i n u i t yb e t w e e nt h e N o . 1 a n d
N o . 4 t e r m i n a l sw h e n p o w e ri s d i s c o n n e c t e d .
tF-gr
tJ 1l
Rearwindow defonn* *O,
type 1:
6:)
rc*V
.r{{
(n F, t )\
s3.
type2:
type 2;
22-52
lgnitionSwitch
Test
SRScomponentsare locatedin this area.Reviewthe
S R Sc o m p o n e n lto c a t i o n s( s e ep a g e2 3 - 1 3 a
) nd
precautionsand procedures{seepage 23-'l4)in the SRS
sectionbefore performingrepairsor service.
1, Removethe driver's dashboardlower cover {see
page 20-59).
2. Disconnectthe 5P connectorfrom the under-dash
fuse/relaybox.
WHT/RED
Wiresideof
f e m a l tee r m i n a l s
BLK/YEL
BLK/WHT
BLK/RED
Terminal WHT/
22-53
Gauges
\-
ComponentLocationIndex
PARKINGBRAKESWITCH
p a g e1 9 - 1 0
FUELGAUGESENDING
p a g e1 1 - 1 5 6
SWITCH
ENGINEOILPRESSURE
page8-4
GAUGEASSEMBLY
Procedure,page22-56
SelJ-diaqnostic
page22 63
Gauqedulb Replacement,
Rep6cement,page22-64
CoolantTemperatureGauge
page22'64
TroLrbleshooting,
VEHICLESPEEDSENSOR{VSS)
page22-65
Troubleshooting,
Beplacement,page22-67
BRAKEFLUIDLEVELSWITCH
p a g e1 9 - 1 0
22-54
CONNECTOR
B
lgreenJ
CONNECTORA
(bluel
SPEEDOMETER
VehicleSpeedSignalCircuit
page22-65
Troubleshooting,
TACHOMETEB
\7
t----/
\
_ / \
i . . _ ODO/TRIPMETER
FUELGAUGE
Test,page11-156
22-55
Gauges
Self-diagnosticProcedure
The gaugeassemblyhas a self-diagnosisfunction.
. T h e B e e p e rD r i v eC i r c u i C
t heck
. The IndicatorDrive CircuitChecL
. The LCDSegmentsCheck
. The GaugesDrive CircuitCheck(Speedometer,Tachometer,Fuelgauge,Coolanttemperaturegauge)
. T h e C o m m u n i c a t i oLni n eC h e c k( t h ec o o l a n t t e m p e r a t u rsei g n a l i n e b e t w e e nt h e g a u g ea n d E C M )
NOTE:Indicatorsare also controlledvia the communicationline.
Enteringthe self-diagnosis
f unction:
Beforedoing the self-diagnosisfunction,checkthe No. 9 (10A)fuse in the under-hoodfuse/relaybox and No. 10 {7.5A)
fuse in the under'dashfuse/relaybox.
1. Pushand hold the trip/resetbutton.
2 . T u r nt h e l i g h t i n gs w i t c hO N .
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
4 . W i t h i n5 s e c . ,t u r n t h e l i g h t i n gs w i t c hO F F t, h e n O N a n d O F Fa g a i n .
5. Within 5 sec.,releasethe trip/resetbutton,then push and releasethe buttonfour times reDeatedlv.
NOTE:
. While in the self-diagnosismode, the dash lights brightnesscontrolleroperatesnormally.
'Whileintheself-diagnosismode,thetrip/resetbuttonisusedtostartthebeeperdrivecircuitcheckandthegauge
drive cicuit check.
. lf the vehiclespeedexceeds1.2 mph 12km/h)orthe ignition switch is tu rned OFF,the self,diagnosis mode ends.
oN flrl
lgnition
OFF
Switch
Lighting
Switch
Trip/Reset
Switch
->
5 sec.
5 sec.
The BeeperDriveCircuitCheck:
When enteringthe self-diagnosismode, the beepersoundsfive times
TheIndicatorDriveCircuitCheck:
When enteringthe self-diagnosismode,the following indicatorsblink.
Seatbelt indicator,Door/hatchindicator,Brakesystem,Lowfuel indicator,Maintenancerequiredindicator(USA),
) , i l p r e s s u r el i g h t .
W a s h e rf l u i d l e v e li n d i c a t o (r C a n a d a O
22-56
The LCDSegmentCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e o d o / t r i ps e g m e n tb l i n k sf i v et i m e s .
TheGaugeDriveCircuitCheck:
W h e ne n t e r i n gt h e s e l f - d i a g n o s m
i s o d e ,t h e s p e e d o m e t e trh, e t a c h o m e t e rt ,h e f u e l g a u g e ,a n d t h e c o o l a n t
g a u g en e e d l e ss w e e pf r o m t h e m i n i m u mp o s i t i o nt o m a x i m u mp o s i t i o nt,h e n r e t u r nt o t h e m i n i m u m
temperature
posrtron.
NOTE:After the beeperstops soundingand the needlesreturnto the minimum position,pushingthe trip/resetbutton
s t a r t st h e b e e p e rd r i v ec i r c u i tc h e c k( o n eb e e p )a n d t h e g a u g ed r i v ec i r c u i tc h e c ka g a i n .
T h e c h e c kc a n n o tb e s t a r t e du n t i l t h en e e d l e sr e t u r nt o t h e m i n i m u mp o s i t i o n .
Self-diagnosis
mode
ON
OFF
Trip/Reset
switch
9loFF _---
causeneedlesXl"
Beeper
ON
;;
n =--llJL--
f---U---------l
r-r r-r r-r .-1 r-r
r-r
lll u u l_lL__l
I
@,
[-----l
l-l
5 sec
Faulty:
Normal:
iD
:-l!:!!JlJ!J
t l
i-
f l
O i -
,-
t
--
,-
r-
i-
| | | t t f
i-
r-
Endingthe self-diagnosisfunction:
T u r nt h e i g n i t i o ns w i t c hO F F .
N O T E lrf t h e v e h i c l es p e e de x c e e d s1 . 2m p h { 2 k m / h ) t, h e s e l f d i a g n o s i sf u n c t i o ne n d s .
22-57
Gauges
CircuitDiagram
'
UflOEN fiOOOFUSE/8ILAY
8OX
ECM/PCM
V
I
-r'
r--l
l J ,
I
I 8|
COOLANI
TEMPfNAIUFT
SPIEDOMEIENTACHOMEIIR FUTLGAUGI GAUGE
Norll0AlFUSE
8L(
-o-
22-58
ii-ciorurnn
coNNECron
N o 2 0 i o A: lU S A
ti) l To mxr I
MAi{IIiIANCE
ft0unlD
[{0tcaTo8
LIGH]
(LEDI
(cont'd)
22-59
Gauges
CircuitDiagram(cont'dl
No2il5AlFUSE
ilnlh.undi hooq
llu!./rcl.ybox r
DASH
LGHTS
Yt
Yl
'-
-t
WASHEF
Itut0
I!VEL
6t0tc ToR
UGHT
(tDl
ls?2
BLUIYEL
I
J
cSutsE
m n0L
a
22-60
'-
./
ib-n'rnoL
UNIT
tNGniEorL
PRESSUBE
swtTcH
lCld.d Eisin.3topp.d
l
iopd Ersin.runni.s
i
I
!
i
I
I
--t
DAYTIME
BUNN|NG
LIGHTS
@NTROL
UNII
I
;
I
-.-..
icmadd
(cont'd)
22-61
Gauges
CircuitDiagram(cont'dl
\"
GRNIfiED
I
\""'7
GAUGIASSEi|BLY
LEFTTUN
SIGI'IAL
II'{DICATOR
LTCHTS
HIGHSEAM
-|.
IMMOBITIZER
f,il
CoME|NAT|ON
LtctlTswtTclt
vll9i,]
\,
tMf,tOBtUZEn
@l\tTRoL
UN|I ftCtIVER
J
22-62
GaugeBulb Replacement
LIGHT{1.4WI
RIGHTTURNSIGNALINDICATOR
CRUISE
HIGHBEAMINOICATOR
LIGHT{1.4W)
ITORLIGHT{I.4W)
LEFTTURNSIGNALINDICATORLIGHTl1.il wl
GAUGLIGHT{1.4WI
GAUGELIGHT{1.4W}
IMMOBILIZENINDICATOR
LTGHT
{1.4Wl
22-63
Gauges
GaugeAssemblyReplacement
CoolantTemperature
Gauge
Troubleshooting
2. P l a c ea c l e a ns h o pt o w e l ( A )u n d e rt h e g a u g e
assemblyto preventscratchingthe steering
c o l u mn o r d a s hp a n e l .
Beforetesting,checkthe No. I { 10A)fuse in the underhood fuse/relaybox and the No. '10(7.5A)fuse in the
under dash fuse/relaybox.
1. Startthe engine,and checkthe malfunction
i n d i c a t o lra m p ( M l L ) .
g a u g ea s s e m D r y .
I n s t a l l t h eg a u g ea s s e m b l yi n t h e r e v e r s eo r d e ro f
removal.
22-64
VehicleSpeedSignalCircuitTroubleshooting
Special Tools Required:
Test Harness07LAJ-PT3020A
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
le thara
h2ltarv
v^ltada?
Y E S - G o t o s t e p7 .
Connectthe test harnessonly to the enginewire
harness.
wire betweenthe
NO Repairopen in the BLK,/YEL
VSS and the under-dashfuse/relaybox.l
ls there continuity?
YES Go to step 5.
N O R e p a i ro p e ni n t h e B L Kw i r e b e t w e e nt h e V S S
a n dG1 0 1 . I
Is there 5 V or more?
YES- Go to step 9.
NO Repairshort or open in the BLUMHT or WHT/
GRNwire betweenthe VSS and the cruisecontrol
u n i t ,o r t h e E C M . I
(cont'd)
22-65
Gauges
VehicleSpeedSignalCircuitTroubleshooting(cont'dl
9 . Turn the ignitionswitch OFF.
GAUGE
ASSEMBLY
CONNECTOR
B (22P)
'15.
Connectthe positiveprobe of a voltmeterto the
BLU/WHTwire and the negativeprobeto ground.
1 1 .R aisethe front of the vehicle,and make sure it is
securelysupported.
' t 2 .Put
t5.
'16.
o N { |)| ,
22-66
VSS Replacement
1. Removethe intakeresonator.
2. Disconnectthe 3P connectorfrom the vehicle
speed sensor{VSS)(A).
22-67
ExteriorLights
GomponentLocationIndex
UNDER.HOOD
FUSE/RELAY
BOX
HEADLIGHT
RELAY1
Test,page22-51
HEADLIGHT
RELAY2
Test,page22-5'l
BRAKEPEDALPOSITION
swtTcH
Test,page22-84
Adjustment,page l9'6
0/
/
FRONTTURNSIGNAL
LIGHT
, g e2 2 8 1
B u l bB e p l a c e m e npt a
HEADLIGHTS
page22 79
Replacement,
Adjustment.page22-78
page22-81
Eulb Replacement,
22-68
PARKINGLIGHT
B u l bR e p l a c e m e npt a, g e2 2 - 8 1
FRONTSIDEMARKERLIGHT
Bulb Replacement,page22 83
-a-.,_
z
HIGHMOUNTBRAKELIGHT
page22-82
Replacement,
LICENSE
PLATELIGHTS
page22-83
Replacement,
BACK.UPLIGHT
page22-82
Replacement,
REARSIDEMARKERLIGHT
page22-83
Replacement,
TAILLIGHTSsnd BRAKELIGHTS
page22-82
Replacement,
REARTURNSIGNALLIGHT
Beplacement,page22-82
(cont'd)
22-69
ExteriorLights
ComponentLocationIndex(cont'dl
DAYTIMERUNNINGLIGHTSRELAY{Canadal
[Wirecolors:RED,REDryEL,
I
andRED/BLU I
LRED/BLK
Test,page22-51
BEAMCUTRELAY
{Canadal_
_LOW
WirecolorsrREDMHT,
RED/BLK,I
andRED/BLU
I
LREDryEL
Test,page22-51
DASH LIGHTSBRIGHTNESS
CONTROLLER
. . i
'
:'
--,': -
' i,-'-'l
DRLINDICATOR
LIGHT{Canadal
HIGH BEAM INDICATORLIGHT
page22-63
Bulb Replacement,
COMBINATION
LIGHTSWITCH
page22-80
TesVReplacement,
oAYTIME RUNNING LIGHTSCONTROLUNIT lcanada)
InputTest,page22-76
I
t-
FUSE/
UNDER.DASH
RELAYBOX
22-70
LET]
FBOIII
SIDE
MAiKEE
L.IGHT
f,IGHT
TSONT
s]0E
MANXtF
IJGIIT
IETT
NEANSIDE
MAircN
IIGHT
I ucEr\6E
I PI.ATE
|fiIli
I
8L.l(
_o
22-71
ExteriorLights
CircuitDiagram- Canada
UNOEN
HOOO
FUSE/8ELAY
BOX
N ol 9 l 8 0 A l
) to.o
- i50Al
No.1'l
loa)
WHT ED
IT
N o . ! 0S( 7A lusE
r
d.3hl
RED,I
I- _ l
'2
/', t-\
\ rc|'/moN
. rcz/ swfrcH
I EAr
,'orrro"
-.
vG2Horin0N{ll)
) INDICAIOF
-/ l'lcli;
*01
I
I
BED
BU1
'l'I
I
=
.|
DNL
\y
II
TIGHT
luDl
RED/
BLU
12
t1
{ r-
oorr,",rr.,ro
uctrrscournoLu,'r"
J
l
I I
8
SLU/BID
!3
||MoS|UZEn
CONTNOL
UNIT RECEIVEB
SYSIIMUGHI
VY
I
t0
,{
--t
RE
ll
GNfl/FEO
DAYTIME
BUNNINC
LIGHTS
EfLAY
II
tU
HT/BI
In
RE
fifili{*1l,.H'
I
) No12
i l7.5Al
BI(
BI
BI
G8N
17
Y
GRI\/NED
II
I
f'
r\
88A(E
I FiUrD
2 , LTVEL
[./ SWITCH
F\ PANKNG
; } BNAXE
+./ swrTcH
'nddoM
I
G301
cl.1
G501
\,
22-72
J
DASH
LIGHTS
COMEINATION
LIGHT
SWIqI
TTFT
TRONT
3r0E
MABKER
LIG}IT
LEFT
PAfiX*'IG
LIG}IT
BLI(
BL](
G301
G301
BIGHT
PANKNG
LIGIIT
FIGIIT
FBONT
SIDE
MAfircF
LJGHT
l5w)
LEFT
TAIILGl T
LEFT
BEAFSIDE
LJGHT
RIGHT
RIAFSIDI
I/IAFrc8
UCHT
NEHI
I LICENSE
IAILUOHI I PLAII
I LIGNTS
(twr2l
|
8LI
G552
I
22-73
ExteriorLights
CircuitDiagram- BrakeLights
UiDENHOOD
FUSE/NEUYBOX
SATIISY
\
22-74
r!o7l15A)
I
|
,r-T-v--rrni'citr
CircuitDiagram- Back-upLights
UiDEN H@DFUSI/8EIAY
80)(
22-75
ExteriorLights
DaytimeRunningLightsControlUnit InputTest- Canada
T h e D R Li n d i c a t o lri g h ti n t h e g a u g ea s s e m b l yw i l l c o m e o n w h e n y o u t u r n t h e i g n i t i o ns w i t c ht o O N ( l l )w i t h t h e
headlightswitch off and the parkingbrakese1.lt should go off when you turn on the headlightswitch and releasethe
parkingbrake.lf it comes on at any other time, do the control unit input test.
r i l l g l o w a t h a l fi t s n o r m a li n t e n s i t y .
N O T EW
: h e nt h e d a y t i m er u n n i n gl i g h t sa r e o n ,t h e h i g h b e a mi n d i c a t ow
1. Removethe driver'sdashboardlower cover (seepage 20-60).
2 , D i s c o n n e c t t hle4 P c o n n e c t o r ( Af)r o m t h e d a y t i m er u n n i n gl i g h t s c o n t r oul n i t ( B ) .
RED/BLU
RED/BLU
GRN/BLK
GNN/BLK
GRN/ORN
BLU/RED
RED/YEL
YEL/RED
22-76
Wire
Test condition
RED/BLU U n d e a
r ll
conditions
12
YEL/RED
Cavity
lgnitionswitch
o N( r )
BLK
10
U n d e ra l l
conditions
BLK
U n d e ra l l
conditions
REDI/EL C o m b i n a t i o n
light switch ON
/ =f\\
'11
3
5
6
8
RED/BLU
Combination
light switch ON
{iD), and
dimmer switch
inHIGH
RED/BLK C o m b i n a t i o n
light switch ON
(iD), and
dimmer switch
inHIGH
G R N / B L K C o mb i n a t i o n
light switch ON
(iD), and
dimmer switch
inHIGH
G R N / O R NParkingbrake
l e v e ro u l l e d
B L U / R E DC o m b i n a t i o n
l i g h ts w i t c hO F F
WHT/BLU lgnitionswitch
o N0 r )
t5
GR N / R E D lgnition switch
o N( | | )
Test:Desiredresult
C h e c kf o r c o n t i n u l t yt o g r o u n d
T h e r es h o u l db e c o n t i n u i t y .
. Faultycombinationlight switch
. P o o rg r o un d { G 5 0 1 )
. A n o p e ni n t h e w i r e
C h e c kf o r c o n t i n u i t yt o g r o u n d :
There should be continuitv.
Checkfor voltageto ground:
Thereshould be batteryvoltage.
Faultyparkingbrakeswitch
A n o p e ni n t h e w i r e
F a u l t yh e a d l i g hrt e l a y s
Short to ground
A n o o e ni n t h e w i r e
. B l o w nN o . 1 0 ( 7 . 5 A f)u s e i n t h e
under-dashfuse/relaybox
. FaultyDRLindicator
. A n o o e ni n t h e w i r e
Faultybrakesystem indicator
A n o p e ni n t h e w i r e
Attachto ground:
T h e D R Li n d i c a t o lri g h ts h o u l d
c o m eo n .
Attachto ground:
T h e b r a k es y s t e ml i g h ts h o u l d
c o m eo n .
22-77
ExteriorLights
\
HeadlightAdjustment
2. Parkthe vehicle7.5 m (25 ft) away from a wall or a
screen(A).
Headlightsbecomevery hot during use;do not
touch them or any attachinghardwareimmediately
afterthey have beenturned off.
7.5m {25ftl
Beforeadiustingthe headlights:
. Parkthevehicleon a levelsurface.
. Makesurethetire pressures
arecorrect.
. Thedriveror someonewho weighsthe sameshould
sit in the driver'sseat.
'1.
3 . O p e nt h e h o o d .
22-78
HeadlightReplacement
T u r nt h e l o w b e a m so n .
'1.
Verticaladjustment:
Measurethe height ofthe headlights(A).The lights
should reflect52 mm (2.'1in.) below headljght
h e i g h t( B ) .
22-79
ExteriorLights
CombinationLight Switch Test/Replacement
1. Removethe driver's dashboardlower cover (seepage 20-60).
2. Removethe steeringcolumn covers(seepage 17-9).
3 , D i s c o n n e c t t hle6 P c o n n e c t o r ( Af)r o m t h e c o m b i n a t i o nl i g h ts w i t c h( B ) .
Telmint
12
Position
OFF
Headlight switch
o--
LOW
Passingswitch
HIGH
OFF
o--
ON
o-
Turn signalswitch:
Terminal
10
Position
LEFT
----o
NEUTRAL
RIGHT
22-80
o--
11
13
Bulb Replacement
Headlight:
FrontTurn SignalLight:
ParkingLight:
Frontturn signallight:
Parkinglight:
21W
5W
f-rI
A-
-'-+l
)/
removat.
22-81
ExteriorLights
TaillightReplacement
HighMount BrakeLight
Replacement
1 . Removethe rearbumper(seepage20-86).
2 . Openthetailgate,anddisconnect
the connectors
(A)fromthetaillight(B).
2. Removethe plastictrim.
Brako/Taillight; 2115W
TurnSignalLight: 21 W
Back-upLight:
21W
5W x 5
=\\
ili--- _\
, \ .
r B ---'a
t
\r
\
Removethe mounting nuts and bolts,then remove
t h et a i l l i g h t .
'
22-82
LicensePlateLight Replacement
1 . Removethe hatch lower trim panel (seepage20-
P u l l t h el i c e n s ep l a l el i g h ta s s e m b l yo u t . a n d
disconnectthe 2P connector(A) from the light.
5W
LicensePlateLight: 5Wx2
'[-J^
,^f , t lo \
+tiP'-
' f l ^
t
\-J
"/
\==-^
3 . S e p a r a t et h e l e n s( B )a n d h o u s i n g( C ) ,t h e n r e m o v e
the bulb.
4 . l n s t a l l t h el i g h ti n t h e r e v e r s eo r d e ro f r e m o v a l .
22-83
ExteriorLights
BrakePedalPositionSwitch Test
1. Disconnectthe4P connector(A) from the brake
pedal positionswitch {B).
5W
22-84
TurnSignal/Hazard
Flasher
ComponentLocationIndex
COMBINATION
LIGHT/TURN
SIGNALSWITCH
Test,page22-80
page22-80
Beplacement,
TURNSIGNALINDICATOR
LIGHTS
(lnthegaugeassembly)
page22'63
BulbReplacement,
HAZARDWARNINGSWITCH
Test,page22-88
page22-88
Replacement,
TURNSIGNAL/HAZARDRELAY
InputTest,page22-87
FUSE/RELAY
BOX
UNDER.DASH
22-85
TurnSignal/Hazard
Flasher
CircuitDiagram
DASH
Ut\toEB
TUSVRILAY
8OX
UNDff HOOD
FUSUftIIY8OX
'No20lr0A
USA
No.2{
l50A):Cmada
fiIGHTT
INDICATON
IIGHT
11.1W)
FBONT
!
22-86
RelayInputTest
TurnSignal/Hazard
1 . R e m o v e t h e t u r ns i g n a l / h a z a rrde l a y( A )f r o m t h e u n d e r - d a sfhu s e / r e l a yb o x ( B ) .
000i0!1000
00u!u0
Inspectthe relay and fuse/relaybox socketterminalsto be sure they are all makinggood contact
. lf the terminalsare bent.loose,or corroded,repairthem as necessary,and recheckthesystem.
. lf the terminalslook OK, go to step 3.
Make these input tests at the fuse/relaybox.
.lfanvtestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. l f a l l t h e i n p u t t e s t sp r o v eO K , t h e t u r ns i g n a l / h a z a rrde l a ym u s t b e f a u l t y .R e p l a c ei t
Cavitv
1
22-87
TurnSignal/Hazard
Flasher
HazardWarningSwitch Test
1 . Removethe centerpanel (seepage 20-62).
2 . Disconnectthe 10Pconnector(A)from the hazard
w a r n i n gs w i t c h( B ) .
Termin6l
1
;;;-_-\
OFF
ON
22-88
10
CEILINGLIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING
LIGHT
Test,page22-96
page22-96
Replacement,
FRONTPASSENGER'S
DOORSWITCH
IGNITIONKEYLIGHT
Test,page22-91
IGNITIONKEY SWITCH
lest, page22-91
HATCHLATCHSWITCH
Test,page22-97
DRIVER'SDOORSWITCH
AREALIGHT
CARGO
Test,page22-97
page22 97
Replacement,
22-89
EntryLightControlSystem
CircuitDiagram
'No.20({0A)
USA
UiIOTf,HOOD
fUSE/8ELAY
BOX
EiIIpN
SMTqI
lGlHoTin0Nilll
nd STAnT
0D
CEILING
UGHT
Y
I
I
DtrVTN'S
DOOR
Locx
(NOB
s!t/tTc8
ORIVEBS
DOOR
SWITCH
PASSTNGERS
DOOB
SWITCH
i9r"..d l
IGNIlx)N
KEY
SWtTCH
l'
BU
G()t
J
22-90
i'
/.'
2. Disconnectthe 6P connector.
22-91
EntryLightControlSystem
Control Unit Input Test
1. Beforetesting,trou bleshootthe m u ltiplex control system (seepage22-172).
2. Removethe dashboardlower cover.
3. Disconnectthe under-dashfuse/relaybox connectors.
NOTE:All connectorsare wire side of femaleterminals.
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
K Il7PI
UNDEB-DASIJ
FUSE/RELAYBOX CONNECTOR
O {,I2PI
GRN/RED
UNDEB.DASH
FUSE/RELAY
BOXCONNECTOR
P {18PI
6),/18.
GRN LT GRN/REO
UNOER.DASHFUSE/REI"AY
BOX CONNECTOBX I8PI
,/13
8ED/WHT WHT/BLK
UNDER.DASH
FUSE/RELAY
BOXCONNECTOR
Y {13PI
YEL/RED
4 . Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseorcorroded, repairthem as necessary,and recheckthe system.
. lf the terminalslook OK, go to step 5.
22-92
I
maketheseinputtestsat theconnector'
stilldisconnected,
5. Withtheconnectors
. lf anvtestindicates
the system
a problem,find andcorrectthe cause,then recheck
. lf allthe inpultestsproveOK,go to step6.
Cavitv
K2
o7
X8
Test:Desiredresult
Test condition
Wire
8LU/ORN lJnderallconditions Checkfor continuitybetweenthe K2
terminalandthe keylessreceiver
No.2 terminal:
unit5Pconnector
Thereshouldbecontinuitv.
GRN/RED C e j l i n gl i g h t s w i t c h i n Attachto ground:
comeon.
Ceilinglight(s)should
middle position.
r l l c o n d i t i o n s Attachto ground:
WHT/BLK U n d e a
lgnitionkeylightshouldcomeon.
on the under-dash
connectors
box,and maketheseinputtestsat the appropriate
to the underdashfuse/relaV
the connectors
6. Reconnect
fuse/relay
box.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder'dashfuse/relaYboxassemblY
Cavitv
P18
Q3
o4
X5
Wire
RED
GRN
Test condition
C h e c kf o r v o l t a g et o g r o u n d :
Thereshould be 1 V or less.
H a t c hc l o s e d
Driver'sdooropen
C h e c kf o r v o l t a g e t o g r o u n d :
Thereshould be 1 V or less.
Driver'sdoorclosed
door
LTGRN/ Passenger's
BED
Passenger's
door
croseo
RED^vHT lgnitionkey inserted
intothe ignition
lgnitionkey removed
from the ignition
Y8
YEURED Driver'sdoorlock
knob switchlocked
Driver'sdoorlock
kn6h cwirch Inl6cke.l
Posq!!!c sq!!ej1!.9!!!!j
Poorground(G552)
Fauhyhatchlatchswitch
An openinthewire
Faultyhatchlatchswitch
Shorttooround
Faultydrlver'sdoorswitch
An oDenin thewire
Faultydriver'sdoorswitch
Test:Desiredresult
H a t c ho p e n
'
'
.
.
doorswitch
Faultypassenger's
An oneninthewire
doorswitch
Faultypassenger's
Shor o oround
Poorground(G401)
Faultyignitionkeyswitch
An ooenin the wire
C h e c kf o r v o l t a g et o g r o u n d :
Thereshould be 5 V or more.
F a u l t yi g n i t i o n k e y s w i t c h
Short to ground
Poorground{G501)
Faultydriver'sdoorlockknobswitch
An ooenin thewire
Faultydriver'sdoorlockknobswitch
Shortto oround
22-93
InteriorLights
ComponentLocationIndex
CEILING
LIGHT/SPOTLIGHTS
Test,page22-96
page22-96
Replacement,
REARCEILING
LIGHT
Test,page22-96
page22-96
Replacement,
HATCHLATCHSWITCH
Test,page22-97
CARGOAREALIGHT
fesl, page 22-97
page22-97
Replacement,
22-94
CircuitDiagram
STAB
ctu[G
LIGHT
MUITIPLEX
c0NTlot
UIIIT
HATCH
LATClI
swtTcH
22-95
Interior Lights
CeilingLight/SpotlightsTest/
Replacement
RearCeilingLight Test/
Replacement
CeilingLight:
Spotlight:
5W
5Wx2
CeilingLight: 8 W
x 1-0 mm
5x1.0mm
\A
A.
P."lil;-
Terminal
-----_l
il
oFF
celL,"ca,c",
MIDDLE
isoottiohts\
'uir
a}-+4
oN
re
SPOTLIGHTS
I C e i l i n ql i o h t
r o F F - - i
ON
-o
-o
(.F.O
G-
OFF
MIDDLE
OFF
ON
{c).
ON
o
G -@- O
OFF
22-96
'1.
Open the hatch.
Removethe hatch lower trim panel (seepage 20-
s3).
CargoArea Light: 5W
Disconnectthe 2P connector{A) from the hatch
l a t c h( B ) ,
22-97
AudioSystem
ComponentLocationIndex
AUOIOUNIT
Removal/f
nstallation,
Daoe22-100
pa-ge
Connector
Terminals,
22-101
RIGHTDOOBTWEETER
page22-102
Replacement,
ROOFANTENNA
page22-'1
Replacement,
03
DRIVER'SDOORSPEAKER
page22 102
Replacement,
LEFTREARSPEAKER
page22-102
Replacement,
RIGHT
REARSPEAKER
page22-102
Replacement,
ANTENNA LEAD
22-98
CircuitDiagram
'
/ 8AT
--------F
\
f!tACC
/
No.20ioA)
:USA
WHT/FED
ACC
HoTinACC
lllmd0Nllll
AUDIO
UflIT
DRIVER'S
DOORSPEArcF
IEFITWEETER
PASSE!{GIF'S
DOOB
SPEAKES
SIGIITTWEETEB
LEFTFEAB
SPEA(I8
NrcBTREAF
SPEAKEF
22-99
AudioSystem
!\,
7 . I n s t a l l t h ea u d i ou n i ti n t h e r e v e r s eo r d e ro f
removal,and note these items:
22-100
\v
2
3
4
5
Wire
YEUGRN
YEURED
PNK
Connectsto
Roof antenna
ACC (Power)
Not used
Not used
R i o h tr e a rs D e a k e(r+ I
BLU^/vHT
(+)
LeftrearsDeaker
7
8
GRN/YEL
9
10
GRN/BLK
RED/BLK
WHT/RED
11
12
Notused
14
ta
to
11
18
19
20
BLU/YEL
BLU/BLK
GRY/RED
LT GRN
RED
BLK
Gr o u n d( G 5 0 3 )
AUDIOUNIT2OPCONNECTOR
22-101
AudioSystem
SpeakerReplacement
DoorSpeaker:
Rear:
1 . R e m o v et h e d o o r p a n e l( s e e p a g e 2 0 - 4 ) .
Tweeter:
Carefullypry the tweeter (A) out of the mirror mount
cover,then disconnectthe 2P connector(B)from the
tweeter.
'-----d
22-102
RoofAntennaReplacement
1. Removethe rear part of headliner(seepage20-54).
2, Disconnectthe antennalead connector(A) and 1P
connector(B)from the roof antenna(C).
22-103
RearWindow Defogger
ComponentLocationIndex
*:Rearwindow defoggerswitch is built into the heatercontrol panel.
UNDER.HOOD
FUSE/RELAY
BOX
REARWINDOWDEFOGGER
RELAY
Test,page22-51
REARWINDOW
DEFOGGER
SWITCH+
NOISE
CONDENSER
page22 107
CapacityTest,
REARWINDOWDEFOGGEB
Function
Test,page22 106
J
22-104
CircuitDiagram
;Hl}lj.'fl,1fl1fi"
T f,rAiwrxDow
,74 DEfOGGES
I SWrcfl
BEATERcoNrf,oLpANrL(\iP\/
L
INDIATOR
ILEDI
22-105
RearWindowDefogger
FunctionTest
DefoggerWire Repair
NOTE:
. Be carefulnot to scratchor damagethe defogger
wires with the testerprobe.
. Beforetesting,checkthe No. 11 (30A)fuse in the
'14('10A)
under-hoodfuse/relaybox and No.
fuse in
the under-dashfuse/relaybox.
oK.
. lf the voltage is not as specified,repairthe
defoggerwire.
- l f i t i s m o r et h a n 6 V , t h e r ei s a b r e a ki n t h e
n e g a t i v eh a l fo f t h e w i r e .
- lf it is lessthan 6 V, there is a breakin the
positivehalf of the wire.
22-106
NoiseGondenserCapacityTest
1 . Removethe right rear side trim panel (seepage 2066).
Disconnectthe 2P connector(A)from the noise
condenser.
Noise condenser capacity:
0.47 a 0.09 microfarads
Wiresideol femaleterminals
Use a commerciallyavailablecondensertester.
Connectthe condensertester probes,and the
measurecondensercapacity.
4. lf it is not within the specification,replacethe noise
condenser.
22-107
Moonroof
ComponentLocationIndex
MOONROOF
SWITCH
f e $ , p a g e2 2 - 1 1 2
R e p l a c e m epnat ,g e2 2 - 1 2
T e s tp. a g e 2 2 - 1 1 2
page20-41
Replacement,
MOONROOFLIMIT SWITCH
Test,page22-113
\|.
MOONROOF
CONTROLUNIT
InputTest,page22-'l10
MOONROOFAUTO-STOPSWITCH
Test,page22'113
22-108
MOONROOF
OPENRELAY
GRN, I
lwire colors:GRN/YEL,
BLKandYEUGRNI
LRED/YEL,
Test,page22-51
MOONROOF
CLOSERELAY
GRN, I
lwire colorsrGRN/BLK,
BLKand YEL/GRNI
LGRN/WHT,
Test,page22-51
CircuitDiagram
UNDIR OAS8FUSE/NILAY
MX
No.20lOAl:US
No.20150
) :Canda
BL|(
8LI
G50t
G5{1
22-109
Moonroof
MoonroofControlUnit Input Test
1 . R e m o vteh eh e a d l i n e( sr e ep a g e2 0 - 5 4 ) .
(A)fromthecontrolunit(B).
2 . Disconnect
the 5Pconnector
GRN/WHT
LT GRN
Wire sideof
f e m a l et e r m i n a l s
RED/YEL BLK
Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, looseor corroded,repairthem asnecessary.and recheckthesystem.
. lf the terminalslook OK, go to step 4.
$ J
22-110
4- Reconnect
the moonroolcontrolunit5Pconnector,
andmaketheseinputtestsattheconnector.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,go to step5.
Caviiy
Wire
BLK
,l
Test condition
Test:Desiredresuh
Underallconditions
Poorground(G501)
An openin the wire
C h e c kf o r v o l t a g e t o g r o u n d :
There should be baftery voltage.
lgnitionswitchON (ll)
Moonroofclosed
C h e c kf o r v o l t a g et o g r o u n d :
Thereshould be 1V or less.
Poorground(G501)
Faultymoonroof auto-stopswitch
An openinthewire
Moonroof open
Shorttoground
Faultymoonroofauto-stop
switch
LT GRN
Disconnectthe
moonroofcontrolunit5Pconnector,
andmakethese;nputtests
at the connector
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,the controlunit mustbefaultv.Replace
it.
Cavity
Wire
Test condition
cRN,4/VHTl g n i t i o n s w i t c h O N ( l l )
Test:Desiredrosult
Connecta jumperwire betweenNo,
3 and No.5 terminals.
Moonroofmotorshouldrun
(opened).
22-111
Moonroof
Motor Test
Switch Test/Replacement
'1
. Carefullypry the moonroof switch (A) out of the
headlin
er.
1 . R e m o v et h e h e a d l i n e(rs e ep a g e2 0 - 5 4 ) .
2. Disconnectthe 2P connectorfrom the moonroof
motor.
Terminal
pl.iri""---\
OPEN
\7
CLOSE
(,
TILT
-o
22-112
FO
CLOSE
OPEN
Auto-stopSwitch Test
limit switch.
NOTE:
. Turn the motor by hand with the wrench,
. The auto-stoppositionis about 145 mm (5.75in.)
from fully closed.
Terminal
\
Position
TILT
o-
o-
Terminal
OPEN
Position
CLOSE
BotwoenAUTO-STOP
andCLOSE
22-113
PowerMirrors
ComponentLocationIndex
POWERMIRRORS
FunctionTest,page22-116
page20-15
Replacement,
ActuatorTest,page22-117
ActuatorReplacemenl,page22-118
q3:.[
---\,--,-'/
-:,)
'\ \,
-,''
-o
t:
'
-lo'
,.'7
POWERMIRRORand
MIRRORDEFOGGERSWITCH
lesl, page22-111
page22-117
Replacement,
$r22-114
CircuitDiagram
'1
UiIDTSrcODR]SE/RLAY
8OX
rcilmoN
s1/vtTcH
UiD$ DASH
N'SUnIIAY8OX
22-115
PowerMirrors
FunctionTest
1. Removethe driver's pocket(seepage 20-60).
2. Reachthrough the pocketopening,and push out
the power mirror switch (A).
, \
Left mirror
7 . C o n n e ctth e N o . 2 t e r m i n a tl o t h e N o . l 0 t e r m i n a l ,
a n dt h e N o . 5 ( o r N o . 1 2 )t e r m i n a tl o t h e N o . 6
t e r m i n aw
l i t h j u m p e rw i r e s .T h e l e f tm i r r o rs h o u l d
t i l t d o w n ( o r s w i n gl e f t ) w i t ht h e i g n i t i o ns w i t c hO N
flr).
. l f t h e m i r r o r d o e sn o t t i l t d o w n ( o r d o e sn o t s w i n g
left),checkfor an open in the GRN/WHT(or BLU/
Wl-lT)wirebetweenthe left mirror and the 13P
conneclor,lf the wire is OK, checkthe left m irror
actualor.
. lf the mirror neithertiltsdown nor swings left.
r e p a i rt h e B L U / B L K
wire.
. l f t h e m i r r o r w o r k sp r o p e r l yc, h e c k t h em i r r o r
RED B
SWIICN,
Right mirror
W i r es i d eo f
t e m a l et e r m i n a l s
WHT/RED
RED/BLK
RED/YEL
o n n e c t o(rB )f r o m t h e s w i t c h .
3 . D i s c o n n e c t t h e ' 1 3cP
4. Choosethe appropriatetest basedon the
symptom:
. Both mirrors don't work, go to step 5.
. Left mirror doesn'twork, go to step 7.
. Rightmirror doesn'twork, go to step 8.
. Defoggerdoesn'twork (Canada),go to step 9.
8 . C o n n e ctth e N o . 2 t e r m i n a l t ot h e N o . 1 1t e r m i n a l ,
a n d t h e N o . 5 { o r N o . 1 3 )t e r m i n a tl o t h e N o . 6
terminaw
l i t h j u m p e rw i r e s .T h e r i g h tm i r r o rs h o u l d
tilt down (or swing left)with the ignition switch ON
( ).
. lf the mirror does not tilt down (or does not swing
left),checkfor an open in the GRN/WHT(or WHT/
R E D ) w i r eb e t w e e nt h e r i g h tm i r r o ra n d t h e 1 3 P
connector.
lf the wire is OK, checkthe right mirror actuator.
. l f t h e m i r r o r n e i t h e r t i l t s d o w n o r s w i n g sl e f t ,
repalrthe RED|YELwire.
' l f t h e m i r r o r w o r k sp r o p e r l yc. h e c k t h em i r r o r
swrrcn.
Both mirrors
Defogger(Canada)
5. Checkfor voltage betweenthe No. 2 terminal and
b o d y g r o u n dw i t h t h e i g n i t l o ns w i t c hO N ( l l ) .
There should be batteryvoltage.
. lf there is no batteryvoltage,checkfor:
- b l o w n N o . 1 4 ( 1 0 A )f u s e i n t h e u n d e r ' d a s h
fuse/relaybox.
- a n o p e ni n t h e B L K r y E L
wire.
. lf there is batteryvoltage,goto step 6.
6. Checkfor continuitybetweenthe No. 6 terminal
a n d b o d yg r o u n d .
T h e r es h o u l db e c o n t i n u i t y .
. lf there is no continuity,checkfor:
- a n o p e ni n t h e B L Kw i r e .
- p o o r g r o u n d( G 5 0 1 ) .
. lf there is continuity,checkboth mirrors
i n d i v i d u a l la
y s d e s c r i b e di n t h e n e x tc o l u m n .
22-116
9 . C o n n e ctth e N o . 1 a n d N o . I t e r m i n a l sw i t h a
jumper wire, and checkfor voltage betweenthe
N o . 2 t e r m i n a lo f t h e m i r r o rc o n n e c t oar n d b o d y
ground.Thereshould be batteryvoltageand both
m i r r o r ss h o u l dw a r m u p w i t h t h e i g n i t i o ns w i t c h
oN t).
. l f t h e r ei s n o v o l t a g eo r n e i t h e r w a r m su p , c h e c k
for:
- a n o p e n i n t h e B L K I / E Lo r o R N w i r e .
- b l o w n N o . 1 4 ( ' l 0 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
. l f o n l y o n e f a i l st o w a r m u p , c h e c k :
- its defogger.
- p o o r g r o u n d( G 5 0 1G
, 502)
. l f b o t hw a r m u p , c h e c k t h e d e f o g g e r s w i t c h .
Mirror Switch:
\.f9.-'"1L
Position
2
CF
UP
10
o-
11
12
13
--o
o-
-c)
TILTDOWN
oo
SWINGLEFT
SWING RIGHT
o
o
-o
RIGHT
TILTUP
-o
o-
Terminal
\
Position
-o
UP
"[T
5 . C h e c kf o r c o n t i n u i t yb e t w e e nt h e N o . 1 a n d N o . 2
terminalsof the 6P connector.Thereshould be
continuity.lf there is no continuity,checkfor an
open circuit.
RIGHT
Te.minal
tlf
il;;;
ON
OFF
22-117
PowerMirrors
PowerMirror Actuator Replacement
'1.
3 . Disconnectthe connector.
4 . Removethe cover,then removethe two Torx
screwsfrom the mirror connector.
5 . Recordthe terminal locationsand wire colors.
6 . Cut the wire harnesswith the wire cutter.
J
22-118
LEFTMIRROR
CONNECTOR RIGHTMIRROR
CONNECTOR
*:Canada
'l'1.
Wiresideof femaleterminals
1 2 .R e i n s t a l l t h m
e i r r o ra s s e m b l yo n t h e d o o r .
tJ.
22-119
Horns
\
ComponentLocationIndex
UNDER-HOOD
FUSE/RELAY
BOX
HORNRELAY
Test,page22-51
.-
:.."'
HORNSWITCH
fesl, page22-122
HORNS
Test,page22 122
B e p l a c e m e npt a
, g e2 2 1 2 2
CABLEREEL
page23,119
Replacement,
*r
22-120
GircuitDiagram
22-121
Horns
Horn Test/Replacement
1 . Removethe front bumper {seepage 20-85).
|. . . . : .../..
...,
22-122
I
wire harnessB 5P
4. Reconnect
the dashboard
the hornswitch
connector
{A),anddisconnect
(B).
positive1Pconnector
wheelto
1 . Usinga jumperwire,connentthe steering
b o d yg r o u n d .
8 . Closethecontactsbetweenthe hornplateandthe
contactplate.
. lf the hornssound,replacethesteeringcolumn.
. l f t h eh o r n s d on o t s o u n dr,e p l a c e t hheo r na n d
contactplate.
22-123
PowerWindows
ComponentLocationIndex
UNDER.DASH
FUSE/RELAY
BOX
POWERWINDOWRELAY
Iest, page22-51
FRONTPASSENGER'S
WINDOWMOTOR
Test,page22-132
DRIVER'SWINDOWMOTOR
Test,page22-129
POWERWINDOW MASIER SWITCH
InputTest.Daqe22.126
Test,page22--128
page22-133
Replacement,
FRONTPASSENGER'SWINDOW SWITCH
I n D uT
t e s l ,p a q e2 2 - 1 3 0
f est, page 22-132
Beplacement,page22-133
22-124
CircuitDiagram
'No.20il0A)
: USA
UNOERHMO FUSI/8tLAY8OI
tGt'TtoitswtTcfi
--+r
U/
o'F
BTTYEL
WHT/BU
22-125
PowerWindows
MasterSwitch Input Test
NOTE:Thepowerwindowcontrolunitis builtintothe powerwindowmasterswitch,andit onlycontrolsthe driver's
windowoperations.
1. Removethe windowmasterswitch{A)(seepage22-133).
(B)from the masterswitch.
2. Disconnect
the 14Pconnector
GRN/WHT
22-126
Cavity
Wire
Test condition
10
BLK
U n d e ra l l c o n d i t i o n s
14
11
GRN^,^/HT l g n i t i o ns w i t c hO N ( l l )
GRN/BLK
RED/YEL C o n n e ctth e N o .
RED/BLK
'l'1
and
N o . 7 t e r m i n a l sa, n d t h e
N o , 4 a n d N o . 1 4t e r m i n a l s ,
and turn the ignition switch
Test:Desiredresult
Checkfor continuityto
grouno:
Thereshould be continuity.
Checkfor voltageto
ground:
Thereshould be battery
voltage.
Checkfor driver'swindow
molor operaflon:
I t s h o u l dr u n ( t h ed r i v e r ' s
w i n d o w m o v e sd o w n ) .
oN flr).
3
fir),
Faultypassenger'swindow
motor
Faultypassenger'swindow
swatch
An open in the wire
Cavity
Wire
Test condition
13
ORN
C o n n e ctth e N o . 1 1 a n d
N o . 7 t e r m i n a l sa, n d t h e
N o . 4 a n d N o . 1 4t e r m i n a l s ,
and turn the ignition switch
Checkfor voltagebetween
t h e N o . 1 3a n d N o . 1 4
termtnals:
About6Vshouldbe
indicatedwith the driver's
window motor running.
o N0 r ) .
22-127
Motor Test:
1 . Removethe door panel (seepage 20-4).
Terminal
il;;'-\
UP
DOWN
o
e
22-129
PowerWindows
Passenger's
Window Switch Input Test
1 . Removethe switch panel (seepage 20-4).
2 . Disconnectthe 5P connector(A)from the switch (B).
'' "'"1.
Wire side of femaleterminals
BLU/WHT
GRN/BLK
Inputthe connectorand socketterminalsto be sure they are all making good contact.
. lf theterminals are bent, looseor corroded,repairthem as necessary,and recheckthesystem.
. lf the terminalslook OK, go to step 4.
4 . Reconnectthe connector,and using a back probe, makethese input tests at the connector.lf any test indicatesa
Cavitv
3
Wire
Test condition
G R N / B L K lgnitionswitch ON
{l l )
BLD,A/VHT lgnitionswitch ON
( )
At the master
window switch,
pressand hold
down the
passenger'sswitch
BLU/RED lgnitionswitch ON
(||)
At the master
window switch,
p u l lu p a n d h o l d
the passenger's
switch
22-130
Test:Desiredresult
Checkfor voltageto
grouno:
There should be battery
voltage.
Checkfor voltageto
ground:
Thereshould be battery
voltage.
Checkfor voltageto
grouno:
Thereshould be battery
voltage.
Faultymasterwindow switch
An open in the wire
5. Disconnect
the 5Pconnector,
andmaketheseinputtests.
Cavitv
1
Wire
Test condition
Test: Desired result
RED
Checkfor passenger's
Connectthe No. 2
RED/BLU t e r m i n a tl o t h e N o . window motor operation:lf
22-131
PowerWindows
Passenger's
Window Switch Test
1 . Removethe switch panel (seepage 20-4).
Removethe power window switch (A) from the
doorpanel.
Passenger's
Window Motor Test
1 . Removethe passenger'sdoor panel (seepage204).
Disconnectthe 2P connector(A)from the
passenger'spower window motor.
tfiTtTtT;Etl
'-r--r-,Jl
l'
\Torminal
Poiition\
Terminal
Dl*;;;__\
UP
UP
DOWN
I
o
o
o
OFF
DOWN
22-132
MasterSwitch Replacement
'1.
Passenger's
Window Switch
Replacement
switch panel.
22-133
Wipers/Washers
ComponentLocationIndex
WINDSHIELD
WIPERARMS and LINKAGE
page22-'145
Replacement,
WIPER/WASHERSWITCH
Test,page22-140
Replacement,page
22 140
WINDSHIELD
WIPERMOTOR
Test,page22-'143
page22-145
Replacement,
UNDER.DASH
FUSE/RELAY
BOX
INTERMITTENT
WIPERCIRCUIT
l l nt h em u l t i p l ecxo n t r oul n i t )
InputTest,page22-138
22-134
WASHER
TUBES
page22-147
Replacement,
WASHER
RESERVOIB
page22'146
Replacement,
WASHERFLUIDLEVELSWITCH{Canada)
TesI,page22-144
page22-144
Replacement,
REARWINOOWWASHERMOTOR
Test,page22-144
page22 146
Replacement,
WINDSHIELD
WASHERMOTOR
fesl, page22 144
page22-146
Beplacement,
CONDENSER
CapacityTest,page22 107
REARWINDOWWIPERINTERMITTENT
CONTROL
UNIT
InputTest,page22'138
REARWINDOWWIPERMOTOR
f e$, page22-143
page22 146
Replacement,
BEARWINDOWWIPERARM
page22 146
Replacement,
22-135
Wipers/Washers
\ 1
CircuitDiagram- Windshield
'7{
FL]SE/8ELAY
BOX
UNOENHOOD
F;^--il
U-I^--
I
-':-;--u,Hr-
IGNITIONSWITCN
6\
o,f-''*""
MULTIPIIX
coiln0L
UNIT
L\'
\,!
22-136
CircuitDiagram- RearWindow
UI\IOIF H@OFUSE/RELAY
MX
BATTERY
-;i
r--------------l No'g,soA, ro2o. |
(-;1_=l----_--_fww{"-'
No2olaoAl
:USA
GNMOIIISW|ICH
/,^1\
\+y
lErHorb0Ni||l
andsra8r
0
ffAn w$tDowwtPEE
INTE$'ITTEI'IT
C{)NNOL
UI'/IT
f---------------
li
22-137
Wipers/Washers
RearWindowWiperIntermittentGontrolUnit InputTest
1 . Remove
the rightrearsidetrim panel{seepage20-51).
(A)fromthe rearwindow.wiDer
the 20Pconnector
intermittent
controlunit(B).
2 . Disconnect
WHT/RED
WHT/RED
LT GRN
LT GRN/BLK
Inspecttheconnector
andsocketterminalsto be suretheyareall makinggoodcontact.
. lf theterminalsare bent,looseorcorroded,repairthemas necessary,
andrecheckthe
system.
. lf theterminalslookOK,go to step4.
22-138
\
4. With the connectorstill disconnected,maketheseinput tests at the connecrors.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
' lf all the input tests prove OK, the control unit must be faultv. Replaceit.
Cavitv
Wire
GRN
Tesl condition
lgnitionswitch ON
flr)
10
6
BLK
U n d e ra l l
conditions
WHT/RED lgnitionswitch ON
LT GRN/
RED
LT GRN
( l l )a n d r e a r
window washer
switch ON
lgnition switch ON
( l l )a n d r e a r
window wiper
switch ON
lgnition switch ON
flr)
20
LT GRN/
BLK
lgnitionswitch ON
(ll)
. B l o w nN o . 9( 1 0 A ) f u sien t h e
under-dash
fuse/relay
box
. An openin thewire
Checkfor continuity
to
grouno:
Thereshouldbe continuitv.
B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
under-dashfuse/relaybox
Faultyrearwlndow wiper/
washer switch
A n o p e ni n t h e w i r e
Attachto groundl
The rearwindow wiper motor
s h o u l dr u n .
Attachto ground:
The rear window wiper motor
s h o u l dr u n .
Checkfor voltageto ground:
Thereshould be battery
voltage.
B l o w nN o . 9 ( 1 0 A ) f u s ei n t h e
under-dashfuse/relaybox
Faultyrearwindow wiper motor
An open in the wire
B l o w nN o . 9 ( 1 0 A )f u s ei n t h e
under-dashfuse/relaybox
Faultyrearwindow wiper motor
A n o D e ni n t h e w i r e
22-139
Wipers/Washers
Wiper/WasherSwitch Test/Replacement
lowercover{seepage20-60).
1 . Remove
the driver'sdashboard
Removethesteeringcolumncovers(seepage17-9).
(A)fromthewiper/washer
switch{B)
Disconnecl
the 14Pconnector
14
l2
12
11
o- -{
o-
OFF
tNl
o-
LO
HI
Mist switchON
Washor 3witch ON
22-140
ControlUnit InputTest
l . Beforetesting,troubleshootthe multiplexcontrol system lsee page22-jj2).
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
G {1OP)
UNDER-DASH
FUSE/RELAY
BOX
CONNECTOR
J {8PI
WHT/BLU
\
l-,1
l l
l-rl
l-,1
- llTtl
F_j-JF-#
1 4 1 5 1 76 l 8 l
lslrlzlol
\
BLU/RED
BLU/WHT
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
X I8PI
BLU/BLK
4. Inspectthe connectorand socketterminalsto be sure they are all makinggood contact.
. lf the terminalsare bent, looseor corroded,repairthem as necessary,and recheckthesystem.
. l f t h e t e r m i n a l sa r e O K ,g o t o s t e p5 .
(cont'd)
22-141
Wipers/Washers
ControlUnit Input Test (cont'dl
Y6
BI
E'0
Wire
BLK
Test condition
U n d e ra l l
conditlons
BLK
U n d e ra l l
conditions
WHTiBLU lgnitionswitch ON
{ l l )a n d w a s h e r
switch ON
BLU/RED lgnitionswitch ON
( l l )a n d w i p e r
switch OFF(wiper
motor stopped)
G7
BLUA/VHT lgnitionswitch ON
( l l )a n d w i p e r si n
p a r kp o s i t i o n
x1
B L U / B L K l g n i t i o ns w i t c hO N
( l l )a n d w i p e r
switch in INT
Test:Desiredresult
C h e c kf o r v o l t a g et o g r o u n d :
T h e r es h o u l db e 1 V o r l e s s .
Checkfor voltageto ground:
T h e r es h o u l db e 1 V o r l e s s .
Checkfor voltageto ground:
Thereshould be battery
vortage.
Checkfor voltageto ground:
There should be battery
voltage.
L
22-142
RearWindow:
LOWSPEED
HIGHSPEED
Telminal
Battery
Connected
.l
J
22-143
Wipers/Washers
WasherFluidLevelSwitch Test/
- Canada
Replacement
WasherMotorTest
1. Partiallyremovethe right inner fender (seepage
20-'t021.
2. Disconnectthe 2P connectors(A) from the washer
motors (B).
Battery
Connected
reservoir.
NOTEF
: l u i dm a y f l o w o u t t h e o p e n i n g .
4 . Checkfor continuitybetweenthe terminalsin each
float (B) positionaccordingto the table.
Terminal
Position
FLOATUP
FLOATDOWN
o- ---o
22-144
5 . S c r i b ea l i n e ( A )a c r o s st h e l i n ka n d w l n d s h i e l d
wiper linkageto show the original adjustment.
Separate
t h e w i n d s h i e l dw i p e r l i n k a g e( B )f r o m t h e
w i p e r m o t o r( C ) .
N.m
(3.2ksf.m,23 lbt.ft)
R e m o v et h e b o l t s( C ) ,m o v ew i n d s h i e l dw i p e r
l i n k a g ea s s e m b l y{ D ) t o w a r dt h e p a s s e n g e r 'ssi d e
of the vehicle until it slidesoff of the pin (E),then
removethe assembly.
22-145
Wipers/Washers
RearWindow Wiper Motor
Replacement
WasherReservoirReplacement
1 . Partiallyremovethe right inner fender.
A
9.8N.m {1.0kgf.m,
7.2rbf.ftl
B
8 N.m 10.8kgt.m,
6.0rbf.ft)
Disconnect
the 4Pconnector
{A),removethethree
mountingbolts(B),thenremovethe rearwindow
wiDermotor(C).
A
9.8 N.m
(1.0kgt.m,
7.2 tbf.tt)
B
9.8 N.m
{1.0kgt.m,7.2lbfftl
these items.
Apply multipurposegreaseto the moving parts.
Beforereinstallingthe wiper arm, turn the wiper
switch ON, then turn OFFto returnthe wiper
shaft to the Darkoositon.
lf necessary,replaceany damagedclips.
Checkthe wiDer motor operation.
22-146
WasherTubesReplacement
1 . Removethe rightinnerfender{seepage20-102).
2 . Remove
the washernozzles
andclips,thenremovethetubes.
<=>
r"-----------='
--==':?-
L-!
(cont'd)
22-147
Wipers/Washers
WasherTubesReplacement(cont'dl
22-148
AccessoryPowerSocket
CircuitDiagram
22-149
DoorLockSystem
Keyless/Power
ComponentLocationIndex
Test,page22-161
P r o g r a m m i n gp,a g e2 2 - 1 6 1
DRIVER'SDOORLOCKSWITCH
Test,page22-160
RECEIVER
UNIT
lnput Test,page22-153
IGNITIONKEYSWITCH
Test,page22-91
PASSENGER'S
DOORLOCKACTUATOR
Test,page22 158
MUTIPLEXCONTROLUNIT
InputTest,page22-155
DRIVER'SDOORSWITCH
DRIVER'S
DOORLOCK
SWTICH
ACTUATOR/KNOB
Actuator
Test,page22-158
KnobSwitchTest,page22 160
HATCHLATCHSWITCH
Test,page22-97
HATCHLOOKACTUATOR
Test,page22 159
PASSENGER'SDOORSWITCH
22-150
CircuitDiagram
UNOEE
DASH
fUSE/SELAYBOX
8OX
UiDENHooDFUSE/RETIY
-)
/ 8Ar
\
cl-
lG1,/
lG1HoTin0N(lllaidSTAfft(llll
l3
IT
BLK
G502
UI'IDE8DASH
f USE/RETAY
80X
MULTIPUX
CONTNo!
Uflfi
000R
Loc(KNOE
tl
xtY
\"2
PASSTNGtrS
0008100(
ACTUATOi
t'-F>
Li___JDBt!'t8'S
000R100(
ACTUATOB
t
(cont'd)
22-151
Keyless/PowerDoor LockSystem
CircuitDiagram(cont'dl
HOOD
UNDEN
FU8E/BELAY
MX
l\br t15a)FUSE
t"-
HORN
SWTCH
UNDEN
DAS}I
FUSE/8ELAY
8OX
t J
Y,,,
mMErNAllofl
LIGHISWITCH
DFIVES'S
DOOB
TOCK
6WTCH
Df,IVEB'S
0008
swtrcH
plo'.d
l
tG tltot\t
IGY
stvrTcH
HATCH
LATCH
swlrol
22-152
WHT/RED
Wiresideof femaleterminals
e a kl li n gg o o dc o n t a c t .
4 . I n s p e c t t h e c o n n e c t o r a n d s o c k e t t e r m i n a l s t o b e s u r e t h e y a rm
. lf the terminalsare bent.Iooseorcorroded, repairthem as necessary,and recheckthesystem.
. lf the terminalsare OK, go to step 5.
t
(cont'd)
22-153
Keyless/PowerDoor LockSystem
KeylessReceiverUnit Input Test (cont'dl
With the connectorstill disconnecled,makethe input test at the connector.
.lftestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf the inputtest provesOK, goto step 6.
Cavity
Wire
Test condition
BLU/ORN U n d e ra l l
conditions
Test:Desiredresult
Checkfor continuitybetween
t h e N o . 2 t e r m i n a la n dt h e
N o . 2 t e r m i n a lo f t h e
under-dashfuse/relaybox
connectorK { 17P).
There should be continuitv.
Cavitv
1
Wire
BLK
YEL
Test condition
U n d e ra l l
conditions
lgnition switch
o N( | | )
WHT/RED U n d e a
r ll
conditions
22-154
Test:Desiredresult
Checkfor voltageto ground:
There should be 1 V or less.
Checkfor voltageto ground:
There should be battery
voltaqe.
Checkfor voltageto ground:
There should be battery
voltaqe.
BLU
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
F I12P)
BOX
UNDER-OASH
FUSE/RELAY
CONNECTOR
J {8PI
BLU/RED
FUSE/RELAY
BOX
UNDER.DASH
CONNECTOR
K {17PI
BLU/ORN
UNDER.DASH
FUSE/RELAY
BOX
CONNECTOR
M Il2PI
FUSE/RELAY
BOX
UNDER.OASH
P I18PI
CONNECTOR
,/1,/ 3
GRN
UNDER-DAsH
FUsE/neLeY
sbx
X (8P)
CONNECTOR
YEL YEL/BLK
FUSE/RELAY
BOX
UNDER.DASH
Y {13P)
CONNECTOR
LT GRN/RED
RED/WHT
4. Inspectthe connectorand socketterminalsto be sure they are all making good contact.
. lf the terminalsare bent, loose orcorroded, repairthem as necessary,and recheckthesystem.
. lf the terminalslook OK, go to step 5.
(cont'd)
22-155
Keyless/PowerDoor LockSystem
Control Unit Input Test (cont'dl
5. Reconnect
all connections
to the underdashfuse/relay
box,and maketheseinputtestsat the appropriate
connectors
on the under-dash
fuse/relay
box.
'lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
. lf all the inputtestsproveOK,goto step6.
Cavitv
c1'l
Wire
8LU
Test condition
Underall conditions
Test:Desiredresult
Aftachto ground:
Parking,
sidemarker,license
platelights,andtajllightsshould
comeon.
Possible
causeif resultis notobtained
B l o w nN o . 2( 1 5 A ) f u si en t h eu n d e r
hoodfuse/relaybox
Faultytaillightrelay
Faultyunder-dash
fuse/relay
box
An onen in rhc wire
Attachto ground:
Headlights
shouldcomeon.
B l o w nN o .1 5o r 1 7( 1 5 A ) f u si en t h e
underhoodfuse/relay
box
Faultyheadlight
relay'1or 2
An ooen in the wire
J2
B l o w nN o . 9( 1 5 A ) f u si e
n t h eu n d e r hoodfuse/relay
box
An oncn in thc wirc
J6
BLK
Underall conditaons
OBN
Under allconditions
Attachto ground:
The horns should sound.
Poorground(G501)
An ooenin the wire
BlownNo.7 (15A)fuse
in the under
hoodfuse/relay
box
Faultyhornrelay
Faultyhorns
H a t c ho p e n
H a t c hc l o s e d
Driver'sdooropen
C h e c kf o r v o l t a g et o
There should be 1 V
C h e c kf o r v o l t a g e t o
Thereshould be 5 V
J7
P18
BED
Poorground(G552)
Faultyhatchlatchswitch
An oncn in rhc wirF
GBN
Driver'sdoorclosed
o4
X5
Y1
LT GRN
/RED
REDAVHT
Passenger's
dooropen
Passenger's
doorclosed
C h e c kf o r v o l t a g e t o g r o u n d l
There should be sVor more
C h e c kf o r v o l t a g e t o g r o u n d :
There should be 1 V or less.
lgnitionkeyremovedfrom
rhe ionitionswitch
WHT/BLK Driver'sdoorlockknob
switchunlocked
Driver'sdoorlockknob
Y8
g.ound:
or less
ground:
or more.
YEURED Driver'sdoorlockknob
switch locked
C h e c kf o r v o l t a g e t o
There should be 5 V
C h e c kf o r v o l t a g e t o
There should be 1 V
ground:
or more.
groundl
or less.
C h e c kf o r v o l t a g e t o
Ihere should be 5 V
C h e c kf o r v o l t a g e t o
There should be 1 V
groundl
or more.
groundl
or less.
. Faultydriver'sdoorswitch
. An ooenin thewire
Faultydriver'sdoorswitch
Shortto oround
Faultypassenger's
doorswitch
An ooeninthewire
. Faultypassenger's
doorswitch
. Shortto oround
Poorground{G401)
Faultyignitionkeyswitch
An ooeninthewire
Faultyignitionkeyswitch
Shortto oround
Poorground(G50'l)
Faultydriver'sdoorlockknobswitch
An openin thewire
Faultydriver'sdoorlockknobswitch
Shortto oround
Poorground(G50'l)
Faultydriver'sdoorlockknobswitch
An oncn inihewire
Driver'sdoorlockknob
switch unlocked
Y10
Driver'sdoorlockswitchin
Y12
WHT/BLU Driver'sdoorlockswitch
locked
Driver'sdoorlockswitchin
C h e c kf o r v o l t a g e t o g r o u n d :
There should be 5Vor more
C h e c kf o r v o l t a g e t o g r o u n d l
There should be 1 V or less.
C h e c kf o r v o l t a g e t o g r o u n d :
Therc shorl.l be 5V or m6rp
C h e c kf o r v o l t a g e t o g r o u n d :
'l
There should be V or less.
C h e c kt o r v o l t a g e t o g r o u n d :
There should be 5Vor more
' Faultydriver'sdoorlockknobsw;tch
. Shorrto oround
Poorground(G501i
Faultydriver'sdoorlockswitch
An ooenin the wire
Faultydriver'sdoorlockswitch
Short to o rolrnd
Poorground(G501)
Faultydriver'sdoorlockswitch
An oDenin the wire
F a u l t yd r i v e r ' s d o o r l o c k s w i t c h
22-156
6. Disconnect
the M, P,K andJ connectors
fromthe underdashfuse/relay
box,and maketheseinputtestsat the connectors.
.lfanytestindicatesaproblem,findandcorrectthecause,thenrecheckthesystem.
.lfalltheinputtestsproveOK,themultiplexcontrolunitmustbefaulty.Replacetheunder-dashfuse/relayboxassembly.
Cavitv
K2
Wire
Test condition
BLU/ORN Underall conditions
M7
M9
YEUBLK
M6
M8
YEUBLK
P16
P17
YEL
YEUBLK
YEL
YEL
Test:Desiredresult
Checkfor continuitybetween
the K2terminalandthe keyless
receiver
unit5Pconnector
disconnected:
Thereshouldbe continuitv.
Checkactuatoroperation:
Thedriver'sdoorlockactuator
shouldlock lunlockl
ConnectJ7 terminalto M6
lMSl terminal,and M8
lM6l terminaltoJ4
Checkactuatoroperation:
The passenger's
doorlock
actuatorshouldlock iunlockl
Connect
J7 terminalto P17
lP16l terminal,and P16
l P 1 7 l t e r m i n a l t Jo4
Checkactuatoroperation:
The hatchlockactuatorshould
lock lunlockl
Faultydriver'sdoorlockactuator
An openin the wire
Faultypassenger's
doorlockactuator
An openin the wire
. Faultyhatchlockactuator
. An openin the wire
22-157
I
Keyless/Power
DoorLockSystem
Door LockActuatorTest
Driver'sdoor:
Passenger'sdoor:
1 . R e m o v et h e d r i v e r ' sd o o r p a n e l( s e e p a g e 2 0 - 4 ) .
1 . R e m o v et h e p a s s e n g e r 'dso o r p a n e l( s e e p a g e 2 0 4).
Terminal
ilil;lll
LOCK
UNLOCK
'l
e
e
e
e
Terminal
P."I,l.;--\
LOCK
UNLOCK
e
e
e
o
repracerr.
22-158
Terminalside of
m a l et e r m i n a l s
J
4. Checkactuatoroperationby connectingpower and
ground accordingto the table.To preventdamage
to the actuator,apply batteryvoltage only
momentaflty.
\Terminal
Po.irion\
LOCK
UNLOCK
22-159
Keyless/Power
DoorLockSystem
Door LockKnob Switch Test
1 . Remove
the driver'sdoorpanel(seepage20-4).
Disconnect
fromthe actuator.
the3Pconnector
Tr
NO
I
. t i
. l
I
(
. 1
22-160
TransmitterTest
TransmitterProgramming
NOTE:
. l f t h e d o o r su n l o c k o r l o c k w i t h t h e t r a n s m i t t ebru, t
the LEDon the transmitterdoes not come on, the LED
is faulty. Replacethe transmitter,
. l f a n y d o o r i s o p e n ,y o u c a n n o t l o c k t h e d o o r w i t h t h e
transmrtter.
. lf you unlockedthe doors with the transmitter,but do
not open any of the doors within 30 seconds,the
doors relockautomatically.
. The doors do not lock or unlockwith the transmitterif
the ignition key is insertedin the ignition switch.
Storingtransmittercodes:
The codes of up to three transmitterscan be storedin
the keylessreceiverunit memory. (lf a fourth code is
stored.the code which was input first will be erased.)
NOTE:lt is importantto maintainthe time limits
betweenthe steps.Make sure the doors and the hatch
are closed.
1 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i .
7 . W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
8. Within 1 to 4 sec.,push the transmitterlock or
unlockbuttonwith the transmifteraimed at the
receiverin the mupltiplexcontrol unit behindthe
driver's side of the dash.
9. Within 1 to 4 sec.,turn the ignition switch OFF,
'10.
W i t h i n4 s e c . t, u r n t h e i g n i t i o ns w i t c hO N ( l l ) .
1 1 . W i t h i n1 t o 4 s e c . ,p u s ht h e t r a n s m i t t elro c ko r
unlockbutton with the transmitteraimed at the
r e c e i v e irn t h e m u l t i p l e xc o n t r o lu n i t b e h i n dt h e
driver'sside of the dash.
1 2 . C o n f i r my o u c a n h e a r t h es o u n do f t h e d o o r l o c k
actuators.Within 1 to 4 sec.,push the transmitter
lock or unlockbutton again,
22-161
lmmobilizerSystem
ComponentLocationIndex
INOICATOR
LIGHT
page 22 63
Bulb Replacement,
ECM
page 11-4
Replacement,
Substituteknown-goodfor testing,
p a g e1 1 - 5
IMMOBILIZER
CONTROLUNIT.RECEIVER
page22-165
Troubleshooting,
page22-167
Replacement,
TRANSPONDER
(8uiltintothe ignitionkey)
22-162
SystemDescription
The vehicleis equippedwith an immobilizersystemthat will disablethe vehicleunlessthe proper ignition key is used.
This system consistsof a transponderlocatedin the ignition key, an immobilizercontrol unit-receiver,an indicator
l i g h t ,a n d t h e E C M .
When the key is insertedin the ignition switch and turned to the ON {ll) position,the immobilizercontrol unit-receiver
sendspower to the transponderin the ignition key.The transponderthen sendsa coded signal backto the immobilizer
control unit-receiverwhich then sendsa coded signalto the ECI\4.
IMMOBILIZER
CONTROLUNIT.RECEIVER
KEYCYLTNDER
iEl'JUiliii'tlun"oona"|.r
lf the proper key has been used,the immobilizerindicatorlight will come on for about 2 seconds,then go off.
lf the wrong key has been used or the code was not receivedor recognizedby the unit,the indicatorlight will come
on for about 2 seconds,then it will blink until the ignition switch is turned OFF.
lf the ignition switch is turned OFF,the indicatorwill blinkfor about 5 secondsto signalthat the unit has reset
correctly,then the indicatorwill go off.
lf the customerhas lost his key,and cannot startthe engine,contactHondaCustomerRelations.
IMMOBILIZER
INDICATOR
LIGHTBLINKING
PATTERN:
IGNITIONSWITCH
ON
OFF
PROPER
KEY
INSERTED
INDICATOR
LIGHT
WRONGKEY
INSERTED
INDICATOR ON
LIGHT
ON
OFF
(| i.,
22-163
lmmobilizerSystem
CircuitDiagram
'
UNDTRrcODFUSE/RELAY
8OX
No20(LAl r USA
rGNtTt0i/
swlrcH
lct HoTin0N{ll)
.ndSIAnTl|l)
F G N
8ELAY1
YEUBIJ(
0R8
itAWStY
tct
tGPl
tGPz
EC
LGI
22-164
LG2
LG3
|M0CD
. PA8(II'IG
DATA
LIN(
SMIG
CONNECIOR SWITCH
.8nA{E
{0Lcl
FTUID
I!VEL
SWTfi
Troubleshooting
Beforetroubleshootingthe immobilizersystem,
troubleshootany EClvlDiagnosticTroubleCodes(DTCS)
( s e ep a g e1 1 - 3 )a, n d m a k es u r et h e E C Mh a s n o
malfunction.
YES-Go to step 7.
. B l o w nN o . 9 { 1 0 A ) f u s ei n t h e u n d e r - h o o fdu s e /
relay box.l
. An open in the WHT/REDwire.l
. B l o w nN o . 6 ( 1 5 A ) f u s ei n t h e u n d e r - h o o d
fuse/relaybox,I
. F a u l t yP G M - Fm
l a i n r e l a y1 , t
. A n o p e ni n t h e Y E U B L Kw i r e . l
l
(cont'd)
22-165
lmmobilizerSystem
Troubleshooting(cont'dl
8. Checkfor voltage betvveenthe immobilizercontrol
unit-receiver7P connectorNo. 6 terminal and No. 1
rermlnat.
ls there continuity?
Y E S - G o t o s t e p1 3 .
wire.I
N O - R e p a i tr h e o p e ni n t h e R E D / B L U
22-166
lmmobilizerControl Unit-ReceiverReplacement
'L
(c).
22-167
MultiplexControlSystem
lr,
ComponentLocationIndex
REARCEILINGLIGHT
Test,page22'96
LIGHT/SPOTLIGHTS
Test,page22-96
ASSEMBLY
GAUGE
IGNITIONKEYLIGHT
Test,page22'91
ECM
MULTIPLEXCONTROLUNIT
{Builtinto the under-dash
fus6/relav boxl
Troubleshooting,page22'172
InputTest,page22-175
22-168
CircuitDiagram
UiIDM HOOD
IUSE/NEUY
BOX
'
I'10.20
:usA
{a0AJ
UNDEf,
DASH
ib.a)l50A):C.nd.
FUSE/NEUYBOX
IGNITiON
SWITCH
--_to
/ BAI \
oJ\
tcl ./
BLI,'YEL
MULTIPLEX
c0NT80r
tNsPECTror!
CONNECIOF
HAICII
LATCH
SWITCH
G201
{cont'd)
22-169
MultiplexControlSystem
CircuitDiagram(cont'd)
l'1o.3
tUSt
l7.5AJ
lln$.uidt hoodr
itutefd4bor I
V
I
wHTPLU
l0
t--t---
lrfl |
lE
lnv*| > | ucHT
lt A
l'*'
Y l
I'
CIILINGLIGHT
I.l|MOBItEER
@NTIOL
UIIIT
RECEIVEE
VI
I
22-170
SystemDescriptions
The MultiplexControlSystem hasfour internal
functions:
. Multiplexing
( s e n dm u l t i p l es i g n a l so v e rs h a r e d
wtres)
. Wake up/sleep(runsat full power only on demandto
reducebatterydraw)
. Fail-safe(fixesor ignoresfaulty signals)
. Self-diagnosis(Mode 1 for the system,Mode 2 for
i n p u tl i n e s )
The systemcontrolsthe functionof these circuits:
. E n t r yl i g h t c o n t r o(l i g n i t i o nk e y l i g h t a n d c e i t i n gl i g h t )
. Wiper/washerintermittentwipe and park functions
. Keyless/powerdoor lock
. Meter assembly,temperaturegauge,and indicator
lights
. HVAC(compressorand fan control)
. K e y - i nr e m i n d e r
. H e a d l i g hrte m i n d e r
. Seatbeltreminder
MultiplexCommunication
To reducethe number of wire harnesses,digital signals
a r e s e n tv i a s h a r e dm u l t i p l e xc o m m u n i c a t i o lni n e s
r a t h e rt h a n s e n d i n gn o r m a le l e c t r i c asl i g n a l st h r o u g h
i n d i v i d u awl i r e s .
. The input signalsfrom each switch are convertedto
digital signalsat the centralprocessingunit (CpU).
. T h e d i g i t a ls i g n a l s a r e s e n t f r o m t h e t r a n s m i t t i nu gn i t
t o t h e r e c e i v i n gu n i t a s s e r i a ls i g n a l s .
. The transmittedsignalis convertedto a switch signal
at the receivingunit, and it operatesthe related
componentor monitors a swltch.
. There are exclusivecommunicalionlines between
the ECM,the gauge assembly,and the under,dash
fuse/relaybox.
Wake-upand Sleep
The multiplexcontrol system has "wake-up" and
"sleep" functions
to decreaseparasiticdraw on the
batterywhen the ignitionswitch is OFF.
. ln the sleep mode,the multiplexcontrol unit stops
functioning(communicationand CPUcontrol)when it
is not necessaryfor the systemto operate.
. As soon as any operationis requested(for example,a
door is unlocked),the relatedcontrol unit in the sleep
mode immediatelywakes up and beginsto function.
. When the ignition switch is turned OFF,and the
driver'sor front passenger'sdoor is opened,then
closed,there is about a 10 seconddelay beforethe
control unit goes from the wake-upmode to the sleep
mode.
. lf any door is open,the sleep mode will not function.
. l f a k e y i s i n t h e i g n i t i o ns w i t c h ,t h e s l e e pm o d ew i l l
not function.
. When in sleep mode,the draw is reducedfrom
70 80 mA to lessthan 10 mA.
Fail-safe
To preventimproper operation,the multiplexcontrol
system has a fail-safefunction.In the fail-safemode,
the output signal js fixed when any part of the system
malfunctions(for examplea faulty control unit or
c o m m u n i c a t i o lni n e ) .
Eachcontrol unit has a hardwarefail-safefunctionthat
fixes the output signalwhen there is any CPU
malfunction,and a softwarefail-safefunctionthat
i g n o r e st h e s i g n a lf r o m t h e m a l f u n c t i o n i ncgo n t r o lu n i t
and allowsthe systemto operatenormally.
22-171
/ar
Multiplex ControlSystem
Troubleshooting
Mode 1 Tset
1. Removethe driver's dashboardlower cover {see
page 20-59).
YES Go to step 9.
NO Go to the Mode 2 test.
9. Troubleshootthe DTC(S)in the order indicated
u s i n gt h e f o l l o w i n gc h a r t s .
lf a faulty control unit is suspected,substituteit
with a known food part and recheckfor DTCS,
. lf the DTC(s)isstill present.go to the next step
listedfor the DTC.
. lf the DTC(S)is no longer presentreplacethe
originap
l art.
NO Go to step 7.
22-172
I
Individual
Multiplex
DTC
Probable Cause
The multiplexcontrol unit cannot
receivesignalsfrom the gauge
assemDty.
'l
2 . Faultygauge assemblv
3 . Faultyunder-dashf use/relay
box
The multiplexcontrol unit cannot
receivesignalsfrom the ECM
1
Faultypower or ground to the
ECM
2 . F a u l t yE C M
?
Faultyunder-dash
fuse/relay
box
box
5
I
6
DTCs
Multiplex
DTC
1 , 2a n d3
Probable Cause
&
communicationwires.
ECMDTC
Short to ground on the YELwire
P0600
betweenthe PCMterminal E24
Simultane
and the under-dashfuse/relay
ously
b o x t e r m i n a lE 1 0
2 . Short to ground on the WHT/
GRNwire betweenthe Gauge
assemblyterminal A2 and
under-dashfuse/relaybox
t e r m i n a lK 1 0
1 a n d 6 Open in the communicationwire
Simultane I
Open in WHT/GRNwire
o u sl y
betweenthe under-dashfuse/
relay box terminal K10 and the
GauqeassemblVterminal 42
2 a n d 5 O p e ni n t h e c o m m u n i c a t i o w
n ire
S i m u l t a n e 1 Open in the YELwire between
ously
the under-dashfuse/relaybox
t e r m i n a lE 1 0a n d E C Mt e r m i n a l
'Before
(cont'd)
22-173
CONNECTOR
E I13P)
3
6
GRN/ORN
BLU
4
10
/V
1 0) . / 12
GRN/RED
,/1,/l,/ 12
WHT/BLK
RED/WHT
17
CONNECTORY {13P)
BRN/YEL
BLU/RED BLU/RED
RED
CONNECTOR
X {8P)
LTGRN/RED GRN/ORN
15
GRN/RED
CONNECTOR
O (8P}
coNNECTOR
P (18P)
,/ l,/
2
5
BLK
CONNECTOR
O I12P)
WHT/GBN
CONNECTOR
J {8PI
WHT/RED
YEL
CONNECTOR
K {17P)
CONNECTOR
F {12P}
GRN/RED
{USAI
(Canada)
GRN/ORN
,/1,/
r0
12
BLK
{cont'd)
22-175
MultiplexControlSystem
MultiplexControl Unit lnput Test (cont'd)
andsocketterminals
to be suretheyareall makinggoodcontact
the connector
3. Inspect
.lftheterminalsarebent,looseorcorroded,repairthemasnecessary,andrecheckthesystem
. llthe terminalslookOK,go to step4.
Test condition
J4
Wire
BLK
[ Jn d e r a l l c o n d i t i o n s
Y6
BLK
lJnderall conditions
Cavitv
Test:Desired.esult
Check{or voltage1oground:
Therc sholl.l he 1V or less
C h e c kf o r v o l t a g et o g r o u n d :
There should bc 1 V or less.
Y1
BFNryEL Parkingbrakelever
J2
Possible
causeif resullEqS!q!!e!!ed
Poorground(G20'l)
An ooenin the wire
Poorground1G501)
An ooenin thewire
An openin thewire
Shorttoground
unit
FaultyABSmodulatorcontrol
in the under'hood
BlownNo.9 (10A)fuse
box
fuse/relay
An oncnin rhc wire
connectors
on lhe underunderdashfuserelaybox,andmakesuretheseinputtestsatthe appropriate
4. Reconnectthe
connectorstothe
box.
dashfuse/relav
. lf anytestindicates
the system
a problem,{ind andcorrectthe cause,then recheck
fuse/relay
box assembly
. lf alltheinputtestsproveOK,the multiplexcontrolunit mustbe faulty.Replace
the under_dash
Cavitv
o3
GRN
Test condition
Driver'sdooropen
Driver'sdoorclosed
door
LT GRN/RED Passenger's
O4
door
Passenger's
osI]l
.
GRN/ORN Parkingbrakelever
4.,
GRN/ORN
F1
GRN/RED
(USA)
GRN/ORN
(Canada)
F8
Tesi: Oesiredresult
C h e c kf o r v o l t a g e t o g r o u n d :
There should be 1 V or lessC h e c kf o r v o l t a g e t o g r o u n d :
There should be 5 V or more.
C h e c k. f o rv o l t a g e 1 0 g r o u n d :
There should be 1 V or less.
o5
Q6
P18
H",=
f-9*:li:'^:**:':s*:*
X5
22-176
l g n i r i o nk e y i n t h e
ignit on switch
C h e c kf o r v o l i a g e t o g t o u n d :
Thpre should be I V or lcss
l g n r t r o nk e v o u r o { t h e
C h e c kf o r v o l l a g e t o g r o u n d :
Possible
causeifresultis notobtained
Faultydriver'sdoorswitch
An ooenin the wire
Faultydriver'sdoorswitch
Shortto qround
doorswitch
Faultypassenger's
An ooeninthewire
doorswitch
Faultypassenger's
Shortto oround
F a u l t yp a r k i n gb r a k e s w i t c h
. An ooen in thewire
. Faultyparkingbrakeswitch
Shorttoground
Faultydriver'sseatbeltswitch
P o o r g r o u n(dG 5 5 1 )
An oDenin the wire
Faultydriver'sseatbeltswitch
Shorttoground
Faultyhatchlatchswrtch
Poorground(G552)
An openin the wire
F a u l t yh a t c h l a t c hs w i t c h
. F a u l t yi g n i t i o n k e y s w i t c h
. Poorground (G401)
. An open in the wire
**6
I : [11y.'::i':::1"'
J
Cavitv
X8
o7
Wire
WHT/BLK
GRN/RED Ceilinglightswitchin A t t a c h t o g r o u n d : T h e c e i l i n g l i g h t ,
the middleposition, s p o t l i g h t ss h o u l d c o m e o n .
all doorsclosed
c]1
BLU
F8
GRN/RED
E10
Test condition
Test:Desiredresult
Underallconditions Attachto ground:Theignitionkey
lightshouldcomeon.
YEL
Brakefluidreservoir C h e c kf o r v o l t a g et o g r o u n d :
float in down
T h e r e s h o u l d b e l e s st h a n I V .
position(brakefluid
Brakelluid reservoir Checkfor voltageto ground:
floatin up position
Thereshouldbe 5 V or more.
(brakefluidat full
level)
Underall conditions C h e c kf o r v o l t a g et o g r o u n d :
Possible
causeif resukis notobtained
BlownNo.3 (7.5A)fuse
in the under,hood
BlownLED
An ooenin the wire
ElownNo.3 (7.54)fusein the undeFhood
Faultyceilinglight
An oDenin the wire
BlownNo.2 (15Aifusein the under-hood
fuse/relaybox
Faultytaillightrelay
An ooenin the wire
Faultybrakefluidlevelswitch
An openin thewire
Faultybrakefluid levelswitch
Shorttoground
. An openor shortin thewire
T h e r e s h o u l d b e b a t t e r yv o l t a g e i n
t h e s l e e pm o d e a n d 3 T v o l t s w h e n
K10
I J
22-177
I
Restraints
Restraints
SpecialTools
.............
23-2
SeatBelts
Component
LocationIndex .........................................
23-3
FrontSeatBeltReplacement
.......................................
23-4
RearSeatBeltReplacement
........................................
23-6
Inspection
..................
23-8
ChildSeatTetherAnchorRemoval/lnstallation
........23-9
SRS(SupplementalRestraintSysteml
Component
LocationIndex .........................................
23-13
Precautions
and Procedures
,,.,.........
23-14
General
Troubleshooting
Information.......................
23-23
DTCTroubleshooting
Index
..............
23-28
SymptomTroubleshooting
Index...............................
23-30
SystemDescription.................
...........
23-31
CircuitDiagram
.........23-34
DTCTroubleshooting
...............
..........
23-36
Indicator
SRS
CircuitTroubleshooting
.......................
23-105
ComponentReplacemen(/lnspection After
Deployment
..............23-112
Driver'sAirbagReplacement
............
23-113
FrontPassenger's
AirbagReplacement
.....................
23-114
SideAirbagReplacement
..................
23-115
A i r b a gD i s p o s a.l . . . . . . . . . . . . . . . . . . . . . .
........2
. .3. - 1 1 6
l eplacement
C a b l eR e eR
. . . . . . . . . . . . . .2. .3. .- .1. 1 9
SRSUnitRepfacement
.......................
23-122
SidefmpactSensorReplacement
..........,....................
23-123
OPDSUnitReplacement
....................
23-124
FrontfmpactSensorReplacement
..............................
23-125
Restraints
SpecialTools
'
07HAZ-SG00500
8t
oTPM-oo101oo
oTsM-TB4o114
oTTM-sz5o114
o-'
07TM-0010204
@
-1
o7xAz-s140200
07xAz-s230100
DeploymentTool
SCSServiceConnector
r i mu l a t o r
S R SI n f l a t o S
S R SS i m u l a t o rL e a dC
B a c k p r o bA
e dapter1
, 7m m
S R SS i m u l a t o rL e a dE
S R SS i m u l a t o rL e a dF
S R SS i m u l a t o rL e a dH
* 1 : I n c l u d e di n S R ST o o l S e t0 7 M M ' S M 5 0 0 0 8
*2: Use with the stackingpatchcords from T/N 07SAZ-0010004,
BackprobeSet.
Gl
ro
L .
23-2
SeatBelts
ComponentLocationIndex
REARCENTER
BELTand
REARSEATBELTBUCKLES
step1 on page23-8
page23 9
Inspection,
SHOULDER
ANCHOR
ADJUSTER
step8 on page23-4
FRONTSEATBELT
page23-4
Replacement,
page23 9
Inspection,
I
CHILDSEATTETHER
ANCHORS
Removal/lnstallation,
page23-11
REARSEATBELT
page23.7
Beplacement,
page23-9
Inspection,
FRONTSEAT
BELTBUCKLES
step1 on page23'6
23-3
SeatBelts
FrontSeat Belt Replacement
SRScomDonentsare locatedin this area.Reviewthe
SRScomponentlocations(seepage23-13)and the
precautionsand procedures(seepage23-14)in the SRS
sectionbefore performingrepairsor service,
5 . R e m o v et h e r e a rs i d et r i m p a n e l( s e e p a g e 2 0 - 5 1 ) .
7/16-20
UNF
32 N.m(3.3kgf m,2irlbf.ft)
8. lf necessary,removethe front seat belt protecto
(F).
qt
23-4
Upperanchorbolt construction:
UPPERANCHOR
BOLT
UPPERANCHOR
BUSHING
COLLAR
TOOTHED
LOCKWASHER
WASHER
22 N.m(2.2kgf.m,16lbf.ftl
1 1 .Installtheseat belt in the reverseorder of removal,
and note these items:
. lf thethreads on the retractormounting selftapping ET screw are worn out, use an oversized
self-tappingET screw (P/N90133-SZ4-0030)
made specificallyfor this application.
. Checkthat the retractorlockingmechanism
functions(seepage 23-9).
. A s s e m b l et h e w a s h e r sc, o l l a r s a, n d b u s h i n go n
the upper and lower anchorbolts as shown.
. lf the seat belt tensionerhas been deployed
replacethe front seat belt protectorwith a new
one.
. A p p l y l i q u i dt h r e a dl o c kt o t h e a n c h o rb o l t s
beforereinstallation.
. Beforeinstallingthe anchorbolts,make sure
there are no twists or kinksin the front seat belt.
. Make sure the seat belt tensionerconnectoris
pluggedin properly.
. Reconnectthe negativecableto the battery.
. Enterthe anti-theftcode for the radio,then enter
the customer'sradio stationpresets.
. Resetthe clock.
. Do the ECM/PCMidle learn procedure{seepage
11,139).
LOWERANCHORBOLT
TOOTHEDLOCKWASHER
{cont'd)
23-5
Seat Belts
Front Seat Belt Replacement(cont'd)
SeatBelt Buckle
1. Make sure you have the anti-theftcode for the radio,
then write down the frequenciesfor the preset
buttons.
2. Disconnectthe negativecablefrom the battery,
and wait at least3 minutesbefore beginningwork.
3. Removethe front seat (seepage 20-7'1).
4. Detachthe seat belt switch connectorclip (A),seat
belt buckletensionerconnectorclip (B),and
h a r n e s sc l i p ( C ) .
.-..:.a--
7/16-20
UNF
32N m {3.3kgf m,24lbf.ft)
6. Pullthe seat belt switch/tensionerharness(C)out
through the hole on the seattrack.
23-6
COLLAR
RearSeatBelt
1 . R e m o v et h e r e a rs e a tc u s h i o n( s e ep a g e2 0 8 0 ) .
2. Removethe lower anchor bolt {A}.
A
7/16-20UNF
32 N.m (3.3kgf.m,
24 tbf.ftl
3 , R e m o v et h e r e a rs i d et r i m p a n e l( s e ep a g e2 0 - 5 1 ) .
4 . Removethe retractormounting self-tappingET
screw (A),and the retractorbolt (B),then remove
the rear seat belt (C)and retractor{D).
B
7/16-20
UNF
N m {3.3kgf.m,2irlbf.ft)
A
6x1.0mm
3.4 N.m {0.35kgl m,2.5 lbf.ftl
(cont'd)
23-7
SeatBelts
RearSeat Belt Replacement{cont'd)
CenterBelt and Seat Belt Buckles
1. Removethe seatcushion{seepage 20-80).
'.;r'"
1-..i, ,
<i..
-"':''
"':
A
6x1.0mm
9.8 N.m (1.0kgf m,
7.2 tbl.ttl
7/16-20UNF
32 N.m(3.3kgf m,
24 tbf.ftl
.:.',
t.)
23-8
Inspec'tion
9. lnstallthe seat belt and bucklesin the reverseorder
of removal,and note these items:
. Checkthat the retractorlockingmechanism
functions(seestep 1 on page 23-10).
. Assemblethe washerson the centeranchor bolt
as shown (exceptcentershoulderbelt).
. Apply liquidthread lock to the anchor bolts
beforereinstallation.
. Beforeinstallingthe centeranchor bolt, make
sure there are no twlsts or kinksin the centerbelt,
Canler anchor bolt construction:
WASHER
with seatbelttensioners.
Forfrontseatbeltretractors
locations(seepage23-13)
reviewtheSRScomponent
(seepsge23-14)in
andprocedures
andthe precautions
the SRSsectionbeforeperformingrepairsor service.
Forward
lnside
Rear:
Forward
Inside
(cont'd)
23-9
Seat Belts
Inspection(cont'd)
In-vehicle
RetraEtor,RearCenter
1. Beforeinstallingthe retractor,checkthat the seat
belt can be pulled out freely.
2, Make sure that the seat belt does not lockwhen the
retractor(A) is leanedslowly up to 15' from the
mounted position.
lnside
Forward
\,J
23-10
ChildSeatTetherAnchorRemovaUlnstallation
Side
Middle
1. Removethe child seattether anchorcover (A) in
t h e r e a rt r i m p a n e l( B ) .
f-..- t"
.i..].-
,tltl
8 x 1.25mm
22 N m {2.2ksf.m, 16lbf.ft)
v\
2 . R e m o v et h e a n c h o rb o l t( C ) ,t h e n r e m o v et h e c h i l d
seattether anchor(D).Do not removethe toothed
washer (E)from the tether anchor.
8 x 1 . 2 5m m
22 N.m {2.2kgt m. 16lbfft)
l n s t a l l t h ea n c h o r si n t h e r e v e r s eo r d e ro f r e m o v a l .
3 . I n s t a l l t h ea n c h o ri n t h e r e v e r s eo r d e ro f r e m o v a l .
I J
23-11
sRs
ComponentLocationIndex
LEFTFRONTIMPACTSENSOB
RIGHTFRONTIMPACTSENSOR
SRSINOICATOR
page23-105
Troubleshooting,
SIDEAIRBAG CUTOFFINDICATOR
AIRBAG
DRIVER'S
page23-113
Replacement,
page
Disposal, 23 1'16
FRONTPASSENGER'SAIRBAG
page23-114
Replacement,
Disposap
l , a g e2 3 ' 1 1 6
SENSOR/
SEATBACK
Replacement,
page20-75
FRONTPASSENGER'S
SIDEAIRBAG
Replacement,
p a g e2 3 ' 1 ' 1 5
Disposal,
p a g e2 3 ' 1 1 6
FRONTPASSENGER'S
SEATBELT
TENSIONER
Beplacement,
page23-4
Disposal,
page23-'116
CABLEREEL
Beplacement,
p a g e2 3 - 1 1 9
MEMORYERASE
(MES}
SIGNAL
CONNECTOR
I2PI
OPDSUNIT
page23-27
Initialization,
page23-124
Replacement,
SIOE
PASSENGER'S
IMPACTSENSOR
Replacement,
p a g e2 3 - 1 2 3
DATA LINK
CONNECTOR
(DLCI16P
FRONTPASSENGER'SSEAT
BELTBUCKLETENSIONER
DRIVER'SSEATBELTTENSIONER
page23 4
Replacement,
D i s p o s a pl ,a g e2 3 - 1 1 6
23-13
sRs
Precautionsand Procedures
GeneralPrecautions
Steering-related
Plecautions
CableReelAlignment
. Exceptwhen performingelectricalinspections.
alwaysturn the ignition switch OFF,disconnectthe
negativecablefrom the battery,and wait at least3
minutesbefore beginningwork.
NOTE:The memory is not erasedeven if the ignition
switch is turned OFFor the batterycablesare
disconnectedfrom the battery.
. Use replacementpans which are manufacturedto the
same standardsand quality as the original parts.Do
not installused SRSpartsfrom anothervehicle.Use
only new pans when making SRS repairs.
. Carefullyinspectany SRS part beforeyou installit.
Do not installany part that shows signs of being
droppedor improperlyhandled,such as dents,cracks,
or deformation.
23-14
. M i s a l i g n m e not f t h e c a b l er e e lc o u l dc a u s ea n o p e ni n
t h e w i r i n g ,m a k i n gt h e S R Ss y s t e ma n d t h e h o r n s
inoperative.Centerthe cable reelwheneverthe
following is performed(seestep 6 on page23-121).
-
\rc
AirbagHandlingand Storage
(cont'd)
23-15
sRs
.j
Precautionsand Procedures{cont'dl
SRSUnit, Front lmpact Sensors,and Side
lmpact Sensors
23-16
I
WiringPrecautions
Precautions
for ElectricalInspections
(cont'd)
23-17
sRs
Precautionsand Procedures(cont'dl
Spring-loaded
LockConnector
Disconnecting
T o r e l e a s et h e l o c k ,p u l l t h es p r i n g - l o a d esdl e e v e( A )
a n dt h e s l i d e r{ B )w h i l e h o l d i n gt h e o p p o s i t eh a l fo f t h e
connector.Then pullthe connectorhalvesapart.Be
sure to pull on the sleeveand not on the connectorhalf.
Connecting
1. To reconnect,hold the pawl-sideconnector,and
presson the backof the sleeve-sideconnectorin
the directionshown. As the two connectorhalves
are pressedtogether,the sleeve(A) is pushedback
by the pawl (C).Do not touch the sleeve.
Connecting
Hold both connectorhalves,and pressthem firmly
togetheruntil the projection(C)of the sleeveside
connectorclicks.
\ J
23-18
Backprobing
Spring-loaded
LockConnectors
Seatswith SideAirbags
"SIDEAIRBAG" label
Seatswith side airbagshave a
on
the seat-back.Becausethe componentpans (seat-back
cover,cushion,etc.)of seatswith and without airbags
are different,make sure you installonly the correct
replacementparts.
A
To removethe retainer(A),inserta flat-tipscrewdriver
(B) betweenthe connectorbody and the retainer,then
carefullypry out the retainer.Takecare not to breakthe
connector.
W h e n c l e a n i n gd, o n o t s a t u r a t e t h es e a t w i t hl i q u i d ,
and do not sDravsteam on the seal
Do not reoalra torn or fraved seat-backcover.
ReDlacethe seat-backcover.
A f t e ra c o l l i s i o ni n w h i c ht h e s i d ea i r b a gw a s
deployed,replacethe side airbagwith new parts.lf
the seat-backcushion is split, it must be replaced.lf
the seat-backframe is deformed,it must be replaced.
Never put aftermarketaccessorieson the seat{covers,
pads,seat heaters,lights,etc.).
(cont'd)
23-19
sRs
Precautionsand Procedures(cont'dl
DisconnectingSystemConnectors
Beforeremoving a front airbag.side airbag,or other SRS relateddevices{the SRS unit,the cable reel,the front impact
sensors,the side impact sensors,the seat belt buckletensioners,and the seat belt tensionerconnector),disconnecting
connectorsfrom relateddevices,or removingthe dashboardor the steeringcolumn, disconnectthe airbagconnectors
or the side airbagconnectorsto preventaccidentaldeploVment.
Turn the ignition switch OFF,disconnectthe negativecablefrom the battery,and wait at least3 minutesbefore
beginningthe following procedures.
'BeforedisconnectingSRSunitconnectorA(1)fromtheSRSunit,disconnectthedriver'sairbag4Pconnector(3).
the front passenger'sairbag4P connector(4),the driver'sseat belt tensioner2P connector(6),and the front
passenger'sseatbelt tensioner2P connector(7).
. BeforedisconnectingSRS unit connectorB (8)from the SRS unit, disconnectboth side airbag2P connectors(11.'12),
and both seat belt buckletensioner4P connectors(9, 10).
. Beforedisconnectingthe cable reel 4P connector(2),disconnectthe driver'sairbag4P connector(3).
'Beforedisconnectingthefloorwireharness4Pconnector(5),disconnectbothseatbelttensioner2Pconnectors
(6.7).
23-20
Side Airbag
4. Disconnectboth side airbag2P connectors(Alfrom
the floor wire harness.
Front Passenger'sAirbag
3. Disconnectthe front passenger'sairbag4P
connector(A)from dashboardwire harnessB.
(cont'd)
23-21
sRs
Precautionsand Procedures(cont'd)
SeatBelt Tensioner
bothseatbelttensioner2Pconnectors
5. Disconnect
(A)fromthefloorwire harness
4
SRS Unit
7. DisconnectSRS unit connectorA, SRS unit
connectorB, and/or SRS unit connectorC from the
S R Su n i t .
\ J
23-22
GeneralTroubleshooting
Information
DTC(Diagnostic
TroubleCodesl
Readingthe DTC
The self-diagnostic
function of the SRSsystem allows it
to locatethe causesof system problemsand then store
this informationin memory. For easiertroubleshooting,
this data can be retrievedvia a data link circuit.
. W h e ny o u t u r n t h e i g n i t i o ns w i t c hO N ( l l ) ,t h e S R S
indicatorwill come on. lf it goes off after 6 seconds,
the system is normal.
. lf there is an abnormality,the svstem locatesand
definesthe problem,storesthis informationin
memory, and turns the SRS indicatoron. The data
w i l l r e m a i ni n t h e m e m o r ye v e nw h e n t h e i g n i t i o n
switch is turned off or if the batteryis disconnected.
. When you connectthe HondaPGlMTesterto the 16P
d a t al i n kc o n n e c t o(rD L C ) t os h o r tt h e S C St e r m i n a l ,
a n d t u r n t h e i g n i t i o ns w i t c hO N ( l l ) .t h e S R Si n d i c a t o r
will indicatethe diagnostictrouble code (DTC)by the
n u m b e ro f b l i n k s .
. When you connectthe HondaPGM Testerto the 16P
data link Connector(DLC),you can retrievethe DTCin
t h e H o n d aS y s t e m s" S R S " m e n u .
. After readingand recordingthe DTC,proceedwith
the troubleshootingprocedurefor th is code.
Precautions
. U s eo n l y a d i g i t a lm u l t i m e t etro c h e c kt h e s y s t e m .l f
it's not a Hondamultimeter,make sure its output is
1 0 m A ( 0 . 0 1 Ao) r l e s sw h e n s w i t c h e dt o t h e s m a l l e s t
v a l u ei n t h e o h m m e t e rr a n g e A
, t e s t e rw i t h a h i g h e r
o u t p u tc o u l dd a m a g et h e a i r b a gc i r c u i to r c a u s e
a c c i d e n t aal i r b a gd e p l o y m e nat n d p o s s i b l ei n j u r y .
. Wheneverthe ignition switch is ON (ll),or has been
turned OFFfor lessthan 3 minutes,be careful not to
b u m pt h e S R Su n i Ut h e a i r b a g sc o u l da c c i d e n t a l l y
d e p l o ya n d c a u s ed a m a g eo r i n j u r i e s .
. Beforeyou removethe SRSharness,disconnectthe
driver's airbagconnector.the front passenger's
airbagconnector,both side airbagconnectors,both
seat belt buckletensionerconnectors,and both seat
b e l tt e n s i o n ecr o n n e c t o r s .
. Make sure the batteryis sufficientlycharged.lf the
batteryis dead or low, measuringvalueswon't be
correct.
. Do not touch a tester probe to the terminalsin the
SRSunit or harnessconnectors,and do not connect
t h e t e r m i n a l sw i t h a j u m p e rw i r e . U s eo n l y t h e
backprobeset and the HondaPGM Tester.Backprobe
spring loadedlocktype connectorscorrectly.
(cont'd)
23-23
sRs
L
GeneralTroubleshootingInformation(cont'd)
PGM Tester "SCS" Menu Method {retrieving the flash
codes):
The SRSindicator(A) indicatesthe DTCby lhe number
of blinkswhen the Honda PGM Tester(B) is connected
to the DLC(datalink connector)( 16P)(1).
'1.
*t**t*l*l
""_f]_flfl
Maincodo= 1
=3
In caseot 11..'15
Fourfastblinkscountas 10.
Add anyfunherblinkstogetheras shown.
Example:
0 . 1s
,A
/// t\\\
//lii\\
|
""ffi
Main code=
=12
10
l n c a s eo f 2 0 o r m o r e
T w o s e t s o f f o u r f a s t b l i n k sc o u n t a s 2 0 .
A d d a n y f u n h e r b l i n k s t o g e t h e ra s s h o w n .
Examplo:
0 . 1s
4. Readthe DTC.
0.1s
12s12s
,y'fl\,,. /[N *l*FtftffN*+fH-t-ff
Main code=
10
10
Readingthe subcode:
Count
thenumber
of blinks.
T h e D T C c o n s i s t so f a m a i n c o d e a n d s u b c o d e .
Example:
S: Second
6S
25
o N
[ l I t l - l- - - -|- L [l - - - l
oFFl
First emitting Main code
l**t**t*t*t*l
35
Subcode
""ffi
S
e
'3',
a n d t h e s u b c o d ei s
'
' 4 ' , r e c o r da
\ J
23-24
0.3s
0.3s 0.3s
S: Second
ON
OFF
Bulb check
period
Maincode(21 Subcode
l1)
ON
OFF
Bulb check
DTC 5-1
period
(no
3. Normal
failure|,SRSIndicatorblinks like this:
lndicator stays on in
case of i nterm ittent failu re.
ON
OFF
Bulb chock
period
(cont'd)
23-25
sRs
GeneralTroubleshootingInformation(cont'dl
Erasingthe DTGMemory
Troubleshootinglntermittent Failures
07PAZ-0010100
3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
4. The SRS indicatorwill come on for about 6 seconds,
and then go off. Removethe SCSserviceconnector
from the MES connectorwithin 4 secondsafterthe
indicatorgoes off.
5. The SRS indicatorwill come on again.Reconnect
the SCSserviceconnectorto the MES connector
within 4 secondsafter the indicatorcomes on.
6. When the SRSindicatorgoes off, removethe SCS
serviceconnectorfrom the MES connectorwithin 4
seconds.
7 . T h e S R Si n d i c a t ow
r i l l b l l n kt w o t i m e s i n d i c a t i n g
that the memory has beenerased.
8. Turn the ignition switch OFF,and wait for
seconds.
'10
. h e S R Sj s
9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l )a g a i n T
OK if the SRSindicatorcomes on for 6 secondsand
then goes off.
23-26
\ J
I
Initializingthe OPDS{OccupantPositionDetectionSystem}Unit
Special Tool Required
SCSserviceconnector07PAz-00'1
0100
When a seat-backcover,seat-backcushion,and/or OPDSunit is replaced,initializethe OPDSby following the
procedurebelow.
NOTE:Make sure the front passenger'sseat is dry. Set the seat-backin the normal position,and make sure there is
nothing on the seat.
'1.
07PAZ-00r0100
4 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) .
5. The SRS indicatorcomes on for about 6 secondsand goes off. Removethe SCSserviceconnectorfrom the MES
connectorwithin 4 secondsafterthe SRSindicatorwent off.
6. The SRSindicatorcomes on again.Reconnectthe SCSserviceconnectorto the MES connectorwithin 4 seconds
afterthe SRS indicatorcomes on.
7. The SRSindicatorgoes off. Removethe SCSserviceconnectorfrom the MES connectorwithln 4 seconds.
8. Watch the sRS indicator.
'lftheindicatorblinkstwotimesandthenstayson,theOPDSisinitialized.buttheDTCSneedtobeerased.
step 9, then erasethe DTCS.
.lftheindicatorblinkstwotimesandthengoesoff,theOPDSunitisinitialized.Gotostep9.
' lf the indicatorstayson without first blinking.theOPDSis not initialized.Readthe DTC.lf DTC 15-'lis indicated,
repeatthe initializationprocedure.lf anotherDTCis indicated,go to the appropriatepage in the DTC
TroubleshootingIndex.
9. Turn the ignition switch off, and disconnectthe PGM Tester.
SBS indic.ror
MES
I J
DISCONNECTED
23-27
sRs
t .
DTCTroubleshootingIndex
DTC
t- |
t-5
1-4
t-5
2-1
2-2
2-3
2-4
2-5
3-1
3-2
3-3
3-4
3-5
21-1
2't-4
2't-5
4-'l
4-2
4-3
4-4
4-5
22-3
22-4
22-5
5-1
5-2
5-4
5-8
6-3
6-4
Detection ltem
O D e ni n d r i v e r ' sa i r b a qi n f l a t o r
Increasedresistancein driver'sairbaq inflator
Shon to anotherwire or decreasedresistancein driver's airbag
inflator
Shortto Dowerin driver'sairbao inflator
Shortto qround in driver'sairbaq inflator
Open in front Dassenqer's
airbaq inflator
I n c r e a s e rde s i s t a n cien f r o n tp a s s e n q e r 'asi r b a qi n t l a t o r
Short to anotherwire or decreasedresistancein front passenger's
airbao inflator
Short to oower in front oassenoer'sairbaq inflator
Short to qround in front passenqer'sairbaq inflator
ODenin driver'sseat belttensioner
lncreasedresistancein driver's seat belt tensioner
Short to anotherwire or decreasedresistancein driver'sseat belt
tensioner
Short to oower in driver'sseat belt tensioner
Short to oround in driver'sseat belt tensioner
ODenor increasedresistancein driver'sseat belt buckletensioner
Short to anotherwire or decreasedresistancein driver'sseat belt
buckletensioner
Short to Dowerin driver'sseat belt buckletensioner
Shon to oround in driver'sseat belt buckletensioner
ODenin front oassenoer'sseat belt tensioner
lncreasedresistancein front oassenqer'sseat belttensioner
Short to anotherwire or decreasedresistancein front passenger's
seat belt tensioner
seat belt tensioner
Shon to Dowerin front Dassenqer's
Short to qround in front oassenoer'sseat belt tensioner
Open or increasedresislancein front passenger'sseat belt buckle
tensioner
Short to anotherwire or decreasedresistancein front passenger's
seat belt buckletensioner
Short to oower in front oassenqer'sseat belt buckletensioner
Short to oround in front oassenoer'sseatbelt buckletensioner
lnternalfailure of SRSunit
NOTE:
BeforetroubleshootingDTCS5-1 through 8-6,checkbattery/system
voltage.lf the voltage is low, repairthe charging system before
troubleshootinothe SRS.
Notes
(seeDaqe23-36)
(seeDaoe23-36
(seepage23-37)
(seepaqe23-39
{seepaqe23-40
{seeoaoe23-42
(seeoaqe 23-42
(seepage23-43)
(seepaqe23-45
(seepaqe 23-46
(seepage 23-48
(seepaqe 23-48
(seepage 23-49)
(seeDaqe23-51
(seeoaoe 23-52
(seepaqe 23-54
(seepage23-55)
(seepaqe 23-56)
(seeoaqe23'57
{seepage23-58)
{seepaqe23-58)
{seepage23-60)
t J
lsee oaqe23-61
(seeDaqe23-63
(seepage 23-64)
(seepage 23-65)
(seepaqe 23-66
(seepaqe 23-68
(seepage23-69)
6-7
6-8
1-)
7-3
8-1
a-2
8-4
8-5
8-6
23-28
\ J
J
DTC
9-1
Detection ltem
Internalfailure of the SRS unit. lf intermittent,it could mean internal
failure of the unit or a faulty indicatorcircuit.Referto
TroubleshootingIntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem before
t r o u b l e s h o o t i nt gh e S R S .
Internalfailure of the SRSunit. lf intermittent,it could mean internal
failure of the power supply (VB line).Referto Troubleshooting
IntermittentFailures(seepage 23-26).
NOTE:BeforetroubleshootingDTC9-1 or 9-2,checkbattery/system
voltage.lf the voltage is low, repairthe chargingsystem or replace
the btterybeforetroubleshootingthe SRS.
Faultydriver'sseat belt buckleswitch
9-2
9-3
9-4
9-6
9-7
FaultLtglt passenger's
seatbeltbuckleswitch
13-1
13-4
14-1
i i
(seepage23-92)
(seepage23-70)
N o s i g n a lf r o m t h e f r o n t p a s s e n g e r 'ssi d ei m p a c ts e n s o r
Faultypower supply to the front passenqer'sside impact sensor
F a u l t vO P D Su n i to r O P D Sn o t i n i t i a l i z e d
Faultyside airbagcutoff indicatorcircuit
FaultyOPDSsensor
(seepaqe 23-94)
(seepage 23-95)
( s e ep a q e2 3 - 9 6 1
(seeDaqe23-99)
(seeoaoe 23-104)
10-2
r0-3
'10-4
'10-5
10-6
10-7
11-1
11-4
I t-5
12-4
Iz-5
N o s i g n a lf r o m t h e d r i v e r ' ss i d ei m p a c ts e n s o r
- 7
(seeDaqe23-71)
lgqgfage 23-74)
{see Daqe23-77)
(seepaqe 23-79)
10-1
l r
Notes
(seepage23-69)
14-3
14-4
15-1
15-2
15-3
(seepage23-69)
( s e ep a q e2 3 - 8 1 )
(seepage23-82)
(seeoaqe 23-83)
{seepaqe 23-85)
(seepage 23-86)
(seepage 23-87)
{seeDaqezJ-uu}
(seeoaqe 23-90)
(seepage 23-70)
( s e ep a q e2 3 - 9 1 )
I J
23-29
SRS
\
Symptom TroubleshootingIndex
Symptom
SRSindicatordoesn'tcome on
SRSindicatorstayson when in
"SCS" menu method
Diagnosticprocedure
S R SI n d i c a t oTr r o u b l e s h o o t i n(gs e e
p a o e2 3 - 1 0 5 )
SRSIndicatorTroubleshooting(see
step 1 on page 23-107)
. M a k es u r en o t h i n gi s o n t h e f r o n l
passenger'sseat.
. lf the side airbagcutoff indicator
stayson after the ignition switch
i s t u r n e dO N ( l l ) ,i n i t i a l i z teh e
OPDSunit (see page23-271.
- lf the side airbagcutoff
i n d i c a t o or p e r a t e sn o r m a l l Yt,h e
system is OK.
- lf the side airbagcutoff
indicatorstayson, replacethe
nUl.
u F U 5 S e n S O{ rS e eS e C r O Z
The sensor is part of the seatback Dad.
t r J
\ J
23-30
SystemDescription
SRSComponents
Airbags
The SRSis a safetydevicewhich, when used with the seat belt, is designedto help protectthe driver and front
passengerin a frontal impact exceedinga certainset limit. The system consistsofthe SRS unit, includingsafing
sensorand impactsensor(A),the cable reel (B),the driver's airbag(C),the front passenger,sairbag (D).seat belt
tensioners(l),seat belt buckletensioners(J), and front impactsensors(K).
Sincethe driver'sand front passenger'sairbagsusethe same sensors,both normally inflateat the same ttme.
However,it is possiblefor only one airbagto inflate.This can occurwhen the severityof a collision is at the margin,or
threshold,that determineswhether or not the airbagswill deploy.In such cases,the seat belt will provide sufficient
protection,and the supplementalprotectionofferedby the airbagwould be mininal.
Side Airbags
The side airbags(E)are in eachfront seat-back.They help protectthe upper torso of the driver or front seat passenger
during a moderateto severeside impact.Side impact sensors(F) in each door sill and in the SRS unit detectsuch an
impactand instantlyinflatethe driver'sor the passenger'sside airbag.Only one side airbagwill deploy during a side
impacl. lf the impact is on the passenger'sside,the passenger'sside airbagwill deploy even if there is no passenger.
Seat Belt and Seat Belt Buckle Tensioners
The seat belt and seat belt buckletensionersare linkedwith the SRSairbagsto further increasethe effectivenessof
the seat belt. ln a front-endcollision,the tensionersinstantlyretractthe belt and bucklefirmly to securethe occupants
in their seats.
OPDS
The side airbagsystemalso includesan occupantpositiondetectionsystem (OpDS).This systemconsistsof sensors
( G ) a n da n O P D Su n i t( H )i n t h e f r o n t p a s s e n g e r 'sse a t - b a c kT.h e O P D Su n i t s e n d so c c u p a nht e i g h la n d p o s i t i o nd a t at o
the SRS unit. lf the OPDSunit determinesthat the front passengeris of small stature(for example,a child) and the
front passengeris leaninginto the side airbag deploymentpath,the SRSunit will automaticallydisablethe passenger's
side airbag.The SRSunit will also disablethe airbagwhen the OPDSdetectscertainobiectson the seat.When the
side airbag is disabled,the side airbagcutoff indicatoron the instrumentpanel alertsthe driver that the passenger's
side airbagwill not deploy in a side impact.When the object is removed,or the passengersits upright,the side airbag
cutoff indicatorwill go off after a few seconds,alertingthe driver that the passenger'sside airbagwill deploy in a side
imDact.
(cont'd)
23-31
sRs
SystemDescription(cont'dl
!J
SRSOperation
The main circuit in the SRS unit sensesand judgesthe force of impact and, if necessary.ignitesthe inflatorcharges.lf
batteryvoltage is too low or power is disconnecteddue to the impact,the voltage regulatorand the back-uppower
circuit,respectively,will keepvoltageat a constantlevel.
For the SRS to operate:
Seat Belt Tensioners and Seat Belt Buckle Tensioners
(1)A front impact sensormust activateand send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signalsand send them to the tensioners.
(3)The chargesmust ignite and deploy the tensioners.
Driver's and Front Passenger'sAirbagls)
(1)A front impactsensor musl activate.and send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signals.and dependingon the severityof the collisionand whetherthe seat
belt buckleswilch is ON or OFF,it sendsthe appropriatesignalsto the airbag inflator(s).
(3)The inflatorsthat receivedsignalsmust ignite and deploy the airbags.
Side Airbaglsl
( 1)A side impact sensormust activate,and send electricsignalsto the microprocessor.
(2)The microprocessormust computethe signalsand send them to the side airbag inflator(s).However,the
microprocessorcuts off the signalsto the front passenger'sside airbag if the OPDSunit determinesthat the tront
passenger'shead is in the deploymentpath of the side airbag.
(3)The inflatorthat receivedthe signal must ignite and deploythe side airbag.
lw$ad..n sl
T'
n0m
S I
P gsfrlctR
S oXrVEr
9oEAiA$ SOtlr&G I
J
sEctto
f'**)r !
\ J
23-32
Self-diagnosis System
A self-diagnosiscircuitis built into the SRS uniUwhen the ignition switch is turned ON (ll),the SRS indicatorcomes on
and goes off after about 6 secondsif the SRS is operatingnormally.
lf the indicatordoes not come on, or does not go off after 6 seconds.or if il comes on while driving, it indicatesan
abnormalityin the SRS.The SRSmust be inspectedand repairedas soon as possible.
For betterserviceability,the SRSunit memory storesa DTCthat relatesto the causeof the malfunction,and the unit is
connectedto the data link circuit.This informationcan be read with the Honda PGM Testerwhen it is connectedto the
data link connector(DLc) (seepage 23-23).
23-33
SRS
J
CircuitDiagram
srarsftr
rrl$0[n
rrssf c s
r-----Tr-i
i___':--_:"1
\ J
23-34
J
tr ozr"*
tr ul"ar
NJfl
t
1i
|-(tzl
I J
23-35
sRs
J
DTCTroubleshooting
DTC1-1:Openin Driver'sAirbagInflator
Resistance
in Driver's
DTC1-2:Increased
AirbagInflator
Special Tools Required
. SRS inflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead F 07XAZ-S230100
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC,
ls DTC 1-1or DTC 1-2indicated?
YES-Go to step 9.
07sAz-TB4011A
07xaz-s230100
5. Connectthe SRS inflatorsimulator(2 Q
connectors)and the simulatorlead F to the cable
reet.
23-36
22t.
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oA
r ( 1 8 P ) f r o mt h e
SRSunit (seestep7 on page 23-22).Do not
disconnectthe specialtool from the cable reel.
'16
SRSUNITCONNECTOR
A I18P)
Wiresideof femaleterminals
07sAz-T84011A
07xAz-s230100
ConnecttheSRSinflatorsimulator{2 0
connectors)and the simulatorlead F to the cable
reel.
Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
(cont'd)
23-37
sRs
DTCTroubleshooting{cont'd)
8. Readthe DTC.
Is DTC 1-3indicated?
YES Go to step 9.
NO Short in the driver'sairbag;replacethe
driver's airbag (seepage 23-'l13).1
SRSUNITCONNECTOR
A {18P)
GRN/WHT GRN/RED
GRN/YEL
GRN/BLK
22t.
ls the rcsistance as specified?
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t o r A( 1 8 P ) f r o mt h e
SRS unit (seestep 7 on page 23-221.
IJ
23-38
Readthe DTC.
ls DTC 1-4indicated?
SpecialToolsBequired
. sRS inflatorsimulator07SAZ-T84011A
. SRSsimulatorlead F 07XAZ-S230100
1. Erasethe DTCmemory (seepage 23-26).
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
SRS indicatorcomes on for about 6 secondsand
then goes off.
YES-Go to step 9.
NO-Short to power in the driver's airbag;replace
t h e d r i v e r ' sa i r b a g( s e ep a g e2 3 - 11 3 ) . 1
te
9 . T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
batterynegativecable,and wait for 3 minutes.
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and the simulatorlead F to the cable
reel.
6 . Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
(cont'd)
23-39
SRS
DTCTroubleshooting(cont'd)
Turn the ignition switch ON {ll).
1 6 . Checkfor voltage betweenthe No. 7 terminal of
) n d b o d y g r o u n d ,t h e
S R Su n i tc o n n e c t oA
r ( 1 8 Pa
N o . 1 6t e r m i n a a
l n d b o d y g r o u n d ,t h e N o . 6
t e r m i n a la n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l
and body ground.Thereshould be 0.5 V or less.
SRSUNITCONNECTOR
A {18P)
Wiresideol lemaleterminals
NO Go to step 17.
1 1 . Turn the ignition switch OFF.
1 8 . Disconnectthe cable reel from dashboardwire
harnessB.
1 9 . Turn the ignition switch ON (ll).
07sAz-T84011A
07xaz-s230100
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and the simulatorlead F to the cable
reet.
YES Replace
t h e c a b l er e e l . l
Reconnectthe batterynegativecable.
N O - R e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
1 . Erasethe DTCmemory.
IJ
23-40
8. Readthe DTC.
ls DTC 1-5 indicated?
YES-Go to step 9.
NO Short to ground in the driver's airbaginflator;
replacethe driver's airbag(seepage 23-113).I
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
GRN/RED
'10.
Disconnectthefront passenger'sairbag 4P
connectorfrom dashboardwire harnessB (seestep
2 on page 23-21).
11. Disconnectboth seat belt tensioner2P connectors
from the floor wire harness (seestep 5 on page 23-
22t.
12. DisconnectSRSunit connectorA (18P)fromthe
SRS unit (see step 7 on page 23-22],.
1 3 . D i s c o n n e c t t hsep e c i a l t o o l f r o mt h e c a b l er e e l .
Wiresideof femaleterminals
ls the resistance as specified?
YES-Faulty SRS unit; replacethe SRS unit {see
page 23-1221.f
N O - G o t o s t e p1 5 .
Disconnectthe cable reel from dashboardwire
h a r n e s sB .
1 6 . Checkresistancebetweenthe No.7 terminal of
S R Su n i tc o n n e c t oA
r ( 1 8 P )a n d b o d y g r o u n d ,t h e
N o . 1 6t e r m i n a a
l n d b o d y g r o u n d .t h e N o , 6
terminaa
l n d b o d y g r o u n d ,a n dt h e N o . 1 5t e r m i n a l
a n d b o d y g r o u n d .T h e r es h o u l db e a n o p e nc i r c u i t ,
or at least 1 fvlQ .
ls the resistanceas specified?
t h e c a b l er e e l . I
YES Replace
NO Replacedashboardwire harnessB.l
23-41
sRs
DTCTroubleshooting(cont'dl
DTC2-1:Openin FrontPassenger's
Airbag
Inflator
DfC 2-2:Increased
Resistance
in Front
Passenger's
AirbagInflator
Readthe DTC.
ls DTC 2-1 or DTC 2-2 indicated?
YES Go to step 9.
YES Go to step 3.
NO Intermittentfailure,system is OK at this time,
Go to TroubleshootingIntermittentFailures(see
page 23-261.
3. Turn lhe ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
07sAz-T84011A
07xAz-s230100
5 . Connectthe SRS inflatorsimulator(2 0
connectors)and the simulatorlead F to dashboard
w i r e h a r n e s sB .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
! J
23-42
Wiresideof femaleterminals
YES-Go to step 3.
NO Intermittentfailure, system is OK at this time.
Go to TroubleshootingIntermittentFailures{see
page23-26).
3. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
4. Disconnectthe front passenger'sairbag 4P
connector(A) from dashboardwire harnessB.
07sAz-T84011A
07xAz-s230100
C o n n e ctth e S R Sl n f l a t o rs i m u l a t o r( 2 0
c o n n e c t o r sa)n d t h e s i m u l a t o rl e a dF t o d a s h b o a r d
w i r e h a r n e s sB .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
T J
(cont'd)
23-43
sRs
qJ
DTGTroubleshooting(cont'd)
Readthe DTC.
'12.
T J
23-44
8. Readthe DTC.
ls DTC 2-4 indicated?
YES-Go to step 9.
NO-Short to power in the front passenger'sairbag
inflator;replacethe front passenger'sairbag (see
p a g e2 3 - 1 1 4 ) . I
9. Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10. Disconnectthe driver's airbag4P connectorfrom
the cable reel (seestep 2 on page 23-21).
YES-Go to step 3.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootinglntermittentFailures(see
page23-26).
07sAz-T84011A
07xAz-s230100
Connectthe SRSinflatorsimulator(2 Q
connectors)and the simulatorlead F to dashboard
w i r e h a r n e s sB .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTc memory.
{cont'd)
23-45
sRs
DTCTroubleshooting(cont'd)
DisconnectSRSunit connectorA (18P)from the
SRSunit (seestep 7 on page23-221.
1 4 . Reconnectthe batterynegativecable.
1. Erasethe DTCmemory (seepage 23-26).
1 5 . Turn the ignition switch ON (ll).
t o . Checkfor voltage betweenthe No. 4 terminal of
SRSunit connectorA (18P)and body ground,the
N o . 1 3t e r m i n a a
l n d b o d y g r o u n d ,t h e N o . 5
terminal and body ground,and the No. 14 terminal
and body ground.Thereshould be 0.5 V or less.
07saz-T84011A
07xAz-s230100
5 . Connectthe SRSinflatorsimulator(2 Q
connectors)and the simulatorlead F to dashboard
wire harnessB.
\ J
23-46
I
Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
h a r n e s sB .
't4.
Checkresistancebetweenthe No. 4 terminal of
SRS unit connectorA (18P)and body ground,the
No. 13 terminal and body ground.the No. 5
terminaa
l n d b o d y g r o u n d ,a n d t h e N o . 1 4t e r m i n a l
and body ground.Thereshould be an open circuit,
o r a t l e a s tl M Q .
A {18P}
SRSUNITCONNECTOR
BLU/RED
BLU/YEL
I
23-47
sRs
DTCTroubleshooting(cont'dl
DTC3-1:Openin Driver'sSeatBeltTensioner
DTC3-2:Increased
Resistance
in Driver's
SeatBeltTensioner
6. Reconnectthe batterynegativecable.
8. Readthe DTC.
7. Erasethe DTCmemory.
07sAz-T84011A
07sAz-T8401'lA
1 1 .Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to dashboardwire
harnessB.
1 2 . Reconnectthe batterynegativecable.
Erasethe DTCmemory.
07TAZ-52501'lA
1 4 .Readthe DTC.
5. ConnecttheSRSinflatorsimulator(2 0 connector)
and simulatorlead C to the floor wire harness.
23-48
\ J
I
to.
A (18P)
SRSUNITCONNECTOR
RED/WHT
2
10 1 l 1Z t 3
t 5 16
i-4
\lel a;
E a
RED/BLU
I
]
Wiresideof femaleterminals
YES Go to step 3.
NO-lntermittent failure,system is OK at this time,
Go to TroubleshootingIntermittentFailures{see
page 23-26).
Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
Disconnectthe driver'sseat belt tensioner2P
connector(A) from the floor wire harness.
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dC t o t h e f l o o rw i r e h a r n e s s .
I
(cont'd)
23-49
sRs
DTCTroubleshooting(cont'd)
6. Reconnectthebatterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC.
ls DTC 3-3 indicated?
YES-Go to step L
NO-Shon in the driver'sseat belt tensioner;
replacethe driver's seat belt (seepage 23-4).1
L Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10. Disconnectfloor wire harness4P connectorC403
(A)from dashboardwire harnessB.
RED/WHT
RED/BLU
07sAz-TB4or
1A
W i r es i d eo f f e m a l e
terminals
1 1 .ConnecttheSRSinflatorsimulator(2 Q
connectors)and simulatorlead F to dashboardwire
harnessB.
Reconnectthe batterynegativecable.
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.
ls DTC 3-3 indicated?
YES-Go to step 15.
NO Short in the floor wire harness;replacethe
floor wire harness.l
Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
t J
23-50
J
DTC3-4:Shortto Powerin Driver'sSeatBelt
Tensioner
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
SpecialToolsBequired
. SRSlnflatorsimulator07SAZ-TB4011A
. S R Ss i m u l a t o lre a dC 0 7 T M - S 2 5 0 1 1 A
. SRSsimulatorlead F 07XAZ-S230100
8. Readthe DTC.
Is DTC 3-4 indicated?
YES- Go to step 9.
L
]
07sAz-T84011A
1 1 .C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0
connectors)and simlator lead F to dashboardwire
h a r n e s sB .
1 4 . Readthe DTC.
ls DTC 3-4 indicated?
YES-- Go to step 15.
N O - S h o n t o p o w e ri n t h e f l o o rw i r e h a r n e s s ;
r e p l a c et h e f l o o rw i r e h a r n e s s . I
te
T u r nt h e i g n i t i o ns w i t c hO F F .D i s c o n n e ct h
batterynegativecable,and wait for 3 minutes.
(cont'd)
23-51
sRs
DTCTroubleshooting(cont'dl
16. Disconneclthe driver'sairbagconnector(seestep
2 on page23-21l,Irontpassenger'sairbag
connector(seestep 3 on page 23-2'l),and front
passenger'sseat belt tensionerconnector(seestep
5 on page 23-221.
17. DisconnectSRSunit connectorA (l8P)from the
SRS unit (see step 7 on page 23-22).
YES Go to step 3.
-T84011A
YES-FaultySRSunit;replace
the SRSunit{see
page23-122],
.a
wire harnessB;
NO Shorttopowerin dashboard
replacedashboard
wire harnessB.l
07TAZ-S25011A
L J
23-52
t
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC.
16. Disconnectthedriver'sairbagconnector(seestep
2 on page23-211,lrontpassenger'sairbag
connector(seestep 3 on page 23-21),and front
passenger'sseat belt tensionerconnector(seestep
5 on page 23-22).
17, DisconnectSRS unit connectorA ('l8P)from the
SRS unit (seestep 7 on page 23-221.
)
07sAz-T84011A
Y E S - F a u l t yS R Su n i u r e p l a c et h e S R Su n i t{ s e e
page 23-122l,.a
NO Short to ground in dashboardwire harnessB;
r e p l a c ed a s h b o a r dw i r e h a r n e s sB . l
Reconnectthe batterynegativecable.
Erasethe DTCmemory.
1 4 . Readthe DTC.
ls DTC 3-5 indicated?
YES Go to step 15.
NO-Short to ground in the floor wire harness;
replacethe floor wire harness.l
23-53
sRs
DTCTroubleshooting{cont'd)
DTC21-1:Openor Increased
Resistance
in
Driver'sSeatBeltBuckleTensioner
8. Readthe DTC.
l s D T C 2 1 - 1i n d i c a t e d ?
SpecialTools Required
. SRSinflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead F 07XAZ-S230100
1. ErasetheDTCmemory (seepage 23-261.
2. Turn the ignition switch ON (ll),and checkthat the
SRS indicatorcomes on for about 6 secondsand
then goes off.
Does the SBS indicatot stay on?
YES Go to step 3.
NO-lntermittent failure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
3. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
4. Disconnectthe driver's seat belt buckletensioner
4P connector(A) from the floor wire harness.
YES Go to step 9.
NO Open or increasedresistancein the driver's
seat belt buckletensioner;replacethe driver'sseat
b e l tb u c k l e . I
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable.and wait for 3 minutes.
10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-2lland the front passenger's
seatbelt buckletensioner4P connector(seestep 6
on page 23-22).
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t o B
r ( 1 8 P ) f r o mt h e
SRSunit (seestep 7 on page 23'22).Do not
disconnectthe specialtool from the floor wire
narness.
12. Checkresistancebetweenthe No. 1 and No. 10
t e r m i n a l so f S R Su n i tc o n n e c t oB
r ( 1 8 P )T. h e r e
s h o u l db e 2 . 0- 3 . 0 O .
SRSUNITCONNECTOR
B Il8PI
GRN/YEL
l t ' '
A\ I' ?
Y
l r 0t l
1 5 t 6 17 t6
TI
GRN/BLK
W i r es i d eo f f e m a l tee r m i n a l s
5. ConnecttheSRSin{latorsimulator(2 Q connectors)
and simulatorlead F to the Iloor wire harness.
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
L J
23-54
I
DTC21-3:Shortto AnotherWireor
Decreased
Resistance
in Driver'sSeatBelt
EuckleTensioner
Special Tools Required
. SRSinflatorsimulator07SAZ-T840't1A
. SRSsimulatorlead F 07XAZ-S230100
8. Readthe DTC.
ls DTC 21-3 indicated?
YES-Go to step 9.
NO- Short in the driver'sseat belt buckle
tensioner;replacethe driver's seat belt buckle.l
YES Go to step 3.
NO Intermittentfailure.system is OK at this time.
Go to TroubleshootingIntermittentFailureslsee
page 23-26).
Turn the ignitionswitch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
D i s c o n n e ct h
t e d r i v e r ' ss e a tb e l tb u c k l et e n s i o n e r
4P connector(A) from the floor wire harness.
1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e
SRS unit {seestep 7 on page 23-22l .
'12.
GRN/YEL
GRN/BLK
Wiresideof femaleterminals
7 . Erasethe DTCmemory.
23-55
sRs
(cont'dl
DTCTroubleshootang
DTG21-4:Shortto Powerin Driver'sSeatBelt
BuckleTensioner
Readthe DTC.
ls DTC 21-4 indicated?
SpecialToolsRequired
. SRSinflatorsimulator07SAZ-TB4011A
. SRSsimulatorlead F 07XM-S230100
1. Erasethe DTCmemory (seepage23-26).
2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand
then goes off.
YES Go to step 9.
NO Shon to power in the driver'sseat belt buckle
tensioner;replacethe driver's seatbelt buckle.l
L Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
t,
.J
5 . ConnecttheSRSinflatorsimulator{2 0
connectors)and the simulatorlead F to the f loor
wireharness.
Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
\, .J
23-56
Reconnectthe batterynegativecable.
1 4 . Turn the ignitionswitch ON (ll).
Checkfor voltage betweenthe No. 1 lerminal of
SRSunit connectorB {18P)and body ground, and
t h e N o . 1 0t e r m i n a la n d b o d y g r o u n d .T h e r es h o u l d
be 0.5 V or less.
SRSUNITCONNECTOR
B I18PI
J
ls the voltageas specitied?
YES FaultySRSunit;replace
the SRSunit(see
page23-1221
.f
NO Shortto powerin thefloorwire harness;
replace
the floorwire harness.l
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and simulatorlead F to the floor wire
n ar n e s s .
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
(cont'd)
23-57
sRs
DTCTroubleshooting(cont'dl
DTC4-1:Openin FrontPassenger's
SeatBelt
renstoner
DTC4-2:lncreasedResistance
in Front
Passenger's
SeatBeltTensioner
Readthe DTC.
ls DTC 21-5 indicated?
YES Go to step9.
NO Short to ground in the driver's seat belt
buckletensioner;replacethe driver's seat belt
buckle.l
07TAZ-525011A
N O - S h o r t o g r o u n di n t h ef l o o rw i r eh a r n e s s ;
replace
thefloorwire harness.l
\ J
23-58
)
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC.
ls DTC 4-1 or DTC 4-2 indicated?
Disconnectthe driver'sairbagconnector{seestep
2 on page23-211,
tront passenger'sairbag
connector(seestep 3 on page 23-21),and driver's
seat belt tensionerconnector(seestep 5 on page
23-221.
YES Go to step 9.
NO-Open or increasedresistancein the front
passenger'sseat belttensioner;replacethe front
passenger'sseat belt (seepage 23-4).t
L Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10, Disconnectthe floor wire harness4P connector
C403(A)from dashboardwire harnessB.
RED/YEL
1
3 4
1 0 11 12
5
15
l 6
1 7 r8l \t
r l
RED/BLK
07sAz-T840't
1A
1 2 .Reconnectthe batterynegativecable.
Erasethe DTCmemory.
1 4 . Readthe DTC.
ls DTC 4-l or DTC 4-2 indicated?
YES-Go to step
'15.
I
23-59
sRs
DTCTroubleshooting(cont'dl
DTC4-3:Shortto AnotherWire or Decreased
Resistance
in FrontPassenger's
SeatBelt
Tensioner
Special Tools Required
. SRSinflatorsimulator07SAZ-TB40l1A
. SRSsimulatorlead C 07TM-S25011A
. SRSsimulatorlead F 07XAZ-S230100
8. Readthe DTC.
ls DTC 4-3 indicated?
YES-Go to stepL
NO-Short in the front passenger'sseatbelt
tensioner;replacethe front passenger'sseat belt
( s e ep a g e2 3 - 4 ) . 1
TB40,I1A
1 3 .Erasethe DTCmemory.
1 4 .Readthe DTC.
ls DTC 4-3 indicated?
07TAZ-S25011A
Y E S - G o t o s t e p1 5 .
NO Short jn the floor wire harness;replacethe
f l o o rw i r e h a r n e s s . I
1 5 .Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
7 . Erasethe DTCmemory.
\ J
23-60
16. Disconnectthedriver'sairbagconnector(seestep
2 on page23-211,
front passenger'sairbag
connector(seestep 3 on page 23-21),and driver,s
seat belt tensionerconnector(seestep 5 on page
23-221.
17. DisconnectSRSunit connectorA (18p)from the
SRS unit (see step 7 on page 23-22).
18. Disconnectthe specialtool from dashboardwire
harnessB.
19. Checkresistancebetweenthe No. 9 terminal and
t h e N o . 1 8t e r m i n a o
l f S R Su n i tc o n n e c t oA
r (18p).
T h e r es h o u l db e a n o p e nc i r c u i t o
, r a t l e a s t1 M e .
SRSUNITCONNECTOR
A I18P}
RED/YEL
2 3
10 t l 12 t 3
It 6]
RED/BLK
r8l \P
15 16 1 7
07TAZ-S2501'lA
{cont'd)
23-61
sRs
DTCTroubleshooting(cont'd)
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
tront passenger'sairbag
2 on page23-211,
connector(seestep 3 on page 23-21),and drivefs
seatbelt tensionerconnector(seestep 5 on page
23-22t.
8. Readthe DTC.
ls DTC 4-4 indicated?
YES Go to step 9.
NO-Short to power in the front passenger'sseat
belt tensioner;replacethe front passenger'sseat
b e l t( s e ep a g e2 3 - 4 ) . I
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable.and wait for 3 minutes.
'10.Disconnectfloor wire harness4P connector
20. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
t'
07sAz-TB4o11A
1 1 .Connectthe SRSinflatorsimulator(2 0
connectors)and simulatorlead F to dashboardwire
h a r n e s sB .
tJ.
terminals
WiresideoJJemale
Reconnectthe batterynegativecable.
Erasethe DTCmemory.
1 4 . Readthe DTC.
ls DTC 4-4 indicated?
N O S h o r t t o p o w e ri n d a s h b o a r dw i r e h a r n e s sB ;
w i r e h a r n e s sB . l
r e p l a c ed a s h b o a r d
Y E S - G o t o s t e p1 5 .
NO- Short to power in the floor wire harness;
replacethe floor wire harness.l
J
23-62
I
DTC4-5:Shortto Groundin FrontPassenger's
SeatBeltTensioner
8. Readthe DTC.
ls DTC 4-5 indicated?
YES-Go to step 9.
NO Short to ground in the front passenger'sseat
belt tensioner;replacethe front passenger'sseat
b e l t( s e ep a g e2 3 - 4 ) . I
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10. Disconnectthe floor wire harness4P connector
C403(Alfrom dashboardwire harnessB.
Y E S - G o t o s r e p3 .
NO-lntermittent failure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-26l,.
3. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
TB40t 1A
Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
(cont'd)
23-63
sRs
DTCTroubleshooting(cont'dl
16. Disconnectthe driver's airbagconnector(seestep
2 on page 23-21),front passenger'sairbag
connector(seestep 3 on page 23-21).and driver's
seat belt tensionerconnector(seestep 5 on page
23-22).
in
Resistance
DTC22-1:Openor Increased
FrontPassenger's
SeatBeltBuckleTensioner
SpecialTools Required
. SRSinflatorsimulator07SAZ-T84011A
. SRSsimulatorlead F 07XAZ-S230100
r ( 1 8 P ) f r o mt h e
1 7 . D i s c o n n e cSt R Su n i tc o n n e c t oA
SRSunit (seestep 7 on page 23-221.
w i r e s i d eo f l e m a l et e r m i n a l s
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 Q
connectors)and the simulatorlead F to the floor
w t r eh a r n e s s .
23-64
\,
t
6. Reconnectthe bafterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC.
SpecialToolsRequired
. SRS inflatorsimulator07SAZ-TB4011A
. SRSsimulator lead F 07XAZ,S230100
'1.
DTC22-3:Shortto AnotherWire or
Decreased
Resistance
in FrontPassenger's
SeatBeltBuckleTensioner
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r ( 1 8 P ) f r o mt h e
SRSunit (seestep 7 on page 23-22).Do not
disconnectthe specialtool from the floor wire
harness.
1 2 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1
terminalsof SRS unit connectorB ('l8P).There
s h o u l db e 2 . 0 3 . 0 0 .
SRSUNITCONNECTOR
B I,I8PI
)m
3
r5 r6 1T 1 8
W i r es i d eo f f e m a l tee r m i n a l s
I t
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 Q
connectors)and the simulatorlead F to the floor
w t r eh a r n e s s .
6. Reconnectthe batterynegativecable.
7 . E r a s et h e D T Cm e m o r y .
23-65
sRs
DTCTroubleshooting(cont'dl
8. Readthe DTC.
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-TB4011A
. S R Ss i m u l a t o rl e a dF 0 7 X A z5 2 3 0 1 0 0
1. Erasethe DTCmemory (seep age23-26).
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l } ,a n d c h e c kt h a tt h e
S R Si n d i c a t ocr o m e so n f o r a b o u t6 s e c o n d sa n d
then goes off.
Does the SHS indicator stay on?
YES Go to step 3.
N O I n l e r m i t t e n t f a i l u r e , s y s t ei smO K a t t h i s t i m e .
Go to TroubleshootingIntermittentFailures(see
page 23-261.
1 3 . C h e c kr e s i s t a n cbee t w e e nt h e N o . 2 a n d N o . 1 1
terminalsof SRS unit connectorB ( 18P).There
'l
should be an open circuit,or at least M !) .
B {18P}
SRSUNIT CONNECTOR
GRN/RED
GRN
WiresideoI femaleterminals
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 ! J
connectors)and simulatorlead F to the floor wire
h ar n e s s .
\ J
23-66
t
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
8. Readthe DTC.
ls DTC 22-4 indicated?
YES Go to step g.
' t 2 .Disconnect
harness.
NO-Short to power in the front passenger,sseat
belt buckletensioner;replacethe front passenger,s
seat belt buckle.!
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes,
t5.
Reconnectthe batterynegativecable.
23-67
sRs
DTCTroubleshooting(cont'dl
DTC22-5:Shortto Groundin Front
SeatBeltBuckleTensioner
Passenger's
8. Readthe DTC.
ls DTC 22-5 indicated?
SpecialTools Required
. SRSinflatorsimulator07SAZ-T84011A
. SRSsimulatorlead F 07XAZ-S230100
1. Erasethe DTCmemory (seepage 23-26).
2. Turn the ignition switch ON (ll),and checkthat the
SRSindicatorcomes on for about 6 secondsand
then goes off.
Does the SRS indicator stay on?
YES-Go to step 3.
NO - Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-26).
YES-Go to step 9.
NO Short to ground in the front passenger'sseat
belt buckletensioner;replacethe front passenger's
s e a tb e l tb u c k l e . l
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10. Disconnectboth side airbag2P connectors(see
step 4 on page 23-21)and the driver'sseat belt
buckletensioner4P connector(seestep 6 on page
23-22t.
r ( 1 8 P l f r o mt h e
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
(see
page
7
23-221.
step on
SRS unit
b U
g {18PI
SRSUNITCONNECTOR
5 . Connectthe SRSinflatorsimulator(2 Q
connectors)and simulatorlead F to the floor wire
narness.
6 . Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
!U
23-68
I
DTCs-1,5-2,5-4,s-8,6-3,6-4,6-7,6-8,7-1,
7-2,7-3,A-1,4-2,8-3,8-4,8-5,8-6,9-1,9-2:
Internal
Failureof the SRSUnit
DTC10-1,10-2,10-3,10-4,10-s,10-6,10-7:
Airbags,SideAirbags,and/orSeatBeltand
Deployed
SeatBeltBuckleTensioners
I
23-69
SRS
DTCTroubleshooting(cont'd)
DTC13-1,13-2:InternalFailureof the Driver's
SidelmpactSensor
DTC14-1,14-2:InternalFailureofthe Front
Passenger's
SidelmpactSensor
I J
23-70
I
DTC9-3:Faulty Driver'sSeatBeltBuckle
Switch
1. Erasethe DTCmemory (seepage 23 26).
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,t h e n b u c k l ea n d
u n b u c k l et h e d r i v e r ' ss e a tb e l ts e v e r atl i m e s .
3. Readthe DTC.
ls DTC 9-3 indicated?
YES Go to step 4.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
4 . Turn the ignition switch OFF.
BLU/RED
T e r m i n asl i d eo f m a l et e r m i n a l s
t
T e r m i n as li d eo f m a l et e r m i n a l s
Ate the resistancereadings as specified?
YES- Go to step 7.
NO Replacethe driver'sseat belt buckleassembly,
t h e n c l e a rt h e D T C . I
I
(cont'd)
23-71
sRs
(cont'dl
DTCTroubleshooting
7, Unbucklethe driver'sseat belt.
Checkresistancebetweenthe No. 1 and No.2
terminalsofthe driver'sseat belt buckleswitch 3P
c o n n e c t o rT. h e r es h o u l db e 0 1 Q .
Wiresideof femaleterminals
T e r m i n asl i d eo f m a l et e r m i n a l s
BLU/RED
T e r m i n as li d eo I m a l et e r m i n a l s
\ J
23-72
I
11. Checkresistancebetweenthe No. 2 terminal of the
floor wire harness3P connectorand body ground.
Thereshould be an open circuit.or at least 1 fvlQ ,
FLOORWIRE
HARNESS SRSUNITCONNECTORC
I8P}
3PCONNECTOB
Wiresideot temaleterminals
Y E S - G o t o s t e p1 2 .
SRSUNITCONNECTOR
C IsPI
LT GRN
Wiresideof femaleterminals
ls the resistanceas specified?
ls the resistance as specified?
YES Replace
t h e S R Su n i t ( s e ep a g e2 3 - 1 2 2 ) . 1
YES Go to step 13.
N O - S h o r t t o g r o u n di n t h e f l o o rw i r e harness;
replacethe floor wire harness.I
N O O p e ni n t h e f l o o rw i r e h a r n e s so r m u l t i p l e x
control unit, or poor connectionat the floor wire
harness,the under-dashfuse/relaybox, and the
multiplexcontrol unit. Checkthe connectionat the
floor wire harness,the under-dashfuse/relaybox,
and the multiplexcontrol unit. lf the connectionis
OK, replacethe faulty harnessor part.l
23-73
SRS
DTCTroubleshooting(cont'dl
DTC9-4:FaultyFrontPassenger's
SeatBelt
BuckleSwitch
1. Erasethe DTCmemory {seepage 23-26).
2 . T u r nt h e i g n i t i o ns w i t c hO N { l l ) ,t h e n b u c k l ea n d
unbucklethe front passenger'sseat belt several
times.
3. Readthe DTC.
ls DTC 9-4 indicated?
YES-Go to step 4.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermiftentFailures{see
page 23-26)'.
T e r m i n asl i d eo f m a l et e r m i n a l s
23-74
Wiresideof femaleterminals
Terminalside of maleterminals
Terminalsideof maleterminals
(cont'd)
23-75
sRs
DTCTroubleshooting(cont'dl
1 1 . C h e c kr e s i s t a n c be e t w e e nt h e N o . 2 t e r m i n a o
l fthe
floor wire harness3P connectorand body ground.
There should be an open circuit,or at least 1 M 0 .
FLOORWIREHARNESS
3PCONNECTOR
FLOORWIRE
HARNESS SRSUNITCONNECTOR
C (8P)
3PCONNECTOR
Wiresideof femaleterminals
Wiresideof femaleterminals
Y E S - G o t o s t e p1 2 .
L J
Wiresideof temaleterminals
23-76
\ J
DTC9-6:FaultyLeftFrontlmpactSensor
8. Disconnect
the enginecompartment
wire harness
2Pconnector
{A)fromthe leftfrontimpactsensor.
2 3
5 6 7 8 9
10 t l 1Z t 3
15 16 17 1 8
RED
I
T
ILK
{cont'd}
23-77
sRs
DTCTroubleshooting(cont'dl
13. Checkvoltagebetweenthe No. 10terminalof SRS
unitconnector
A (18P)andbodyground.There
'l
shouidbe V or less.
SRS UNIT CONNECTORA {,I8P)
10 11 12 l 3 t 4 15 1 6 1 1 t6
RED
\y,
07YAZ-S3AA100
07SAZ-TB,O11A
\."r1
23-78
DTC9-7:FaultyRightFrontlmpactSensor
'10.Checkresistancebetween
F!t 1 t 2 ) l
I r o l r l r13
1 6 1 7 18
SLK
Y E S G o t o s t e p1 1 .
N O - S h o r t i n t h e e n g i n ec o m p a n m e nw
t ire
harnessor dashboardwire harnessB; replacethe
f a u l t yh a r n e s s , I
1 1 .Reconnectthe batterynegativecable.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
I
(cont'd)
23-79
sRs
DTCTroubleshooting(cont'd)
13. Checkvoltagebetweenthe No.1terminalofSRS
unitconnector
A (18P)andbodyground.There
shouldbe 1 V or less.
SRSUNIT CONNECTOR
A I18P}
J_
l r 1 2 l r
tE.]I
/A
Wiresideof femaleterminals
t 3 1 1 r5 16 1 1 t6
BLK
07YAZ-S3AA100
23-80
L J
I
DTC11-1:Openor Increased
Resistance
in
Driver'sSideAirbagInflator
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SM-TB4011A
. SRSsimulatorlead E 07XM-S140200
8. Readthe DTC.
ls DTC 11-1indicated?
YES Go to step 3.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
07sAz-T84011A
I
{cont'd)
23-81
sRs
DTCTroubleshooting(cont'dl
' It . D i s c o n n e c t
S R Su n i tc o n n e c t oB
r ( 1 8 P ) f r o mt h e
SRS unit (seestep 7 on page 23-22).Do not
disconnectthe specialtool from the floor wire
harness2P connector.
12
DTC11-3:Shortto AnotherWireor
Decreased
Resistance
in Driver'sSideAirbag
lnflator
SpecialToolsRequired
' S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
1. Erasethe DTCmemory (seepage 23 26).
SRSUNITCONNECTOR
B I18PI
WHT/BLU
1
10 t l
rr--r-{
lTlslsl a
15IdFFI \
WHT/BLK
Wiresideof femaleterminals
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
SRS indicatorcomes on for about 6 secondsand
then goes off.
Does the SRS indicatot stay on?
YES Go to step 3.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-26).
Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
Disconnectthe floor wire harness2P connector(A)
f r o m t h e d r i v e r ' ss i d ea i r b a g .
07sAz-T84011A
C o n n e ctth e S R Si n f l a t o rs i m u l a t o r( 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
Reconnectthe batterynegativecable.
1 . Erasethe DTCmemory.
23-82
I
DTG11-4:Shortto Powerin Driver'sSide
AirbagInflator
8. Readthe DTC.
ls DTC 11-3indicated?
YES-Go to step 9.
NO*Shon to anotherwire in the driver's side
airbag inflator;replacethe driver'sside airbag (see
p a g e2 3 - 1 1 5 ) . I
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable.and wait for 3 minutes.
10. Disconnectthefront passenger'sside airbag2P
connector(seestep 4 on page 23-21)and both seat
belt buckletensioner4P connectors(seestep 6 on
page 23-22l,.
11. Disconnectthe specialtool from the floor wire
harness2P connector.
1 2 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r { 1 8 P ) f r o mt h e
SRSunit {seestep 7 on page23-221.
SRSUNITCONNECTOR
B {18PI
WHT/BLU
07sAz-TB4011A
WHT/BLK
Wiresideof femaleterminals
5 . C o n n e ctth e S R Si n f l a t o rs i m u l a t o (r 2 0 c o n n e c t o r )
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
(cont'd)
23-83
sRs
(cont'd)
DTCTroubleshooting
6. Reconnect
the batterynegative
cable.
7. Erasethe DTCmemory,
' t 2 .T u r n
t h e i g n l t i o ns w i t c hO N ( l l ) .
8. Readthe DTC.
1 3 .Checkfor voltage betweenthe No. 6 terminal of
Is DTC 11-4indicated?
YES-Go to step9.
NO Shortto powerin the driver'ssideairbag
inflator;replacethe driver'ssideairbag(seepage
23-115).t
' 1 0 Disconnect
.
the front passenger'sside airbag2P
connector(seestep 4 on page 23-21)and both seat
belt buckletensioner4P connectors(seesteD6 on
page 23-221.
U J
\.J
23-84
I
DTC11-5:Shortto Groundin Driver'sSide
AirbagInflator
8. Readthe DTC.
ls DTC 11-5indicated?
YES Go to step 9.
NO Short to ground in the driver'sside airbag
inflator;replacethe driver'sside airbag (seepage
23-115).t
9. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
10. Disconnectthe front passenger'sside airbag2P
connector(seestep 4 on page 23-21)andboth seat
belt buckletensioner4P connectors(seestep 6 on
page 23-221.
1 1 . D i s c o n n e c t S RuSn i t c o n n e c t o r B( 1 8 P ) f r o m t h e
SRS unit (seestep 7 on page 23-22).
'12.
Checkresistancebetweenthe No. 17 and No. 15
t e r m i n a l so f S R Su n i tc o n n e c t oB
r ( 1 8 P )a. n d
'17
b e t w e e nt h e N o . a n d N o . 1 6t e r m i n a l sT. h e n
checkresistancebetweenthe No. 17 terminal and
body ground.Thereshould be an open circuit,or at
l e a s t1 M 0 .
SRSUNIT CONNECTOR
B I18P)
WHT/BLK
07saz-TB,r011A
Wiresideof femaleterminals
Connectthe SRSinflatorsimulator(2 Q connector)
and simulatorlead E to the floor wire harness.
6 . Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
NO-Short to ground in the floor wire harness;
r e p l a c et h e f l o o rw i r e h a r n e s s . I
I
23-85
sRs
DTCTroubleshooting(cont'd)
Resistance
in
DTG12-1:Openor Increased
FrontPassenger's
SideAirbagInflator
Reconnectthe batterynegativecable.
7 . Erasethe DTCmemory.
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
Readthe DTC.
ls DTC 12-l indicated?
YES Go to step 3.
NO - Intermittentfailure, system is OK at this time.
Go to TroubleshootinglntermittentFailures(see
page23-26).
07xAz-s1A0200
5. Connectthe SRSinflatorsimulator(2 Q connector)
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
I J
23-86
I
1't. DisconnectSRS unit connectorB ('l8P)from the
SRSunit (seestep 7 on page 23-22).Do not
disconnectthe specialtool from the floor wire
h a r n e s s2 P c o n n e c t o r .
DTC12-3:Shortto AnotherWireor
Decreased
Resistance
in FrontPassenger's
SideAirbagInflator
SpecialToolsRequired
. S R Si n f l a t o rs i m u l a t o 0
r 7SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
1. Erasethe DTCmemory (seep age 23-261.
SRSUNITCONNECTOR
B {18P)
WHT/RED
WHT/GRN
Wiresideof femaleterminals
07xAz-s1A0200
5. Connectthe SRSinflatorsimulator(2 0 connector)
a n d s i m u l a t o rl e a dE t o t h e f l o o rw i r e h a r n e s s .
(cont'd)
23-87
sRs
DTCTroubleshooting(cont'dl
6. Reconnectthe batterynegativecable.
7, Erasethe DTCmemory.
Special Tools Required
. sRS inflatorsimulator07sAz-TB4011A
. SRSsimulatorlead E 07XM-S140200
8. Readthe DTC.
ls DTC 12-3indicated?
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a t t h e
SRS indicatorcomes on for about 6 secondsand
then goes off.
Does the SRS indicator stay on?
D i s c o n n e ct h
t e s p e c i a l t o o l f r o mt h e f l o o rw i r e
harness2P connector.
YES-Go to step 3.
NO- Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures{see
page 23-26).
3. Turn the ignition switch OFF.Disconnectthe
banery negativecable,and wait for 3 minutes.
4. Disconnectthe floor wire harness2P connector(A)
from the front passenger'sside airbag.
2 3
10 l l
15
' 8lel
n
-T
i['tl,Bl S
07xAz-s1A0200
WHT/GRN
Wiresideof {emaleterminals
\.J
23-88
\
6. Reconnectthe batterynegativecable.
7. Erasethe DTCmemory.
1?
8. Readthe DTC.
'10.
Disconnectthe driver'sside airbag2P connector
(seestep 4 on page 23-21)and both seat belt buckle
tensioner 4P connectors (see step 6 on page 23-22l,.
23-89
sRs
DTCTroubleshooting(cont'dl
DTC12-5:Shortto Groundin Front
Passenger's
SideAirbagInflator
.t
6. Reconnectthebatterynegativecable.
7. Erasethe DTCmemory.
SpecialToolsRequired
. SRSinflatorsimulator07SAZ-T84011A
. SRSsimulatorlead E o7XAZ-S140200
8. Readthe DTC.
ls DTC 12-5indicated?
YES-Go to step 3.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-261.
1 1 . D i s c o n n e cSt R Su n i tc o n n e c t oB
r ( 1 8 P ) f r o mt h e
SRS unit (see step 7 on page 23-22).
B {18PI
SRSUNITCONNECTOR
2
1 0 11
t6 1 7 1E
LTGRN/REDd
i 116\l
WHT/GRN
9 Y 9
07xAz-s1A0200
5. Connectthe SRS inflatorsimulator(2 Q connector)
and simulatorlead E to the floor wire harness.
GRY/RED
23-90
07sAz-TB4011A
ls the connectionOK?
YES Go to step 5.
NO-Replace the driver'sside impact sensorand/
or the floor harness,as needed.I
)
(cont'd)
23-91
sRs
DTCTroubleshooting{cont'd)
B (18P)fromthe
SRSunitconnector
8. Disconnect
(see
page
23-221.
SRSunit
step7 on
9. Checkresistance
betweenthe No.8 andNo.15
B ('l8P).There
terminalsof sRSunitconnector
s h o u l db e0 1 . 0Q .
B I18P)
SRSUNITCONNECTOR
BRN/YEL
3
10 tl
:fr;f;l n
\
l r ol r zl r s|
LT GRN/RED
Wire side of temaleterminals
23-92
t
(A)
5. Disconnect
thefloorwire harness2Pconnector
fromthedriver'ssideimpactsensor.
BRN/YEL
2 3
10 11
flliT;l
1tr6l1tf;l \
LT GRN/RED
SRSUNITCONNECTOR
B {18PI
BRN/YEL
23-93
sRs
DTCTroubleshooting(cont'dl
DTC14-3:No Signalfromthe Front
SidelmpactSensor
Passenger's
SpecialToolsRequired
. SRSinflatorsimulator07SAZ-TB401'lA
. SRSsimulatorlead H 07YAZ'S3AA100
1. ErasetheDTCmemory (seepage 23-26).
23-94
07sAz-TB4o11A
)
8. DisconnectSRSunit connectorB (18P)fromthe
SRSunit (seestep 7 on page 23-221.
9. Checkresistancebetweenthe No.9 and No. 16
terminalsof SRSunit connectorB (18P).There
s h o u l db e 0 - 1 . 0 S 2 .
SRSUNITCONNECTOR
B {18PI
PNK/BLU
2
1 0 t1
0
t5
t-
l-u5l n
iFf;l \
GRY/RED
Wiresideol lemaleterminals
"-;s.\
\
\f r l/
\--)
- F.,=
I
(cont'd)
23-95
sRs
DTGTroubleshooting(cont'd)
7. Checkresistancebetweenthe No. 9 terminal of
SRS unit connectorB (18P)and body ground.There
should be an ooen circuit,or at least 1 N4Q.
B {18PI
SRSUNIT CONNECTOR
PNK/BLU
DTC15-1:FaultyOPDSUnit
NOTE:
. An incorrectOPDSunit can causeDTC 15-1.
. A n e w ( u n i n i t i a l i z eO
d )P D Su n i t i n s t a l l e d
witha faulty
O P D Ss e n s o rc a nc a u s eD T C 1 5 - 1 .
. lf you installa new OPDSunit and a new SRSunit at
t h e s a m et i m e , i n i t i a l i z teh e O P D Sm a n u a l l y( s e e
page 23-27),do not usethe HondaPGM Tester.
1. Make sure nothing is on the front passenger'sseat.
2. Initializethe OPDSunit (seepage23-27).
3. Erasethe DTCmemory (seepage 23-26]'.
4. Readthe DTC.
Is DTC 15-1indicated?
ls the tesistance as specilied?
YES Go to step 5.
YES Go to step 8.
NO-Short to ground in the floor wire harness;
replacethe floor wire harness.l
Checkresistancebetweenthe No.9 and No. 16
terminalsof SRSunit connectorB (18P).There
should be an open circuit,or at least 1 M O .
B (18P)
SRSUNITCONNECTOR
PNK/BLU
2
10 tl
_-r
'18 sl
/i
tltlis-l \
YES Go to step 6.
NO Go to step 9.
DisconnectOPDSunit harness8P connector(A)
from the OPDSunit (A) (seepage23-124).
GRY/RED
Wiresideot femaleterminals
23-96
7 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
)
8. Checkfor voltage betweenthe No. 4 terminal of
OPDSunit harness8P connectorand body ground.
Thereshould be batteryvoltage.
Wiresideof femaleterminals
9. Replace
t h e N o . 9 ( 1 0 A ) f u s ei n t h e u n d e r - d a s h
fuse/relaybox.
to.
turn it off.
1 1 .C h e c kt h e N o . 9 ( 1 0 A ) f u s e .
l4V-'l^l
TVjEl
#
BLK
@
I
W i r es i d eo f f e m a l et e r m i n a l s
)
(cont'd)
23-97
sRs
DTCTroubleshooting(cont'dl
1 8 . Turn the ignition switch OFF.Disconnectthe
batterynegativecable.and wait for 3 minutes.
1 9 . Disconnectboth side airbagconnectors(seestep 4
o n p a g e2 3 - 2 1 ) a n db o t hs e a tb e l tb u c k l e t e n s i o n e r
4P connectors(seestep 6 on page23-22).
SRSUNITCONNECTOR
B I18PI
BLU
GRN/ORN
Reconnect
the bafterynegative
cable.
ls the resistance as specified?
YES- Go to step 22.
NO Short to ground in the floor wire harnessor
OPDSunit harness;replacethe faulty harness.l
23-98
DTC15-2:FaultySideAirbagCutoffIndicator
Circuit
1. Make sure nothing is on the front passenger'sseat.
B (18P)
SRSUNITCONNECTOR
PNK
Wiresideof temaleterminals
then
26. Replacethe OPDSunit (seepage 23-'124),
initializethe system (seepage 23-27).
NO Go to step 6.
YES Replace
t h e S R Su n i t( s e ep a g e2 3 - 1 2 2 ) . 1
{cont'd)
23-99
sRs
DTCTroubleshooting(cont'd)
7. Checkthe No. 10 (7.5A)fusein the under-dash
fuse/relaybox.
ls the f use OK?
YES Go to step 8.
NO Replacethe fuse, then turn the ignition switch
ON (ll).lf the fuse blows again,checkfor a short in
the No. 10 {7.5A)fuse circuit(ECMwire harness.
floor harness,or OPDSharness).1
8. Disconnectthe OPDSunit harness8P connector(A)
from the OPDSunit (seepage 23-124).
W i r es i d eo f f e m a l et e r m i n a l s
YES-FaultyOPDSunit;replacethe OPDSunit(see
page23-124)
.a
NO-Go to step15.
23-100
)
t5.
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) .
1 7 . Turn the ignition switch ON (ll).
\t
OPOSUNITHARNESS
8PCONNECTOR
Wiresideof femaleterminals
ls the voltage as specified?
ls the voltageas specified?
YES Short to power in the gaugeassembly;
replacethe gaugeassembly.l
NO Go to step 19.
\,
(cont'd)
23-101
sRs
(cont'dl
DTCTroubleshooting
23. Turn the ignitionswitch OFF.
2 9 . T u r nt h e i g n i t i o ns w i t c hO N ( l l i
3 0 . ' 0 2 m o d e l :C h e c k f o r v o l t a g e
b e t w e e nt h e N o . 4
terminal of dashboardwire harnessA 6P connector
C509and body ground.Thereshould be battery
vorlage.
'03 model: Checkfor voltagebetweenthe No. 5
terminal of dashboardwire harnessA 8P connector
C509and body ground.Thereshould be battery
vollage.
'02 Model:
OASHBOARD
WIREHARNESS
A 6PCONNECTOF
A {22P)
GAUGEASSEMBLY
CONNECTOR
Wiresideof femaleterminals
ls thete battery voltage?
'03 Model:
WIREHARNESS
A 8PCONNECTOR
DASHBOARD
23-102
\ J
ASSEMBLY
GAUGE
CONNECTOR
B {22P)
YEL
1
1t 12
3 4
IJ
,/1,/1,/)1 1
9 10
21 22
Wiresideof femaleterminals
\,
(cont'd)
23-103
sRs
DTGTroubleshooting(cont'dl
37. Checkresistancebetweenthe No. 15 terminal of
gauge assemblyconnectorA (22P)and body
ground.Thereshould be an open circuit,or at least
1M0.
A I22PI
GAUGEASSEMBLY
CONNECTOR
DTC15-3:FaultyOPDSSensor
1. Erasethe DTCmemory {seepage 23-261.
2 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d c h e c kt h a tt h e
SRS indicatorcomes on for about 6 secondsand
then goes off.
Does the SRS indicator stay on?
YES-Go to step 3.
NO Intermittentfailure,system is OK at this time.
Go to TroubleshootingIntermittentFailures(see
page 23-26).
NOTE:Aftermarketdevices(fluorescentlights,
laptop computers,etc.)used near the front
passenger'sseat-backcan interferewith the seatbacksensorsand causea false DTC15-3.lf one of
these deviceswas used,erasethe DTC,operatethe
devicenearthe seat-back,and recheckfor DTCs.lf
DTC15-3is reset,eraseit, and do not usethe
devicenearthe seat-back.
3 . Checkthe connectionat the OPDSsensorharness
connectorand the OPDSunit connector.
Are the connectionsOK?
YES-Go to step 4.
NO Reconnectthe OPDSsensorharness
connector,and clearthe DTC.I
foam (seepage
4 . Replacethe OPDSsensor/seat-back
20-141,and initializethe OPDS(seepage 23-27).
Erasethe DTCmemory,then checkfor DTC15-3.
ls DTC 15-3indicated?
YES Replacethe OPDSunit (seepage 23-1241.a
NO The system is OK.l
23-104
SRSIndicatorCircuitTroubleshooting
TheSRSIndicatorDoesn'tComeOn
1. Turn the ignition switch ON (ll),and see if the other
indicatorscome on {brakesystem,etc).
Do the other indicatorscome on?
YES Go to step 2.
N O - G o t o s t e p8 .
2. Turn the ignition switch OFF,then removethe
gauge assembly{see page22-641.
Disconnect
gauge assemblyconnectorA and B from the gauge
assembly.
Wiresideof femaleterminats
Is the voltage as specified?
Y E S - F a u l t yS R Si n d i c a t o cr l r c u i ti n t h e g a u g e
assembly;replacethe gauge assembly.I
N O - G o t o s t e p5 .
\9
11 12 l 3
/)x
1 1 1B
9 10
21 22
BLK
o.
Wiresideof femaleterminals
Is the resistance as specified?
YES Go to step 4.
l{,
N O O p e ni n t h e B L Kw i r e o f d a s h b o a r d
wire
h a r n e s sA o r f a u l t yb o d y g r o u n dt e r m i n a l( G 5 0 1 )l.f
t h e b o d y g r o u n dt e r m i n a li s O K ,r e p l a c ed a s h b o a r d
w i r e h a r n e s sA . I
(cont'd)
23-105
sRs
SRSIndicatorCircuitTroubleshooting(cont'dl
6 . DisconnectSRSunit connectorC (8P)from the SRS
unit {see step 7 on page 23-22).
7 . DisconnectgaugeassemblyconnectorA (22P).
Connecta voltmeter betweenthe No, l4terminal of
gauge assemblyconnectorA (22P)and body
g r o u n d .T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d
measurevoltage.There should be 0.5 V or less.
A {22P)
CONNECTOR
GAUGEASSEMBLY
ll
12
,/
,/
,/x
6
11
9 10
21 22
Wiresideof femaleterminals
ls the voltageas specitied?
YES-Faulty SRSunit; replacethe SRSunit (see
page23-'l22l.a
NO-Short to power in the PNKwire of dashboard
wire harnessA or in the floor wire harness;replace
t h e f a u l t yh a r n e s s . l
L Turn the ignition switch OFF.Checkthe No. 10
{7.5A)fusein the under-dashfuse/relaybox.
NO Go to step 9.
N O R e p a i tr h e s h o r tt o g r o u n di n t h e u n d e r - d a s h
f u s e / r e l a yb o x N o . 1 0 ( 7 . 5 A ) f u s ce i r c u i t . l
23-106
I J
TheSRSlndicatorStaysOn Whenln "SCS"
MenuMethod
NOTE:
. lf you cannot retrieveDTCSwiththe PGM Tester
usingthe SRSmenu method.retrievethe flash codes
with the Testerin SCS mode {seepage 23-24|,.
. A new SRS unit must sensethe entire system is OK
beforecompletingits initialself-test.The most
common causeof an incompleteself-testis the
failureto replaceall deployedpartsafter a collision,
in particular,seat belt tensionersand seat belt buckle
tenstoners.
. An incompleteself-testpreventsthe PGM Testerfrom
retrievingDTCS,althoughflash codesare availablein
the Tester'sSCSmode.
1. Erasethe DTCmemory usingthe MES connector
(seepage 23-26).
Does the SRS indicatorgo off while you are
erasing the DTC memory?
6. Replace
t h e N o . 1 3 ( 1 0 A )f u s e .
7. Turn the ignition switch OFF.Disconnectthe
batterynegativecable,and wait for 3 minutes.
8. Disconnectthe driver'sairbag 4P connector(see
step 2 on page 23-21).
9. Disconnectthe front passenger'sairbag4P
connector(seestep 3 on page 23,21).
10. Disconnectboth seatbelt tensioner2P connectors
(seestep 5 on page 23-221.
'11.
D i s c o n n e c t S RuSn i t c o n n e c t o r A { 1 8 P ) f r o m t h e
SRS unit (see step 7 on page 23-22],.
'12.
Reconnectthe batterynegativecable.
1 3 . T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0
seconds.Then turn the ignition switch OFF.
1 4 . C h e c k t h eN o . 1 3 ( ' 1 0 Af)u s e .
Y E S - S h o r t t o g r o u n di n t h e S R Su n i t ;r e p l a c et h e
SRS unit (seepage 23-122).a
N O G o t o s t e p1 5 .
l s t h e f u s eO K ?
15. Replace
t h e N o . 1 3 ( 1 0 A )f u s e .
YES--Goto step 19.
NO Go to step 3.
3 . R e p l a c e t h eN o . 1 3 ( 1 0 A )f u s e .
T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ,a n d w a i t f o r 3 0
seconds.Then turn the ignitionswitch OFF.
C h e c kr h e N o . 1 3 ( 1 0 A )f u s e .
ls the f use OK?
Y E S T h e s y s t e mi s O K a t t h i st i m e . I
NO Go to step 6.
I
{cont'd)
23-107
sRs
SRSIndicatorCircuitTroubleshooting(cont'd)
'16.
Disconnectdashboardwire harnessB connectorS
from the under-dashfuse/relavbor.
Wiresideof femaleterminals
1 8 . C h e c kt h e N o . 1 3 ( 1 0 A )f u s e .
ls there battery voltage?
ls the f use OK?
YES Go to step 29.
YES Short to ground in dashboardwire harness
B; replacedashboardwire harnessB.I
NO-Short to ground in the under-dashfuse/relay
box; replacethe under-dashfuse/relaybox.l
NO Go to step 26.
23-108
I
28. Checkresistancebetweenthe No. 3 terminal of
SRSunit connectorA (18P)and the No. 2 terminal
of dashboardwire harnessB connectorS. There
s h o u l db e 0 1 . 0 0 .
3 1 . C o n n e ctth e N o . 3 t e r m i n a lo f S R S u n i t c o n n e c t o r A
(18P)and the No. 5 terminal of SRSunit connector
C ( 8 P ) w i t ha j u m p e rw i r e .
SRS UNIT CONNECTORC I8P}
DASHBOARD
WIREHARNESS
B CONNECTOR
S
l
Wire side of
femaletermr n al s
PNK
a,SRSuNrr CONNECTOR
A I18P)
PNKT
l
PNK
Wire side of femaleterminals
JUMPER
WIRE
A I18P)
PNK SRSUNITCONNECTOR
1 0 11 12 l 3 1 4 1 5 16 1 1 l 8
Wiresideof femaleterminals
32. Turn the ignition switch ON (llf.
ls the rcsistance as specified?
33. Checkthe SRS indicator.
3 6 . C h e c kt h e N o . 1 3 ( 1 0 A ) f u s ei n t h e u n d e r , d a s h
fuse/relaybox.
ls the f use OK?
YES Go to step 40.
NO Go to step 37.
37. Replace
t h e N o . 1 3{ 1 0 A ) f u s e .
I
(cont'd)
23-109
sRs
SRSlndicatorGircuitTroubleshooting(cont'dl
38. Removethe gauge assembly(seepage 22-64),then
disconnectgauge assemblyconnectorA from the
g a u g ea s s e m D l y ,
Wiresideof lemaleterminals
23-110
47. Checkresistance
betweenthe No.6 terminalof
SRSunitconnector
C (8P)andbodyground.There
shoulb
d e0 - 1 . 0 Q .
SRS UNIT CONNECTORC I8P)
BRN
n
NO Go to step 45.
4 5 . D i s c o n n e cSt R Su n i tc o n n e c t oC
r ( 8 P )f r o m t h e S R S
unit (see step 7 on page 23-221.
46. Connectthe HondaPGM Tester{A) to the Data Link
Connector(B),and follow the Tester'sprompts in
the "SCS" menu (seethe Tester'soperating
m a n ual ) .
.r9
Wiresideof femaleterminals
,l
I
IL,
23-111
sRs
After Deployment
ComponentReplacement/lnspection
NOTE:Beforedoing any SRS repairs.use the PGM
TesterSRSmenu method to checkfor DTCS;referto the
DTCTroubleshootingIndexfor the lessobvious
deployedparts (seatbeit tensioners,front sensors,side
airbagsensors,etc.)
After a collisionwhere the seat belt tensioners
deployed,replacethese items:
' Seat belt tensioners
. Seat belt buckletensioners
. S R Su n i t
. Front impactsensors
After a collisionwhere the front airbag(s)deployed.
replacethese items:
. S R Su n i t
. Deployedairbag(s)
. Seatbelt tensioners
. Seat belt buckletensioners
. Front impactsensors
After a collisionwhere the side airbag{s)deployed,
replacethese items:
. S R Su n i t
. D e p l o y e ds i d ea i r b a g ( s )
. Side impact senso(s)for the side(s)that deployed
Duringthe repair process,inspectthese areas:
. lnspectallthe SRSwire harnesses.Replace,don't
repair,any damagedharnesses.
. I n s p e c t t h e c a b l ree e l f o rh e a t d a m a g el.f t h e r ei s a n y
damage,replacethe cable reel.
Afterthe vehicleis completelyrepaired,turn the
ignitionswitch ON (ll).lf the SRSindicatorcomes on for
about 6 secondsand then goes off, the SRSairbag
system is OK. lf the indicatordoes not function properly,
use the PGM TesterSRS Menu Methodto readthe DTC
(seepage23-23).lf this doesn't retrieveany codes,use
the Tester'sSCSmenu method (seepage23-24).lf you
still cannot retrievea code,go to SRS IndicatorCircuit
Troubleshooting.
\|J
23-112
Installation
1. Disconnectthebatterynegativecable,and wait at
least3 minutes beforebeginningwork.
a
9.8 N.m {1.0kgf.m,7.2 lbt.ft)
A
\'l9
4. Connectthe batterynegativecable.
5 . After installingthe airbag,confirm proper system
operation:
. T u r nt h e i g n i t i o ns w i t c hO N ( l l ) ;t h e S R Si n d i c a t o r
should come on for about 6 secondsand then go
off.
. Make sure the horn works.
lfc
23-113
sRs
AirbagReplacement
FrontPassenger's
Removal
1. Disconnectthebatterynegativecable,and wait at
least3 minutes before beginningwork,
Installation
1. Placethe new front passenger'sairbag(A) into the
dashboard.Tightenthe front passenger'sairbag
m o u n t i n gn u t s( B ) .
airbag4P
thefrontpassenger's
3. Disconnect
(A)from dashboard
wire harnessB.
connector
9.8N m {1.0kgf.m,7.2lbfft}
Connectthe front passenger'sairbag4P connector
( A ) t o d a s h b o a r dw i r e h a r n e s sB .
trr
23-114
SideAirbag Replacement
NOTE:Reviewthe seatreplacement
pro6edure
in the
Bodysectionbeforepertormingrepairsor service.
Removal
1. Disconnectthe
batterynegative
cable,andwait at
least3 minutesbeforebeginning
work.
2. Disconnect
thesideairbagharness2P
connector
{A).
Installation
NOTE:
. l f t h e s i d ea i r b a gl i d i s s e c u r e db y a t a p e , r e m o v e l h e
rape.
. Do not open the lid of the side airbagcover.
. Use new mounting nutstightenedto the specified
torque.
. Make sure that the seat-backcover is installed
properly,lmproper installationmay preventproper
deployment.
. Be sure to installthe harnesswires so that they are
not pinchedor interferingwith other parts.
1. Placethe new side airbagon the seat-backframe
(A).Tightenthe side airbag mounting nuts (B).
3 . Removethe seatassembly(seepage20-71)and
seat-backcover (seepage 20-75).
Removethe mounting nut (A) and the side
a i r b a g( B ) .
2. Installtheseat-backcover {seepage 20-75).
3. Installtheseat assembly(seepage 20-71),then
connectthe side airbagharness2P connector.
4. Move the front seat and the seat-backthrough their
full rangesof movement,making sure the harness
wires are not pinchedor interferingwith other parts.
5. Reconnectthe batterynegativecable.
6. After installingthe side airbag,confirm proper
system operation;Turnthe ignition switch ON (ll);
t h e S R Si n d i c a t o sr h o u l dc o m e o n f o r a b o u t6
secondsand then go off.
l,o
23-115
sRs
Airbag Disposal
Special Tool Required
Deploymenttool 07HAz-SG00500
Beforescrappingany airbags,side airbags,seat belt
tensioners,or seat belt buckletensioners(including
those in a whole vehicleto be scrapped),the airbags,
side airbags,seat belt tensioners,or seat belt buckle
tensionersmust be deployed.lf the vehicleis still within
the warranty period,the HondaDistrictService
Managermust give approvaland/orspecialinstruction
beforedeployingthe airbags,side airbags,seat belt
tensioners,or seatbelt buckletensioners.Only afterthe
airbags,side airbags,seat belt tensioners,or seat belt
buckletensionershave been deployed(asthe resultof
vehiclecollision,for example),can they be scrapped.
lf the airbags,side airbags,seat belt tensioners,and
seat belt buckletensionersappearintact(not deployed),
treat them with extremecaution.Follow this Drocedure.
Driver's Airbag:
4. Removethe accesspanelf rom the steeringwheel,
then disconnectthe driver'sairbag4P connector
from the cable reel (seestep 2 on page 23-21).
Front Passenger'sAirbag:
5. Lowerthe glove box,then disconnectthefront
passenger'sairbag 4P connectorfrom dashboard
wire harnessB (seestep 3 on page 23-211.
Side Airbag:
6. Disconnectthe side airbag2P connectorsfrom the
floor wire harness(seestep 4 on page23-211.
Seat belt tensioner:
7. Disconnectthe seat belt tensioner2P connectors
from the floor wire harness{seestep 5 on page 2322).Pullthe seat belt out all the way, and cut it off.
Seat belt buckle tensioner:
8, Disconnectthe seat belt buckletensioner4P
connectorsfrom the floor wire harness(seestep 6
on page 23-221.
$ J
23-116
/ :
i'..-':
!
(cont'd)
23-117
sRs
Airbag Disposal(cont'dl
DeployingComponentsOut of the Vehicle
lf an intactairbagor tensionerhas been removedfrom
a scrappedvehicle,or has beenfound defectiveor
damagedduring transit,storage,or service,it should be
deolovedas follows:
DeploymentTool Check
1. Connect
the yellowclipsto bothswitchprotector
handleson thetool;connectthetoolto a battery.
2. Pushthe operationswitch:greenmeansthetool is
OK;redmeansthetool is faulty
3. Disconnectthe
batteryandthe yellowclips.
Disposalof DamagedComponents
1. lf installedin a vehicle,follow the removal
procedurefor the driver'sairbag (seepage23-113),
front passenger'sairbag (seepage 23-114),side
a i r b a g( s e ep a g e2 3 - 1 1 5 )s.e a tb e l tt e n s i o n e (r s e e
page23-4),and seat belt buckletensioner.
2. In all cases.make a short circuit by cutting,
stripping,and twisting togetherthe two inflator
wires.
NOTE;The driver'sand passenger'sairbageach
have four wires:twist each pair of like-colored
wires together
Packagethe componentin the same packagingthat
the new reolacementDartcame in.
Mark the outsideof the box "DAMAGEDAIRBAG
NOT DEPLOYED'"''DAMAGEDSIDEAIRBAGNOT
"DAMAGED
DEPLOYED",
SEATBELTTENSIONER
NOT DEPLOYED"or "DAlvlAGEDSEATBELT
BUCKLETENSIONERNOT DEPLOYED"so it does
not get confusedwith your parts stock.
Contactyour HondaDistrictServiceManagerfor
how and where to return it for disposal.
23-118
I|J
CableReelReplacement
Removal
1 . M a k es u r et h e f r o n tw h e e l sa r e a l i g n e ds t r a i g h t
ahead.
Disconnectthe batterynegativecable,and wait at
least3 minutes.
)
5 . Align the front wheels straightahead,then remove
the steeringwheel with a steeringwheel puller (see
'17-6).
step 3 on page
Do not tap on the steeringwheel or steering
c o l u m ns h a f t w h e nr e m o v i n gt h e s t e e r i n gw h e e l .
I,
(cont'd)
23-119
sRs
CableReelReplacement(cont'd)
Disconnectthe dashboardwire harness4P
connector(A)from the cable reel,then disconnect
the dashboardwire harness5P connector{B}from
the cable reel.
Installation
1. Beforeinstallingthe steeringwheel. align the front
wheels straightahead.
2. lf not alreadydone, disconnectthe batterynegative
cable,and wait at least3 minutes.
3. Setthe cancelsleeve(A) so the projections(B)are
a l i g n e dv e r t i c a l l y .
9 . R e l e a s teh e t a b ( B ) ,t h e n p u l l o f f t h e c a b l er e e l( A ) .
J
23-120
8 . l n s t a l l t h ed r i v e r ' sa i r b a g( s e ep a g e2 3 - 1 1 3 ) .
9. Reconnectthe batterynegativecable.
10. After installingthe cable reel,confirm proper
syslem operalton:
. Turn the ignition switch ON (ll);the SRS indicator
should come on for about 6 secondsand then go
off.
. After the SRS indicatorhasturned off, turn the
steeringwheel fully left and right to confirm the
SRSindicatordoes not come on.
. M a k es u r et h e h o r nw o r k s .
. Make sure the cruisecontrolworks,
) c
23-121
sRs
SRSUnit Replacement
Removal
'1.
lnstallation
1 , I n s t a l l t h en e w S R Su n i t ( A ) w i t hT o r x b o l t s( B ) ,t h e n
connectthe connectors{C)to the SRSuniu push
them into positionuntil they clicks.
NOTE:When tighteningthe Torx boltsto the
specifiedtorque, be carefulto turn them in so that
their headsrest squarelyon the brackets.
9.8 N.m (1.0kgf m, 7.2 lbf ft)
211.
Reconnectboth seat belt tensionerconnectors(see
page 23-221and both seat belt buckle tensioner
connectors (see page 23-22).
7. Pull down the consolecarpeton the driver'sside,
then disconnectthe connectors.Removethe Torx
bolts (A),then pull out the SRSunit.
6 . Reconnectthe batterynegativecable.
7 . I n i t i a l i zteh e O P D Su n i t ( s e ep a g e2 3 ' 2 7 ) .
23-122
lnstallation
1 . I n s t a ltlh e n e w s i d ei m p a c ts e n s o rw i t h a n e w T o r x
bolt (A),then connectthe floor wire harness2P
connector{B)to the side impact sensor{C).
2. Reconnectthe negativebatterycable.
3 . After installingthe side impact sensor,confirm
23-123
sRs
OPDSUnit Replacement
NOTE:Reviewthe seat replacementproceduresin the
body sectionbeforeperformingrepairsor service.
Removal
1. Disconnectthe batterynegativecable.and wait at
least3 minutesbefore beginningwork.
Installation
1. Placethe new OPDSunit (A) on the seat-backframe.
Tightenthe two screws(B),and connectthe OPDS
unit harness8P and sensorconnectors(C)to the
OPDSunit. Reinstallthecover (D).
23-124
Installation
1. Installthe new front impact sensorwith new Torx
bolts (A),then connectthe engine compartmentwire
harness2P connector(B)to the front impactsensor
{c).
A
9.8N.m
(1.0kgf.m,7.2lbf.ftl
Reconnectthe batterynegativecable.
23-125
) s
ServiceManuallndex
NOTE:Refertothe lollowing listto look up
DTCS,
symptoms,
fuses,connectors,
wire
harnesses,
specifications,
maintenance
schedules,
andgeneralservice
inlormation:
DTCTroubleshootingIndexes
ABS/TCS
Components
........................
19-34
'17-22
EPSComponents
.................................
Fueland
Emissions
11-i
Heating/Ventilation
................................
21-9
A/C SignalCircuit
Troubleshooting.........................-......
11-'133
Back-upLightSwitch
Test.........................................................
13'3
Back-upLi9ht3
CircuitDiagram
22-75
A-Dillar
CornerTrim
Replacement
...............-.....-..............-....
20,96
BallJoint Boots
. .8. . . . . . . . . . . . . . . . . .
s R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .3. -. 2
Replacement
......
1 81 6
ABS IndicatorCircuit
SymptomTroubleshootingIndexes
Troubleshooting
... 19-52
BallJoints
ABS/TCSComponents........................
1935
R e m o v a 1 . . . . . . . . . . . . . - . . ................ . . . 1 8 - 1 0
CruiseControlSystem..........................4
38
ABSModulator-contml
Unit
EPSComponents
.................................
17-23
Bemoval/lnstallation
............................
19-57
Betterv
FanControls
10,12
. . . . . . . 2520
Fueland Emissions..............................
11-10
ABS/TCSComoonents
Heating/Ventilation..............................21
10
Component
LocationIndex.................
19-30
Beverage
Holder
. . . . . . .C. .i.r.c. .u.i.t.D i a q r a m . . . . . . . . . . . . . . . . . . . .1. 9. .' .4. 2
S R S. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .' .3. 0
.
Blower Motor
Fuse/Relaylndexes
Replacement
.....
2 14 1
AccessoryPoworSocket Front
Power0istribution...............................22-46
TesVReplacement
..............................
22'149
Under-dash
Fuse/Relay
Box ...............
22 45
Blowor PowrTransistor
Under-hood
Fuse/Belay
Box ...............22
44
Accessory
PowerSockets
21-38
CircuitOiagram..................................
22-149
Connectorand Wire Harnesslndexes
Blower Unit
Component
Connectors
Air Cleaner
Removal/lnstallation
............................
21-39
(to harness)
......2214
Rep1acemen1.....................................11-162
Meintenence
section....................
Section3
19-14,23
Gene.allnlormationsection........Section1
) s
Airbag.Driver's
Irake Discs
Replacement
.......................................
23 1'l3
Inspection
....................
...................
19-13,22
R e p a i.r. . . . . . . . . . - . . . . . . . . . . . . . . . . . . .2. .3. 1. 1
. .6. . . . . . . . . . . . .
A
BrakeFluidLevelSwitch
Airbag.Front Passenger's
Test
19.10
Beplacement.......................................
23-114
AIC
BrakeLights
Locationfndex...................21-3 Altemator
Component
CircuitDiagram....................................22-7
D e s c r i p t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B- e. .p. .l 2
' 1m' l e. n. .t. . . . . . .............. . . . . . . . . . . 4. .2. .9. . . . . .
a1
ce
CircuitDiagram....................................21-14
Overhaul.................................................4-30
BrakeLinesand Hoses
21.57
Inspection.............................................
19-24
AhernatorFRSignalCircuit
R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .9. -. .2. 5.
A/C Compressol
T r o u b l e s h o o t i n. .g. . . . . . . . . . . - . . . . . . .1. 3
. .41 1
Replacement
.......-...-.............................
BiekeMeder Cylinder
21-41
Antenna
Rep1acement.........................................
19-15
Replacement
A/C ComprssorClulch
.........22-103 Inspection.............................................
19-16
Inspecton........
21-44
2l-49
AudioUnit
BrakePads
Overhaul..........
Removal/lnstallation
..........................22-100
Inspection/Rep1acement................
19-11,20
A/C CompressorClutchCircuit
Troubleshooting
...................................
21-30
AudioUnitConnector
BrakePedal
Replacement
22101
Adjustment..............
19,6
ArfCComoressorReliefValvc
Replacement
..........-...-..........................
21-51
Audio/Entertainment
Breke Pedal Posilion Switch
Component
LocationIndex.................22-9A Test.....
..-..............
22-84
A/C Compr$sor ThermalProtector
CircuitDiagram
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .1. -. 5
. .1. . . . . . . . . . . . .
BrakePedalPositionSwitch SignalClrcuit
Troubleshooting
11-137
A/C Condenser
Replacement,.,
.....25
12
A/C CondenserFanCircuit
Troubleshooting
...................
. . . . . .....21-28
(cont'd)
ServiceManualIndex
(cont'dl
BrakeSystemIndicatorCircuit
CircuitDiagram
Conventional
BrakeComponents.....
19-9
Troubleshooting
ABS/TCS
Components...........
......19-55
CombinationLight Swilch
CylinderHeadAssembly
TesVReplacement
..............................22
80
Component
LocationIndex.....................
6-3
Inspection.................................................
66
ConnectingRod Bearings
Removal..........
&23
R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .-.. . . . 7 - 8
I n s t a 1 1 a l .i .o. n. . . . . . . . . . . . . . . . . . . . . . . . . .6. .3. 9. . . . . . . . . . . . . .
Bulb,Geuge
R e p | a c e m e n l . . . . . . . . . . . .......... . . . . . . . 2 2 6 3
ConnectingRod Bolts
CylinderHeadCover
fnspection....................-.-.-.-....................
7-24
8emova1
..............-.-.................................
6-22
Installation
..............................................6-41
Bulb,Headlight
ConnectingRods
Replacement
.........................................
Inspection........,,.,.,...,.,.,.,.,,,,.,,,.,.,.,.,.,.,.,..
22-A1
75
CylinderHead,Bare
Inspecton..,.....,.
Bumper,Front
Removal/1nsra11ation
............................
20 85
Connectors
(Seefirstpageof thisIndex)
Bumper,Rear
R e m o v a l / l n s t a l l a t i o.n. . . . . . . . . . 2 0 . 8 6
ConventionalBrakeComponent3
D
ComponentLocationIndex...................
19'3
Troub1eshootin9
.....................................
19-4
R e p a i.r. . . . . . . . . . . . . . . . .
Dampers.Front
19-8
R e p l a c e m e n t . . . . . . . .................. . . . . . 1
. .8. 2
. .0. .
Coolant
Inspectio
. .n. . . . . . . . . . . . ........ .
. .1 0 6
Oampers,Rear
R e p l a c e m e n t . . . . . . . . . . . . ....... . . . .1 06
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . .1
. .8. .-.3. .4. . . . . . . . . . . . .
CableReel
Replacement.......................................
23-119
DashVents
CoolantTemperatureGat|ge
T r o u b 1 e s h o o t i n 9 . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . Bemoval/lnstallation
......
.-..........................
20-64
Camshaft
Inspection.......................-...-...................
CoolingSyslem
6-29
Dashboard
Component
LocationIndex...................
Bemoval/1nsta11ation
............................
20-66
10-2
CargoArea Light
TesVRep1acement
................................
CountershaftBearings
22-97
OashboardCenterPanel
R e p l a c e m e n t . . . . . . . .. . . . . . . . . . . . . . 1
. .3. .-.4. .2
Removal/1nstaf
1ation............................
20 62
Carpet
R e p l a c e m e n t . . . . . - . . ..-. . . . .... . . . . - . 2 0 - 5 5
Cowl Cover
DashboardLower Cover
R e p l a c e m e n t . . . . . . . . . . . ........ . . . . . 2 0 - 9 5
Removal/lnstallation
......................
20-59,63
CeilingLight
-estrReplacement
................................
22.96
DashboardUnderCover
Crankshaft
R e m o v a. l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7. .- .1. 2. . . . . . .Removal/lnstallation
........
............................
20 60
ChargingSystem
Inspec(on,,,,,
........14
l n s t a l l a t i o n . . . . . . . . . ... . . . . . . . . . . . . . 1 - 2 4
LocationIndex...................
4-20
Component
DifferentialCarrierBearings,M/T
C i r c u iDt i a g r a m. . . . . . . . . . . . . . . . . . . . . . . .4. .-.2. .1. . . . . . . . .
Rep1acement,,......,...,...,.,.,,,.,.,,,........,.,.
13-54
Troubleshooting
. . . . . . . 4 - 2 2 CrankshaltMain Bearings
R e p l a c e m e n t . . . . . . . . - . - . . . . . . . . . . . . .7. .-.6. . . . . . .Ditferential
. . . . . . . . . . . Oil Seals,M/T
ChildSeatTetherAnchor
8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 5
. .5. . . . . . . . . . . . .
R e m o v a l / l n sl at at ;fo n. .. . . . . . . . . . . . . . . .2. .3. .1.1. . .
CrankshaftOilSeal,TransmissionEnd
1nstanation
..............................................
7 28
DifferentialPinionGears,M/T
CKP(CrankshaftPosition)Sonsor
I n s p e c t i o. n, . . . . - , . , , , . , . . , . - , . , . . . . . .1. .3.5, .3, . , , ,
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1.1. .-.1. .1. 6. . . . . . Crankshafl
.....
Pulley
Removal/lnstallation
-..................-..........
6-11
OLCCircuit
Clutch
Troubleshooting
................................
11-109
CruiseControlActuator
ComponentLocation
1ndex...................
12-3
......................
R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . . . .1. .2. -. 9
. . . . . . .Test
..........
4-43
Door Glass
RepIacement.......................4
. .-. 4. .4. . . . . . R
. . e. .p. .1. a. .c e m e n t . , . , , , , , , , , , , , . , , , , , , , 2
, ,0, .-,9. , . , . , . , , , , , , . , ,
ClutchInteYlockSwitch
Adjustment. .. .....................20-11
T e s t . . . . . - . . . . . . . . - . . . - .......-.-.-. .. -. . . . . . . . 4 - 6 CruiseControlActuatorCable
Adjustment.............................................
4 45
Door GlassWeathelstrips
ClutchMasterCylinder
R e p l a c e m e. n
. .t. . . . . . . . . . -. .. .. . . . . . . . . - . . . 1
. .0. 2 0
Replacement.......................1
. .2. .5. . . . . . . Cruise
. . . . . . . .Control
.
Main Switch
TesVRep1acement
..................................
4 42
Door Latches
clutch Pedal
Replacement
..........-.-..............................
20-7
Adjustment.............................................
12 4
CruiseControlSet/Resume/Cancel
Switch
TesVRep1acement
..................................
4 42
Door LockActuators
ClutchPedalPositionSwitch
Test......................................................
22-154
T e s t . , . , , , , , . , , , . , . , , , , , , . , . ,.,.,.,.,.,.,4, ,4. 5, , , , , . . CruiseControlSystom
Component
LocalionInde\...................
4-36
Door LockKnob Switches
Clutch Slave Cylindor
C i r c u iDt i a g r a m. . . . - . . . . . . . . . . . . . . . . . . .4. .3. 7
. . . . . . . .Test
. . . -.........
. . . - . . . . . . . . ......22-160
Beplacemeit...
12-1
CruiseControl Unit
Door LockSwitches
CMP{CamshaftPositionlSenso]
I n p u t T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. ., 4 0
T e s t. . . . . . . ........ . . . . . . . . . . . . . ..................2...2
. .-. 1 6 0
R e p l a c e m e n t . . . . - . . . - . . . . . . . . . . . .1.1. .- .1. 2
. .8. . . . . . . . . . .
Door Outer Handles
CMP(TDC)Sensors
Rep1acemen1
...........................................
20-6
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . .1.1. .1. 1. .4. . . . . . . . . . . .
)
Door Panels
Removal/lnstallation
-.............................
20-4
Front Speakers
Rep|acement.......................................
22-102
Door SashTrim
EPSIndicatorCircuit
Rep1acement.........................................
20 10
Troubleshooting
...................................
17-47
Front Suspension
ComponentLocation
Index...................
18-3
Door Strikers
EPSMotor
Adiustment...........................................
20-13
Removal/lnstallation
.-..........................
17-49
FuelandEmissions
Description
...........................................
11-12
Door Weatherst ps
EVAPCanister
Beplacement...........-.............................
20 11
R e p 1 a c e m e n t . . . . . . . . . . . .. . . . . . . . 1
. .1. ., .1 8 9
FuelFill Door
Adjustment..........-................................
20 93
OriveBeh
Inspecaron
................
4-26
R e p | a c e m e n t . . . . . . . . . ................ . . . . . .4. .2.6. . . .
EPSConirol Unit
Removal/1nsta11ation
..................-.........
17-67
EVAPControlSystm
FuelFill Door Openet
ComponentLocation
Index ..............'11-170 B e p l a c e m e n t . . . . . . . . . . . ... . . . . . . . .2. .0. . 1 0 9
EVAPTwo-WeyValve
FuelFill Door OpenerCable
DriveBelt Auto-tensionel
T e s t. . . . . . . . . . - . . . . . . . . . . . . . - . . . . . . . . 1
. .1. .1. 8. .6. . . . . . .Replacement.......................................
......
20-lO7
lnspection...............................................
4 21
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .....4. .-.2. .8. . . . . . .Evaporetor
..
FuelFilter
Core
R e p 1 a c e m e n t . . . . . . . . . . . . ... . . . . . . . 2
. .1. - 4 2
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2
.........
Driver'sPocket
Removal/lnstallation
-...........................
20-60
EvaporatorTomperatureSensor
FuelGaugeSendingUnit
Replacement.........................................
T e s t. . . . . . . . . . . . . . . . . . . . . . - . - . . . . . . . . 1
. .1- .' 1
. .5. .6. . . . . . . . .
21-37
Driver'sTray
Test..................................... 2137
Removal/lnstallation
.........................-.20-65
FuelInjectionSyslem (PGM"FIl
EvaporrtoFHeaterUnit
Component
Location1ndex.................
11-49
DRL{DaytimeRunningLightsl
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. 4. .3. . . . . . . . . . . . .
Control Unit
FuelIniectors
lnputTest ....................
........
. . . ......22-16
ExhaustManifold
R e p 1 a c e m e n 1 . . . . . . . . . . . . . . . . . . . .1.1. .1.1. l. . . . . . . . . . .
Removal/1nsta11ation
................................
I 7
DTCs
FuelLinesand Hoses
(Seefirstpageolthis Index)
ExhaustPipe
I n s p e c t i o. n. . . . . . . . . . . . . . . . . . . . . . . . . .1. 1. .' .1. 4
. .6. . . . . . . .
8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . .9. -. .8. . . . . . .R. .e. .m. .o. .v.a.. l. . . . . . . . . . . . . . ... . . . . . . . . . . .1 1 - 1 4 9
Dust and PollenFiller
I n s t a | 1 a t i.o. .n. . . . . . . . . . . . . . . . . . . . . . . 1
. .1. .1. 5. .0. . . . . . . . .
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .1. -. .3.9. . . . . . . . . . . . .
FuelPipeProtectol
DynamicDamper,Driveshafts
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0.-. 1
. .0. .4. . . . . . . .
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1
. .6. .-.8. . . . . . . . . . . . . . .
FuelPressureRegulatot
FanControls
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .-.1. .5. 2
.........
C o m p o n e nL to c a t i oInn d e x . . . . . . . . . .1. .0. .' l.1. .
C i r c u iDt i a g r a m. . . . . . .. . .. . . . . . . . . . . . .1. .0. 1. .3.
FuelPulsationDamper
R e p l a c e m e n l . . . . . . . . . . . . . . . . . . . . .1. .1. 1
. .5. .4. . . . . . .
FenderFairing,Front
ECTSensor
R e p l a c e m e n t . . . - . . . . . . . . . . . . . . . . .2. 0
. .-.1. .0. .3. . . . . Fuel
. . . . . Pump
R e p l a c e m e n t . , . , , , . , . , , , , , , , , , , , ,1,1, .-.11. .4. . . . . . . . . . . .
R e p l a c e m e n t , , , , , . , . , . , , , . , , , , , , ,1, ,1, -, 1
, .5, .3, . , , , . . ,
FinalDrivenGear.M/T
ElctricalPowerSteeringIEPS)
R e p l a c e m e n t.... . . . . . . . . . . . . . . . . . . . . 1
. .3. .-.5. .3. . . . . FuelPumpCircuit
SignalCircuit
T r o u b l e s h o o t i-n. g
. . . . . . - . . . . . . . . . . .1. 1
. .-. 1. .4. .1. . . .
T r o u b l e s h o o t i n. .g. . . . . .
. . . . .1 1 - 1 3 5
Frame
R e p a iCr h a n . . . . . . . . . ...... . . . . . . . . . . . .2. .0. 1. .1.4. .
FuelSupplySystem
Emblems
Component
Locationlndex ..............
11 140
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. -0.-.1. .0. .0. . . . . Frame
. . . . . Stiffenel
A d j u s t m e n t . . . . . . . . . . . . . . . . . . . . 1. .1. .- .1. 4. .4. . . . . . .
R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .2. 0
. .-J. .' .1. 3. . . . . . T
. .e. .s. t . . . . . . . . - . . . - . . . . . ....... . . . . . . . . . . .1. 1. -- 1 4 5
EngineAssembly
R e m o v a. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. .2. . . . . . . .Front
. . . . . .Console
....
FuelTank
Installation
............._..................................
5-9
Removal/lnstallation
............................
20 5l
B e p l a c e m e n l . . . . . . . .. . . . . . . . .1 11 5 5
DisassembJy/Reassemb|y
...................
20 58
EngineBlockAssembly
FuelTankVapor ControlValve
C o m p o n e nL to c a t i oInn d e r. . . . . . . . . . . . . .7. . 3. . . . . Front Doors
T e s t. . . . . . . . . . . . . . . . . . . . . . -. . . . . . . . . 1 1 - 1 8 7
Component
LocationIndex...................
20-2
R e p l a c e m e n t , , . , , . . . , . , , , . ,. . , ,.,., .1. .1 1 8 9
EngineBlock,Bare
A d i u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .2. .0. . 1. .2. . . . . . . . . .
Inspect|on
................7-15
Fuses
Repair
. . . . . . . . . . . . .1. 1
..1
Front DriveshaftAssembly
{Seefirstpageofthis Index)
I n s p e c l i o. .n. . . . . . . . . . . . . . . . . . . . . . 1 6 3
Entry Light ControlSystem
R e m o v a 1 . . . . . . . . . . . . . . . ....... - .. .. .. .. .. .1 6 - 3
Component
LocationIndex...............-.
D i s a s s e m b l. y. . . . . . . . . . . . . . . . . . . . . . . . . .1. 6. .5.
22-89
CircuitDia9ram....................................
22 90
Resassemb|y
................................-.........
16-9
I n s t a 1 1 a r.i.o. .n. . . . . . . . . . . . . . . .......... . . . l. 6. . .1 7
EPSComponents
Component
Location1ndex..........-......
17-!7
Front lmpact Sensors
D e s c r i p t i o. n
. . . . . . . . . . . . . . ............. . . . . 1 7 - 2 4
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . .2. 3. . 1
. .2. .5.
C i r c u i tD i a g r a m
1 12 6
(cont'd)
ServiceManualIndex
(cont'dl
HeaterValveCable
A d j u s t m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .?. .1. -. .4.6.
GenoralInformation
(Seeseclion 1)
Hood Latch
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .1
20 8
InstrumentPanel
Removal/1nsta11ation.................
.......20-59
GloveBox
Removal/1nsta11ation
.......................-....
20-63
HoodOpenerCable
ComponentLocation
Index ..............20
105
R e p l a c e m e. n
. .t. . . . . . . . . . ...... . . . . . . . . . 2 01 0 6
IntakeAir BypassControlThermalValve
T e s r . . . . . . . . . . . . . . . . . . . ........... . .....1. .1. - 1 6 1
lmmobilizerSystem
Component
LocationIndex ..............
22-162
Description
High Mount BrakeLight
C i r c u i t D i a g r a.m
..........................22-164
GaugeA3sembly
8 e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2
. .2. .8. 2. . . . . . . .Troubleshooting
......
............................
22,165
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. .2. 6. .4. . . . . . . . . . . . . .
Hood
InnerFender,Fronl
Gaugs
Adjuslment
Repfacemenl.......................................
20-102
Component
LocationIndex..........-......
22 54
H o w - t ol n f o r m a t i o n
. . . . . . . . . . . . . . . . . . . . . . . . 2 2 - 5Hood
6
lnsulator
InsideRearviewMirror
CircuitDiagram
22-54
Replacement.........................................
20-89
R e p l a c e m e n t . . . . . . . . . . - . . . . . . . . . . .2. .0. 1. .6. . . . . . . . . . . . . .
Grille
IntakeAir System
Replacement...........-.............................
20-94
Hood Seal
ComponentLocationIndex...-.-........
11-159
Beplacement.-...........................-...........
20-88
IntakeManitold
Horn
Removal/1nsta11ation
................................
I 2
H
TesVReplacement
. . ................
......22-122
lntermediateShaft Assembly
Horn Switch
R e m o v a. 1
. . . . . . . . . . . . . . . - . - . . . - . . . . . . .1. 6. .-.1. .9. . . . . . . . . . . .
Test ............-........
22-122
D i s a s s e m b | y . . . . . . . . . . . . . . . . . . . . . - .1. 6. ., 2 0
Adiustment.......
R e s a s s e m b. |. y. . . . . . . . . . . . . . . . . . . . . . .1. .6. 2. .2. . . . . . . . . .
Horns
Installation
.........-...-..............................
16-24
HatchHandle
Component
LocationIndex. . . . . . . . . . . . . . 2 2 - 1 2 0
Replacement
20-110
Circ!itDiagram
22 121
Hatch Latch
Replacement
Replacement
. . . 1. 11 1 3
Hubs
KeylessEntry Transmitter
R e p l a c e m e n. .t.. . . . . . . . . . . . . . . . . . . . . . 1. .A.2. .6. . . . . . . Repair...............
22-161
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .6.1. . . . . . . . . . . . . .
Test
H.tch Lock Actuator
Test
H02S.Secondary
20-'110
22-159
KeylessEntry/SecurityAlarm System
ComponenlLocationIndex..............
22 150
C i r c u iDl i a g r a m. . . . . . . . . . . . . . . . . . . . . 2
. .2. .1. 5 1
HatchLockCylinder
R e p | a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .0. ,. 1. .1. .1. . . . . . . . . .
IAT {lntakeAir Temperature}Sensor
KeylessReceiverUnit
'11
HatchSpoiler
Replacement.,.........-...
115
lnputTest ............................................
22-153
Replacement
ldle ControlSystem
KnockSensor
HatchSupport Struts
ComponentLocation
Index ..............
11-129
R e p l a c e m e n t . . . . . . - . . . . . . . . . . . . . .1.1. .1. .1. 5
............
Beplacement.....
I n s p e c t i o n , . , . . . . . . . . . - . . . . . . . , . , . ,1,',l,1, 3, .8, , , . , . , . . . . .
20-91
Knuckles
HatchWeatherstrio
lgnition Coillsl
Replacement
Replacement....
Bemoval/lnstallation
20-92
...............-..............
4 18
F r o nS
t u s p e n s r o. .n. . . . . . . . . . . . . . . . .1. 8. .-.1. . . . . .
RearSuspension........
.................-...
18-28
HazardWarningSwitch
lgnition Key Light
test
....................
22_88
T e s t , , . , , , , . , . . . , . . . . . . -.......................
.
22-91
H6adlight
Adjustment
..22-78
Test
. . . . . . . . . . . . . . .2. 2
. .-. 9. .1. .
ReQ\ace$ent
Hcadlights
CircuitDiagram..............................
22-71,72
lgnition Switch
Test .,,,.,.,.,,,,.,.,.
......22-53
.....22-83
lgnition System
LicenseTrim
Component
LocationIndex...................
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . - . . .2- 0
. .-. 9. .8. . . . . - . . . . . . .
4-15
C i r c u i t D i a 9 r a. m
. . . . . . . . . . . . . . . . . . . . . . .4. .' 1
. .6. . . . . . . .
1nspection
...............................................
4-17
Lights,Exterior
HeaterControlPanel
ComponentLocalionIndex.................22
68
Removal/1nsta11ation
............................
21-38
lmmobilizerControl Unit-Receiver
Lights,Interior
22-161
HeaterControl Powerand GroundCircuits
Component
LocationIndex.................
22-94
T r o u b f e s h o o t i n g . ................ . . . . . . . . . . . . . . . 2 1 - 2 7
C i r c u i t D i a g r.a. m . . . . . . . . . . . . 2 2 - 9 5
Headliner
Removal/lnstallalion
............................
20-54
Oil PressureSwitch
MoonroofDrainChannelSlider
T e s t. . . . . . . . . . . . . . . . - . - . . . . . . . . - . . . . . . . . .8. -. .4. . . . . . . . . .
20'44
. . . . . . . . 1 1 - 1 5 8 Replacement.........................................
R e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . . .8. .-.1. .6. . . . . . . . . .
Moonroof Frame
LowerArms
18 19
R e p 1 a c e m e n t , , , , , , , , , , . , . , . , . , . , . 2, .0, ,4,2, , , . . . . .Oil
. . .Pump,
. . . . Engine
Removal/1nsta11ation............................
8-8
Overhau1
..................................................
MoonroolGlass
LubricationSystem
Oil, Engine
20-37
LocationIndex.....................
8-3
Adiustment...........................................
Component
. .7. . . . . . . .R. .e. p. .l.a. c e m e n t . . . - . . . . . . . . . . . . . . . . - . - .8. .-.5. . . . . . . . . .
Test....................................8
. .4
. . . . . . . .R
. .e
. .p. .1. a
. .c. .e. m
. . e n t . . . . . . . . . . . . . . . . . . . . . 2. .0. 3
Low Fuellndicator
Test.............
OPDSUnit
Moonroot Limit Switch
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .2. .3.-1
. .2. .4. . . . . . . . . .
20 46
Adjustment........................................-.T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2. .1. .1.3. . . . . . . . . . . . . .
M
OutsideMirror Holders
20-15
Beplacement.........................................
Moonrool Motor
R e p l a c e m e n t . . . . - . . . . . . . . . . . . . . . . .2. .D. .-.4. .1. . . . . . . . . . . .
M/TAssembly
Test
. . . . . . . . . . . . . .2. .2. .- .1. 2
..
OutsidePower Mirror Actuators
Removal
..........
13-4
22-117
Test......................................................
. . . . .1. 3 - 8
lnstallation.......
22-114
Bepfacement..-....................................
Sunshade
D i s a s s e m b.l.y. . . . . . . . . . . . . . . . . . . . . . . .1. .3.-. 1
. .4. . . . . .Moonrool
...
R e p 1 a c e m e n t . . . . . . . . . . . ....................2
....0.4. 0
. .3. .- 4 6
R e s a s s e m b .l y. . . . . . . . . . . . . . . . . 1
OutsidePower Mirror Switch
22-111
Test..-...................................................
MoonroofSwitch
M/TChangeLever
TesVRep1acement
..............................
22-l 12
13-19
lnspection.............................................
OutsidPower Mirrors
13-20
8eassemb1y
...................
Disassembly
R e p l a c e m e n t . . . . . . . . . . . . . . . . .. .. . .....2. .0. -. .1.5
Mooniool Wind Deflector
22-114
Locationlndex ..............
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .2. -0. -. 3
. .8. . . . . . Component
.......
M/T CountershaftAssembly
22-115
CircuitDiagram..................................
. . . . . . . . . . . . . . . . . . . . . . . .1. 3. .3. 1. .,3. .3. . . . . .
I n s p e c t i o. n
22-116
Test-.....................................................
. .-. 3. .2. . . . . .Moonroof/Sunroof
...
D i s a s s e m b.1. .y. . . . . . . . . . . . . . . . . . . . . . .1. 3
ComponentLocationIndex ...20-35,22-108
........................................
13-34
Resassemb|y
. .-.4. .8. . . . . . . . . . . . . . .
T e s t. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. 0
......
C fr c u i tD i a g r a m. . . . . . . . . . . . . . . . . . . . . .2.2. .-1. .0. 9
M/T Differential
P
Index.................
13-52
ComponentLocation
. .6. . . . . .MTF
....
A d i u s l m e n. .t . . . . . . . . . . . . . . . . . . . . . . . . .1. .3. -. 5
I n s p e c t i o n / R e p 1 a c e.m
. .e. .n. .t....... . . . .1. 3
. .- 3
Parking Erake
M/T Maifthaft Assembly
Inspection
A d j u s t m e n t. . . . . . . . . . . . . . . . . . 1
. .9. .- 7
MuhiplexControlSystem
13-23,
26
1nspection
......................................
lndex ..............22
168
ComponentLocation
1325
Disassembly
.........................................
Parking Brake Cable
22-169
CircuitDiagram..................................
13 28
Resassembly
........................................
Rep1acement.........................1
. .9. .-.2. .6. . . . . . . . .
22-171
0escription.........................................
13-43
Adjustment...........................................
................................
22-17
2
Troubleshooting
ParkingErakeSwitch
M/T ReverseShift Fork
. . . .1. 9 - 1 0
Test.................
I n s p e c t i o. n. . . . . . . . . . . ................ . . . . . . . .l .3. .1. 9
. . . . Muliiplex ControlUnit, Under-dash
InputTest
Passenger's
TraV
22-92
EntryLightControlSysiem.............
M/T Shift Level
............................
20-65
Removal/lnstallation
Alarm
Entry/Security
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . .1. .3. .- .5. 1. . . . . . . . .Keyless
....
22-155
Systern.-.......................................
PCVValve
115
MultiplexControl
System.............22
MainshaftBearings
B e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . .1. 1. .'.1. 6
. .9. . . . . . . . . .
22'141
R e p l a c e m e n t . . . . , . . . . . . . . . . . . . . . . .1. .3.4. .1. . . . . . . . . Wiper/Washer.................................
.....
T e s t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l. 1. . 1. .6. .9. . . . . . .
Mairtenance
PistonRings
lSeesection3)
8 e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .7. .- .2. 1. . . . . - . - . .
N
MIL
Pistons
.............................
11.46
How to Informatron
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . - . . .7. .-.1. .8. . . . . . . . . .
NoiseReductionCondenser
..........................1
. .-.2. .3. . . .
. . . . . . . . . . . . .1. 0
21
2
1 n s t a | 1 a t.i .o. n
Test,,
MIL Circuit
.- . . . . .........
1197
Troubleshooting
..........
PowerRlay
22-51
Test...............-.-......................................
Mirrors
20'14
Index.................
ComponentLocation
PowerWindow Motor, Driver's
t e s l . . . . . , ,.,,,. , , , . . . . . . . . . . . .
Mode ControlMotor
. . . . . . . . . 2 1 , 3 5 Oil Filte]
Replacement
. . . . . . Window Motors, Passenger's
T e s t . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 2 1 3 5 R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8. -. 6. . . . . . . . Power
l' ,e
MoonroofDreinChannel
B e p l a c e m e n. .t .. . . . . . . . . . . . . . . . . . . . . .2. .0.3. .9. . . .
(cont'd)
ServiceManuallndex
(cont'dl
PowerWindow Switch, Passenger's
lnputTest .............-......
22-130
22 132
Replacement...,-.-.-...,..
22-133
RockerArm Assembly
Removal
6-26
D;sassembly/Reassembly
.....................
6-27
lnstallation
6-38
sRs
C o m p o n e n t L o c a t i o nI n d e x . . . . . . . . . . . . . . 2122 4
CircuiD
t i a 9 r a m. . . . . . . . . . . . ............ . . . . .2. 2
. . .1 2 5
RockerArms
Test
Inspecton
LocationIndex.................
Component
23-13
D e s c r i p t i o n. . . . . . . . . . . . . . . . . . . . . . . . . .2. 3. .-.3. .1. . . . . . .
C i r c uD
i t; a g r a m
... .... ...........2334
lnspection/Replacemenl
...................
23 112
Roof Moldings
Replacement
o
Ouaner Window Glass
8ep1acement
.........................................
20-29
R e p l a c e m e n t. . . . . . . . . . .
10-3
10-10
RadiatorFanSwhch
Replacement
Test
RadiatorFanSwitch Circuit
Troubleshooting
RearAir Outlet
Replacement
1A-17
18-30
StabilizerLinks
Removal/lnstallation
FrontSuspension
RearSuspension
1 81 8
18-31
20-75
Startel
Test
Replacement
Overhaul
Replacement
20-84
StarterSolenoid
Test
Seat,Driver's
Removaf/lnstaf
lation............................
20 11
Disassembly/Reassemb1y
...................
20-73
4-7
StartingSystem
Component
LocationIndex...............-.....
4-3
CircuitDia9ram
........................................
44
Troubleshooting
10-14
10-17
10-17
1 01 6
2Q-104
RearWindow Defogger
Index ..............22
104
ComponentLocalion
22-105
CircuilDiagram
22 106
Test
RearWindow DroggerWires
Repair
SeatCover,Front
Replacement
23-1
SeatCushionCover,R6ar
RadiatorFanAssembly
........................
r0-4
Test
RadiatorFanCircuit
Troubleshooting
23-9
StabilizerBar
Replacement
FrontSuspension
RearSuspension
SeatBehs,Rear
Replacement
10-3
23 105
SRSUnit
Replacement..-....................................
23-122
s
Seat8ehs, Front
Replacement
rnspec!on
Radiatorand CondenserFans
CommonCircuit
T r o u b l e s h o o l i n g . . . ........... . . . . . . . . . 2 12 9
RadialorCap
Test..-.-...
SRSlndicatorCircuil
Troubleshooting
Seat Belts
Component
LocationIndex...................
23-3
R
Radiator
Test......
6-7
6-28
Specifications
(Seesection2)
Sedt,FaontPassenger's
Disassembly/Reassemb1y
...................
20-74
Seat,Rear
Removal/lnstallation
............................
20-80
Steering
Component
LocationIndex................-..
17-3
Inspectaon
...................
11-4
Seat-backCover,Reer
SteeringColumn
Removal/lnstallation
Replacement
Inspection
SteeringGearbox
Removal
Overhaul
lnstallation
Seat-backStriker.Rear
Replacement
17-9
1 11 1
17-51
1 75 5
17 63
SteeringHangerBeam
Seats
Component
LocationIndex....-............
20-70
Replacement
20 68
SteeringLinkage
22-106
Shift Forks
Inspefiron
13,21
Disassembly/Reassembly
...................
13-22
Steering Lock
Inspectton
RearWindow Glass
Replacement
SecirculationControlMotor
Replacement
Test.....
20-25
Replacement
17-13
SideAirbag,Drivel's
Replacement
SteeringRackGuide
Adiustment
.....11-12
23-115
Sidelmpact Sensors
Replacement
23 123
Refrigerant
Replacement
..-.-.-......................
21 53,54,55
Side Marker Light
Test........................................................
21-56
R e p 1 a c e m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. .2. .-.A. .3. . . .
RetrigerantOil
Spark Plugs
R e p l a c e m e n t . . . . . . . . . . . . . . . . . . . . . . .2
. .1. .-.6. . . - . . . . . . . . . . .
. .._..4_19
174
Removal
17-6
D i s a s s e m b l y / R e a s s e m b l.y. . . . . . . . . . . . . . . .1. .7. .7
1 n s t a 1 1 a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. 7. .-.8. . . . . .
Sublrames
Replacement
20 112
\'
Suspension
A d j u s t m e n t . . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . .V. . . . . . . . 1 8 4
ComponentLocationIndex.................
20-17
SynchroRing,Triple-cone
WindshieldGless
I n s p e c t i o n . . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . . .V. .a. l.v1e3G
39
uides
R e p l a c e m e n t . . . . . . . . . . . . - . . . . . . . . .2. .0. 1. .9- . . . . . . . . . .
Inspection............-.-................................
6 32
SynchroSleeve
Beplacement
..........-................................
6 33
WiperIntermittentControlUnit,
Inspectaon/Reassemb1y
.......................
1339
RearWindow
ValveSeats
InputTest
.....22-134
R e p a i .r. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6. 3
. .5. . . . . . . . . . . . . . . . .
WiDerMotor, RearWindow
Rep1acement.......................................
22-146
Adjustment.-.-.......
6-9
Removal...-...-......................................-...
6-31
WiDerMotor,windshield
Taillight
Inspec!on
.....6-32
Test.......-..........-.....-.........................
Thermostai
Test ........................
10 4
R e p l a c e m e n t . . . . . - . . . .- . . . . . . . . . . . . . 1. .0. I. . . . .
vss
Throttle Body
Replacement
-..............
............
.............22
61
Test..................
11-160
Removal/lnstallation
.. . . . . . .. ... 11-'165
VTCActuator
Disassembly/Feassemb|y................-11-166
Inspection
.................68
Wiper/Washor
Switch
TesVReplacement
..............................
22-140
WireHarnesses
R e p l a c e m e n. t. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . .2.4. . . . . . . . .( .S e e f i r s t p a g e o f t h i s l n d e x )
ThrottleCable
A d j u s t m e n t. . . . . . . . . - . . . . . . . . . . . .1. .1. 1
. .6. .3.
V T CO i lC o n l r o l S o l e n oVi d
alve
R e m o v a l / 1 n s t a 1 1 a t i o n . . . . . . . . . . . . . . . . . . . . . .R. .e. m
. 1o1v1a6l4. . .
. - . . . - .| .1.- 1 2 7
t s
Tie-rodBallJoint Boots
VTCSystem
B e p l a c e m e n t . . . . . . . . . - . . . . . . . . . . . .1. .7. .6.7. . . . . . . C
. . o. .m
. .p
. o n e n t L o c a t i o n l n d e x . . . . 1. .1. .-.1. 1
. .7. .
Timing/CamChain
...612
lnstallation
Wi.ing System
H o w t o I n { o r m a t i o. .n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2
BelayandControlUnit
Locations
.-....-..............
-.-.-....22-7,4, 11, 12
VTECSolenoidValve
Femoval/lnspection....-......................11-128
...........6
. . .1. 5
.
Timing/CamChainCaseOilSeal
Installation......................-......................6,21
WasherFluidLevelSwitch
TesVReplacement
..............................
22 144
TrailingArms
Removal/lnstallation
..............
. . . . .....1833
WasherFluidReservoir
Replacement
.......................................
22-146
tnm
Component
Locationlndex................20 49
WasherMotor,Windshield
R e m o v a l / l n s t a l l a. t. i-o. .n. . . . .5200, 5 1 , 5 2 , 5 3
T e s t- . . . . . . . . . . . . . . - . . . . . . . . . . . . . . . . . . . . .1. .4. 4. . 2 2
Troubleshooting
{Seefirstpageot thisIndex)
Turn SignalLight
Replacement
Turn Signal/HazardRelay
InputTest........
WasherTube,Windshield
Replacement......-...-............................
22 147
.........22
A4
Weter Passage
22-87
Turn Signal/HazardWarningLights
Component
LocationIndex.................22
85
Circuit Diagram................-...................
22-86
],s
W.ter Outlet
'10-9
Installation
..................-...........................
UndeFdashFuse/RlayBox
Removal/lnstaf
lation............................
22-49
lnstallation
Water Pump
Inspection...........................
.. . . . .......10 5
Replacement
.-.........................................
10 5
WheelBearings
I n s p e c | i o n. . . . . . . . . . . . . . . . . . . . . . . . . . ............1...8. 8. . . .
Wheel Speed Sensors
I n s p e c t i o n . . - . . , . , . , , . , , , , , . , . , , , . . . . . . . . . . . .1. .9.-. 5
. .9. . . .
R e p l a c m e n. t. . . . . . . - . . . ..... . . . . . - . . . 1
. 9-59
WheelsandTires
UpperArms
R e m o v a l / | n s t a 1 1 a t i o n . . . . . . . .. .. ..1. .8. -. .3. 2.
. . . . . . . . . . .1. 0
. .I. .
Inspect|on